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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to copending U.S. patent applications Ser. Nos. H-2257 and H-2256B, having the same inventive entity and being assigned to the same assignee.
BACKGROUND OF THE INVENTION
The present invention generally pertains to a conference calling arrangement for a digital switching network and more particularly to an arrangement for capturing data of a time shared conference circuit for examining the data for error or verification conditions.
Historically, switching systems were equipped with a number of conference circuits. When a request for a conference call is detected by such a switching system, this system would select an unused conference circuit to connect each of the conferees in a conference call arrangement. In this scheme, one conference call would require one conference circuit.
With the advent of time division switching systems, conference circuits are required to manipulate PCM voice samples in an associated time slot switching environment. Time division switching systems utilize common equipment for a number of subscribers. One conference circuit for each conference call is inefficient. Since a time shared conference circuit handles a large amount of conference calls, it is required that for a fault the data and time slot of the fault be preserved.
One such conference circuit for manipulating PCM voice samples is taught by U.S. Pat. No. 4,126,766, issued on Nov. 21, 1978, and having the same successor in interest as the assignee of the present application. This conference circuit is a three-port device for use in a private automatic branch exchange. This conference circuit handles only a single conference call at a time. Each conference call requires a separate conference circuit. No provision is made for obtaining data and time slot information for detection of a fault. Threshold level detection and last speaker retention features are provided by this circuit. In addition, all three conferees' voice samples are compared before outputting the resultant loudest speakers' samples.
Another digital multiport conference circuit is taught by U.S. Pat. No. 4,175,215, issued on Nov. 20, 1979, and having the same successor in interest as the assignee of the present application. This circuit provides for handling a single conference call at a time. Again, no provision is made for obtaining data and time slot information from the voice data stream for a fault detection. In addition, threshold level detection and last speaker retention features are provided.
Another multiport conference circuit is taught by U.S. Pat. No. 4,274,155, issued on June 16, 1981, and having the same successor in interest as the assignee of the present application. Similar to the above mentioned circuits, this circuit also handles one conference call at a time and provides no data and time slot information for fault detection.
Each of the above mentioned circuits suffers from the same deficiency of not providing data and time slot information for a fault detection in a time shared conference circuit.
Accordingly, it is the object of the present invention to provide for obtaining data and time slot information for fault or normal conditions in a time shared conference circuit.
SUMMARY OF THE INVENTION
A time-space-time switching system includes a time shared conference circuit with a data capture arrangement. A number of subscribers are connected to the switching system in a first conference call. The switching system includes a time-space-time digital switching network which transfers PCM voice data samples in particular time slots.
A number of interface units connect at least one subscriber each to the switching network. These interface units generate and transfer PCM voice data samples between the subscribers and switching network in particular time slots.
A processor arrangement is connected to each interface unit and the switching network. The processor arrangement controls the transfer of the voice data between the interface units and the switching network.
The data capture arrangement includes a timing generator connected to the switching network for producing a number of periodic pulses. A first buffer is connected to the timing generator on the switching network and sequentially stores voice data samples of three consecutive switching network time slots. These samples are the voice data samples of the three subscribers in a conference call.
A second buffer is connected to the first buffer and to the timing generator. This second buffer simultaneously stores the voice data samples of the first buffer. The first buffer then stores a voice sample of another subscriber in a second conference call.
First gating logic is connected to the second buffer and the timing generator and the first gating logic transmits two voice samples of the three stored voice samples, during each time slot. First comparing logic is connected to the first gating logic and determines which of the two transmitted voice data samples is greater in magnitude. Second comparing logic is connected to the first gating logic and determines whether the two voice data samples are greater in magnitude than a predefined threshold level.
Second gating logic is connected to the second comparing logic and determines whether at least one of the two voice data samples is greater in magnitude than the threshold level. Third gating logic is connected to the second gating logic and to the first comparing logic. The third gating logic generates a second signal for selecting the voice data sample which is greater in magnitude and also above the threshold level. The third gating logic also generates a signal indicating that neither voice sample is above the threshold level.
A memory arrangement is connected to the timing generator and a third gating logic. The memory arrangement operates in response to the signal indicating that neither subscriber's voice sample is above the threshold level, to produce an identity of the voice data sample with greater magnitude in the same time slot in the preceding time frame. The third gating logic operates in response to this identity to generate the signal indicating which voice sample is greater in magnitude. In addition, the memory arrangement stores the identity of the voice sample of greater magnitude for use during the next time frame.
A multiplexer is connected to the second buffer through the first gating logic and is also connected to the third gating logic. The multiplexer is operated in response to the signal indicating which voice sample has greater magnitude, to transmit the voice sample to the switching network.
A decoder is connected to the memory arrangement and the decoder indicates that a data capture request has occurred. Fourth gating logic is connected to the timing generator and the decoder. Fourth gating logic produces a number of activation signals in response to the data capture request. A number of data capture devices are connected to the timing means, the fourth gating logic and to the processor arrangement. The data capture devices store particular voice data samples and a binary value of the associated time slot. The data capture device operates in response to the activation signals produced by the fourth gating logic. The processor arrangement may read the capture voice data sample and time slot value.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a conference call arrangement in a digital switching system in accordance with the principles of operation of the present invention.
FIG. 2 is a block diagram of the time shared conference facility interface unit of FIG. 1.
FIG. 3 is a schematic diagram of a maintenance data insertion arrangement.
FIG. 4 is a schematic diagram of the time shared speaker buffer arrangement of the present invention.
FIG. 5 is a schematic diagram of the time shared threshold level detection and last speaker retention logic.
FIG. 6 is a schematic diagram of the output control logic and a portion of the data capture logic of the conference facility interface unit.
FIG. 7 is a schematic diagram of the remaining portion of the data capture logic.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, telephone subscribers A, B and C are respectively connected to Facility Interface Units (FIUs) 1, 2 and 3. Telephone subscriber A has the ability to initiate a conference call arrangement between himself and other subscribers. This means that all three subscribers may talk and hear the other subscribers simultaneously. Upon the initiation of a request of subscriber A, a connection will be established through FIU 1, to digital switching network 5.
Digital switching network 5, which is connected to peripheral processor (PP) 6, will establish connection to conference facility interface unit 4. Telephone subscriber A, then selects the number of telephone subscribers B and C. As a result, digital switching network 5 establishes a connection to subscriber B through FIU 2 and a connection to subscriber C through FIU 3. Voice samples of each of the telephone subscribers A, B and C are time switched by the digital switching network 5 to conference FIU 4 in sequential order. Peripheral processor 6 is connected to each of the FIUs 1 through 4. Peripheral processor 6 controls the operation of each of the FIUs for switching voice samples.
Each FIU 1-3 may have a number of subscribers (not shown) with the ability to initiate conference calls. The switching network 5 orders the conferees of each conference call in consecutive time slots for use by the conference FIU 4. For example, the switching network 5 sequentially orders the PCM voice samples of subscribers A, B and C in three consecutive time slots for use by the conference FIU 4.
A switching office may contain many FIUs and conference FIUs. A particular conference FIU may connect up to 64 independent conference calls, each conference call includes three subscribers in conversation.
FIG. 2 is a block diagram of the conference FIU shown in FIG. 1. The conference FIU is a three-port device. Each of the three ports includes three consecutive input time slots and three consecutive output time slots having a fixed relationship between them. PCM voice samples from the digital switching network are input into speaker buffers 30 of the conference FIU 4 of FIG. 1. Speaker buffers 30 include three twelve-bit input buffers and three twelve-bit working buffers. Voice samples of the three conferees of a conference call are sequentially stored in one of the three input buffers. When each of the input buffers has a PCM voice sample, their data is simultaneously transferred to the working buffers while three other conferees' PCM voice samples are collected by the input buffers.
This arrangement permits the conference FIU to be time shared among a number of conference calls (up to 64). The conference FIU logic performs one comparison for each time slot of 648 nanoseconds. During one time slot, the conference FIU compares the voice levels of the conferees of the conference call, with the loudest conferee being the one to prevail in the conference. In addition, the conference FIU detects basic threshold levels of the speakers and defaults to retaining the conferee who was the speaker in the preceeding time frame for the conference call, if no conferee is above the threshold level. The conference FIU outputs a PCM voice sample in the next time slot after these comparisons are made. The following table depicts the time slot performance of the conference FIU.
TABLE______________________________________ PCM Input PCM OutputTime Sample Comparison SampleSlot (PCMR) Made (PCMX)______________________________________0 A1 B2 C3 D B-C4 E A-C B or C to A5 F A-B A or C to B6 G E-F A or B to C7 H D-F E or F to D8 I D-E D or F to E9 H-I D or E to F10 G-I H or I to G11 G-H G or I to H12 G or H to I______________________________________
Before PCM samples are received by speaker buffers 30, the samples are examined by parity check for 38 for proper parity. Improper parity will result in an alarm being output and in the operation of TSC trap 15, receive trap 37 and transmit trap 55. In addition, the sample will be processed by the remainder of the circuitry.
Receive trap 37 may be selectively operated to remove any particular PCM voice sample from the input stream and return it to the peripheral processor 6. After buffering by speaker buffers 30 as mentioned above, two PCM voice samples are transmitted through multiplexers 31 and 32, respectively, to speaker select and threshold logic 40 via the SPKA and SPKB buses. During each time slot, the voice samples of two conferees are compared.
PCM voice samples consist of twelve bits of data. Eight bits of data represent the voice sample of the speaker. Of these eight bits, seven bit represent the magnitude and one bit represents the sign. Three bits of the PCM voice sample are supervisory bits having various uses by the network. The remaining bit of each PCM sample is the parity bit.
Speaker select and threshold logic 40 compares the seven magnitude bits of the two PCM voice samples input to it. This comparison detects the louder of the two conferees. Each PCM voice sample is also tested against a predefined minimum threshold level (a binary "1001" in the most significant bits of the seven-bit magnitude.) If either or both conferees' voice sample is greater than the threshold level, the result of this comparison will be output during this time slot. That is, the louder conferee's voice sample will be the one output to the remaining conferee. If however, both conferees' PCM voice samples are less in magnitude than the threshold level, the resultant output to the other conferee will be the PCM voice sample having the greater magnitude of the same time slot of the previous PCM time frame.
The identity of the louder speaker will be stored in last speaker memory 35, as a function of the time slot counter, to be used during the next time frame, if needed. As a result, the PCM voice sample of the SPKA or SPKB bus is enabled through multiplexer 34 and through multiplexer 50, where the PCMX signal is transmitted back to the network 5 for switching. An examination for proper parity is made by parity check 57. Invalid parity results in activation of traps 15, 37 and 55. In addition, the PCMX data may be captured by transmit trap 55 for examination by peripheral processor 6. In addition, the PCMX data will be transmitted to the network for switching.
The network 5 is connected to timing generator 10 via the MCLK bus for providing synchronization between the network 5 and the conference FIU 4. The timing generator 10 counts from 0 to 192 at a rate of one count per 648 nanoseconds. This provides the basic time slot operation for the conference FIU 4 synchronously with network 5. An eight phase clock is also generated by the timing generator 10. In addition, the timing generator 10 provides a divide by three counter to control the storage of voice samples in speaker buffers 30. Timing generator 10 is also connected to TSC trap 15 via the TSC (time slot counter) lead.
The TSC trap 15 is connected to the peripheral processor and operates to capture and transmit the value of the time slot counter to the peripheral processor. If an error is detected, compare logic 16 transmits the value of the TSC which was trapped to compare and double look logic 39. During the next succeeding time frame, another comparison is performed by double look logic 39. A second consecutive error in the same time slot will result in an alarm being output by double look logic 39.
PP access logic and control 20 is connected to the peripheral processor 6 and receives both address and data via corresponding buses. These buses are examined by parity check 11 with an alarm resulting for detection of any parity errors. A parity error will result in an address or data parity failure indication being returned to the peripheral processor.
Channel select memory 22 is connected to multiplexer 12. The TSC lead connects timing generator 10 to multiplexer 12. The address bus connects PP access logic 20 to multiplexer 12. The channel select memory 22 provides for storing control information for operating traps 15, 37 and 55 and controlling the output of multiplexer 50.
Maintenance register A 24 and maintenance register B 25 are connected to PP access logic 20 via the data lead. The peripheral processor 6 has the capability to load maintenance register A 24 or maintenance register B 25 with data to insert into the PCM voice data stream output by the conference FIU. Channel select memory 22 stores the instructions and time slots in which maintenance data, stored in maintenance registers A 24 and B 25, is to be inserted into the output PCM voice data stream. The stored instructions are decoded by decode circuit 44. In addition, channel select memory 22 contains coded instructions for enabling decode logic 44 to select the trapping of any PCM data by receive trap 37, TSC trap 15, or transmit trap 55.
Multiplexer 50 provides for transmitting the resultant voice samples of speaker select and threshold logic 40, the contents of maintenance register A 24, the contents of maintenance register B 25, or quiet code from quiet code circuitry 42. It is to be noted that the binary value of the minimum magnitude of a PCM voice sample is seven bits of logic "1" and the maximum magnitude being seven bits of logic "0." Therefore, quiet code circuitry 42 generates seven bits of logic "1."
TSC trap 15 may be operated via stored instructions in the channel select memory 22. These instructions are decoded by decode circuit 44. In addition, a PCM receive data miscompare between this conference FIU and a duplicate copy will cause compare and double look logic 39 to operate the traps, as mentioned above.
Receive trap 37 may be operated via stored instructions in channel select memory 22, which are decoded by decode circuit 44 to trap any particular voice sample. Other internal receive conditions may cause receive trap 37 to operate. Transmit trap 55 may also be operated via these stored instructions by decode circuit 44 to trap any particular voice sample.
FIG. 3 is a schematic diagram of multiplexer 12, channel select memory 22, maintenance register A 24, maintenance register B 25, and decode circuit 44 as shown in FIG. 2. PP access logic 20 of FIG. 2 is connected via eight-bit PP address bus to multiplexer 12 as shown in FIG. 3. Another eight-bit bus is connected from timing generator to multiplexer 12. This bus is the time slot counter bus. The timing generator is also connected to multiplexer 12 via the SELTSC and enables either the values of the TSC bus or the PP address bus to be transmitted through multiplexer 12 to be stored in channel select memory 703. Channel select memory 703 is connected to multiplexer 12 via an eight-bit bus. In addition, a signal on lead CSMWE controls writing the channel select memory 703. The data to be written in the channel select memory 703 is transmitted via the PP data bus, a twelve-bit bus. The five low order bits of the PP data bus are transmitted to channel select memory 703 to select storage locations.
Maintenance register A 24 and maintenance register B 25 are each connected via twelve-bit PP data bus to PP access logic and control 20. PP access logic 20 selectively enables maintenance register A 24 or maintenance register B 25 via the MRAWE and MRBWE leads, respectively. The timing generator 10 provides for resetting each of the maintenance registers via the RESETA lead.
Twelve-bit PCM data samples are stored in maintenance register A 24 and maintenance register B 25 to be inserted into the PCM voice stream by the peripheral processor 6 for network diagnostic purposes. Channel select memory 703 is connected to HEX D-type flip-flops 709 and 710. These flip-flops are selectively enabled by timing signals P2 and P6 from the timing generator. The four outputs of flip-flop 709 are read control signals for use when the PP reads data from channel select memory 22. The outputs of flip-flops 710 control the gating of the multiplexer 50 of FIG. 1 and enable traps 15, 37 and 55 to operate.
FIG. 4 depicts a schematic diagram of speaker buffers 30 of FIG. 2. Buffer A 1002 stores the first PCM voice sample from network 5. Buffer B 1004 and buffer C 1006 store the second and third speakers' voice samples, respectively, transmitted in the next two time slots of the particular frame.
When all three buffers have been clocked by their various clock signals, the INCNT 1 signal causes the contents of each of the buffers to be shifted to a corresponding working buffer. That is, contents of buffer A 1002 are transferred to working buffer A 1008; the contents of buffer B 1004 are transferred to working buffer B 1010; and the contents of buffer C 1006 are transferred to working buffer C 1002. Working buffer A 1008 is connected to multiplexer 31. Working buffer C 1012 is connected to multiplexer 32. Working buffer B 1010 is connected to both multiplexers 31 and 32. Gate 1013 provides for selectively enabling multiplexer 31 or 32 in response to signals from the timing generator to transmit the appropriate two speaker samples per time slot for speaker selection and threshold determination. Refer to the above table for selection sequence.
FIG. 5 depicts the speaker magnitude comparison and threshold level detection circuitry as shown by item 40 of FIG. 2. The SPKA bus and SPKB bus represent the output of multiplexers 31 and 32, respectively. The four least significant bits of each bus, SPKA and SPKB, are connected to four-bit magnitude comparator 1101. The three most significant bits of each bus are connected to four-bit magnitude comparator 1102.
Magnitude comparator 1101 is connected to comparator 1102 via a three-bit bus, so that the results of seven bits may be analyzed in total. Comparator 1102 produces a signal on the AGTB lead. This signal indicates that voice sample of the SPKA bus is louder than voice sample of the SPKB bus. This signal has a value logic "1, " if conferee A is louder than B. Otherwise, the AGTB lead has a value of logic "0." Comparator 1102 is connected to gating arrangement 1107.
Next, the magnitude of the SPKA bus and SPKB bus is compared against a predefined minimum threshold level. Comparator 1103 examines the PCM voice sample of the SPKA bus against the threshold level and comparator 1104 examines the voice sample of the SPKB bus against the threshold level. These comparators work with the four most significant bits of each PCM voice sample. The predefined minimum threshold level of a voice sample is set equal to the binary value of "1001" for the most significant four bits by threshold logic 1110. This threshold level may be set at various binary values with +5 volts being logic "1" and ground being logic "0." If either speaker voice sample is greater than the threshold, gates 1105 and 1106 will allow multiplexer 34 to gate out the PCM voice sample of SPKA bus or SPKB bus, whichever is larger in magnitude.
If both speakers are less than the threshold level, gate 1107 will enable multiplexer 34 to gate out the present voice sample of the louder speaker, during the same time slot of the previous time frame. In addition, the identity of the louder conferee of the present time slot will be stored into last speaker memory 1111, via a signal on the NEWA lead, as a function of the appropriate time slot counter. This identity could be used in the same time slot of the next frame. Flip-flop 1112 operates to latch the value of the last speaker for each particular time slot and transmits this to gate 1107.
FIG. 6 is a schematic diagram of the PCM transmission section of the conference FIU. The PCM voice sample resultant from the speaker select and threshold logic is transmitted via the CONF bus to data selector 1214. In addition, twelve-bit buses maintenance data A and maintenance data B are connected between the data selector 1214 and registers 24 and 25 for transmitting the contents of maintenance register A 24 and maintenance register B 25, respectively, into the PCMX data stream to the network. In addition, a +5 volt source is connected through registor 1215 to data selector 1214 and provides for the generation of the quiet code.
Data selector 1214 receives enabling signals from flip-flops 710 via line decoder 1201 and gates 1209 and 1210. Decoder 1201 is connected to AND gates 1208, 1209 and 1210. Gate 1209 provides an output for selecting maintenance register A 24 to be gated through the data selector 1214. Similarly, gate 1210 provides for selecting maintenance register B 25 through data selector 1214. Gate 1208, which is connected to gating logic 1207, provides for selectively enabling the traps 15, 37 or 55 to operate.
Data selector 1214 normally permits the result of the CONF bus to be transmitted through selector 1214. If no speaker is indicated in the particular time slot, the quiet code supplied through resistor 1215 will be gated out through data selector 1214. The output of data selector 1214 is stored in latch array 1220. Latch array 1220 is connected to buffer 1227 via a twelve-bit bus. Buffer 1227 is connected to the network via the PCMX bus for transmitting the conference PCM sample to the network for switching.
Trap latch array 1222 is also connected to latch array 1220 and operates in response to the trap signal produced by gating logic 1207. The enabling signal to gating logic 1207 is produced by AND gate 1208. Gating logic 1207 combines the enabling signal of gate 1208 with timing signal P2 from the timing generator to produce the XTRPCLK signal to enable the trap latch array 1222 and to produce the TTRP an RTRPCLK signals to enable the other traps. Data collected by the trap latch array 1222 is transmitted to the peripheral processor.
FIG. 7 depicts the receive trap 37 and the TSC trap 15 of FIG. 2. Receive trap latch 904 is connected to the peripheral processor via the PCMR bus. Receive trap latch 904 operates in response to the RTRPCLK signal of gating logic 1207 to latch the value of the PCM voice sample currently on the PCMR bus. This trapped data may be transmitted to the peripheral processor via the receive trap data bus.
Flip-flops 301 are connected via the TSC bus to the timing generator and latch the value of the TSC bus in response to the P5 signal of the timing generator. When the gating logic 1207 detects a request for a TSC trap the TTRP signal is transmitted to flip-flops 302 from gating logic 1207. Flip-flops 301 are connected to flip-flops 302 and latch the value of the TSC bus. The output of flip-flops 302 may be gated to the peripheral processor via the eight-bit TSC trap data bus.
Although the preferred embodiment of the invention has been illustrated, and that form described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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A time shared conference circuit for establishing conference calls in a T-S-T digital switching network provides for trapping certain PCM voice data from the output PCM voice data stream of the conference circuit. Data is automatically trapped for detection of errors such as parity. Data in any specific time slot may be trapped for a non-error condition under control of a processor.
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RELATION TO OTHER PATENT APPLICATIONS
This patent application is an outgrowth of our previously-filed Provisional Patent Application, filed Aug. 1, 1995 to which Ser. No. 60/001,737 has been assigned, and not abandoned prior to the filing date of this patent application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a system for operating one or more drawers that are housed in cabinets, either alone or in multiples of many drawers in a single cabinet, such as in medication or supply cabinets or stations for dispensing pharmaceutical or other supply items from locked storage. More particularly, the invention pertains to a system for controlling the drawers such that they may be opened only a certain distance to expose only certain items with the rest of the items remaining securely stored in the cabinet and, more importantly, that the drawers cannot be jerked open in an effort to expose unauthorized supplies.
2. Description of the Prior Art
The practice of storing and dispensing pharmaceutical items and hospital supplies from locked storage has, over the past several years, become a rather common practice. The benefits of such a practice are readily apparent and are increasingly needed to reduce medical costs and improve efficiency. With controlled storage and dispensing, the existing stock of items is completely used up before new stock is added, resulting in reduced loss from exceeding the expiration dates on certain items. Theft is controlled and/or virtually eliminated, especially theft of controlled substances such as narcotics, steroids, and the like. The patient*s records are more accurately controlled and more efficiently handled by computers interconnected the storage and dispensing cabinets. And, reordering of exhausted or near-exhausted supplies is faster and more carefully controlled. There appears to be no limit to the benefits of these practices. Our previous inventions, disclosed and claimed in U.S. Pat. No. 5,014,875 and U.S. Pat. No. 5,346,297, have been greatly assimilated into the aforesaid practice and represent the state-of-the-art.
Presently, the storage and dispensing of small items, such as ampules, syringes and other small, cylindrically-shaped items are handled by high-density storage and dispensing devices, as disclosed and claimed in U.S. Pat. No. 5,263,596. Larger items are stored in and dispensed from large, supply cabinet-sized auxiliary units, as disclosed and claimed in U.S. Pat. No. 5,346,297. For smaller items that are not slender in size or that are loosely housed in small packets, such as packages of aspirin, packets of laxatives, bandages, and the like, neither the high-density devices nor the auxiliary units are extremely efficient. These items would be more efficiently stored and dispensed from drawers of various sizes.
Unfortunately, most drawers housed in cabinets operate only between fully-open and closed positions, thus allowing access to all the contents in the entire drawer. This is not acceptable where controlled dispensing is required. There are some patents that control the motion of a drawer from a closed to an open position, such as in U.S. Pat. No. 5,392,951. However, total control over the drawer is not thought to be necessary in some medical circles. What is needed is a drawer-operating system that allows graduated access to a drawer so that items stored in the drawer may be extracted from the front of the drawer and access given to deeper and more rearward parts of the drawer only after inventories in the front have been exhausted. If the distance the drawer slides open can be controlled, then the cabinet can function as a security device, retaining therein those items that are not authorized to be dispensed when the drawer is partially opened. Unfortunately, there are those who would abuse any such system in an effort to obtain access to items to which they are not authorized. With drawer storage, there is the ever-present threat that a user will jerk the drawer open in an effort to by-pass any security device lock and achieve full opening of the drawer whether authorized or not.
The benefits of a workable security arrangement of this type are many. First, only one drawer is opened so that the user does not have to search through all of the drawers to locate the needed item. Secondly, all other items in all other drawers are retained in locked storage and not accessible until appropriate clearance is obtained. Third, with the drawer openable only a limited distance out of the cabinet, items at the rear are retained in locked storage. Fourth, with only partial opening and graduated access, the user is forced to use items stored in the front of the drawer, thus insuring the utilization of existing inventory before access to fresher inventory is granted. Finally, should theft occur, identification of the culprit is easily determined, because only the previous user had access to the other inventory in the drawer. Thus, the blame falls on his or her shoulders.
An important feature would be to allow the user to manually pull the drawer open to its fully authorized extent, instead of having it driven fully open. This is because a driven drawer might strike the user who is unaware it is opening. In addition, the user may wish to place a tray or other device under the drawer for aid in unloading the bin. If the drawer is driven open, it may interrupt this activity or knock the tray from the user's hands.
Another important feature that does not exist in the prior art is the ability to pre-load the bins in the drawer at a location remote from the dispensing cabinet. Presently, one must go to the dispensing cabinet, shut it down, open all the drawers and fill the bins with new supplies. This causes downtime of the cabinet and interrupts the normal work schedule of the personnel that use the cabinet. If a way could be found to fill the drawers at a remote location, say at the pharmacy, and seal the bins with a cover, then the newly filled drawers could be brought to the cabinet and inserted therein to eliminate the downtime.
SUMMARY OF THE INVENTION
This invention is a unique drawer operating system comprising an interconnected "engine" and a "dispensing drawer" for allowing graduated access to consecutively spaced bins, partitioned in the drawer, so that access to the bins is controlled. The engine is housed at the rear of each system and remains out of sight and out of the reach of potential thieves. It tracks the previous activity of the drawer and, when later accessed, allows the drawer to be pulled opened to a length that will expose the contents of a bin either not emptied or not uncovered in previous openings, thus retaining the other item-filled bins inside the cabinet and secure from access.
In the preferred embodiment, the drawer is driven from its fully-closed position to a slightly-opened position of one inch or so, to indicate to the user that this particular drawer is further openable by merely pulling it outward. When the drawer is later pushed toward its closed position, it encounters a bias pressure that reduces the effect of "slamming" the drawer into a locked position in the cabinet. This latter feature reduces the potential for the shock of slamming a drawer from causing damage to the rest of the contents therein. Even further, this invention tracks the rate of change of acceleration of the drawer as it is manually pulled open. When a rate of change is measured, that is indicative of the drawer beginning to be jerked open, the drawer is immediately locked against further opening and the user advised to open the drawer more slowly. This invention also solves the problem of loading the supplies at a location remote from the cabinet. This invention separates the engine from the bin-filled drawer and allows the drawer to be remotely filled and later joined to the engine for use in the cabinet.
Accordingly, the main object of this invention is a drawer-operating system that controls drawers in a cabinet by providing graduated access to a plurality of consecutively arranged bins. Other objects include a system that monitors the previous activity of a drawer to insure that emptied bins are bypassed in subsequent openings and that the next drawer opening will be to a bin containing items stored therein; a system that powers the drawer slightly open to allow subsequent manual opening to the appropriate item-filled bin; a system that reduces the shocking effect of slamming of the drawer into the cabinet during closing so that other items stored in the drawer and the rest of the cabinet are protected against shock; a system that can be utilized in a larger drawer-sized opening to take the place of a drawer used in a cabinet of the type shown in U.S. Pat. No. 5,014,875; a system that provides manual opening in the case of a power failure; a system that permits the drawer to be loaded with supplies and sealed against theft and opened for use at the cabinet to replenish exhausted supplies; and, a system that immediately locks the drawer in a safe position should the user attempt to jerk it open in an effort to obtain access to items in the rear of the drawer.
These and other objects of the invention will become more apparent when reading the description of the preferred embodiment along with the drawings that are appended hereto. The protection sought by the inventor may be gleaned from a fair reading of the claims that conclude this specification.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative view of a prior art pharmaceutical item dispenser station showing this invention used in place of one of the drawers thereof;
FIG. 2 an illustrative view of a prior art supply cabinet wherein this invention may be placed for utilization;
FIG. 3 is a block diagram of the logic used in the utilization of stations and cabinets that use this invention;
FIG. 4 is an illustrative view of the preferred embodiment of the invention;
FIG. 5a is a top illustrative view of the embodiment shown in FIG. 4; FIG. 5b is a side illustrative view of the same embodiment; and, FIG. 5c is a schematic view of the way the dispensing drawer in FIGS. 5a and 5b are connected to the engine in the same figures;
FIG. 6 a top illustrative view of the preferred embodiment of the invention showing the components and how they are arranged;
FIG. 7 is a top plan view of the ladder which is a part of the linear encoder of this invention;
FIG. 8 is a side illustrative view, partially in section, of the drawer jerk-resistant locking portion of this invention showing it in the locked configuration;
FIG. 9 is another side illustrative view, partially in section, drawer jerk-resistant locking portion of this invention showing it in the unlocked configuration;
FIG. 10 is a top view of the mechanism locking the drawer in storage in the cabinet;
FIG. 11 is an illustrative view of the emergency release lever used to release a plurality of drawers from locked storage in the cabinet in the event of a power failure;
FIG. 12 is a top, illustrative view of the engine-release mechanism; and,
FIG. 13 is a top view of the components of the invention utilizing outriggers to center the engine in a wide drawer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings wherein like elements are identified with like numerals throughout the fifteen figures, FIG. 1 shows the invention 1 utilized in a drawer module for use in a medical dispenser station of the type disclosed and claimed in U.S. Pat. No. 5,014,875.
FIG. 2 shows the invention utilized in an auxiliary storage and dispensing unit of the type disclosed and claimed in U.S. Pat. No. 5,346,97. The invention may also be used in a wide variety of other configurations and the description here should not be taken as limiting the utilization of the invention in any way.
FIG. 1 shows the typical prior-art dispenser station 3 to compromise a compact cabinet 5 which may be supported on wheels 7 for convenient portability. A control unit 9, designed for quick and easy access and relatively easy keyboard entry of appropriate pre determined authorization access codes and other information, is mounted generally within the upper extent of cabinet 5 and includes a keyboard 13. Keyboard 13 includes an array of keys 13 or similar entry devices for entering information, in conjunction with a display, which utilizes liquid crystal elements or the like in programmed interaction with entered information.
FIGS. 1 and 3 depict a controller unit 16 in schematic form with keyboard 13, for processing information controller 16 is programmed to regulate access to the station drawers and to generate an access record which is stored in an internal memory 17 or via a disk drive having an exposed disk port 1 to receive a conventional disk 25. Alternatively, the access record can be displayed on the cabinet display 27 and/or otherwise printed by means of an integral printer unit 29 for appropriate printout onto paper 31.
Controller 16 is preprogrammed with appropriate information regarding the medication types associated with a group of controllers assigned to station 3. In a preferred form, this programming occurs by virtue of a data link 33 which interconnects station 3 to a main computer such as a pharmacy computer 37 of the type used commonly in a centralized hospital pharmacy to track patient requirements for medication and other pharmaceutical items. In this regard, pharmacy computer 37 desirably includes appropriate software for programming and updating a group of dispenser stations located at centralized sites throughout a hospital facility thereby permitting regular updating of each dispenser station according to the most current patient information.
As shown in FIG. 1, dispenser station 3 includes a stack of four drawers labelled 39, 41, 43 and 45. Drawer 41 has a generally conventional drawer geometry and is mounted on slides 49 for sliding movement with respect to station housing 3. While the instant invention applies to single drawers housed in a cabinet, it also applies to an array or plurality of drawers housed in a cabinet the size of, and that takes the place of, one or more drawers 39-45. This array can be in groups of smaller or mini-drawers of four (51), six (53), nine (55) and eighteen (57). The housing 59, wherein this array of mini-drawers is contained, comprises spaced-apart top and bottom sheet metal or molded plastic walls 61 and 63 respectively, held in place by spaced-apart similarly constructed side walls 65 and 67 and a rear wall 69, all said walls joined along their respective contacting peripheral edges. A front wall 73 covers over housing 59 and has a plurality of rectangular openings 75 formed therein through which the drawers 51-57 pass during opening and closing.
This same housing can be used in an auxiliary storage and dispensing unit as disclosed and claimed in U.S. Pat. No. 5,346,297. As shown in FIG. 2, this unit comprises a tall cabinet 77 made up of spaced-apart top and bottom panels 79 and 81 respectively, joined about three marginal edges by spaced-apart side panels 85 and 87 respectively, and a rear cabinet panel 89 integrally connected along their mutually adjacent marginal edges such as by welding or other secure fastening. Panels 79 through 89 define an interior dispensing cavity 91 accessible through a front opening 93 covered over by a door 97. Housing 59 may be fitted in cavity 91 or in any subcompartment formed therein.
As shown in FIG. 4, the mini-drawer 99 of this invention comprises two basic parts, an "engine" 103 and a "dispensing drawer" 105. Engine 103 is located to the rear of dispensing drawer 105 and the two operate as a complete power-controlled drawer for insertion in housing 59 through front wall opening 75. Engine 103 is bounded by an engine enclosure 106 comprising vertically oriented, spaced-apart front and rear walls 109 and 111 respectively, held apart by a pair of spaced-apart upwardly extending side walls 113, and supported on the bottom by a flat pan 115. Optionally, a top cover plate (not shown) may be used. All said walls and pan are attached together along their marginal edges, or more preferably molded as a single unit.
Dispensing drawer 105 is shown in FIG. 4 to comprise an open top enclosure that includes an elongated bottom plate 119 which supports vertically oriented and spaced-apart front and rear walls 121 and 123 respectively, as well as spaced-apart side walls 125 and 127, all said walls attached together at their intersecting marginal edges or molded as a single unit that is supported on and rides along a cabinet dividing base or drawer support surface 129 (see FIG. 9.) A plurality of transverse walls 131 is formed in drawer 105 in consecutive spaced-apart arrangement from front wall 121 to rear wall 123 forming a plurality of open top bins 133 aligned coincident with the axis x--x of the sliding motion of said drawer into and out of housing 59 through front wall 73.
A unique feature of this invention is shown in FIGS. 5a, 5b and 5c where drawer 105 is shown to be connectable to the front of engine 103 through a coupling 135. Coupling 135 is shown to comprise an upwardly and rearwardly directed hook 137 attached to engine front wall 109, preferably above the center line or central axis x--x thereof. Hook 137 is formed in front wall 109 for receipt in a hook-receiving opening 141 formed in drawer rear wall 123. Extending forward from the bottom of engine housing front wall 109 is a connector arm 145. A rectangularly-shaped latch 147 terminates connector arm 145. A latch-receiving aperture 153 is formed in bottom plate 119, inboard from drawer rear wall 123 and is opened through rear wall 123 by a passageway 155.
As shown in FIGS. 5b and 5c, when engine 103 is pitched downward slightly at front wall 109 and drawer 105 is pitched upward slightly at rear wall 123, and hook 137 on engine rear wall 109 is inserted in hook-receiving opening 141, and then both drawer 105 and engine 103 are rotated toward a flat surface, as shown in FIG. 5c, connector arm 145 enters passageway 155, and latch 147 snaps into aperture 3 and becomes part of the floor of bin 133 that is located inside drawer rear wall 123 to temporarily lock engine 103 to dispensing drawer 105 in end-to-end fashion.
This is a unique aspect of the invention because it now means that dispensing drawers may be pre-loaded at a distance from cabinet 5, such as in a hospital pharmacy, the open top of bins 133 possibly sealed with a removable covering and then brought to and loaded into the cabinet and the seal removed. This reduces downtime at cabinet 5 and allows persons to merely pick up a sealed dispensing drawer, remove the top sealing film, if any, and load it directly into the dispensing drawer while simultaneously attaching it to engine 103.
To remove an empty drawer 105 from cabinet 5, latch 147 is merely pressed downward with the finger through aperture 153 and the drawer and engine pitched upward at coupling 135 to uncouple drawer 105 from engine 103. The close-fitting tolerances of latch 147, in latch-receiving aperture 153, retains dispensing drawer 105 in tight contact with engine 103.
As shown in FIGS. 6 and 7, a linear encoder 9 is provided in this invention and comprises a radiation source 161 and a pair of radiation receivers 163 and 165, the latter two preferably in close, spaced-apart arrangement and aimed downward in engine enclosure 106 through an aperture 167 formed in flat pan 115. Also as part of encoder 159 is at least one plurality of reflective areas 169 and non-reflective areas 171 arranged in a consecutive line or order under drawer 99 and spaced alternately along cabinet base wall 129 where drawer 99 moves along its path 175 during opening and closing in cabinet 5.
Radiation source 161 emits a beam of radiation, preferably in the ultraviolet range, downward through aperture 167 that strikes reflective and non-reflective surfaces 169 and 171 to provide a scattered return. Radiation receivers 163 and 165, spaced-apart from source 161 and from each other, receive some of the reflected radiation as drawer 99 moves along its path. The radiation receivers provide data used to determine the velocity of drawer 99 during its opening movement and its closing movement as well as its exact position in cabinet 5 at any given time. Further, the arrangement of receivers 163 and 165 also allows determination of the rate of change of velocity as drawer 99 is being pulled open. Two pluralities of areas 169 and 171 may be employed, as shown in FIG. 7, in spaced-apart arrangement. This extra or additional information is necessary to operate the drawer-opening mechanism and to prevent someone from attempting to by-pass the authorized opening distance of the drawer by trying to jerk it open to an extended opening for unauthorized access to deeper parts of the drawer
A drawer stop means 177 is shown in FIGS. 7-9 to comprise a plurality of cross-arms 179 set in consecutive order for contact with a trigger 181, as will be hereinafter more fully explained. Cross-arms 179 are preferably in the form of raised surfaces into which trigger 181 will drop and prevent drawer 99 from opening further. In the preferred embodiment shown in FIG. 7, drawer stop means 177 is in the form of a horizontal ladder 183, comprising a pair of side arms 185, arranged in spaced-apart relationship, and joined together by said plurality of the aforesaid cross-arms 179, leaving a plurality of apertures 180 in sequential order in the general form of a ladder, said ladder punched or stamped out of a piece of metal, such as steel, having a thickness of about 1/16 of an inch, and fastened to drawer support surface 129 by screws 187. Conveniently, linear encoder reflective areas 169 and non-reflective areas 171 are formed into thin paper or metal foil encoder strips 189 and are glued or otherwise attached along one side arm 185 of ladder 183 directly below the intake slot or eye of radiation receivers 163 and 165.
A controller 191 (see FIG. 6) is mounted apart from engine enclosure 106 and is connected to radiation receivers 163 and 165 by a wire cable 193 and mateable plug halves 195a and 195b, said cable carried in folded condition in a trough 197.
Controller 191 contains a read only memory (ROM), a random access memory (RAM), and other computer sub-components (not separately shown) that work, in conjunction with a software program, to initiate, control and terminate certain functions of this invention. Controller 191 receives the electronic signals from linear encoder 159 and other information from controller unit to allow drawer 99 to be pulled open a controlled distance for access to a partially or fully-filled bin 133.
As shown in Figures, an electrically-operated solenoid 201 is mounted in engine enclosure 106 and includes a solenoid coil 203 and a plunger 205 reciprocally mounted therein. Trigger 181, including a front edge 209, is attached to plunger 205 and arranged for pivotal movement, about a hinge 211, over an opening 213 formed in engine compartment pan 115, to be lowered into contact with cross-arms 179 to stop the withdrawal movement of drawer 99.
The arrangement of linear encoder 159, drawer stop means 177, and solenoid 201, with their associated hardware hereinbefore described, is only one of such engine arrangements. Other engine arrangements would be where linear encoder 159 is mounted on drawer 99, drawer stop means 177 is mounted in cabinet 5 and solenoid 201 is mounted on or in cabinet 5. All of these arrangements are fully contemplated in this invention and the above description should not be taken in any way as limiting the scope and spirit of this invention.
It is an object of this invention that pharmaceuticals and other medical supplies are stored in each bin 133 in mini-drawer 99 and the drawer is opened only far enough to allow these materials to be extracted from the first full or partially full bin therein. As the supplies are extracted, and the bins emptied, the drawer is allowed to be pulled open further and further to allow access to bins located deeper in the drawer. Controller 1 receives information, each time drawer 99 is opened, so that a running count is made of the materials extracted and of the materials remaining in bins 133 to which access has not yet been given. Upon subsequent opening of any particular drawer 99, this invention has the function of allowing unrestricted withdrawal of the drawer from cabinet 5 to a position exposing all empty bins 133, from which material and supplies have already been extracted, and stopping only when a first full or partially full bin 133 is exposed.
This invention also has the function of moving the appropriate mini-drawer 99 open a short distance out of cabinet 5 to provide the user with a visual indication that this particular drawer contains the items he or she desires. This is in marked contrast to the prior art device disclosed in U.S. Pat. No. 5,392,951 wherein a spring is used to power the drawer all the way from its fully-closed position to its fully-open and controlled position. It is not the practice of this instant invention to provide means for linearly moving the drawer to the fully-open position; it is left to the user to manually open the drawer after it is partially opened.
To provide this function FIGS. 10 and 11 show, a shaft 217 is slidably mounted in engine enclosure 106 for reciprocal motion, in the direction of drawer movement along path 175 in and out of cabinet housing 59, and passes through a first aperture 219 formed in rear engine wall 111, as shown in FIGS. 6 and 10. A first collar 221 is attached to shaft 217 to block rearward motion of said shaft to a controlled extent. A first spring 223 is formed around shaft 217 and is captured between a second collar 222 on shaft 217 and an apertured tab 225, through which shaft 217 is supported and passes. Each time mini-drawer 99 (engine enclosure 106) is closed into the cabinet, the rear terminal end 227 of shaft 217 strikes a portion of rear housing wall 228 and spring 223 is partially compressed. At the same time, trigger 181 is forced by a spring 233, stretched about solenoid shaft 205, into a downward position in locked engagement with cross-arms 179 (as shown in FIG. 8) and locks drawer 99 into closed position in housing 59 or the cabinet in which it is housed. Upon input of appropriate information in keyboard 13, controller unit 16 provides electronic signals to controller 191 and said controller energizes solenoid 201 to raise solenoid plunger 205 and pull trigger 181 out of contact with cross-arm 179. Thereupon, spring 223 is released from its constraints and allows shaft 217 to push drawer 99 open approximately one inch. Thereafter, the user manually pulls drawer 99 open using a front-mounted drawer handle 231.
In operation, upon receipt of the appropriate information via keyboard 13, solenoid 101 is activated by controller 191 and plunger 205 raises trigger 181 from interference or abutment against cross-arm 179 and spring 223 moves shaft 217 against cabinet rear wall 228 to move drawer 99 outward from the front wall of the cabinet, about an inch. The user then manually pulls the drawer further open using drawer handle 231 until controller 191 determines, from information programmed into its control unit 9 and from signals received from linear encoder 159, that the appropriate bin 133 has been uncovered. At this point, solenoid 201 is de-energized and spring 223 drives plunger 205 and trigger 181 downward into jamming contact with one of cross-arms 179 and prevents further opening of drawer 99.
Upon finishing removal of the items from bins 133 in drawer 99, the user begins to close it. Linear encoder 159 immediately determines the rearward movement of drawer 99 and signals controller 191 to energize solenoid 201 to raise plunger 205 and trigger 181 against the bias pressure of spring 223, out of contact with cross-arm 179 to allow drawer 99 to be closed. Linear encoder 159 determines when drawer 99 is about to reach full closure and signals controller 191 to de-energize solenoid 201 and allow spring 223 to bias trigger 181 back into contact with a cross-arm 179 to hold drawer 99 in locked position in cabinet 5. The compression of spring 223 during the final few centimeters of closing drawer 99 in cabinet 5 places a forward bias pressure on drawer 99 and reduces the incidence of slamming drawer 99 in cabinet 5. This compression of spring 233 provides the potential energy available to re-open drawer 99 approximately an inch, as aforesaid, the next time it is programmed to be opened. Accordingly, spring 223 serves a dual purpose in not only preventing or reducing the destructiveness of slamming a drawer closed, but also of storing potential energy necessary to partially open drawer 99 on its next programmed opening.
Any effort by the user to quickly pull the drawer outward, during drawer closure, or pull it quickly outward at any time will be noticed by linear encoder 159, using the calculated rate of change of acceleration from data furnished by radiation receivers 163 and 165 in picking up the passage of the radiation reflected from radiation surfaces 169. That information is used to signal controller 191 that will, in turn, determine that the rate of change of acceleration of the drawer has exceeded a pre-set value. Such information will immediately generate a signal to de-energize solenoid 201 and allow spring 233 to immediately push plunger 05 downward and drive trigger 181 into jamming relationship with a cross-arm 179. A visual or oral alarm, such as a message: "YOU HAVE PULLED THE DRAWER OPEN TOO RAPIDLY. PLEASE CLOSE THE DRAWER AND PULL IT OUTWARD MORE SLOWLY" may be programmed to appear on cabinet display 27 or other display or broadcast by electronic voice, to warn the user that h is or her activity has exceeded allowable tolerances.
Power failures are not uncommon in areas where this inventive device is useful. This invention contains the function to allow access to the drawers in the event of such an occurrence. As shown in FIGS. 10 and 11, a lever 239 is pivotally mounted at one end by a hinge pin 241 on engine side wall 113 and extends across engine enclosure 106 terminating at a distal end 243. Lever 239 has a second aperture 245 formed near distal end 243 through which shaft 217 passes. A second spring 247 is wrapped about shaft 217 and extends between hinge pin distal end 243 and a support wall 251 which forms a third aperture 253 through which shaft passes in reciprocal motion.
Second spring 247 is held in a partially compressed state between lever 239 and support wall 251 and the movement of shaft 217 during normal closure of drawer 99 serves not to disturb this partially compressed state. Further closure is prevented by a second shaft 255 spaced-apart from first shaft 217 in engine enclosure 106 and supported near its rear terminal end 257 by an aperture 258 formed in inset portion 259 of rear engine wall 111 and further supported near its front terminal end 261 by support wall 251 having an aperture 263 formed therein through which said second shaft 255 passes.
A spring 265 is wrapped about shaft 255 and captured between a collar 269, formed on shaft 225, and support wall 251. As shown in FIGS. 8 and 9, a pivot arm 271 is connected by a pin 273 to shaft front terminal end 275 and extends downward and is pinned to an arm 277 extending from trigger 181. When drawer 99 is closed against cabinet front wall 73, and shaft spring 223 is partially compressed against housing rear wall 228, second shaft rear terminal end 257 bottoms against a pin 279 extending forward from cabinet rear wall 228 (see FIGS. 10 and 11). This forward movement of shaft 269 causes pivot arm 271 to lift arm 277 thereby pivoting trigger 181 about hinge 211 and driving trigger front edge 209 down into jamming contact against cross-arm 179. This locking or jamming feature prevents any drawer from being pulled open because trigger 181 is placed in jamming contact with a cross-arm 179 when drawer 99 is closed against cabinet front wall 73.
As shown in FIGS. 10 and 11 second shaft 225 passes through an aperture 281 formed in lever 239, between hinge pin 241 and lever distal terminal end 243, wherein the tolerances for aperture 281 are set close to the outside diameter of second shaft 225. This results in a jamming condition existing between lever 239 and second shaft 255 when lever 239 is biased rearward by second spring 247. This jamming condition holds second shaft 255 in a forward, and preferably in a forwardmost, configuration with spring 265 being heavily compressed.
Upon the occurrence of a power failure, the drawers remain locked in the cabinet and cannot be accessed by anyone. To place the drawers in a releasable configuration, a lever or other graspable element 285, preferably located at the rear of cabinet 5, is displaced, either by moving it outward, inward, upward, downward, or to one side or the other. This movement displaces pin 279 to one side of second shaft rear terminal end 257 and into alignment with an aperture 287 formed in inset wall portion 259. Prior to this situation occurring, drawer 99 could not be pushed into cabinet 5 any further, in its closed configuration, because of the abutting of pin 279 against second shaft rear terminal end 257 that was fully displaced in its forwardmost position. Now, with the removal of pin 279 from that abutment position, the user may open any drawer by merely pushing the drawer inward a short distance, for example, 1/4 of an inch, to push first shaft 217 slightly forward so that collar 221 comes into contact with the rear side of lever 239. The slightly forward movement of collar 221 against lever 239 pivots lever 239 forward about hinge pin 241 and releases the jamming contact between second shaft 225 and lever 239. Immediately, the loss of jamming contact allows second shaft 225 to trip out of its jammed condition and move rearward thereby straightening pivot arm 271 to press 9 downward on arm 277 and pivot trigger 181 about hinge 211 and out of jamming condition with cross-arm 179.
In operation, upon the occurrence of a power failure, the exterior of cabinet 5 remains absolutely unchanged. The displaced movement of lever 285, preferably at the rear of cabinet 5, still does nothing to change the exterior configuration of cabinet 5. However, any drawer that is to be opened may be opened by merely pressing against the drawer and displacing it slightly into cabinet 5. When releasing pressure on the drawer, it will be propelled by spring 223 outward approximately an inch to an inch-and-a-half and may be opened to extract the contents from any of the bins. However, when that particular drawer is pushed closed, it will not lock in cabinet 5 but will remain unlocked and positioned outward approximately one inch to an inch-and-a-half and remain in that configuration until power is restored. Once power is restored and lever 285 moved back to its original position, all the drawers in cabinet 5 will once again be securely locked, except for the drawer or drawers that were open during the power failure by pushing the drawer slightly inward as aforesaid. Accordingly, this unique feature of the invention permits a ready observation of what drawers have been opened during a power failure and the security of the contents in those particular drawers may be assessed. Should lever 285 not be moved during a power failure, then, upon the resumption of power, cabinet 5 will continue to remain totally locked and secure from unwanted entrance.
One of the overriding considerations of this invention is that it provides controlled access to the materials stored in the bins of each drawer. Accordingly, it is necessary to insure the continued security of the cabinet and of the items stored therein during transient periods when one or more mini-drawers 99 are removed therefrom for purposes of loading new supplies in the bins formed therein, either at the site of cabinet 5 or at a remote location. As previously disclosed, the entire mini-drawer 99 is comprised of an engine 103 attached in a nose-to-tail arrangement with a dispensing drawer 105 with engine 103 at the rear of the arrangement. When dispensing drawer 105 is removed from cabinet 5, through the use of coupling 135, engine 103 remains in cabinet 5. It is imperative that engine 103 not be able to be removed or pushed inward cabinet 5 to create an accessible opening into the interior of cabinet 5 while at the same time it is imperative to be able to remove engine 103 from cabinet 5 for purposes of maintenance, etc., upon demand.
A unique feature of this invention is shown in FIGS. 7 and 12 wherein ladder 183 terminates, at its forwardmost end 289, in a hook 291 and relief area 293. In the forward end of engine enclosure 106 is a latch 295 pivotally mounted by a center pin 297 on engine pan 115 and biased by a spring 301 into a counterclockwise position and retained therein by a pin 303 extending upward from flat pan 115. A trigger 305 extends downward from the rear of latch 295 while a tab 307 extends upward from the forward part of latch 295 inboard of engine front wall 109. An aperture 309 is formed in engine front wall 109 near tab 307 to provide access forward of engine 103 to said tab by virtue of a tool such as a screwdriver (not shown).
In operation, and when engine 103 is attached in end-to-end fashion with dispensing drawer 105 at coupling 135, upon the full withdrawal of dispensing drawer 105, trigger 305 comes into contact with the rear wall 313 of hook 291 that extends further outward from ladder 183 than side arms 185. This contact prevents anyone from pulling engine 103 out of cabinet 5. Engine 103 may be removed through the front of cabinet 5 by first disconnecting drawer 105, as previously disclosed, and secondly by inserting a screwdriver or other such tool into aperture 309 and moving tab 307 to the left thereby pivoting trigger 305 clear of hook 291 and withdrawing said engine using latch 147 as a handle.
In addition, and significantly important, is the fact that once drawer 105 is pulled out of cabinet 5 and disconnected from engine 103, engine 103 may not be pushed back into cabinet 5, so as to provide an opening for a small-handed person to reach into cabinet 5 and extract pharmaceuticals therefrom, because trigger 305 is displaced slightly in a counterclockwise direction during the uncoupling and any attempt to push engine 103 back into cabinet 5 will cause trigger 305 to come into contact with rear wall 315 of relief area 293 and bar such movement. A protrusion 317 extending rearward of the rear wall 319 of dispensing drawer 105 contains a ramp 321 that comes into contact with tab 307 during coupling of engine 103 with drawer 105. Ramp 31 pivots trigger 305 out of contact with relief rear wall 315 but not far enough to clear said trigger from hook 291 thereby allowing drawer 105 to be pushed, along with engine 103, back into its cavity in cabinet 5. This configuration prevents unwarranted entrance into cabinet 5 as hereinbefore set forth.
As shown in FIG. 13, engine 103 may be coupled with dispensing drawers 105 of different widths and heights to make engine 103 extremely versatile. As shown in FIG. 13, engine 103 is coupled with a dispensing drawer 105 having approximately three times the width of drawer 105 shown in FIGS. 5a, 6, 8, and 9. In this situation, engine 103 may be coupled along its sides with spacers or outriggers 323 as shown. Spacers 323 do not provide engine room or extra storage space, but merely render engine 103 compatible with the extended width of drawer 105.
As shown in FIGS. 10 and 11, a pin 327 extends outward a short distance from rear engine wall 1and terminates at a distal end 239. Pin 37 is positioned for the purpose of indicating when drawer 99 is fully closed in cabinet 5. This is done by arranging a radiation transmitter 331 on one side of a detent 333 in rear housing wall 228 and a radiation receiver 335 on the opposite side of detent 333 and allowing a beam of radiation to pass therebetween. When drawer 99 is fully closed into cabinet 5, pin 327 enters detent 333 and pin end 329 passes between radiation transmitter 331 and radiation receiver 335 to interrupt said beam, thereby indicating the position of mini-drawer 99 in cabinet 5. Upon interruption of the beam, solenoid 201 is energized through control unit 16 and controller 191 to advance trigger 181 into jamming position between cross-arms 179. This jammed, closed position of drawer stop means 177 remains as a primary drawer-locking system while bias spring 233 acts as a mechanical backup for the same function.
While the invention has been described with reference to a particular embodiment thereof, those shilled in the art will be able to make various modifications to the described embodiment of the invention without departing from the true spirit and scope thereof. It is intended that all combinations of elements and steps which perform substantially the same function in substantially the way to achieve substantially the same result are within the scope of this invention.
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A drawer operating system for controlling a drawer having a sliding direction, the drawer defined by a front end and a rear end and partitioned by walls into a plurality of bins consecutive with one another along the sliding direction for holding various dispensable items, the drawer housed in a cabinet and arranged to move between a closed position and graduated, progressively open positions to allow access to one or more bins and the contents stored therein, the system including a linear encoder for monitoring the position and direction of movement of the drawer, including the length of opening the drawer on its preceding excursion, and for producing a plurality of electronic signals specific to the position and movement of the drawer, a drawer stop device arranged between the drawer and the cabinet, a controller for receipt of the electronic signals, and an electric solenoid, including a spring-loaded plunger slidingly mounted therein, for activation by the controller, after the beginning of the drawer-opening sequence, and during translational movement along the drawer stop device to drive a trigger attached thereto into contact with the drawer stop device to prevent the drawer from being manually opened beyond a certain distance out from the cabinet wherein a bin containing the items to be withdrawn is exposed.
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[0001] This application claims priority of Provisional Application No. 60/847,305 filed Sep. 26, 2006. The subject application is also related to the following applications:
[0000] Knit Elastic Mesh Loop Pile Fabric for Orthopedic and other Devices
[0000] 60/847,186 filed Sep. 26, 2006; U.S. patent application Ser. No. ______ filed ______,
[0000] Improved High Performance Fire Resistant Fabrics and the Garments Made Therewith
[0000] 60/847,002 filed Sep. 25, 2006; U.S. patent application Ser. No. ______ filed ______, and
[0000] Under Body Armor Cooling Vest and Fabric Thereof
[0000] 60/847,307 filed Sep. 26, 2006; U.S. patent application Ser. No. ______ filed ______.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a fabric for protection against electrical arc hazards, and, more particularly, to a fabric that is both highly visible and which reduces the hazards of electrical arcs.
[0003] A. Garment Visibility
[0004] Personnel employed in all modes of traffic control, utility and survey work, emergency response, construction, equipment operation and vehicle roadway traffic are exposed to accident hazards due to insufficient conspicuity of ordinary workwear worn by them. These hazards are due to the workers' low visibility, which are intensified by the often complex and varying backgrounds of the above mentioned occupations and job assignments.
[0005] A major hazard issue involves situations in which objects can be visible, but are not consciously recognized by the vehicle driver within sufficient time to take corrective action in order to avoid an accident. This conscience recognition is often influenced by the level of task activities, varying daytime or nighttime lighting conditions, the complexity of backgrounds, vehicle speed and the visual performance of the operator. Thus, worker safety is compromised by insufficient decision/reaction time resulting from the use of workwear not designed to provide sufficient visibility. It is thus important that workers are readily perceived by drivers when, for example, directing traffic, operating equipment, digging roadside trenches and doing maintenance work.
[0006] In order to reduce hazards to which the workers are exposed in performance of their tasks, special high visibility garments are available for their protection. These are covered by the requirements of both the American National Standard Institute (ANSI) and ISEA—The Safety Equipment Association. The garments may take the form of a coverall, jacket, vest, trousers, harness/sash belt and others, depending on the work performed by the wearer.
[0007] Fluorescent dyed materials emit optical radiation at wavelengths longer than absorbed. They enhance daytime visibility, especially during dawn and dusk. Accordingly, garments may be provided with strips of retroreflective material placed in appropriate locations in order to enhance their conspicuity. Such retroreflective materials have the property of returning light to its source.
[0008] Garments instead may be made with a fabric dyed with one of three approved fluorescent colors; such colors are intended to be highly conspicuous to ensure visibility against most backgrounds found in urban and rural situations. The three colors are: yellow-green, orange-red and red. The chromaticity (the x and y coordinates) and the minimum luminance factor are stipulated by ISEA standards (see TABLE 1 and 2), as are all the fabric parameters applicable to the fabric. Performance requirements of garments must be tested and verified for conformance with these standards by an accredited testing lab.
[0009] Fabrics currently in use in high visibility garments are of the woven type. While such fabrics are adequate in performance, they leave much to be desired in wearing comfort, durability and economics. Particularly, woven fabrics are, by their nature, tightly configurated in their system of warp and filling threads. This limits the air permeability and hence the comfort factor, which is of a particular importance for workers exposed to the sun for prolonged periods of time.
[0010] Woven fabrics that meet the ISEA performance requirements are relatively stiff and, therefore, to some extent, inhibit the garment wearer's freedom of movement. Also, woven fabrics are prone to ripping, tearing and fraying. This limits the useful life of the garment, which suffers much physical stress when worn at high rough work sites. Finally, there is the question of economics. Woven fabrics that meet the ISEA standards are relatively expensive due to the cost of suitable yarns and the involved processing cycles.
[0011] B. Electrical and Thermal Discharge
[0012] In addition to the problem of personnel workwear and insufficient conspicuity, workers attending to electrical utility lines and related equipment are also exposed to the risk of electrical arc flash hazards, against which such workwear must provide adequate protection.
[0013] In particular, electrical utility linemen, industrial electricians, electrical contractors and electrical service personnel are routinely exposed to the momentary electric arc flash and its related thermal hazards. As a consequence, many workers have been electrocuted, burned or severely injured. In fact, recent U.S. Department of Labor statistics identified electrical workers as being the 3 rd most dangerous profession.
[0014] An arc flash is the explosive release of energy caused by the passage of electrical current between two electrodes through ionized gases or plasma, characterized by a temperature reaching several thousands degrees centigrade. As workers perform their tasks on or near energized wire systems or circuitry, an arc flash may occur as a result of their inadvertent movement, accidental contact or some equipment failure. The electrical energy supplied in the forming arc is converted into an explosive fireball-like phenomenon that is likely to impact or even envelop the worker. The resultant explosive effect of the arc produces intense thermal radiation, noise, melting and even vaporization of metal components of the equipment around the arc. Depending on the severity of the arc flash, burns will occur on bare or unprotected skin. Also, if the worker is wearing non-flame retardant clothing, the arc is likely to ignite it.
[0015] Thus, to provide a safer workplace for the utility workers, the NFPA (National Fire Prevention Assn.) has issued a standard NFPA 70 E-2000 for electrical safety requirements. The standard calls for protective clothing to be tested and rated to the level of the arc flash energy hazards to which the electricity workers could be exposed.
[0016] In addition to the dangers posed by electrical arc discharge, utility workers are also exposed to thermal hazards from the heat of the flash fires caused by ignited gas, combustible vapors, volatile solvents or chemical dust. Flash fires are defined as those lasting no more than three seconds.
[0017] Thus, thermal performance of garments is covered by the AMTM (American Society for Testing Materials) test F 1950, which uses the electric arc to determine the number of calories required to create second degree burns in terms of calories per square cm. There is also an ASTM F 1506 standard for clothing worn around electric arc hazards.
[0018] Yet another consideration in the production of utility workers' protective garments is the hazard of static electricity spark discharge. Such discharge is likely to ignite a flash fire of the kind mentioned above. Static electricity charges of several thousands volts may be generated simply by rubbing one part of the garment against another or against a car seat or a plastic object. These charges can create a spark of sufficient length to ignite gas, fuel vapors, solvents, etc., thus causing a flash fire.
[0019] Yet a further hazard to utility workers is when they come close to high tension equipment such as transformers, switchgear, overhead wires, etc.—the corona discharge. Such discharge occurs from electrodes with sharp points or angles. It is due to the ionization of the air surrounding these points, which makes possible the escape of electrical energy through the air. Corona discharge takes the form of luminous glow; the higher the voltage the more intense the corona discharge. Corona discharge can be hazardous to utility workers servicing high tension installations where the coronal discharge may induce dangerous levels of electrical energy flux in the workers apparel.
[0020] At the present time, protective garments are made with densely woven, heavy fabrics using flame resistant fibers such as modacrylic, Kevlar, Nomex, PBI, FR rayon and others. These fibers not only must withstand the very high arc temperature for a brief span of time, but must also be resistant to melting and dripping, which can cause severe burns. A frequently used fiber in garments is modacrylic spun into medium count yarns. Modacrylics are the copolymers of acrylonitrile fibers, which are very difficult to ignite and have self extinguishing properties. These fibers also have good weathering properties, resistance to acids, alkalis and wide range of chemicals. Their dielectric strength exceeds 1500 volts per mil. of plastic film, which constitutes an important consideration in electrical applications.
[0021] A distinct advantage of modacrylic yarns is their relatively moderate price in comparison with other types of yarns available on the market. Modacrylics feature also superior processability during manufacture.
[0022] Nonetheless, woven fabrics incorporating flame resistant fibers and used in making electric arc protective garments are less than desirable. In the first place, since woven fabrics must be dense and tightly constructed in order to preserve their structural integrity. They have reduced porosity properties, resulting in reduced wearing comfort. In a warm environment, for example, garments made with such fabrics may feel excessively hot and clammy. The consequence being that some workers avoid wearing them altogether. Also, relative stiffness of woven fabrics and the lack of any “give” encumber the freedom of movement of the garment wearer.
[0023] In addition, weaving is essentially a slow process and generally limited to narrow width fabrics. This causes wovens to be relatively expensive in comparison with other fabricating systems like warp and weft knitting.
[0024] Furthermore, woven fabrics have a propensity to distort, rip and fray. Because the yarn components of warp and weft are held in the structure by frictional forces only, there is a tendency for them to slip on each other and distort the fabric in forming cracks and open areas on its face. In that regard, the peculiar geometry and interlacing of the yarn components of woven fabrics renders them susceptible to ripping. Thus, even a minor cut or puncture in the garment caused by a sharp part of the equipment can propagate itself into a long tear or rip, thereby destroying the garment.
[0025] A related problem with woven garments is seam failure. This may be caused by the problem of fraying of the threads from a cut edge of the fabric. This may produce seam failure due to the individual fabric threads “combing out” from the seamed edge. Seam failure may have serious consequences in that it could allow the heat flux of the electric arc to penetrate inside a protective garment so as to cause burns to its wearer.
[0026] Accordingly, it would be desirable to provide a fabric or garment which overcomes the above disadvantages.
SUMMARY OF THE INVENTION
[0027] Generally speaking, in accordance with the invention, an improved knit fabric system for protecting against electrical arch hazards and promoting garment visibility is provided. The inventive knit fabric is either a solid fabric substrate or of a mesh construction and consists predominantly of high performance yarns that are resistant to melting, dripping and burning at high temperatures. The knit fabric absorbs the thermal energy of an electric arc and, especially for the mesh construction, absorbs thermal energy or heat flux to prevent garment combustion.
[0028] In accordance with the invention, either the solid or mesh version of the inventive knit fabric incorporates conductive fibers for draining away and thereby dissipating accumulated electrical charges. Such conductive fibers are incorporated into the fabric of the invention by either being knitted into the fabric as it is formed or by the process of yarn spinning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a fuller understanding of the invention, reference is now made to the following drawings in which:
[0030] FIG. 1 depicts one form of the inventive fabric in which the conductive yarns are arrayed in a diamond-like configuration; and
[0031] FIG. 2 depicts a second form of the inventive fabric comprising a mesh construction.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The fabric of the invention is a knitted fabric produced on either a warp or weft knit system. For warp knits, suitable equipment is either tricot or Raschel machine of a suitable gauge. For weft knits, suitable equipment is either a circular or flat knitting machine. The circular machines may be in 16-18 cut (needles per inch) with the interlock or double knit needle set out.
[0033] In the embodiment with a mesh design, making mesh fabric utilizing circular weft knit machine involves pelerine transfer stitch technology, as is well known in the art; this creates eyelets through the transfer of sinker loops.
[0034] The warp knit version of the inventive fabric is preferred due to its superior physical characteristics. This is because warp knit mesh fabrics are more stable and run-resistant that their weft knit counterparts. Warp knit fabrics can also be made in a much wider variety of mesh openings than is possible for weft knit fabrics. Further, warp knit mesh fabrics are, in general, easier and more economical to construct.
[0035] The yarns used in the inventive fabric are high performance yarns such as those that are resistant to melting, dripping and burning at high temperature conditions (at least 700° F.). The high performance yarns are present in the inventive fabric in an amount between about 85% and 95% weight percent. The preferred high performance yarns are spun modacrylics. Modacrylics are polymers that have between 35 to 85% acrylonitrile units, and which may be modified by other chemicals such as vinyl chloride.
[0036] The choice of modacrylic fibers or yarns for application in the fabric material of the invention is based on their excellent fire retardancy performance combined with their non-melt, non-drip and self-extinguishing properties. These are critically important attributes in many working environments. If sufficiently high temperatures are reached on exposure to fire or explosion, a garment made with the inventive fabric will just carbonize by forming a protective charred barrier. This prevents propagation of flames, thereby protecting the wearer from severe burn injuries.
[0037] Modacrylics have a high so-called LOI value as compared with other fibers. The LOI represents the minimum oxygen concentration of an O 2 /N 2 mix required to sustain combustion of a material. The LOI is determined by the ASTM Test D 2862-77. Modacrylics have an LOI value preferably between about 28 and 33 while conventional polyesters have a much lower value of 20-22.
[0038] Additionally, a very important aspect of wearing comfort is the so-called “moisture management” factor. This is often represented as the moisture vapor transport index of MVT, which reflects the efficiency in which a fabric moves perspiration away from the skin or underlying garment and causes it to evaporate into the ambient atmosphere. The MVT of the modacrylics used in the inventive fabric is approximately 2500 g/meter squared/24 hours ASTME96.
[0039] Modacrylics are spun from an extensive range of copolymers of acrylonitrile. The types of modacrylic fibers that can be produced within this broad category are capable of wide variation in properties, depending on their composition. Some examples of commonly available modacrylics are: “Vere” by Eastman Corp., “Creslan” by Am Cyanamic Co., “Acrillan” by Mosanto Corp., “Kanecaron” by Kaneka Co. and “Orlon” by DuPont Co.
[0040] Modacrylic fibers used in the inventive fabric preferably have a tenacity of up to 2.8 grams/denier, an elongation at break of between about 35 and 40%, and a fusing temperature of between about 371 and 410° F. The modacrylic fibers used in the inventive fabric also have a moisture regain (the amount of water by weight held by the fiber under controlled atmospheric conditions) of between about 0.4 and 4.0%.
[0041] Modacrylic fibers and yarns are moderately priced as compared with other materials of good thermal performance. They are readily available in the industry; they have good knitting performance, ease of fabric processing and dyeing.
[0042] A significant attribute of modacrylics is their charring on prolonged exposure to flames, rather than simply burning and dripping. The charred portions of the fabric protect the wearer from the effects of fire.
[0043] Other high temperature resistant (high performance) fibers or yarns may also be used in the inventive fabric, either in combination with modacrylics or entirely on their own. One such fiber comprises aramid fibers, such as Kevlar and Nomex. Such fibers feature excellent thermal thermal stability and are virtually non-flammable. These fibers have a very high resistance to heat and are resistant to melting, dripping and burning at a temperature of at least 700° F. Moreover, their LOI value is preferably in the range of between about 28 and 30.
[0044] Kevlar, made by Dupont Co., is a para-aramid fiber having a very high tenacity of between 28 and 32 grams/denier and outstanding heat resistance. Other para-aramid fibers suitable for the inventive fabric include Twaron by AKZO Co. and Technora by Teijin Co.
[0045] Another type of aramid fiber suitable for the inventive fabric is “Nomex”, made by DuPont and “Conex” made by Teijin Co.
[0046] Yet other types of flame resistant fibers are organic fibers composed of polybenzimidazole, such as PBI made by Celanese Corp. These fibers have an LOI of between about 35-40 and are resistant to melting, dripping and burning at a temperature of at least 750° F.
[0047] Further high temperature resistant fibers or yarns may comprise certain polyester yarns that are resistant to melting, burning and dripping at a temperature of at least 700° F.
[0048] In general, the high performance yarns used in the inventive fabric have a yarn count of between about 12/2 c.c. and 32/2 c.c. (two ply yarn).
[0049] In accordance with the invention, the modacrylic or other high performance fibers are blended with from between about 3 and 5 weight percent of conductive fibers in order to impart anti-static properties to the fabric. Such fibers are available from several sources. The conductive yarn fibers are preferably intermixed with the high performance yarns; in other words, the conductive yarns are knitted together with the high performance yarns.
[0050] One example of such conductive fiber is Negastat® produced by DuPont & Co. This is a carbon fiber comprising a carbon core of conductive carbon surrounded by non-conductive polymer cover, either nylon or polyester. Another example is Resistat® made Shakespeare Conductive Fibers LLC. This is a fiber where the fine carbon particles are embossed on the surface of a nylon filament. The yarns of both such fibers are available in a denier of at least 40.
[0051] Instead of conductive fabric fibers, one may use a very fine wire made of steel, copper or other metal. By way of example, a steel wire suitable for use in the inventive fabric is available under the names Bekinox and Bekitex from Bekaert S.A. in a diameter as small as 0.035 millimeter.
[0052] A very effective conductive fiber that is suitable for the inventive fabric is the product X-static made by Noble Fiber Technologies. This is a nylon fiber coated with a metal layer, namely a silver layer; it provides excellent static draining performance as well as germicidical properties. The latter prevents development of objectionable odors. The X-static fibers are blended with modacrylics in the process of yarn spinning. A content of between about 3 and 5% of the X-static in the inventive fabric is sufficient to substantially control the static problem. The X-static fibers in the fabric must meet the standards of static control set forth by Noble Fiber Technologies, Inc.
[0053] The conductive fibers may be introduced in the inventive fabric from warps or individual packages placed on a creel, the latter being the case with circular knitting system. For warp knits, one or two guide bars threaded with the conductive yarns may be employed. These bars could move in a zigzag or diamond configuration in order to provide optimum anti-static coverage.
[0054] In the one preferred embodiment of the present invention, the conductive yarns are arrayed in a diamond-like configuration (See FIG. 1 ). This provides optimum anti-static protection for the entire fabric surface.
[0055] In a second preferred embodiment, the inventive knitted fabric is a knitted mesh. The advantages of such a mesh construction include increasing the permeability of air so as to enhance evaporation of perspiration. This significantly improves wearing comfort, especially in heat stressful applications. The presence of mesh openings in the inventive fabric also contributes to improved visibility by breaking up the fabric texture.
[0056] The mesh openings should have a mesh count of between about 3 and 5 meshes/inch in width and between about 4 and 6 meshes/inch in length. Larger mesh openings will adversely affect the chromaticity and conscupicuity characteristics of the fabric. An embodiment of the inventive warp knit fabric having a mesh construction is shown in FIG. 2 .
EXAMPLE 1
[0057] One type of warp knit fabric according to the present invention contains the following yarns:
30/1's c. modracrylic (90%), polyester (10%) blend—to produce the ground fabric; and
[0059] 30/1's c. modacrylic (87%), polyester (8%), X-static (5%) blend—to produce the diamond overlay for anti-static protection.
KNITTING CONSTRUCTION DETAILS Beam Inches Ends Number Rack Total Yarn 1(front) 90″ 234 30/1 Modacrylic (87%) 2 90″ 234 30/1 Modacrylic (87%) 3 90″ 2340 30/1 Modacrylic (90%) 4 156″ 2340 30/1 Modacrylic (90%) (back)
[0060] The threading chart for Example 1 is as follows:
Bar 1 (front) ....................| .........| ....|............. 1 ..... Bar 2 ............|.......| .........| .................. 0 ..... Bar 3 ...........|||||||||| |||||||||| ||||||||||.......... 1 ..... Bar 4 ...........|||||||||| |||||||||| ||||||||||........ 3 .....
[0061] Stitch construction for example, is as follows:
BAR 1 BAR 4 (front) BAR 2 BAR 3 (back) 1-0 6-7 1-0 3-4 1-2 6-5 1-2 1-0 2-3 5-4 3-4 4-3 4-5 3-2 5-6 2-1 6-7 1-0 6-5 1-2 5-4 2-3 4-3 3-4 3-2 4-5 2-1 5-6
[0062] The finished fabric of Example 1 has a width of 2×60 inches, a fabric weight of 6.5 oz/square yard and a count of 27 courses/inch×18 wales/inch.
[0063] In Example 1, the finished fabric is jet dyed to the desired color and then stabilized and set by tenter framing at a temperature of 250° F. at the speed of 15 yds/min.
EXAMPLE 2
[0064] Another type of warp knit fabric according to the present invention contains the following yarns:
30/1's c. modacrylic (90%), polyester (10%); and 30/1's c. modacrylic (87%), polyester (8%), X-static (5%) blend.
[0067] The fabric in Example 1 is produced on an 18-20 gauge, tricot or raschel machine.
[0068] In constructing the fabric of Example 1, the threading is 5 in, 1 out for both back guide bars and 1 in, 5 out for both front guide bars.
[0069] The threading chart for Example 2 is as follows:
Bar 1 ........||||.....||| .||||| .|||||.|||.... (back) Bar 2 ........||||||.||||| .||||| .|||||.|||.... Bar 3 .............|.....| .....| .............. Bar 4 .................... .|.... .|............ (front)
[0070] Stitch construction for Example 2, is as follows:
BAR 1 BAR 4 (back) BAR 2 BAR 3 (front) 4-5 1-0 6-7 1-0 4-3 1-2 6-5 1-2 4-5 1-0 6-7 1-0 3-2 2-3 4-3 3-4 1-0 4-5 1-0 6-7 1-2 4-3 1-2 6-5 1-0 4-5 1-0 6-7 -3 3-2 -4 4-3
[0071] The finished fabric of Example 2 has a width of 60 inches and a weight of 6 oz/yd squared. Moreover, the finished fabric has a mesh count of 4 holes per inch in width and 5 holes per inch in length.
[0072] In Example 2, the finished fabric is jet dyed to a desired color and then stabilized and set by tenter framing at a temperature of 335° F. at the speed of 15 yds/min.
[0073] In general, the knitted fabric of the invention is advantageous over their prior art woven counterparts.
[0074] For example, knit fabrics, but the virtue of their inherent stretch, elasticity and porosity, are more comfortable to wear than wovens. Both stretch and porosity parameters of knit fabrics may be engineered into the structure to the required degree. The stretch factor contributes to the freedom of movement and comfort of the protective suit wearer, an important consideration for workers. Knitted fabrics are also cheaper to produce than woven fabrics due to substantially higher manufacturing rates of the knitting equipment. Also, the wider width of knit fabrics improves processing economics and reduces the cutting waste in garment manufacture.
[0075] Knit fabrics, by the virtue of their locked loop structure, do not rely on friction between the yarn members of the structure to preserve the fabric integrity. Consequently, there is not fraying from cut edges of the fabric, no ripping from holes or tears, and no distortion due to slippage of the yarn members.
[0076] Furthermore, the so called “overlock” seam used on knit fabrics is superior to what is found in wovens. The “overlock” seam has a system of three sewing threads, which together securely encase the seam in a triple-laced thread system so as to hold it securely in place regardless of the stresses and strains imposed during the course of wearing the garment.
[0077] Moreover, because knit structures are interlooped and therefore not subject to any slippage of constituent threads, mesh fabrics may be constructed with greater ease and economy on a knit basis, especially of the warp type. The latter allows for making the mesh openings into any desired size and shape.
[0078] And by no means of least importance, knit fabrics, in contrast to woven fabrics, allow for the ready introduction of conductive yarns into the thread structure. This is because a weaving system involves the use of one type of yarn that is put up on the beam of a loom. Therefore, to introduce other yarns of different size and characteristics in the weaving process requires setting up a cumbersome external creel in order to accommodate the yarn packages. This in turn impairs the weaving process, thereby causing weaving defects. In contrast, for warp knitting, the different yarns are put up on separate beams and thus carried on appropriate guide bars.
[0079] The scope of the invention will now be set forth in the following claims.
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An improved knit fabric system for protecting against electrical arch hazards and promoting garment visibility is provided. The inventive knit fabric is either a solid fabric substrate or of a mesh construction that absorbs the thermal energy of an electric arc and, especially for the mesh construction, absorbs thermal energy or heat flux to prevent garment combustion. The solid or mesh version of the inventive knit fabric incorporates conductive fibers for draining away and thereby dissipating accumulated electrical charges. Such conductive fibers are incorporated into the fabric of the invention, by either being knitted into the fabric as it is formed or by the process of yarn spinning.
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FIELD OF THE INVENTION
[0001] The present invention relates to the recovery of gases, and more particularly to the recovery of helium gas in the cold spray forming process.
BACKGROUND OF THE INVENTION
[0002] Helium is the gas of choice for cold spray forming (CSF) process. However, the use of helium is economically prohibitive without sufficient helium recovery.
[0003] Generally, high velocities are necessary to accelerate the CSF powder towards the work piece. At 5 mole % nitrogen in helium, the sonic velocity will drop 8%. If the nitrogen concentration increases to 20 mole %, then the sonic velocity will reduce 33%. If a heavier impurity such as carbon dioxide reaches 20 mole % with the balance helium, then the sonic velocity will be reduced 43%. High gas velocities possible with pure helium are a desirable physical property regardless of the specific CSF application.
TABLE 1 Sonic Velocity as a Function of Gas Composition Carbon Sonic Helium Nitrogen Water Dioxide Velocity Mole % Mole % Mole % Mole % Temp. (F.) (Ft/sec) 100 0 0 0 100 3958 95 5 0 0 100 3467 90 10 0 0 100 3120 85 15 0 0 100 2859 80 20 0 0 100 2653 95 0 5 0 100 3645 95 0 0 5 100 3225 90 0 0 10 100 2788 85 0 0 15 100 2489 80 0 0 20 100 2267
[0004] CSF is a newly developed technology that as of this writing has not been made commercial. CSF can be compared to thermal spraying (TS) with a primary difference being the nozzle gas temperature. TS uses particle velocity combined with thermal heat to form a coating on a work piece. A description of both processes will show a problem associated with TS that is solved with CSF and why helium was not used before and is the gas of choice for CSF.
[0005] [0005]FIG. 1 shows a schematic of the equipment enclosure for CSF and TS. One TS application is plasma spray. Passing gas through an electric arc inside nozzle 14 forms the plasma. Thus, for TS, nozzle 14 , must be water cooled or contain refractory to permit high temperatures. The expected life for nozzle 14 is usually less than 100 hours. Gas and powder pass through nozzle 14 to form spray pattern 16 . Typical nozzle gases could be a mixture of argon and hydrogen. In spray pattern 16 the hydrogen will combust to add additional heat to the powder. The powder will partially or completely melt in spray pattern 16 before hitting work piece 18 and forming a coating on work piece 18 . Care must be taken that work piece 18 does not become too hot or the coating applied too thick. If the coating is too hot or applied too thick, then the coating will crack upon cooling. Care must also be taken in selecting the powder particle size. If the particle size is too small, then losses from vaporization will be economically prohibitive. Spray pattern 16 uses gas velocity and density to accelerate the particle at work piece 18 . High temperatures present in spray pattern 16 decrease gas density which minimizes the impact of gas velocity on particle velocity. TS particle velocities of up to 200 m/s could be expected. Helium can provide higher gas velocities but the density would be substantially lower.
[0006] TS may require that a separate fluid be used to cool work piece 18 . The separate fluid could be liquid carbon dioxide or water. Air is also passed through enclosure 12 through gas inlet 22 . A high volume of air passes over work piece 18 and removes excess powder that did not adhere as the coating. The air and powder exhaust from enclosure 12 through gas discharge port 20 . If helium were used in nozzle 14 , then using air to sweep work piece 18 would make helium recovery and purification difficult and expensive.
[0007] CSF differs from TS in that at ambient temperatures the powder can be accelerated with helium to about 1000 to about 1200 m/s in nozzle 14 to work piece 18 . CSF temperatures in nozzle 14 , typically less than about 400° F., allows the use of particulate less than 20 micron in size and containing volatile alloying elements. The high velocities capable with helium give the particles sufficient energy to fuse into a coating when striking work piece 18 . The resulting coating does not cause work piece 18 substrate to change as could happen if it was exposed to TS temperatures. Helium is also passed through inlet 22 to sweep over work piece 18 and remove excess powder. The helium and powder discharge from enclosure 12 through vent 20 to helium recovery and purification equipment. In CSF, helium ultimately serves two functions. One, it accelerates the coating powder, supplying kinetic energy. Two, it serves as a clean sweeping gas to clean the work piece of extraneous particles.
[0008] No known helium recovery system is believed to exist for CSF. The absence of helium recovery systems for CSF is not surprising because current CSF processes are lab scale and use small quantities of helium. However, other processes that use larger volumes of helium have helium recovery systems.
[0009] U.S. Pat. No. 5,377,491 discloses a coolant gas recovery process for a fiber optic cooling tube that uses a vacuum pump/compressor to remove cooling gas from the cooling tube, remove particulate and contaminants and then return the coolant gas to the fiber optic cooling tube. Purification equipment such as pressure swing adsorption, dryer and membrane are discussed with respect to removing water and oxygen, with the maximum quantity of oxygen in the range of 1 to 50 mole percent, and the cooling tube required to cool gas at 0 to 150 psig.
[0010] U.S. Pat. No. 4,845,334 discloses a plasma furnace gas recovery system where the gas exits the furnace at high temperature (˜700C.) and low pressure (<2 psig). The discharge gas is cooled and then followed by particulate removal equipment. The particulate free gas is then compressed, filtered again and then dried. The dry, compressed helium is then recycled back to the furnace at pressure using gas flows and pressures of 150 SCFM and 100 psig via an oil flooded screw machine.
[0011] U.S. Pat. No. 5,158,625 discloses a process for removing helium from a metal hardening (quenching) chamber, purifying the helium and compressing the helium. The quenching chamber was described as 10 M 3 with helium at 2.5 bar absolute (875 SCF of helium). Helium and impurities may be recovered from the hardening furnace through a vacuum pump. Down stream of the vacuum pump the helium plus impurities would be compressed and stored in one receiver. Once all of the desired helium from the hardening furnace was removed, then helium with impurities was passed through a membrane, dryer, PSA or catalytic oxidation of hydrogen to remove oxygen and water from the process. The purified helium is then compressed again and stored at pressure in another receiver until the next hardening cycle starts. The above process uses higher than atmospheric pressures in the quenching chamber to increase the helium density and thus improve the heat transfer capability.
[0012] The prior art does not teach or suggest the recovery and purification system comprised of three continuous loops involving the strategic placement of the purification equipment. Further, each loop has its own separate function. In addition to purification and recovery, the current invention is capable of pressurizing the helium to achieve the requisite sonic velocity.
OBJECTS OF THE INVENTION
[0013] It is therefore an object of the invention to provide a cost effective helium recovery system that will provide acceptable helium purity (>80 mole %), volume and pressure at the CSF nozzle and for the cleansing sweep across the work piece.
[0014] It is another object of this invention to provide for a helium recovery system that will remove contaminants such as oxygen, nitrogen, water, carbon dioxide and particulate from the helium.
SUMMARY OF THE INVENTION
[0015] This invention is directed to a three-stage process for recovering and purifying a gas. The steps comprises a) introducing a gas from a chamber to a particulate removing apparatus to form a particulate-free gas, and recycling a first portion of the particulate-free gas to the chamber; b) passing a second portion of the particulate-free gas to a first compressor prior to passing a selective gas purification membrane to form a purified gas and an exhaust gas, and passing the purified gas to mix with the first portion of particulate-free gas to the chamber; and c) passing a third portion of the particulate-free gas to a liquid separator apparatus and a receiver to form a liquid-free gas, and recycling the liquid-free gas to said chamber.
[0016] In another embodiment, this invention is directed to a three-stage system for recovering and purifying a gas. This system comprises a) a first stage for introducing a gas from a chamber to a particulate removing apparatus to form a particulate-free gas, and recycling a portion of the particulate-free gas to the chamber; b) a second stage for passing a second portion of the particulate-free gas to a first compressor prior to a selective gas purification membrane to form a purified gas and an exhaust gas, and passing the purified gas to mix with the first portion of particulate-free gas to the chamber; and c) a third stage for passing a third portion of the particulate-free gas to a liquid separator apparatus and a receiver to form a liquid-free gas, and recycling the liquid-free gas to the chamber.
[0017] The second stage may comprise adding helium to mix with the second portion of particulate-free gas prior to passing the second portion of particulate-free gas to the first compressor. The first stage may comprise a circulation unit for circulating the flow of gas. The second stage may comprise a gas analyzer to determine the purity of the second portion of particulate-free gas. The selective gas purification membrane may comprise a membrane selected from helium. The third stage may comprise a second compressor, cooler and a liquid separator apparatus. A recovery unit and an adsorption unit may also be added.
BRIEF DESCRIPTION OF THE DRAWING
[0018] Other objects, features and advantages will occur to those skilled in the art from the following description of preferred embodiments and the accompanying drawings, in which:
[0019] [0019]FIG. 1 is a schematic representation of the CPF process according to this invention; and
[0020] [0020]FIG. 2 is a schematic representation of recovering the gas use in the CPF process according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] There is no disclosure in the prior art disclosing recycling and purifying helium using the volume and pressure requirements for a CSF helium recovery system. The flow rates for the CSF are substantially different for that known in the art. The present invention has three separate loops that operate continuously. Each loop has a different function. First, the invention uses a fan in Loop A to recycle helium from the CSF chamber through particulate removal and back to the CSF chamber to supply the cleansing sweep (FIG. 2). The flow in Loop A must remove particulate from the chamber. The flow rates in Loop A are preferably 1000 SCFM or more. A portion of the gas cycling in Loop A is removed to supply Loop B and Loop C. The invention uses a compressor to remove the gas from Loop A. The amount of gas removed will depend on the number of nozzles and the purity requirements. If the CSF chamber contains one nozzle that requires helium having a purity of at least 90%, preferably at least 95%, then the flows in Loop B and Loop C are approximately 80 SCFM and 125 SCFM respectively. Loop C uses a compressor to increase the pressure and control the flow of gas to the nozzle.
[0022] One could consider providing the nozzle and cleansing sweep flow from a single compressor in Loop A. Having a compressor would eliminate Loop C. However, the low pressure cleansing sweep flow in this example is approximately eight times that of the nozzle flow. The nozzle pressure is at least 20 times or more than the cleansing sweep pressure. Therefore, the capital cost and the operating cost would be several times the respective costs for a fan and compressor combined as described above in Loops A and C.
[0023] The invention must use purification to maintain the desirable properties of helium and remove impurities that would harm the coating or substrate.
[0024] The invention also can use PSA, TSA, membrane, catalytic oxidation and cryogenic separation to remove impurities. However, any impurity in the helium can become a process-limiting agent for CSF. Therefore, depending on the application, the purification system must remove nitrogen, oxygen, water, carbon monoxide, carbon dioxide, hydrogen and possibly light hydrocarbons. The majority of impurities will occur when parts enter and leave the CSF chamber. Some CSF applications will process larger parts that are placed in the CSF chamber one at a time. As the parts are placed in the CSF chamber, helium will escape and air will enter into the chamber. The same will occur when the parts are removed from the CSF chamber. An evacuation of the chamber before and after the parts are placed in the enclosure would minimize the amount of helium lost and the amount of air that enters into the enclosure. Even though an evacuation of the enclosure would improve helium recovery, the time cycle extension and capital required for vacuum capable equipment may not justify the effort.
[0025] Higher molecular weight impurities will significantly lower the sonic velocity of helium. Higher sonic velocities than heavier gases is one of helium's several unique physical properties that make it the gas of choice for cold spray forming. A typical commercial application is expected to require helium purities of greater than about 85%, preferably greater than about 90% and most preferably greater than about 95%. Helium recoveries of greater than about 90% (based on the flow in Loop C) are expected.
[0026] Table 2 shows the different purification technologies to meet different gas specifications. The gas specification is dependent on process conditions and materials used for the coating process. For example, Items #1, 10, and 13 are discussed. Item #1 describes a process where equipment allows very little oxygen to leak into the process but requires gas with high purity. A copper oxide getter will effectively remove oxygen to the low PPMV levels. The process of Item #10 shows a process where two different purification technologies located apart from each other provides the most economical purification strategy. The membrane will remove nitrogen and oxygen in Loop B while the TSA will remove water in Loop D.
[0027] In Item #13, the gas specification is less than 2% air, and 10% air was admitted into Loop A when the parts were placed in to the CSF chamber. The CSF process would start with Loop A and Loop B, while Loop C would not start until the gas specification is reached as measured by oxygen analyzer 19 . If oxygen analyzer 19 signals an acceptable level of oxygen, then Loop C starts up and Loop B would continue to increase the helium purity.
TABLE 2 Purification Vs Impurities in CSF Off-Gas Gas Item Impurities Type of Specifications # (FIG. 2, #40) Purifier/Location (FIG. 2, #88) 1 10 PPM to 100 Copper Oxide Getter/ <20 PPM O 2 PPM Oxygen #68 <20 PPM N 2 Only <20 PPM H 2 O 2 H 2 O Only TSA/ #54 or #100 <20 PPM O 2 <20 PPM N 2 <20 PPM H 2 O 3 10 PPM H 2 O Copper Oxide Getter& <20 PPM O 2 10 PPM O 2 TSA/ #13 or #100 <20 PPM N 2 <20 PPM H 2 O 4 <2 PPM O 2 Cryogenic Adsorption/ <20 PPM O 2 <2 PPM N 2 #100 <20 PPM N 2 <2 PPM H 2 O <20 PPM H 2 O 5 <4 PPM O 2 Modified Cryogenic <4 PPM N 2 Adsorption or PSA/ #100 <4 PPM H 2 O 6 <6 PPM O 2 Modified Cryogenic <20 PPM O 2 <6 PPM N 2 Adsorption or PSA/ #100 <20 PPM N 2 <6 PPM H 2 O <20 PPM H 2 O 7 <8 PPM O 2 Modified Cryogenic <20 PPM O 2 <8 PPM N 2 Adsorption or PSA/ #100 <20 PPM N 2 <8 PPM H 2 O <20 PPM H 2 O 8 <10 PPM O 2 PSA/ #100 <20 PPM O 2 <10 PPM N 2 <20 PPM N 2 <10 PPM H 2 O <20 PPM H 2 O 9 <2 PPM O 2 1O% N 2 Membrane/ #54 <20 PPM O 2 1% N 2 1O <2 PPM O 2 1O% N 2 Membrane and TSA/ #54 <20 PPM O 2 <2 PPM H 2 O and #100 1% N 2 <20 PPM H 2 O 11 >2 PPM O 2 10% N 2 Membrane, TSA and <20 PPM O 2 <2 PPM H 2 O Copper Oxide Getter/ 1% N 2 #54 and #100 <20 PPM H 2 O 12 >2 PPM H 2 O Chiller/ #23 <2000 PPM H 2 O 13 10% air at membrane <2% AIR start of coating cycle 14 >100 PPMV TSA or PSA/ #100 <1000 PPMV 15 >2 PPMV TSA or PSA/ #100 <10 PPMV
[0028] [0028]FIG. 2 provides a schematic of the systems of this invention and the process therefore. The CSF process involves applying a coating to a part inside CSF chamber 30 . The chamber geometry will partly depend on size and geometry. In an embodiment of this invention, the part is loaded into the CSF chamber one at a time and one nozzle is used to coat the part. The opening of the enclosure removes the coated part, and releases about 8 cubic feet (CF) of helium and allows 8 CF of air to enter the enclosure. Furthermore, Loop A contains about 80 CF of gas. At start up, fan 42 will draw on CSF chamber 30 and pull gas through duct 32 , valve 38 , particulate removal 38 and ducts 36 and 40 . Fan 42 will discharge into duct 44 at slightly more than 15 psia. A portion of flow in duct 44 will enter duct 46 while the remaining portion will continue past the entrance of duct 46 to the exhaust of duct 56 . Purified helium from duct 56 will enter duct 44 and continue onto CSF chamber 30 . The helium from Loop A will be used to clean sweep the work piece.
[0029] Gas entering duct 46 will feed the suction of compressor 48 . Compressor 48 will discharge into duct 50 at approximately 180 psig. A portion of gas in duct 50 will enter duct 62 and pass through regulator 64 to oxygen analyzer 68 . Oxygen analyzer 68 will sound an alarm if the oxygen content of the gas is above specification. If the gas is above specification, then the operator or software will decide if the coating process should start or continue. If the coating process is not started then the most economical operation of the equipment is to not start Loop C until gas is within specification. However, for alternate equipment configurations where purification occurs in Loop C or Loop D then operation of the compressor in Loop C is needed.
[0030] The remaining portion in duct 50 after passing duct 62 will continue to duct 52 and duct 68 . Duct 52 is the inlet to Loop B. Gas passes through duct 52 to membrane 54 . Retentate leaves the membrane through back pressure regulator 58 to vent 60 . The purified helium leaves the membrane as permeate (low pressure side) through duct 56 and enters duct 44 as described above. Table 3 shows the results when 10% dry air in helium is the feed to a membrane. The permeate stream that will enter duct 56 will have 97.5% pure helium. As the gas from duct 56 mixes with the gas in duct 44 , the impurity concentration will drop.
TABLE 3 Membrane Simulation 1, 10% Dry Air in Feed MOD. FIBER OD FIBER ID ACTIVE POTTED AREA NO. mils mils LENGTH ft LENGTH ft ft 2 1 14.00 7.50 5.667 0.267 5005.1 CALCULATED PROCESS PARAMETERS FEED RAFF PERM Stream # #1 #2 #3 F, MMSCFD (60F) 1 0.08531 0.9147 PRESS, psia 195.00 195.00 16.00 TEMP, F. 108.00 108.00 108.00 Molec. Weight 6.49 26.09 4.66 Viscos, cp 0.0212 0.0190 0.0208 CONCENTRATIONS, mol % HELIUM 90.0000 10.0000 97.4611 NITROGEN 7.9000 77.9749 1.3646 OXYGEN 2.1000 12.0251 1.1744
[0031] Table 4 shows that as the feed to the membrane increases in purity, then the gas entering duct 56 will also increase in purity. In addition, as the feed helium purity increases, then the retentate flow rate decreases. Decreasing the retentate flow rate improves helium recovery.
TABLE 4 Membrane Simulation 2, 10% Air in Feed MOD. FIBER OD FIBER ID ACTIVE POTTED AREA NO. mils mils LENGTH ft LENGTH ft ft 2 1 14.00 7.50 5.667 0.267 3752.4 CALCULATED PROCESS PARAMETERS FEED RAFF PERM Stream # #1 #2 #3 F, MMSCFD (60F) 1 0.01178 0.9882 PRESS, psia 195.00 195.00 16.00 TEMP, F. 108.00 108.00 108.00 Molec. weight 4.66 27.63 4.39 Viscos, cp 0.0208 0.0191 0.0207 CONCENTRATIONS, mol % HELIUM 97.4600 5.0000 98.5619 NITROGEN 1.3600 74.4417 0.4890 OXYGEN 1.1800 20.5585 0.9490
[0032] Duct 68 starts Loop C. Gas enters Loop C at from about 100 psig to about 270 psig, preferably about 155 psig to about 195, and most preferably about 175 psig and is further compressed by compressor 70 to from about 270 psig to about 1130 psig, preferably from about 300 psig to about 1100 psig depending on the application. Higher pressures will allow for higher velocities at the nozzle in CSF chamber 30 . High pressure gas passes through cooler 72 and water separator 74 , to remove any condensed water. The water separator is placed after the compressor since water will condense first at higher pressures keeping gas temperature the same. For additional water removal the water separator can be augmented with a chiller to lower the gas temperature. Duct 76 delivers gas to receiver 78 , which is sufficiently large to dampen any pulsation in the gas flow that could come from a diaphragm or reciprocating compressor. Gas flows from receiver 78 into duct 80 and through valve 82 , which opens when the operator is ready to start coating the part in CSF chamber 30 . Gas flows into duct 84 through regulator 86 . Regulator 86 ensures that the pressure entering duct 88 is the desired nozzle pressure. The gas from here enters the CSF chamber in order to assist in coating the work piece. The helium gas picks up the powder and speeds it up to supply the kinetic energy required for coating. As discussed in Table 2 the gas specification will depend on the application.
[0033] Helium make-up comes from helium storage 90 through duct 92 and valve 96 into duct 46 . Valve 96 opens when pressure as measured at pressure indicator 94 falls below set point.
[0034] This invention also contemplates placing the membrane in duct 68 and feeding the permeate to the suction of compressor 20 . Putting the membrane in duct 68 is desirable if impurities continuously entered duct 32 from CSF chamber 30 . A continuous supply of parts into CSF chamber 30 by a conveyor belt or some other mechanism would be an example of when impurities would continuously enter duct 32 .
[0035] As the gas specification becomes significantly less than 2% impurities in helium, a pressure swing adsorption or cryogenic adsorption unit may optionally be needed. Duct 98 would take a portion of gas from duct 68 pass it through the pressure swing adsorption unit 100 . The pure helium would then enter duct 102 and mix with impure gas in duct 68 . The mixture of gases from duct 68 and duct 102 would meet the gas specification. Regulator 104 would create the needed pressure drop in duct 68 to force gas through pressure swing adsorption unit 100 . As the level of gas purity specification increases, the percentage of gas that passes through Loop D also increases. For specifications of less than 2 ppm, then the pressure swing adsorption unit or cryogenic adsorption unit would be placed in duct 68 .
[0036] If CSF chamber 30 uses evacuation to recover helium and remove air impurities before a part is ready for the coating process Loop B could be removed and Loop D remain for high purity helium applications. If CSF chamber 30 is evacuated and the gas specification is maintainable by a membrane then Loop B would remain.
[0037] If CSF chamber 30 uses evacuation and oxygen must be kept to low levels, then a copper oxide getter could control the oxygen. A membrane would then maintain other impurities to acceptable levels. Similarly, if oxygen or other chemical content must be controlled to a certain level, such as to control a reaction with the coating, then a getter or catalytic oxidation could be used. An example would be a slight oxide layer on an aluminum coating to passivate the metal. Such a system may use hydrogen and a catalyst to react some part or all of the oxygen. The hydrogen would be maintained in the system to a certain level or hydrogen would be introduced into the system at particular level of oxygen. The water from the hydrogen, oxygen reaction would then be removed in separator 74 .
[0038] Flow rate in recovery systems described above assumed one nozzle in the CSF chamber. However, a particular application may have several nozzles in one chamber with each requiring more than about 100 SCFM of helium. For multi-nozzle applications the flows will significantly increase over what was described above.
[0039] Specific features of the invention are shown in one or more of the drawings for convenience only, as each feature may be combined with other features in accordance with the invention. Alternative embodiments will be recognized by those skilled in the art and are intended to be included within the scope of the claims.
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This invention is directed to a three-stage process for recovering and purifying a gas, and a system for using the three-stage process. The steps comprises a) introducing a gas from a chamber to a particulate removing apparatus to form a particulate-free gas, and recycling a first portion of the particulate-free gas to the chamber; b) passing a second portion of the particulate-free gas to a first compressor prior to passing a selective gas purification membrane to form a purified gas and an exhaust gas, and passing the purified gas to mix with the first portion of particulate-free gas to the chamber; and c) passing a third portion of the particulate-free gas to a liquid separator apparatus and a receiver to form a liquid-free gas, and recycling the liquid-free gas to said chamber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims priority to U.S. patent application Ser. No. 10/198,204, filed Jul. 17, 2002 by Nielsen.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention relate to furniture such as an entertainment center.
BACKGROUND OF THE INVENTION
[0003] Component electronics for audiovisual applications conventionally include multiple, free-standing enclosures that receive power and signals from facility wiring and communicate with other components on wired cables or wireless links. Support for numerous components has conventionally been provided by furniture called an entertainment center. A conventional entertainment center may have open shelving and enclosed shelving for supporting and enclosing not only the components but also media used with the components. Such furniture also conventionally provides holes through the back and through the shelving for accommodating the signal cables and power cables associated with the components.
[0004] A conventional entertainment center is spaced away from a facility wall to allow cabling to be tucked behind the cabinetry of the entertainment center because provisions for cabling inside the cabinetry of the entertainment center are inadequate. The space between the entertainment center and the facility wall also supplies ventilation air for the components.
[0005] The conventional entertainment center provides movable shelving for accommodating consumer electronics assemblies of different vertical height; but, provides fixed horizontal dimensions designed for a maximum component width. Use of a conventional entertainment center is limited by the fixed horizontal width of its design. Users seeking, for example, to accommodate a larger home theater display (e.g., a big screen television set, a rear projection system, or a front illuminated screen) have little recourse but to purchase new furniture in the event the larger width display does not fit the fixed horizontal width provided by an existing entertainment center.
[0006] A large market exists for furniture to support consumer electronics. New products of various sizes are launched into this market annually. Without furniture capable of accommodating different horizontal widths, consumers may be reticent to purchase more expensive entertainment center furniture or may forego the acquisition of newer larger components. Consequently, without the present invention, both the consumer electronics and furniture industries face significant economic impairments to growth in sales.
SUMMARY OF THE INVENTION
[0007] A furniture system according to various aspects of the present invention includes an enclosure of a first space to be occupied by a home theater display wherein the enclosure, when placed against a facility wall provides a second space open to the top of the furniture system for ventilation of the home theater display.
[0008] When the enclosure includes shelving for consumer electronics assemblies, the shelving may be located between a first vertical side and a second vertical side. The first vertical side is adjacent to the display. The second vertical side has a depth greater than the depth of the first vertical side so that a portion of the second space is behind the shelving for ventilation of the consumer electronics assemblies.
[0009] Another furniture system according to various aspects of the present invention includes an enclosure of a space to be occupied by a home theater display and a base for transporting the display into and out from the space. The enclosure includes adjustable members that facilitate extending the enclosure to enclose the display at a width of a set of widths.
[0010] Another furniture system according to various aspects of the present invention includes an enclosure of a space to be occupied by a home theater display and a base for transporting the display into and out from the space. The base includes adjustable members that facilitate extending the base to support the display at a width of a set of widths.
[0011] Another furniture system according to various aspects of the present invention includes a pair of cabinets and a base for supporting a home theater display. The base includes wheels attached to a lower surface of the base to facilitate rolling the base between the cabinets. The base includes at least one section, mechanically coupled to the base that may be placed in one of a set of positions apart from a center of the base to give the base an apparent width that approximates a corresponding width of any of a set of home theater displays of various widths. The section includes a trim surface to block viewing of the wheels from the front of the entertainment furniture system when the section is placed in any position of the set.
[0012] The cabinets may include inner sides shorter in depth than outer sides, thereby forming a passage in the rear of the system for ventilation and cabling.
[0013] By including a multi-section base, the load weight of the display is efficiently coupled to the wheels for a variety of displays. By including trim pieces that overlap, the overall appearance of the base is improved. When the furniture system further includes a bridge, an overlapping aspect of the bridge relative to the cabinets is aesthetically similar to the overlapping appearance of the base for improved appearance of the furniture system as a whole.
[0014] A base, according to various aspects of the present invention, supports a home theater display and includes a stage and at least two sections. The stage and each section provide a respective front surface to block viewing of a space beneath the home theater display and to enhance the appearance of the base. The sections facilitate horizontal positioning relative to each other to establish a width of the base to approximate the width of any one of a set of home theater displays having differing respective widths. The base includes a plurality of wheels in the space that allow movement of the stage and display as a unit on a provided surface.
[0015] The stage and sections may be mechanically coupled by slides. Locks may be added to the slides to maintain the selected positioning.
[0016] According to various aspects of the present invention, a method is performed to mount a home theater display in a furniture system. The method includes, in any order: adjusting a horizontal width of a base for supporting the home theater display; placing a first cabinet against a facility wall; placing a second cabinet against the facility wall and spaced apart from the first cabinet a width sufficient for the base; and rolling the base between the first cabinet and the second cabinet. By supporting the display on a wheeled base and transporting the display on the base as a unit, access is facilitated to cabling for power and signals to the display. Cabling may be fully connected and routed prior to rolling the base between the cabinets.
BRIEF DESCRIPTION OF THE DRAWING
[0017] Embodiments of the present invention will now be further described with reference to the drawing, wherein like designations denote like elements, and:
[0018] FIG. 1 is a perspective view of a furniture system according to various aspects of the present invention wherein the doors of one of the cabinets are omitted for clarity of presentation;
[0019] FIG. 2 is a top view of the furniture system of FIG. 1 wherein the bridge and crown of one of the cabinets are omitted for clarity of presentation;
[0020] FIG. 3 is a perspective view of the underside of a base for use in the furniture system of FIG. 1 ; and
[0021] FIG. 4 is a top view of the bridge and a crown of the furniture system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] A furniture system according to various aspects of the present invention supports any of a variety of home theater displays of various widths. The furniture system generally encloses a space for locating the home theater display, the space being enclosed on several sides, for example, the left side, the right side, and the top. The furniture system may further enclose a portion of the rear of the space. Enclosing is typically for establishing, improving, or cooperating with the interior design of a room where the home theater display is to be used. The enclosure provides ventilation for the display according to various aspects of the present invention.
[0023] The display is supported on a base having wheels to transport the base and display as a unit separate from the enclosure portion of the furniture system. The furniture system is typically arranged to abut each vertical side of the home theater display and present to a front view a continuous series of trim surfaces that substantially hide the wheels from view. When the rear of the furniture system is placed against a facility wall, spaces defined by the enclosure accommodate wiring and ventilation and are easily accessible from the front of the furniture system. Conventional materials and techniques of furniture manufacture may be used in the design and construction of furniture systems of the present invention except as described below.
[0024] For example, furniture system 100 of FIGS. 1-4 includes cabinets 102 and 103 , back panel 101 , bridge 104 , and base 105 . Cabinets 102 (and 103 ) support component electronics and media (not shown). Each cabinet 102 ( 103 ) includes inner side 242 ( 244 ), outer side 250 ( 252 ), crown 132 ( 133 ), any number of suitable shelves 121 and 123 , and a cabinet back 246 ( 248 ) having holes 122 and 124 through which power and signal cables may be routed. Because outer side 250 ( 252 ) extends further to the rear than inner side 242 ( 244 ), cabinet 102 ( 103 ) defines a space 216 ( 218 ) for cabling and ventilation.
[0025] A back panel of the furniture system enhances the finished appearance and is retained in a vertical position while cabinets 102 and 103 are moved to establish a suitable width 110 for base 105 . For example, back panel 101 is mounted to allow cabinets 102 and 103 to be repositioned without access to the rear of the furniture system to effect a change in mounting of back panel 101 . Back panel 101 in one implementation rests on a hook 262 ( 264 ) on each cabinet 102 ( 103 ) and slides in groove 414 of bridge 104 . When cabinets 102 and 103 are positioned closer together or farther apart, back panel 101 slides on hooks 262 and 264 and is maintained in a vertical position by groove 414 . Back panel 101 does not obstruct cable passage holes (e.g., 122 and 124 ) or significantly block ventilation holes in cabinet backs 246 and 248 when cabinets 102 and 103 are positioned for a minimum width 110 . Back panel 101 includes stiffeners 210 , 212 , and 214 to reduce warping.
[0026] A bridge provides a visual connection between cabinets, usually at the top of a furniture system, by spanning the width between cabinets. While cabinets are moved to establish a suitable width, the bridge cooperates with the cabinets and the back panel to maintain its position on top of the cabinets. The horizontal position of the bridge can be adjusted (e.g., to center the bridge between the cabinets) without access to the top or rear of the furniture system. A bridge may be supported on the front of crowns of two cabinets and may also be supported via a back panel and hooks on which the back panel is supported. A bridge may have a depth when installed that is substantially equal to the depth of the inner sides of cabinets on which it rests.
[0027] For example, bridge 104 rests on the top of cabinet 102 and rests on the top of cabinet 103 . Bridge 104 nests with back panel 101 in groove 414 to prevent movement of bridge 104 toward the front of furniture system 100 . Preferably, back panel 101 bears no weight of bridge 104 so that back panel 101 slides easily when cabinets are moved. Bridge 104 nests with crowns 132 and 133 via slots 406 and 408 to prevent movement of bridge 104 toward the front or toward the rear of furniture system 100 . A front surface 422 of crown 132 (and a symmetric surface of crown 133 (not shown)) is overlapped by a portion 402 of bridge 104 . When surface 422 includes raised or recessed features, corresponding recesses or raised features may be added to surface 424 to provide an integral appearance when surfaces 422 and 424 are pressed against each other. When supported by cabinets 102 and 103 , bridge 104 covers a space 106 between cabinets 102 and 103 . Bridge 104 may include conventional lighting to illuminate space 106 . In one implementation, bridge 104 is not fastened to either cabinet 102 or 103 but slides on the crown portion 132 and 133 of each cabinet so that bridge 104 is aligned easily over the center of space 106 and flush against crowns 132 and 133 . Bridge 104 may further include U-shaped slots for avoiding interference between body 404 of bridge 104 and lighting in crowns 132 and 133 (e.g., installed in apertures 135 and 137 ).
[0028] A crown provides an aesthetically pleasing top to a cabinet and provides support for lighting and a bridge. A crown cooperates with a bridge according to various aspects of the present invention to support the bridge while the cabinet is being moved toward or away from the other cabinet on which the bridge is supported. For example, crowns 132 and 133 cooperate with bridge 104 as discussed above. Further, crowns cooperate with a bridge of the present invention to provide an aperture 430 for convection cooling of the home theater display and any entertainment equipment components located within cabinets 102 and 103 . Aperture 430 includes a portion 216 rear of cabinet back 246 , a portion 218 rear of cabinet back 248 , and a portion 430 above base 105 . Rear panels, crowns, and/or a bridge of furniture system 100 may include any conventional grills, hole patterns, slots, or voids to facilitate cooling.
[0029] A base, according to various aspects of the present invention provides an adjustable width so as to support one of various width home theater displays and provides a concealed mechanism for moving the base in and out of position between cabinets of the furniture system. Such a base includes sections mechanically coupled to each other and capable of being positioned with respect to each other to provide a base having one of various overall widths. Any mechanical coupling technique may be used to provide discrete or continuously variable positions. Concealment of wheels may be accomplished by expandable trim surfaces, where expansion is accomplished by overlapping, telescoping, deploying, or stretching trim surfaces. A deployed trim surface may be stored as rolled stock in the base. Stretching may include elastic, pleated, or accordioned material. For example, base 105 of FIGS. 1-4 includes stage 113 , section 112 attached to stage 113 by integral slides, and section 114 attached to stage 113 by integral slides. The stage provides wheels for movement of the base; and the sections and the stage provide cooperative overlapping trim surfaces to conceal the wheels. A trim surface of each section overlaps a portion of the nearest cabinet that abuts the base.
[0030] A stage provides support for at least one section and provides transportation for an object placed on the stage or on the section. For example, stage 113 includes platform 111 , casters 302 - 305 , studs 311 - 314 , and trim piece 108 . Section 112 ( 114 ) includes platform 322 ( 323 ), side 306 ( 308 ), and trim piece 107 ( 109 ). Platform 322 ( 323 ) includes a pair of slots 326 ( 327 ) and 328 ( 329 ) for attaching the section to the stage. The underside of section platforms 322 and 323 bears on the an upper side of stage platform 111 . Studs 311 - 314 pass through slots 326 - 329 to accept a stud termination (e.g., a fender washer and nut). Each slot, stud, and termination cooperate to form a slide for mechanically coupling a section to the stage. By loosening stud terminations, each section 112 and 114 may be moved along its respective slides (e.g., along axis 110 ) toward and away from the center of platform 111 . By moving each section a proportional distance from the center of platform 111 , base 113 is extended to any width (W) 110 within the range of the slides. After moving the sections, any suitable lock (e.g., a locking mechanism) may be employed to secure the position, fix the overall width of stage 113 , and more efficiently transfer load borne by base 105 to casters 302 - 305 . For example, stud terminations may be tightened to draw and bind the stage and section together.
[0031] Casters 302 - 305 are fixed to an underside surface of platform 111 and provide load bearing support. Each caster pivots around a vertical axis. Each caster provides a wheel that rotates on a horizontal axis. Any conventional caster may be used. A home theater display placed onto base 113 may rest in part against an upper surface of platform 111 and/or on an upper surface of section platforms 322 and 323 . Weight of the display is communicated via slides to stage 113 and through casters 302 - 305 to the facility surface on which furniture system 100 is placed. In operation, casters 302 - 305 facilitate movement of stage 113 (and a display placed on stage 113 ) along an axis of width 110 so to align stage 113 between cabinets 102 and 103 , and along an axis of depth 120 so to move stage 113 into space 106 . A home theater display atop stage 113 may completely fill the width 110 and depth 120 of space 106 .
[0032] The space directly below stage platform 111 is substantially hidden from view by the cooperation of trim pieces 107 - 109 . Trim piece 107 ( 109 ) extends away from the center of platform 111 and beyond the extremity of platform 322 ( 323 ) to overlap a portion of cabinet 102 ( 103 ) and consequently to cover any portion of space 106 that might remain between base 113 and cabinet 102 ( 103 ). Trim piece 107 ( 109 ) also extends toward the center of platform 111 to overlap a portion of trim piece 108 . When section 112 ( 113 ) is slid toward or away from stage 111 , trim piece 107 ( 109 ) slides in front of trim piece 108 to continue to perform the hiding function.
[0033] Each section 112 and 114 may further include a railing on one or more edges of the section to reduce the risk that an object placed on the base will unexpectedly slide off the base. For example, section 112 ( 114 ) may further include side 306 ( 308 ) that extends above platform 322 ( 323 ) to form a lip 202 ( 206 ). Railings may be added to the upper surfaces of any platform 111 , 322 , and/or 323 . For example, railing 204 ( 208 ) is added on the top rear edge of platform 322 ( 323 ).
[0034] Movement of base 105 is facilitated in any conventional manner. According to various aspects of the present invention, base 105 provides at least one handle or hand-hold to move base 105 . For example, trim piece 108 extends downward yet leaves space for a user to place his or her hand or hands under trim piece 108 and pull on trim piece 108 to move base 105 on depth axis 120 out from between cabinets 102 and 103 . In an alternate implementation, platform 111 is formed with a hand access hole through platform 111 to facilitate pulling base 105 on depth axis 120 out from between cabinets 102 and 103 .
[0035] Assembly of an entertainment system with an entertainment furniture system as discussed above may proceed according to a method performed in any order as follows. Measure the width of the home theater display to be positioned in space 106 . Determine whether it is desired to abut both cabinets 102 and 103 to the sides of the home theater display, and if not add a suitable amount to the width. Assemble sections 112 and 114 to stage 113 . Before tightening stud terminations, extend each section 112 and 114 symmetrically from the center of stage 113 an amount equal to about half the desired width, then lock the sections to the stage (e.g., by tightening the stud terminations). Place back panel 101 against a facility wall. Place cabinet 102 within a few inches of the facility wall as desired, allowing for access to cable TV, power, telephone, Internet, and other facility wiring connections for use by the entertainment system. Place cabinet 103 roughly the desired width from cabinet 102 . Lift back panel 101 onto hooks 162 and 164 . Place bridge 104 on top of the crown portions of cabinets 102 and 103 , centering bridge 104 over space 106 , and fitting bridge 104 onto back panel 101 for maintaining back panel 101 in a vertical position. Move cabinets 102 and/or 103 to obtain the desired width of space 106 . While cabinets 102 and 103 are being moved apart (or together), back panel 101 is confined to slide on axis 120 while being maintained in a vertical position; and, bridge 104 is confined to slide only on axis 120 while being maintained square to the top of cabinets 102 and 103 . If cabinet lighting is provided in bridge 104 or crown portions of cabinets 102 and 103 , connect power wiring. Place a home theater display on base 105 and transport the base and display as a unit to a position in front of space 106 . Place all other entertainment system components (e.g., tuner, amplifier, audio media player, speakers) in cabinets 102 and 103 . Route all cables and wiring from the display to the components. Reach around cabinet inner side 242 ( 244 ) to access cables passing through holes 122 and 124 (and suitable holes in cabinet back 248 (not shown)). Transport the base and display as a unit into space 106 until the trim pieces 107 and 109 meet and overlap a portion of the front trim pieces 142 and 144 of cabinets 102 and 103 .
[0036] Another furniture system according to various aspects of the present invention may include a base as discussed above and an enclosure. The enclosure may include: (a) shelving to one side of a space to be occupied by the base; and (b) a vertical panel on the opposite side of the space. The enclosure may include a bridge and/or a back panel that spans the top and/or rear sides of the space. For example, such a furniture system may include all of the structures discussed above with reference to system 100 , except that: (a) cabinet 102 is replaced by a panel similar to side 250 (e.g., omitting crown, doors, drawer, shelves, as well as front, inside, and rear structures) and supported by being attached to either a back panel similar to 101 and/or to a bridge similar to 104 ; and (b) bridge 104 is replaced with a bridge modified to attach to or cooperate with side 250 (e.g., omitting all of the structure associated with resting on top of and cooperating with a full size cabinet 102 ). The structures and cooperation of the bridge and cabinet 103 would be included in this alternate furniture system. The asymmetric implementation discussed here (cabinet to the right of display) may be implemented as a mirror image (cabinet on left of display) in an alternate implementation.
[0037] In alternative implementations of the furniture systems discussed above, cabinet doors and drawers are partially or entirely omitted. In still further alternate implementations, any arrangement of shelving, doors, and/or drawers may be located between sides 244 and 252 (and/or sides 250 and 242 if implemented).
[0038] Another alternate furniture system according to various aspects of the present invention includes merely a base as discussed above (cabinets 102 and 103 , bridge 104 , and back panel 101 are omitted).
[0039] The foregoing description discusses preferred embodiments of the present invention which may be changed or modified without departing from the scope of the present invention as defined in the claims. While for the sake of clarity of description, several specific embodiments of the invention have been described, the scope of the invention is intended to be measured by the claims as set forth below.
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An entertainment center includes a base that expands horizontally to accommodate different width home theater displays;and, a light bridge that rests on top of one or more cabinets placed on either side of the base. The side cabinets provide a vertical column of open space for accommodating wiring among the entertainment system components and ventilation for heat generated by those components. The base includes casters to facilitate moving the base in and out from between the side cabinets. Sliding portions of the base extend horizontally yet continue to transfer all load weight onto the casters. The front woodwork of the base presents a pleasing seamless appearance as a consequence of overlapping trim pieces.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of pending U.S. patent application Ser. No. 11/608,417, filed Dec. 8, 2006, which claims the priority of U.S. provisional application No. 60/755,954, filed on Jan. 3, 2006, and the entirety of which are incorporated herein for reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to mixed-size design of integrated circuits and, in particular, to packing-based macro placement.
2. Description of the Related Art
Due to use of IP (intellectual property) modules and embedded memories, a modern VLSI chip often comprises a large number of macros. Mixed-size placement of both macros and standard cells has become more popular in different applications. As a result, many mixed-size placement algorithms are disclosed in different publications.
A first type of mixed-size placement algorithm places macros and standard cells simultaneously, which typically does not consider macro orientations and requires a robust macro legalizer to remove overlaps if macros/cells are not distributed evenly. A simulated annealing based multilevel placer mPG-MS, disclosed in Proceedings of ACM/IEEE Asia South Pacific Design Automation Conference by C.-C. Chang et. al in 2003, fixes macros level by level from large macros to small macros. A min-cut based pacer Feng Shui, disclosed in Proceedings of ACM International Symposium on Physical Design by A. Khatkhate et. al in 2004, considers standard cells and macros simultaneously using a fractional cut technique, which allows horizontal cut lines to not align with row boundaries. In addition, several analytical approaches have been proposed to accomplish mixed-size placement. APlace, disclosed in Proceedings of the IEEE/ACM International Conference on Computer-Aided Design by A. B. Kagng et. al in 2004, uses a bell-shaped potential function considering macro heights/widths based on non-linear programming to determine a global placement which evenly distributes macros/cells. mPL, disclosed in Proceedings of ACM International Symposium on Physical Design by T. Chan et. al in 2005, uses a generalized force-directed method for placement. UPlace, disclosed in Proceedings of ACM International Symposium on Physical Design by B. Yao et. al in 2005, uses quadratic programming and a discrete cosine transformation method to distribute macro/cells evenly, and a zone refinement technique for legalization is then applied.
A second type combines floorplanning and placement techniques. A min-cut floorplacer Capo, disclosed in Proceedings of the IEEE/ACM International Conference on Computer-Aided Design in 2004, is an example. The fixed-outline floorplanning is applied when necessary during min-cut placement to find allowable positions for macros. Embedded into a placement flow, floorplacement can consider macro orientations and find legal solutions more easily.
A third type separates the mixed-size placement into two stages, macro placement and standard-cell placement. Macro positions are determined before standard cells are placed into the rest area. A combinational technique is disclosed in ACM Transactions on Design Automation of Electronic Systems by S. N. Adya in 2005. A standard cell placer is used to obtain an initial placement. Standard cells are clustered as several soft macros based on the initial placement, and fixed-outline floorplanning is applied to find an overlap-free macro placement. Then, macros are fixed and standard cells replaced using a standard cell placer in the remaining space. Compared with the other types, the two-stage mixed-size placement is more robust since it guarantees a feasible solution as long as an overlap-free macro placement is obtained. Furthermore, macro orientations and placement constraints, such as pre-placed macros and placement blockages, can be easily handled.
BRIEF SUMMARY OF THE INVENTION
An embodiment of a semiconductor chip comprises first and second groups of macros. The first and second groups of macros are respectively close packed toward first and second directions of the semiconductor chip.
Another embodiment of a semiconductor chip comprises first and second groups of macros. The first and second groups of macros are respectively close packed toward first and second edges of the semiconductor chip.
Another embodiment of a semiconductor chip comprises first and second groups of macros. The first and second groups of macros are respectively close packed toward first and second corners of the semiconductor chip.
An embodiment of a k-level binary multi-packing tree comprises k branch nodes and k+1 packing sub-trees. Each of the k branch nodes corresponds to one level. Each of the k+1 packing sub-trees comprises a group of macros and corresponds to one of the nodes.
An embodiment of a method of macro placement comprises creating a k-level binary multi-packing tree as disclosed and packing the macros of each packing sub-tree in a placement region.
An embodiment of a multi-packing tree (MPT) macro placer comprises reading input files in a LEF/DEF format, creating a k-level binary multi-packing tree, optimizing the multi-packing tree according to a packing result thereof, and generating output files in a DEF format. The k-level binary multi-packing tree comprises k branch nodes each corresponding to one level and k+1 packing sub-trees each corresponding to one of the nodes and comprising a group of macros.
An embodiment of a mixed-size placement design flow comprises reading initial input files in a LEF/DEF format, performing preliminary macro placement with a conventional macro placer, performing detailed macro placement with the disclosed MPT macro placer, and generating final output files in a DEF format.
An embodiment of a cost function for evaluating a macro placement comprises at least one parameter of area of the macro placement, total wirelength of real nets and pseudo nets in the macro placement, total macro displacement from a preliminary macro placement, overlap length of the macro placement, and thickness of the macro placement.
The invention provides a multi-packing tree (MPT)-based macro placer which places macros around a boundary of a placement region and reserves a center thereof for standard cells. The MPT macro placer is very fast for operations and packing of binary trees, with only amortized linear time needed to transform an MPT to its corresponding macro placement. As a result, a solution of macro placement is efficiently searched by simulated annealing. The packing techniques are, further, efficient and effective for area minimization, such that the MPT-base macro placer can solve mixed-size placement problems with very large macros and a large number of macros. Since macro orientations and spacing between macros are considered, the MPT-base macro placer leads to significantly shorter wirelength and less congestion than other mixed-size placers. The MPT-base macro placer can also easily function within various placement constraints, such as pre-placed blocks, corner blocks, and placement blockages. The MPT-base macro placer can be combined with state-of-the-art standard cell placers to obtain better mixed-size placement solutions based on a two-stage mixed-size placement flow.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 shows a mixed size placement flow chart;
FIG. 2 shows a Packing-Tree with its four types of packing;
FIG. 3 shows a general Multi-Packing-Tree;
FIG. 4 shows an example of packing for a Multi-Packing-tree with a BL-Packing-tree and a BR-Packing-tree;
FIG. 5A shows a Multi-Packing-tree with four packing sub-trees;
FIG. 5B is a diagram illustrating macro placement corresponding to FIG. 5A , after the nodes are traversed;
FIG. 6 shows three dimensions of the cluster matrices;
FIG. 7 shows the process of handling a placement blockage;
FIG. 8 shows a rectilinear block sliced into several rectangular blocks;
FIG. 9A shows a macro placement result and its top/bottom contours;
FIG. 9B shows a macro placement area corresponding FIG. 9A ; and
FIG. 10 shows a macro placement flow.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
FIG. 1 shows a mixed size placement flow chart. One feature of the design strategy according to this invention is to place macros around the chip and reverse the chip center to place standard cells. Since macros are usually large and there are routing blockages in the macros, if macros are placed in the chip center they will affect routing very much. The traditional floorplanning techniques cannot directly apply to the macro placement problem since it packs all macros to one corner. To overcome this problem, a new Multi-Packing-tree floorplan representation is proposed based on a new Packing-tree representation to place macros around the chip.
A Packing-tree is a binary-tree for modeling non-slicing or slicing floorplan. Each node in the Packing-tree corresponds to a macro block. There are four types of packing of a Packing-tree. BL-, TL-, TR-, and BR-packing pack the blocks to the bottom-left, top-left, top-right, and bottom-right corners, respectively.
FIG. 2 is a Packing-tree and its corresponding four packing types of placements. Let (x corner , y corner ) as the coordinate of the corner, (x i , y i ) as the bottom-left coordinate of the block b i , and w i (h i ) as the width (height) of the block b i . The root coordinate of a Packing-tree is at
(c x , c y ) for BL-packing, (c x , c y −h root ) for TL-packing, (c x −w root , c y −h root ) for TR-packing, and (c x −w root , c y ) for BR-packing.
If node n j is the right child of n i , the block b j is
the lowest adjacent block on the right with x j =x i +w i for BL-packing, the highest adjacent block on the right with x j =x i +w i for TL-packing, the highest adjacent block on the left with x j =x i −w j for TR-packing, and the lowest adjacent block on the left with x j =x i −w j for BR-packing.
If node n j is the left child of n i , the x-coordinate of block b j is defined as
x j =x i for BL-packing, x j =x i for TL-packing, x j =x i +w i −w j for TR-packing, and x j =x i +w i −w j for BR-packing
The block b j is above the block b i for BL- and BR-packing, while the block b j is below the block b i for TL- and TR-packing. Therefore, given a Packing-tree, the x-coordinate of all blocks can be determined by traversing the tree once in linear time. Further, y-coordinate can be computed by a contour data structure in amortized constant time similar to a known method. See, e.g., Y.-C. Chang, Y.-W. Chang, G.-M. Wu, and S.-W. Wu. B*-trees: A new representation for non-slicing floorplans, in Proceedings of the ACM/IEEE Design Automation Conference, pages 458-463, 2000. So, the complexity of transforming a Packing-tree to the placement is amortized linear time. Note that B*-tree floorplan representation is a BL-type Packing-tree.
A Multi-Packing-tree combines several Packing-trees with different packing types at difference corners. An example of a general Multi-Packing-tree is shown in FIG. 3 . There are k branch nodes in a Multi-Packing-tree to combine k+1 packing sub-trees. A right-skewed stem is used to combine packing sub-trees for convenience and easy implementation, and the order of sub-Packing trees can be determined by the level of the parent node of packing sub-trees. The smaller the level, the earlier the packing sub-tree packs since the DFS order of tree traversal is used for tree packing. If the parent of two packing sub-trees are the same, the packing sub-tree located at the left-child will be packed first. The general Multi-Packing-tree can be used to model any rectilinear floorplan region with each packing sub-tree packs to one convex corner.
Similarly, the x-coordinates of blocks can be determined by a DFS traversal of the Multi-Packing-tree. To compute y-coordinates, two contours are kept, bottom-contour and top-contour, which are initialized according to the bottom-side and the top-side of the given rectilinear region, respectively. All BL- and BR-Packing-trees use one bottom-contour data structure, and all TL- and TR-Packing-trees use on top-contour data structure. FIG. 4 shows an example of packing for a Multi-Packing-tree with a BL-Packing-tree and a BR-Packing-tree. The Packing-trees that use the same contour data structure always generate overlap-free placement since the contour reserves for the space of blocks that are traversed before. So, BL-/BR-Packing-trees may only overlaps with TL-/TR-Packing-trees. However, this kind of solutions should be discarded since they are not feasible.
For a common rectangle VLSI chip area, a Multi-Packing-tree is used with four packing sub-tree to handle it, as an example shown in FIG. 5A . To obtain the corresponding macro placement, the tree is traversed in the depth-first search (DFS) order from the root n 0 . Since n 0 is a branch node, nothing is done and the traversal continues. Then, the left-child of n 0 , n 3 , is the root of the BL-Packing-tree, so b 3 is placed on the bottom-left corner. Since n 3 does not have a left child, n 4 is traversed and the traversal continues. In this example, the packing sub-trees are traversed in the order of BL-Packing-tree, TL-Packing-tree, TR-Packing-tree, and BR-Packing-tree. After all nodes are traversed, the macro placement shown in FIG. 5B is obtained.
Macro clustering can be used to reduce the problem size. The macros with the same height/width within the same group of the design hierarchy are clustered. These macros usually have strong correlation. Clustering macros not only utilizes the area better, but also places strongly correlated macros closer. The cluster dimension is only considered when there is no wasted area. FIG. 6 is an example of a cluster of four blocks, and it has 3 possible dimensions of the cluster matrices, 1×4, 2×2, and 4×1.
When declustering, the blocks are placed according to the current cluster matrix. A branch and bound method is applied to find the best ordering of the blocks based on the placement cost.
The placement blockages are given by the user, and no macro can be overlap with the blockages. During packing, a new macro block is added and checked if it overlaps with blockages. If it overlaps, the y-coordinate of the block is shifted to the position without overlapping. FIG. 7 gives an example. Adding a new block b 2 , it overlaps with the given placement blockage. The block b 2 is shifted up to avoid overlapping, and the contour is updated according to the position of block b 2 . Pre-placed macros are considered as a placement blockage, and no corresponding node will be generated in the Multi-Packing-tree. It can ensure the positions of pre-placed macros.
Corner Macros are described as follows. The analog block is usually fixed at the corner as a corner macro. The node corresponding to the corner block is fixed as the root of the packing sub-tree. Thus, the corner macro can be fixed at the corner.
Rectilinear Macros is described as follows. A known method can be adopted to handle rectilinear macros for tree-based floorplanning. See, e.g., G.-M. Wu, Y.-C. Chang, and Y.-W. Chang. Rectilinear block placement using B*-trees. ACM Trans. on Design Automation of Electronic Systems, 8(2):188-202, 2003. A rectilinear macro is sliced into several rectangular blocks. The location constraint (LC for short) according to the tree topology is created. When packing, the mis-alignment situations are fixed to maintain the rectilinear block shape. As the example shown in FIG. 8 , the rectilinear block is sliced into three rectangular blocks, and n 1 , n 2 , and n 3 nodes keep the LC relation.
Operations on Multi-Packing-Tree are described below. A Multi-Packing-tree can be perturbed to get another Multi-Packing-tree by the following operations:
Op 1 : Rotate a block (cluster). Op 2 : Resize a cluster. Op 3 : Move a node in a packing sub-tree to another place. Op 4 : Swap two nodes within one or two packing sub-trees. Op 5 : Swap two packing sub-trees.
For Op 1 , a block (cluster) is rotated for a tree node. For Op 2 , the clustering dimension of a cluster is changed. Op 1 and Op 2 do not affect the Multi-Packing-tree structure. For Op 3 , a node is selected from a packing sub-tree, and moved to another place of the same or different packing sub-tree. For Op 4 , two nodes are selected from one (two) packing sub-tree(s), and swapped. For Op 5 , two packing sub-trees are swapped, and it makes the packing order of two packing sub-trees exchanged. Note that the stem structure of a Multi-Packing-tree are fixed and does not effect by any type of operation.
Evaluation of a Macro Placement is described as follows. To distinguish the quality of a macro placement result, the cost of a macro placement F is defined as follows: φ=αA+βW+γD+δO+εT, where A is the macro placement area, W is the total wirelength, D is the total macro displacement, O is the vertical overlap length, and α, β, γ, and δ are user-specified weighting parameters. The macro placement area, wirelength, macro displacement, and vertical overlap length are explained in the following paragraphs.
The macro placement area is the area under the bottom contour plus the area above the top contour. As shown in FIG. 9A , the contours are plotted in bolded-dashed lines, and the corresponding macro-placement area is shown in FIG. 9B . Minimizing the macro placement area can avoid generating too many island-like standard cell regions, which is surrounding by macros. The routing from this kind of regions to the center of the chip is hard since the many routing blockages are above macro blocks. The routing may be more congestive. Further, the standard cells in this kind of regions need to use longer routing paths to connect to the standard cells located in the chip center, and the timing may be worse.
For the wirelength, since only macros are considered during placement, the netlist from the circuit cannot be directly used. The design hierarchy is used, and pseudo nets are created between macro blocks that are in the same design hierarchy group. So, minimizing the total wirelength can keep the macro blocks in the same design hierarchy group closer.
The macro placement can be guided by a global placement result. The global placement result does not need to be legal. The given macro positions are extracted, and the macro displacement is added as a penalty of the cost function, so that an optimal macro placement with minimum macro displacement can be found.
The Multi-Packing-tree presentation can guarantee no overlaps between top/bottom packing sub-trees. However, the there may exist vertical overlaps between the top contour and the bottom contour. Adding a penalty for the vertical overlap can guide the simulated annealing to find a non-overlap solution.
Macro Placement Flow FIG. 10 shows an exemplary macro placement flow. After LEF/DEF files are read, the macros with the same height/width and the same design hierarchy level are first clustered. The cluster dimension is initialized with the one most close to the square, and the final dimension will be selected during simulated annealing optimization.
Then, a Multi-Packing-tree with the given number of packing sub-trees is created. Each macro/cluster corresponds to a node in a packing sub-tree. If the initial macro placement is given, the initial packing sub-tree can be assigned to which a node belongs according the nearest corner for the macro. Otherwise, the initial packing sub-tree that a node belongs to is randomly set. Each packing sub-tree is initialized as a complete binary tree.
Simulated annealing is used to find the optimal macro placement. A Multi-Packing-tree is perturbed to get another Multi-Packing-tree by the aforementioned operations. After perturbation, the designers can fix the tree structure to satisfy the given macro placement constraints, pack the Multi-Packing-tree, evaluate the macro placement, and decide whether the new solution is acceptable according to the macro placement quality difference and the current temperature of simulated annealing. Then, the Multi-Packing-tree is perturbed again. The simulated annealing continues until the solution is good enough or no better solution can be found, and all blocks/clusters positions are determined.
After all block/cluster positions are determined, the positions of blocks inside a cluster can be computed according to the matrix dimension of the cluster.
Finally, the spacing between macros is modified. If the routing resource demand between two macros is higher than the original spacing between macros, the spacing between these two macros is added. Otherwise, the original spacing can be decreased to make the macro placement area smaller. Macro orientation can also be set by horizontal/vertical flipping, so that most pins are closer to the chip center. Then, all macro status is set fixed and the final macro placement is outputted.
Two sets of benchmarks, the Faraday benchmark suite disclosed in ACM Transactions on Design Automation of Electronic Systems by S. N. Adya in 2005 and the mchip benchmark suite composed of five recent large-scale real designs, are used for comparative verification of mixed-size and macro placement. Table I shows the statistics of the Faraday benchmarks. It is noted that the DMA circuit is not used in this comparative verification because there is no macro therein. There are two (seven) macros in each of the DSP (RISC) circuits. The macro area ranges from 6.96% to 41.99% of the whole chip area in these benchmarks.
TABLE I
#
#
#
Circuit
# of cell
of nets
of IOs
Row-Util
of Macros
Ma-ratio
DSP1
26299
28447
844
90.66%
2
21.98%
DSP2
26279
28431
844
90.05%
2
6.96%
RISC1
32615
34034
627
93.94%
7
41.99%
RISC2
32615
34034
627
94.09%
7
37.37%
Table II shows the mixed-size placement and routing results for Feng Shei 5.1, Capo 9.4, the MPT (Multi-Packing-tree) macro placer of the invention integrated with Capo, mPL5, APlace 2.0, and the MPT macro placer of the invention integrated with APlace on the Faraday benchmarks. A leading commercial router is used to route all placement solutions. All placers are run on a 3.2 GHz Pentium 4 Linux workstation with 2 GB RAM. The “HPWL” (half-perimeter wirelength) and WL (routing wirelength) are reported in the database unit. “Viol” gives the number of violations in the routing solutions. The MPT macro placer needs only a few seconds for these benchmarks because the number of macros is small, and the runtimes for macro placement alone are thus not reported. The star sign * in Table II indicates that the placement result has many overlaps, or blocks are outside the placement region and cannot be legalized. The word “NR” in Table II means no result is obtained due to no allowable placement.
TABLE II
Feng Shui 5.1
Capo 9.4
Place
Route
Place
Route
HPWL
Time
WL
Time
HPWL
Time
WL
Time
Circuit
(xE8)
(min)
(xE8)
(min)
Viol
(xE8)
(min)
(xE8)
(min)
Viol
DSP1
*(13.25)
6
NR
NR
NR
10.09
8
12.70
9
1
DSP2
9.08
6
12.10
8
0
8.91
8
11.37
8
0
RISC1
*(18.53)
17
NR
NR
NR
16.35
16
25.70
32
265
RISC2
1.35
17
45.10
66
452321
16.02
14
23.75
22
6
Avg.
1.35
1.68
1.15
1.15
MPT macro placer + Capo 9.4
mPL5
Place
Route
Place
Route
HPWL
Time
WL
Time
HPWL
Time
WL
Time
Circuit
(xE8)
(min)
(xE8)
(min)
Viol
(xE8)
(min)
(xE8)
(min)
Viol
DSP1
9.32
7
12.06
7
0
13.41
4
18.69
14
8998
DSP2
8.98
7
11.50
7
0
11.22
4
14.87
13
1
RISC1
14.63
12
21.54
25
6
24.92
8
36.60
70
99613
RISC2
14.04
12
19.51
13
2
23.90
10
33.50
19
29682
Avg.
1.35
1.68
1.63
1.62
Aplace
MPT macro placer + APlace 2.0
Place
Route
Place
Route
HPWL
Time
WL
Time
HPWL
Time
WL
Time
Circuit
(xE8)
(min)
(xE8)
(min)
Viol
(xE8)
(min)
(xE8)
(min)
Viol
DSP1
*(9.04)
20
NR
NR
NR
8.88
13
11.57
8
1
DSP2
8.69
11
11.20
8
0
8.65
12
11.12
8
0
RISC1
*(13.07)
22
NR
NR
NR
13.12
25
19.96
25
0
RISC2
*(13.80)
22
NR
NR
NR
13.27
21
19.87
24
0
Avg.
*(1.01)
1.01
1.00
1.00
From the results, it is found that the min cut placer Feng Shui generates results with many macros/cells outside the chip region. Though mPL5 does not claim to be a mixed-size placer, mPL5 generates high quality solutions for IBM-MS/IBM-MSw Pins benchmarks with mixed-size macros and standard cells. Accordingly, mPL5 placement on the Faraday benchmarks is performed for reference. It is found that mPL5 finds allowable solutions but the quality thereof is not good. In addition, it is found that APlace generates many overlaps between macros for DSP1, RISC1, and RISC2 and cannot be legalized. As a result, only the HPWLs of its global placement solutions are reported. The min-cut floorplacer Capo finds legal solutions and its HPWLs are better than Feng Shui, and mPL5.
The two-stage mixed-size placement approaches utilizing the MPT macro placer according to an embodiment of the invention can determine allowable placement solutions for all the circuits. The MPT macro placer integrated with Capo reduces the respective HPWL and routing wirelength by 8% and 12% on average, compared with Capo alone. In particular, the MPT macro placer integrated with APlace generates feasible placement for all the circuits, and the quality is superior to all the mixed-size placers. The HPWL's are respectively reduced by 63%, 35%, and 15%, compared with mPL5, Feng Sui, and Capo. Furthermore, the routing wirelengths are respectively 62%, 68%, and 15% shorter than mPL5, Feng Sui, and Capo. It is also found that as the total macro area increases, HPWL reduction of the placement flow utilizing the MPT macro placer according to an embodiment of the invention increases accordingly. Wirelength reduction is summarized in Table III, illustrating effectiveness of the MPT macro placer.
TABLE III
Normalized HPWL
Normalized WL
Macro
MPT +
MPT +
MPT +
MPT +
Circuit
Area
Capo
Capo
Aplace
Capo
Capo
Aplace
DSP2
6.96%
1.00
1.01
0.97
1.00
1.01
0.98
DSP1
21.98%
1.00
0.92
0.88
1.00
0.95
0.91
RISC2
37.37%
1.00
0.88
0.83
1.00
0.82
0.84
RISC1
41.99%
1.00
0.89
0.80
1.00
0.84
0.78
Table IV shows statistics of the mchip benchmark suite. The number of cells ranges from 540 k to 1320 k, and the number of macros from 50 to 380. It is known that only Capo can determine allowable placement with good quality for mixed-size placement with large macros, comparisons of macro placement are made with Capo. The experiment is carried out on a dual Opteron 2.6 GHz machine and begins with running the MPT macro placer and Capo to determine the positions of macros. Thereafter, macros are fixed and standard cells placed using a commercial congestion-driven placer in a fast prototyping mode. A commercial router performs global routing. For fair comparison, the standard cells are placed by the same placer.
TABLE IV
Circuit
# of cell
# of nets
Row-Util
# of Macros
Ma-ratio
mchip1
540k
570k
94%
50
66%
mchip2
820k
860k
91%
95
56%
mchip3
910k
960k
88%
110
54%
mchip4
1320k
1300k
90%
380
36%
mchip5
1230k
1260k
58%
138
30%
Table V shows the HPWLs, routing wirelengths (WL), GRC overflows, and maximum overflows. The GRC overflow is the percentage of the global routing cells (GRC's) that have overflow. The larger the value, the more congested the placement. Maximum overflow provides the number of extra tracks assigned for the global routing cell with the maximum overflow. NR in Table V indicates no placement result is obtained for routing due to the segmentation faults in Capo.
TABLE V
Capo
Place
Route
HPWL
Time
WL
Time
GRC
Max
Circuit
(xE7)
(min)
(xE7)
(min)
Overflow
Overflow
mchip1
5.84
16
6.56
23
0.7%
39
mchip2
5.65
28
6.65
32
1.0%
27
mchip3
10.00
23
16.90
180
36.4%
113
mchip4
14.12
41
14.16
323
1.4%
288
mchip5
Seg. fault
NR
NR
NR
NR
MPT macro placer
Place
Route
HPWL
Time
WL
Time
GRC
Max
Circuit
(xE7)
(min)
(xE7)
(min)
Overflow
Overflow
mchip1
5.26
8
6.13
7
0.7%
5
mchip2
4.72
13
5.34
8
0.1%
4
mchip3
5.26
16
6.02
14
0.1%
4
mchip4
11.76
31
13.27
45
0.1%
31
mchip5
8.92
30
9.85
27
0.0%
2
For the five mchip benchmarks, the MPT macro placer consistently obtains much better wirelengths (HPWL and WL) than Capo's macro placement. For the mchip 5 circuit, segmentation faults occur and no solution can be found after several tries when using Capo. Furthermore, Capo's macro placement results in larger GRC overflow and maximum overflow and requires more running time for the cell placement and routing than the MPT macro placer.
The invention provides a multi-packing tree (MPT)-based macro placer which places macros around a boundary of a placement region and reserves a center thereof for standard cells. The MPT macro placer is very fast for operations and packing of binary trees, with only amortized linear time needed to transform an MPT to its corresponding macro placement. As a result, a solution of macro placement is efficiently searched by simulated annealing. The packing techniques are, further, efficient and effective for area minimization, such that the MPT-base macro placer can solve mixed-size placement problems with very large macros and a large number of macros. Since macro orientations and spacing between macros are considered, the MPT-base macro placer leads to significantly shorter wirelength and less congestion than other mixed-size placers. The MPT-base macro placer can also easily function within various placement constraints, such as pre-placed blocks, corner blocks, and placement blockages. The MPT-base macro placer can be combined with state-of-the-art standard cell placers to obtain better mixed-size placement solutions based on a two-stage mixed-size placement flow.
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A multi-packing tree (MPT) macro placer. The MPT macro placer comprises reading input files in a LEF/DEF format, creating a k-level binary multi-packing tree comprising k branch nodes each corresponding to one level and k+1 packing sub-trees each corresponding to one of the nodes and comprising a group of macros, optimizing the multi-packing tree according to a packing result thereof, and generating output files in a DEF format.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2004-033491, filed Feb. 10, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor memory device having memory cells with floating gates and a method of controlling the threshold voltages of the memory cells.
2. Description of the Related Art
Conventionally, flash memories have been extensively used as nonvolatile semiconductor memories.
The erase operation of the flash memories is performed by drawing electrons out of the floating gates. In the erase operation, a block of memory cells is erased at a time. In this case, there will exist overerased cells the threshold voltages of which have dropped too much lower than a constant lower-limiting value. After electrons have been drawn out of the floating gates, therefore, such processing as makes the threshold voltages of the overerased cells higher than the lower-limiting value is performed. The processing includes self-convergence processing and weak program processing. The self-convergence and the weak program have been proposed in, for example, Japanese Patent Application Publication KOKAI No. 11-66898 and U.S. Pat. No. 5,568,419, respectively.
With conventional flash memories, the threshold voltages of overerased cells are set higher than a constant value through the self-convergence or weak program processing. With the processing methods proposed so far, however, it takes a long time to raise the threshold voltages of the overerased cells. In addition, difficulties may be involved in making the threshold voltages of the overerased cells sufficiently high, in which case semiconductor memory devices are often discarded as faulty chips.
BRIEF SUMMARY OF THE INVENTION
A semiconductor memory device according to an aspect of the present invention comprising:
a memory cell array in which a plurality of memory cells each having a stacked gate including a floating gate and a control gate is arranged in rows and columns;
a plurality of word lines each of which connects commonly the control gates of the memory cells arranged in a respective one of the rows;
a plurality of bit lines each of which connects commonly drains of the memory cells arranged in a respective one of the columns;
a control circuit which performs first control to collectively shift the threshold voltages of the memory cells to within a predetermined range with a first level as an upper limit, second control to shift a lower limit of the threshold voltages shifted to within the predetermined range through the first control toward a second level lower than the first level, and third control to shift the lower limit of the threshold voltages shifted through the second control to a third level between the first and second levels; and
a measurement circuit which measures the elapsed time from the start of the second control,
the control circuit repeating
A method of controlling a threshold voltage of a semiconductor memory device according to an aspect of the present invention, the device having memory cells each including a stacked gate containing a floating gate and a control gate, the method comprising:
collectively shifting the threshold voltage of the memory cells to within a predetermined range with a first level as its upper limit;
starting time measurement;
shifting the lower limit of the threshold voltages collectively shifted to within the predetermined range toward a second level lower than the first level;
repeating shifting the lower limit of the threshold voltages toward the second level until the lower limit of the threshold voltages reaches the second level or the elapsed time form the start of time measurement reaches a predetermined time; and
shifting the lower limit of the threshold voltages to a third level between the first and second levels when the lower limit of the threshold voltages reaches the second level or the elapsed time from the start of time measurement reaches a predetermined time.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a block diagram of a flash memory according to a first embodiment of the present invention;
FIG. 2 is a circuit diagram of the memory cell array according to the first embodiment of the present invention;
FIG. 3 is a flowchart illustrating a threshold voltage control method of the flash memory according to the first embodiment of the present invention;
FIGS. 4 through 8 show number of memory cells versus threshold voltage for the flash memory according to the first embodiment of the present invention;
FIG. 9 is a circuit diagram of the memory cell array and shows bias conditions of the memory cell array at bit line leakage check in the flash memory according to the first embodiment of the present invention;
FIG. 10 is a circuit diagram of the memory cell array and shows bias conditions of the memory cell array at self-convergence in the flash memory according to the first embodiment of the present invention;
FIG. 11 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at bit line leakage check in the flash memory according to the first embodiment of the present invention;
FIG. 12 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at self-convergence in the flash memory according to the first embodiment of the present invention;
FIG. 13 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at overerase verification in the flash memory according to the first embodiment of the present invention;
FIG. 14 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at overerase verification in the flash memory according to the first embodiment of the present invention;
FIG. 15 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at weak program in the flash memory according to the first embodiment of the present invention;
FIG. 16 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at overerase verification in the flash memory according to the first embodiment of the present invention;
FIG. 17 is a circuit diagram of a part of the memory cell array and shows bias conditions of the memory cell array at weak program in the flash memory according to the first embodiment of the present invention;
FIG. 18 is a block diagram of a flash memory according to a second embodiment of the present invention;
FIG. 19 is a flowchart illustrating a threshold voltage control method of the flash memory according to the second embodiment of the present invention;
FIG. 20 is a flowchart illustrating a threshold voltage control method according to a modification of the first embodiment of the present invention; and
FIG. 21 is a flowchart illustrating a threshold voltage control method according to a modification of the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the description which follows, in reading data, when a current that flows in a bit line is a predetermined value or more in magnitude (i.e., a memory cell is on), we shall refer it as data “1” or “1” readout. Conversely, when the current is less than the predetermined value (i.e., the memory cell is off), we shall refer it as data “0” or “0” readout. Although the embodiments of the invention will be described in terms of two-valued memories which can store data “0” and “1”, the principles of the embodiment can naturally be applied to multiple-valued (over three data) memories.
Reference is now made to FIG. 1 to describe a semiconductor memory device and a memory cell threshold voltage control method according to a first embodiment of the present invention. FIG. 1 is a block diagram of a NOR type of flash memory according to the first embodiment.
As shown, the flash memory comprises a memory cell array 1 , a control circuit 2 , a bit line bias circuit 3 , a source line bias circuit 4 , a word line bias circuit 5 , a row decoder 6 , a column selector 7 , a column decoder 8 , an I/O circuit 9 , an address buffer 10 , an address counter 11 , a verify circuit 12 , and a timer circuit 13 .
The memory cell array 1 has a plurality of memory cells arranged in a matrix form of rows and columns. FIG. 2 is a circuit diagram of the memory cell array 1 of a NOR type of flash memory by way of example.
As shown in FIG. 2 , a memory cell MC has a MOS transistor with a stacked-gate structure. The stacked-gate structure contains a floating gate FG formed on a semiconductor substrate with a gate insulting film interposed therebetween and a control gate CG formed on the floating gate FG with a gate insulating film interposed therebetween. The memory cell MC has its drain connected to a bit line BL, its source connected to a source line SL, and its control gate connected to a word line WL. The memory cells MC in the same row are connected commonly to the same word line WL. The memory cells MC in the same column are connected commonly to the same bit line BL. The threshold voltage Vth of the memory cell MC can be varied by changing the number of electrons which accumulate at the floating gate FG. Whether data to be stored in the memory cell MC is “1” or “0” depends on its threshold voltage Vth.
The control circuit 2 is responsive to an externally input command CMD to control the threshold voltages of the memory cells MC at data write operation or data erase operation. The control circuit 2 controls the bit line bias circuit 3 , the source line bias circuit 4 , and the word line bias circuit 5 to change the bias conditions of the memory cell array 1 . The threshold voltages of the memory cells MC are controlled by changing the bias conditions of the memory cell array 1 .
The address buffer 10 holds an address signal and supplies row and column addresses to the row decoder 6 and the column decoder 8 , respectively.
The address counter 11 is adapted to, when a need arises to generate an address, which is usually supplied from outside, inside the chip, generate it on the basis of a control signal from the control circuit 2 . The address counter 11 increments the address to generate different addresses in sequence and supplies them to the address buffer 10 .
The row decoder 6 decodes a row address signal from the address buffer 10 to obtain a row address decoded signal. The row decoder selects a corresponding one of the word lines WL.
The column decoder 8 decodes a column address signal from the address buffer 10 to obtain a column address decoded signal. The column decoder selects a corresponding one of the bit lines BL.
The column selector 7 connects the bit line BL selected by the column decoder 8 to the I/O circuit 9 .
The bit line bias circuit 3 applies a bit line bias voltage to the bit line BL selected by the column decoder 8 . The bit line bias circuit 3 is responsive to a control signal from the control circuit 2 to switch the bit line bias voltage between data read operation and data write operation.
The word line bias circuit 5 applies a word line bias voltage to a word line WL selected by the row decoder 6 or to all the word lines WL. The word line bias circuit 5 is responsive to a control signal from the control circuit 2 to change the word line bias voltage according to each of the memory operations: data read, data write, and data erase.
The source line bias circuit 4 applies a source bias voltage to the source lines SL. The source line bias voltage is usually 0 volts. With a data erase scheme based on discharge of electrons to the source lines SL, however, the source line bias voltage is set higher than 0 volts at data erase operation on the basis of a control signal from the control circuit 2 .
The I/O circuit 9 determines whether a bit of read data is either “0” or “1” by making a comparison between a current flowing in a selected bit line BL and a predetermined value IREF.
The verify circuit 12 detects whether or not the threshold voltage Vth of a memory cell MC is at a desired level when the data is written into or erased. In verification after the write operation or the erase operation, the verify circuit 12 detects whether or not the threshold voltage Vth is at the desired level on the basis of the determination by the I/O circuit 9 of whether read data is “0” or “1”.
The timer circuit 13 measures time according to an instruction by the control circuit 2 . More specifically, the timer circuit measures the elapsed time from the start of a self-convergence process at data erase operation.
Next, the threshold voltage control method of the NOR type of flash memory according to this embodiment will be described with reference to FIG. 3 . FIG. 3 is a flowchart illustrating the threshold voltage control method, which is applied to data erase sequence in particular.
First, prior to data erase, a preliminary program (Pre-Program) is executed in step S 1 . At preliminary program, write pulse is applied to all or part of the word and bit lines within a block to be erased and sets all the memory cells to the “0” or “1” state. FIG. 4 shows a distribution of the threshold voltages Vth of the memory cells at the termination of the preliminary program. As shown in FIG. 4 , in this example, the threshold voltages Vth of all the memory cells MC are shifted in the direction of data “0” so that their distribution becomes opposite to that after data erase.
Next, in step S 2 , data erase is carried out, thereby causing a distribution of the threshold voltages of all the memory cells to be shifted in the direction from “0” to “1”.
In this embodiment, a scheme which is referred to as auto-erase is adopted for data erase. In the auto-erase, data is erased in substep S 21 , then erase verification is carried out in substep S 22 and a decision is made in substep S 23 as to whether or not the threshold voltages Vth of the memory cells are less than an erase verification voltage VEV. If the threshold voltages Vth are the erase verification voltage VEV or more, then data erase is repeated (substep S 21 ). FIG. 5 shows a distribution of the threshold voltages during auto-erase and FIG. 6 shows a distribution of the threshold voltages at the termination of auto-erase.
Thus, by repeating the erase verification and the data erase, the threshold voltages Vth of all the memory cells are first set such that Vth<VEV as shown in FIG. 6 .
Next, in step S 3 , the width of the distribution of the threshold voltages Vth is reduced. In this embodiment, to reduce the distribution width, the lower limiting value Vth-min of the threshold voltages Vth is raised stepwise in at least two steps.
To this end, this embodiment contains a first step (step S 31 ) to raise the lower limiting value Vth-min to a first lower limiting value and a second step (step S 32 ) to further increase the first lower limiting value to a second lower limiting value close to the erase verification voltage VEV. The first and second steps (steps S 31 and S 32 ) will be described hereinafter.
The object of the first step (step S 31 ) is to set the lower limiting value Vth-min of the threshold voltages Vth higher than a first overerase verification voltage VOEV 1 . That is, the object is to set the threshold voltages Vth of all the memory cells such that VOEV 1 <Vth<VEV.
A method to achieve the object is to reduce currents flowing in the bit lines below a predetermined value I REF-LEAK under the condition that all the word lines within a block to be erased are supplied with a constant bias voltage.
An example of the constant bias voltage applied to all the word lines is the first overerase verification voltage VOEV 1 , which is, say, −1 volts. To set the threshold voltage Vth higher than −1 volts, it is recommended that a predetermined value I REF-LEAK be set smaller than the predetermined value I REF at data read operation.
Suppose that a current of more than 10 μA flows in the bit lines when the voltage on the word lines goes higher than the threshold voltage Vth by more than 1 volts. The value of 10 μA is taken as the predetermined value I REF for distinguishing between “0” readout and “1” readout at data read operation. In this case, if the bit line current is 10 μA or more, it is taken as “1” readout. Conversely, if the bit line current is less than 10 μA, it is taken as “0” readout.
Thus, when the predetermined value I REF at read time is set at 10 μA, the predetermined value I REF-LEAK at the time of leak current detection (hereinafter referred to as bit line leakage check) is set to less than 10 μA, say, 1 μA. That is, if a current of 1 μA or more flows in the bit line at the bit line leak check time, it is taken as “1” readout. Conversely, if the bit line current is less than 1 μA, it is taken as “0” readout.
Suppose now that a constant bias voltage applied to the word lines is −1 volts. Then, if the bit line current I≧10 μA, it can be assumed that Vth≦−2 V.
Further, if 10 μA>I≦1 μA, it can be assumed that −2 V<Vth≦−1 V.
Thus, setting I<1 μA will lead to Vth>−1 V.
Thus, the predetermined value for distinguishing between “0” readout and “1” readout is set more strictly at bit line leak check time than at data read operation. For example, the bit line current is set to less than 1 μA. Thereby, the threshold voltage Vth can be set to more than VOEV 1 , the first overerase verification voltage.
Although the predetermined value I REF-LEAK has been described as being 1 μA, it is only required that this value be set suitably in consideration of some factors including capacitance associated with the bit lines.
As a method to set the bit line current to less than 1 μA, in other words, to set Vth to more than VOEV 1 (i.e., the first overerase verification voltage), use may be made of self-convergence. Hereinafter, a description is given of the case where self-convergence is used in step S 31 .
Referring back to FIG. 3 , the column addresses are first initialized in substep S 31 - 1 .
Next, in substep S 31 - 2 , the counter in the timer circuit 13 is reset to 0 to start time measurement. The timer circuit 13 measures the elapsed time from the start of the self-convergence process (i.e., the time taken to perform step S 31 ).
Next, a bit line leak check is made in substep S 31 - 3 . This involves selecting the bit line BL 0 through the initialized column addresses and detecting a leak current in the selected bit line BL 0 . The predetermined value I REF-LEAK at this time is set to less than the predetermined value I REF at read operation, say, 1 μA. In FIG. 9 , there are shown the bias conditions of the memory cell array 1 at leakage current detection time.
As shown in FIG. 9 , all the word lines within a block to be erased are placed in non-selected state. That is, they are supplied with a non-selection bias voltage of, say, −1 volts by the word line bias circuit 5 . The selected bit line BL 0 is supplied with a read bias voltage of, say, 0.5 volts by the bit line bias circuit 3 . The non-selected bit lines BL 1 , BL 2 , BL 3 , and so on are placed in the open state or set at 0 volts. The source lines SL are set at 0 volts.
Next, in substep S 31 - 4 , a decision is made as to whether the leakage current flowing in the selected bit line BL 0 is less than 1 μA or not under the bias conditions shown in FIG. 9 . This is performed by comparing the magnitude of the leakage current flowing in the bit line BL 0 with the predetermined value I REF-LEAK to determine either “0” readout or “1” readout.
If the result of the decision is “0” readout, that is, the leakage current is less than 1 μA, then the procedure goes to substep S 31 - 5 .
In substep S 31 - 5 , a decision is made as to whether or not the column address is the final address. If so, the first step S 31 is complete and the procedure then goes to the second step S 32 . Otherwise, the column address is incremented by one in substep S 31 - 6 and then the procedure returns to substep S 31 - 2 .
With the example shown in FIG. 9 , the threshold voltage Vth of the memory cell MC 00 is Vth≦−1 V. Therefore, when the process of substep S 31 - 3 is performed on the bit line BL 0 , a leakage current of 1 μA or more is detected in the selected bit line BL 0 . Thus, it can be assumed that cells the threshold voltage Vth of which is −1 volts or less are connected to the bit line BL 0 .
Therefore, the procedure then goes to substep S 31 - 7 because it will be decided in substep S 31 - 4 that the leakage current is 1 μA or more. In substep S 31 - 7 , the control circuit 2 checks the time being measured by the timer circuit 13 . That is, a decision is made as to whether or not the elapsed time from substep S 31 - 2 is within a predetermined time. If the predetermined time has passed, then the procedure goes to substep S 31 - 5 . Otherwise, the procedure goes to substep S 31 - 8 in which self-convergence is performed. FIG. 10 shows the bias conditions of the memory cell array 1 at self-convergence.
As shown, the bit line bias circuit 3 applies a self-convergence bias voltage higher than the read bias voltage to the selected bit line BL 0 . The self-convergence bias voltage is the same as the write bias voltage, say, 5 volts. The non-selected bit lines BL 1 , BL 2 , BL 3 and so on are placed in the open state or set at 0 volts. The source lines SL are set at 0 volts. The word line bias circuit 5 supplies the word lines WL 0 , WL 1 , WL 2 , and so on with a bias voltage most suitable for self-convergence, which is in the range of, say, 0 to 1 volt. By setting up such bias conditions, self-convergence is performed on the memory cells MC connected to the bit line BL 0 with the result that the threshold voltage of each of the memory cells is raised.
Upon termination of the self-convergence, the procedure returns to substep S 31 - 3 . That is, a leakage check is performed on a bit line and, in the presence of leakage, self-convergence is repeated until the leakage dies out or the time limit is up. When the leakage has died out or when a constant time has elapsed after the start of the self-convergence regardless of the presence of leakage, the self-convergence on that bit line is completed and the same processing is then performed on the next bit line.
In the example of FIG. 9 , suppose that the self-convergence (substep S 31 - 8 ) has raised the threshold voltage Vth of the memory cell MC 00 above −1 volts. Then, the procedure goes to substep S 31 - 5 since no leakage will be detected by the bit line leakage check (substeps S 31 - 3 and S 31 - 4 ). Since the final column address is not yet reached, the column address is incremented by one (substep S 31 - 6 ). The same processing as with the bit line BL 0 is then performed on the bit line BL 1 .
That is, the counter in the timer circuit 13 is reset to 0 to start time measurement (substep S 31 - 2 ). Next, a leakage check is made on the bit line BL 1 (substep S 31 - 3 ). This situation is illustrated in FIG. 11 . Suppose here that the threshold voltage Vth of the memory cell MC 12 connected to the bit line BL 1 is −1 volts or less. Then, a leakage current of 1 μA or more is detected in the bit line BL 1 (substep S 31 - 4 ). Next, the control circuit 2 makes a decision of whether or not the elapsed time measured by the timer circuit 13 is within the predetermined time (substep S 31 - 7 ). If so, the procedure goes to substep S 31 - 8 to perform self-convergence on the memory cells MC connected to the bit line BL 1 . The self-convergence and the leakage check are repeated until the bit line leakage dies out or the time limit is up. Suppose here that, as shown in FIG. 12 , the elapsed time measured by the timer circuit 13 has passed the predetermined time before the threshold voltage Vth of the memory cell MC 12 exceeds −1 volts (substep S 31 - 8 ). That is, assume that the self-convergence has failed to make the threshold voltage higher than VOEV 1 within the predetermined time. In that case, the procedure goes to step S 31 - 5 without performing the self-convergence again with the threshold voltage Vth of the memory cell MC 12 remaining at −1 volts or less. The processes in steps S 31 - 2 through S 31 - 8 are then performed on the bit line BL 3 and so on.
Upon completion of the process in step S 31 on all the bit lines, the procedure next goes to step S 32 . FIG. 7 shows the distribution of the threshold voltages of the memory cells after the termination of the first step (step S 31 ). As shown, the self-convergence changes the threshold voltages of many of the memory cells in which the threshold voltage is −1 volts or less to more than −1 volts. If the bit line leakage has died out for all the bit lines, the threshold voltages Vth of all the memory cells are set such that VOEV 1 <Vth<VEV. In the presence of bit lines in which the bit line leakage has not died out within the time limit, however, the threshold voltages Vth of some memory cells connected to such bit lines still remain at VOEV 1 or less.
Next, the second step (step S 32 ) will be described. In the second step, the weak program scheme is used. The weak program is performed for each individual memory cell unlike the self-convergence which is performed for each bit line.
First, in substep S 32 - 1 , the addresses are initialized.
Next, in substep S 32 - 2 , overerase verification is performed. FIG. 13 shows the bias conditions of the memory cell array 1 at overerase verification. As shown, the word line WL 0 selected by the initialized addresses is supplied with an overerase verification bias voltage from the word line bias circuit 5 . The overerase verification bias voltage is set at 2.5 volts, for example, which is 1 volt higher than a second overerase verification bias voltage VOEV 2 which is set at 1.5 volts. The reason why the overerase verification bias voltage is set 1 volt higher than VEOV2 is that a current which flows in the bit line when the voltage on the word line goes higher than the threshold voltages Vth of memory cells by 1 volt or more is set at 10 μA and this is defined as the predetermined value I REF at overerase verification. This predetermined value I REF is the same as the one at read operation.
The non-selected word lines WL 1 , WL 2 , WL 3 , and so on are supplied with a non-selection bias voltage of the order of, say, −1 volts.
Next, the bit line BL 0 selected by the initialized addresses is supplied with a read bias voltage of the order of, say, 0.5 volts from the bit line bias circuit 3 . Thereby, the memory cell MC 00 is selected as a candidate cell for overerase verification. The non-selected bit lines BL 1 , BL 2 , BL 3 and so on are placed in the open state or supplied with 0 volts. The source lines are supplied with 0 volts.
Next, in substep S 32 - 3 , a decision is made as to whether or not the on current flowing in the selected bit line BL 0 is less than 10 μA under the bias conditions shown in FIG. 13 . This is achieved by comparing the magnitude of the on current in the bit line BL 0 with the predetermined value I REF to determine either “0” readout or “1” readout.
When the threshold voltage Vth of the memory cell MC 00 is Vth>1.5 volts and the bit line leakage current is less than 10 μA, the procedure goes to substep S 32 - 4 .
In substep S 32 - 4 , a decision is made as to whether or not the address is the final address. If the final address is not reached, the procedure goes to substep S 32 - 5 in which the address is incremented by one. The procedure then returns to substep S 32 - 2 .
In substep S 32 - 2 , the bit line BL 1 is selected in place of the bit line BL 0 as the result of incrementing the address and supplied with the read bias voltage (0.5 volts) as shown in FIG. 14 . In this way, the memory cell MC 10 is selected as a candidate cell for overerase verification.
Next, in substep S 32 - 3 , a decision is made as to whether or not the on current flowing in the selected bit line BL 1 is less than 10 μA under the bias conditions shown in FIG. 14 . If the on current is 10 μA or more (NO in substep (S 32 - 3 )), it can be assumed that the threshold voltage Vth of the selected memory cell MC 10 is 1.5 volts or less as shown in FIG. 14 .
The procedure thus goes to substep S 32 - 6 to execute the weak program. FIG. 15 shows the bias conditions of the memory cell array 1 at weak program execution. As shown, the selected word line WL 0 is supplied with a weak program word line bias voltage of the order of, say, 3 volts from the word line bias circuit 5 . The non-selected word lines WL 1 , W 12 , WL 3 , and so on are supplied with a non-selection bias voltage of the order of −1 volts. The selected bit line BL 1 is supplied by the bit line bias circuit 3 with a weak program bit line bias voltage, which is the same as the write bias voltage, of the order of 5 volts. The non-selected bit lines BL 0 , BL 2 , BL 3 , and so on are placed in the open state or set at 0 volts. The source lines SL are set at 0 volts.
By setting up the bias conditions shown in FIG. 15 , the weak program is performed on the memory cell MC 10 , causing its threshold voltage to rise. In such a weak program operation, electrons are injected from the drain into the floating gate by positively applying voltages to the word line WL 0 and the bit line BL 1 which are connected to the selected memory cell MC 10 . To this end, the weak program bias voltage applied to the selected word line WL 0 and the write bias voltage applied to the selected bit line BL 1 are simply applied in the form of pulses with microsecond order width as in the case of usual write operations.
The weak program bias voltage is set to a value less than a usual program bias voltage, which is, say, of the order of 9 volts. This makes the number of electrons injected into the floating gate of the selected memory cell MC 10 at weak program time smaller than at usual program time. Thus, the value by which the threshold voltage Vth of the selected memory cell MC 10 is raised at weak program becomes smaller than at usual program. That is, the weak program allows the threshold voltage Vth to be raised slightly.
Upon completion of the weak program, the procedure goes to substep S 32 - 3 in which the overerase verification is performed under the bias conditions shown in FIG. 14 . If the result is that the on current in the bit line BL 1 is 10 μA or more (NO in substep S 32 - 3 ), then the weak program operation is repeated in substep S 32 - 6 . If, on the other hand, the on current is less than 10 μA (YES in substep S 32 - 3 ), then the procedure goes to substep S 32 - 4 .
In substep S 32 - 4 , a decision is made as to whether or not the final address has been reached. If not, the procedure goes to substep S 32 - 5 to increment the address. The procedure then returns to substep S 32 - 2 .
After the column address has been incremented to the final address, it is initialized to zero (initial value). The row address is then incremented to select the word line WL 1 in place of the word line WL 0 . In this way, a decision is made as to whether or not a weak program is needed for each of the memory cells within a block to be erased. The weak program is performed when necessary. Of course, it is allowed to, after a bit line has been selected, sequentially increment the row address and then increment the column address after the row address has reached the final address.
Naturally, memory cells the threshold voltages Vth of which were not raised above VOEV 1 within the predetermined time in the self-convergence process in the first step (step S 31 ) become candidates for weak program in the second step (step S 32 ). As described with reference to FIG. 12 , for the memory cell MC 12 , although its threshold voltage Vth is less than −1 volts, the self-convergence process was prematurely terminated because the predetermined time has passed. In the overerase verification (substep S 32 - 3 ), therefore, an on current of 10 μA or more will flow in the memory cell MC 12 as shown in FIG. 16 . Thus, as shown in FIG. 17 , the threshold voltage Vth of the memory cell MC 12 is set to go higher than 1.5 volts by the weak program.
Upon termination of the process up to the final address, the second step is completed. FIG. 8 shows the distribution of the threshold voltages of the memory cells after the termination of the second step. As shown, the threshold voltages Vth of all the memory cells are set such that VOEV 2 <Vth<VEV.
Thus, when the second step terminates, the data erase sequence according to this embodiment is completed.
As described above, the flash memory and the memory cell threshold voltage control method according to the first embodiment of the present invention offer the following advantages (1) and (2):
(1) The erase operation can be speeded up.
With the threshold voltage control method according to this embodiment, the timer circuit 12 measures the elapsed time from the start of the self-convergence process (the time taken to perform the self-convergence process). The control circuit 2 terminates the self-convergence process when a predetermined time has elapsed from the start of the self-convergence process. Memory cells for which the self-convergence process have been prematurely terminated are remedied by the next weak program process. Therefore, it is possible to set the self-convergence process time short. More specifically, the self-convergence time, which was conventionally required to be several milliseconds, can be set to several microseconds according to the method of the first embodiment.
(2) The efficiency of remedying memory cells can be improved.
According to the threshold voltage control method of the first embodiment, the threshold voltages of memory cells for which the self-convergence process has failed to set their threshold voltages to within a predetermined range can be set to within the predetermined range by the subsequent weak program process. That is, such memory cells are remedied by the weak program, otherwise the corresponding chip would be judged to be a faulty chip as with conventional memory chips. Thus, chips which would be judged to be faulty according to the conventional method can also be remedied, allowing the efficiency of remedying memory cells to be improved.
Next, a semiconductor storage device and a threshold voltage control method according to a second embodiment of the present invention will be described with reference to FIGS. 18 and 19 . FIG. 18 is a block diagram of a NOR type of flash memory according to the second embodiment. FIG. 19 is a flowchart illustrating the threshold voltage control method. With the second embodiment, the self-convergence process is restricted by the number of times rather than by time.
As shown in FIG. 18 , the flash memory of the second embodiment differs from the flash memory of the first embodiment shown in FIG. 1 only in that the timer circuit 13 is replaced by a counter circuit 14 . The counter circuit 14 counts the number of times the self-convergence process is performed at erase time.
As shown in FIG. 19 , in the threshold voltage control method of the second embodiment, the process of time measurement by the timer circuit 13 in the method described in the first embodiment is replaced by a process of counting by the counter circuit 14 of the number of times the self-convergence process is performed.
That is, in the first step (step S 31 ), after initializing the column address (substep S 31 - 1 ), the control circuit 2 resets the count in the counter circuit 14 to zero (substep S 31 - 9 ). Next, a bit line leakage check is made (substep S 31 - 3 ). If the leakage current is of a predetermined magnitude or more (NO in substep S 31 - 4 ), then the control circuit 2 checks the counter circuit 14 for its count (substep S 31 - 10 ). If the count is less than a predetermined value (NO in substep S 31 - 10 ), then self-convergence is carried out (substep S 31 - 8 ). Upon termination of the self-convergence, the counter circuit 14 increments its count by one. The procedure then returns to substep S 31 - 3 .
That is, if the bit line leakage has fallen below a predetermined level or the number of times the self-convergence was performed has exceeded a predetermined value, the control circuit terminates self-convergence process for the corresponding bit line. Suppose, for example, that the number of times the self-convergence is to be performed is ten. Although the self-convergence has been performed ten times, if the bit line leakage remains greater than the predetermined level, the self-convergence is no longer performed on the corresponding bit line. The memory cells connected to the corresponding bit line are remedied by the next weak program.
The subsequent process remains unchanged from that in the first embodiment and hence a description thereof is omitted.
The flash memory according to the second embodiment will also offer the advantages (1) and (2) described in the first embodiment.
FIGS. 20 and 21 are flowcharts illustrating flash memory threshold voltage control methods according to modifications of the first and second embodiments. In the first and second embodiments, the self-convergence is first performed on all the columns (bit lines) and then the weak program sequence is carried out starting with the first column. The first and second embodiments may be modified such that the self-convergence and the weak program are performed in turn for each column and the column address is finally incremented after the threshold voltages Vth of memory cells have come to exceed the second overerase verification voltage VOEV 2 .
That is, as shown in FIGS. 20 and 21 , if the leakage current flowing in a selected bit line is less than 1 μA (YES in substep S 31 - 4 ), or the time measured by the timer circuit 13 has passed the predetermined time (YES in substep S 31 - 7 ), or the number of times that the self-convergence was performed has exceeded a predetermined value (YES in substep S 31 - 10 ), the procedure goes to substep S 32 - 2 in the second step (step S 32 ) without regard to the column address. Overerase verification is then performed on a selected memory cell.
After the overerase verification, a decision is made as to whether or not the on current caused by the selected memory cell to flow in the bit line is less than 10 μA in substep S 32 - 3 .
If the on current is 10 μA or more (NO in substep S 32 - 3 ), then the procedure goes to substep S 32 - 6 to perform the weak program and then returns to substep S 32 - 2 . If, on the other hand, the on current is less than 10 μA (YES in substep S 32 - 3 ), then the procedure goes to substep S 32 - 7 to make a decision of whether or not the row address is the final one.
If the row address is not the final one, then the procedure goes to substep S 32 - 8 to increment the row address by one and then returns to substep S 32 - 2 . If, on the other hand, the row address is the final one, then the procedure goes to substep S 32 - 9 to make a decision of whether the column address is the final one.
If the column address is not the final one, then the procedure goes to substep S 32 - 9 to initialize the row address and increment the column address by one. The procedure then returns to substep S 31 - 2 ( FIG. 20 ) or substep S 31 - 9 ( FIG. 21 ) in the first step to perform a bit line leakage check on the bit line selected by the incremented column address. If the final column address has been reached, the erase operation is completed.
According to these modifications, the number of times the column address is scanned can be reduced from two (substeps S 31 - 5 and S 32 - 5 in FIGS. 3 and 19 ) in the first and second embodiments to one (substep S 32 - 10 in FIGS. 20 and 21 ), allowing the erase sequence to be simplified.
The first and second embodiments can be applied, as needed, not only to NOR types of flash memories but also to other types of flash memories which perform similar operations.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A semiconductor memory device includes a memory cell array, word lines, bit lines, a control circuit, and a measurement circuit. The memory cell array has memory cells including a floating gate. The control circuit performs first control to collectively shift the threshold voltages of the memory cells to within a predetermined range with a first level as an upper limit, second control to shift a lower limit of the threshold voltages toward a second level lower than the first level, and third control to shift the lower limit to a third level. The measurement circuit measures the elapsed time from the start of the second control. The control circuit repeats the second control, and then terminates the second control when the lower limit reaches the second level or the elapsed time measured by the measurement circuit reaches the predetermined time and performing the third control.
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FIELD OF THE INVENTION
The invention relates to containers for desiccants and is particularly concerned with desiccant containers used within heating, ventilation and air conditioning (HVAC) systems.
BACKGROUND OF THE INVENTION
The invention relates to desiccant containers for any purpose. However, specific embodiments will be described with respect to desiccant containers within HVAC systems.
A typical vehicle air conditioning system, for example, incorporates a compressor, a condenser, an expansion device, an evaporator and a refrigerant storage device. The compressor compresses refrigerant. The refrigerant flows to the condenser, where it changes state from gas to liquid. In a system with a thermal expansion valve (a “TXV system”), refrigerant then passes into a refrigerant storage device called a receiver/dryer (R/D) before passing to the expansion device. In a system with a fixed orifice tube (an “FOT system”), refrigerant then passes directly from the condenser to the expansion device. The expansion device is used to significantly lower the pressure and temperature of the refrigerant before it passes to the evaporator. After the expansion device, the liquid refrigerant then flows to the evaporator. At that stage, an air blower passes air over the evaporator to the passenger compartment of the vehicle, thereby cooling the air within the vehicle. The heat transfer from the ambient air to the evaporator causes most of the refrigerant to change from a liquid to a gas.
In an FOT system, the refrigerant (now mostly gas and some liquid) flows from the evaporator to a refrigerant storage device called an accumulator. (In a TXV system, the refrigerant flows from the evaporator to the compressor directly.)
One purpose of the accumulator is to separate liquid refrigerant from gaseous refrigerant, so that only gaseous refrigerant returns to the compressor. Liquid refrigerant entering the compressor causes “flooding” which in turn reduces system efficiency and can damage the compressor. Hence it is standard practice to include an accumulator between the evaporator and the compressor to separate and store the excess or residual liquid. The residual liquid refrigerant in the accumulator eventually turns to a gaseous state and is then passed to the compressor.
Accumulators and receivers/dryers often incorporate a desiccant to prevent (or at least limit) moisture ingression in the compressor and the resulting damage or loss of efficiency to the air conditioning system. (For simplicity, hereinafter, the term “accumulator” or “refrigerant storage device” will refer to both accumulators and receiver/dryers.)
Particulate desiccants are often used in such systems because of the high area-to-volume ratios of the particles with respect to the surrounding air or fluid. Because the desiccant particles must be held in the air or fluid stream and prevented from contaminating other parts of the air conditioning system, the particles must be held in a container which is permeable to the air or fluid but impermeable to the particles.
In some known cases, loose desiccant is contained within a bag, the bag being constrained between filters. The filters are often discs made of felt, gauze, fiber or plastic (fused). Such bags are problematic because they can be easily damaged during assembly and/or testing. A tear in the bag allows the loose desiccant particles to escape and potentially enter the air-conditioning system, where they can damage the accumulator and other components.
In certain other systems, it is known to confine the desiccant within a hard container. In those cases, filter discs, such as those described above, are typically placed in the top and bottom of the desiccant container during manufacturing. However, there are certain drawbacks associated with the use of such filter discs. For example, the materials used within the filter discs, such as polyester or polypropylene matted or needles felt, for example, have been known to stimulate a reaction with the air conditioning refrigerant R-134A to create a significant noise within the air conditioning system. It would be desirable to eliminate the noise. It would also be desirable to eliminate the cost associated with the purchase of the filter discs. It would also be desirable to eliminate the time and cost associated with their installation within the desiccant cup. It would also be desirable to eliminate filter discs because they deteriorate during service and release high aspect ratio fibres into the air conditioning system.
A number of desiccant cups are known which have a one-piece cup with a one-piece cap, such as that taught in U.S. Pat. No. 5,522,204 in the name of Wood. The cup taught in Wood incorporates holes formed within the cap and cup bottom. However, such cups require additional filter layers placed against the cap and cup bottom. As well, holes formed within the cap and cup bottom in this manner have a number of drawbacks. One drawback is that diameter of the holes is large enough to allow desiccant particles to pass through or become caught or blocked in the holes. Therefore, such cups require a separate filter. As well, it would be desirable to have a more open area for fluid to pass through than is permitted through an array of holes, such as taught in Wood, because more open area reduces pressure drop in the system, thereby increasing efficiency.
SUMMARY OF THE INVENTION
According to a first aspect, the invention provides a desiccant container for use in a refrigerant storage device of a vehicle, the container comprising a lid comprising an inner boundary defining a first aperture, an outer boundary surrounding the inner boundary, and an integral first mesh screen extending between the inner boundary and the outer boundary, wherein the first mesh screen is adapted to prevent small particles from passing therethrough; a body comprising an inner wall defining a second aperture, an outer wall surrounding the inner wall, and an integral second mesh screen extending between the inner wall and the outer wall, wherein the second mesh screen is adapted to prevent small particles from passing therethrough; wherein the lid and the body are adapted to fit together to create an enclosed cavity, and to prevent small particles from passing between an edge of the lid and the body, and when the lid and the body are together, the first aperture and the second aperture are aligned.
According to another aspect, the invention provides a desiccant container for use in a refrigerant storage device of a vehicle, the container comprising at least one integral mesh screen, each mesh screen preventing small particles from passing therethrough.
According to yet another aspect, the invention provides a refrigerant storage device for a vehicle, the refrigerant storage device comprising a desiccant container wherein the container comprises at least one integral mesh screen, each mesh screen preventing small particles from passing therethrough.
Advantageously, different embodiments of the present invention may permit: the elimination of noise created in the air conditioning system when polyester, polypropylene matted, other matted synthetic fibre, cotton fibre, low permeation or needled felt are used as filters; the reduction of cost by eliminating the need to purchase separate filters for the desiccant container; the reduction of time and cost relating to the labour required to install separate filters for the desiccant container; a desiccant container incorporating integral filtration with significant open area, thereby reducing pressure drop (as compared to a container with less open area); the provision of a filter for 100% of the liquid above the oil bleed hole of the accumulator, which provides a significant advantage since a typical oil bleed filter (located in or near the oil bleed aperture) is small in size and can become partially or completely blocked with a relatively small amount of contamination (thereby disrupting oil flow); and increasing the efficiency of the air conditioning system.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the attached drawings in which
FIG. 1 is a side view of a representative accumulator, with certain features inside the accumulator, including a desiccant container, shown by dotted outline in accordance with an aspect of the present invention;
FIG. 2 a is a perspective view of a desiccant container in accordance with an aspect of the present invention;
FIG. 2 b is a perspective view of a lid of the desiccant container of FIG. 2 a;
FIG. 2 c is a side view of the lid of FIG. 2 b;
FIG. 2 d is a perspective view looking down on the body of the desiccant container of FIG. 2 a;
FIG. 2 e is a perspective view looking up at the body of the desiccant container of FIG. 2 d;
FIG. 2 f is a perspective view of an alternate embodiment of a desiccant container;
FIG. 2 g is a perspective view of a desiccant cup of the desiccant container of FIG. 2 f;
FIG. 2 h is a perspective view of the desiccant cup of FIG. 2 g , looking up;
FIG. 3 a is a partial cut-away, side view of a portion of the accumulator of FIG. 1 ; and
FIG. 3 b is cross-sectional view of the desiccant container of FIG. 2 f within the accumulator of FIG. 1 , taken along line 3 b – 3 b of FIG. 1 (with the outlet tube omitted).
DETAILED DESCRIPTION
FIG. 1 shows a representative accumulator or refrigerant storage device 10 for an air conditioning (or heating, ventilation and air conditioning (HVAC)) system of a vehicle. The accumulator 10 as shown in FIG. 1 has certain features omitted for simplicity and certain features inside the accumulator 10 are shown by dotted outline. A desiccant container 12 according to an aspect of the present invention is shown roughly in position within the accumulator 12 , for example purposes.
FIG. 2 a is a perspective view of the desiccant container 12 . The desiccant container 12 has two portions, namely an open body or cup portion 14 and a lid 16 . FIG. 2 b is a perspective view of the lid 16 . FIG. 2 d is a perspective view of the open cup 14 .
As perhaps best seen in FIG. 2 b , the lid 16 is a one-piece casting. The lid 16 is a generally circular, one-piece casting, having a generally circular outer or peripheral boundary 20 and a concentric, generally circular, inner boundary 22 , forming an opening 24 therein. Between the peripheral boundary 20 and the inner boundary 22 is an integrally molded mesh screen 30 , advantageously supported and strengthened by an integrally molded, lattice support structure 32 . Preferably, the mesh screen 30 has a low profile. As shown in FIG. 2 b , the profile of the inner boundary 22 and the profile of the peripheral boundary 20 may be higher than the profile of the mesh screen 30 . Similarly, the profile of the support structure 32 may be higher than the profile of the mesh screen 30 .
As shown in FIGS. 2 b and 2 c , an outer surface 34 of the peripheral boundary 20 advantageously has an integral bead 36 or series of beads extending outwardly therefrom.
As perhaps best seen in FIG. 2 d , the cup 14 is a one-piece casting. The cup 14 incorporates a generally cylindrical inner wall 40 , and a concentric, generally cylindrical outer wall 42 . The inner wall 40 and the outer wall 42 are joined by an integrally molded bottom portion 44 extending between the inner wall 40 and the outer wall 42 and connecting with the inner and outer walls 40 , 42 at or near their bases. The bottom portion 44 comprises a mesh screen 46 supported and strengthened by an integrally molded, lattice support structure or grid 50 . Advantageously, the mesh screen 46 has a low profile. As shown in FIG. 2 d , the profile of the support structure 50 may be higher than the profile of the mesh screen 46 . The support structure 50 also acts as a gating system for the injection molding process.
The support structure 50 for the mesh screen 46 of the cup 14 may be deeper and/or wider than the support structure 32 of the mesh screen 30 of the lid 16 . The support structure 32 in the lid 16 may be less deep and less wide to reduce the weight of the lid and to reduce the height of the lid. The precise geometry, configuration, and size of the support structures 32 and 50 may be varied. Although the support structures 32 and 50 could be omitted, they do provide certain advantages. Among other advantages, the support structures 32 and 50 help maintain a resistance to distortion during the molding process and they provide support for the finished product.
The bottom portion 44 of the cup 14 and the lid 16 each have an open area of approximately 30%. However, this percentage could vary depending upon many factors, including the size of the mesh screen openings 30 and 46 , as well as the strength and configuration of the support structures 32 and 50 , for example. The openings within the mesh screens 30 and 46 are sized to restrict the passage of desiccant particles and other particles that may be detrimental to the air conditioning compressor. Ideally, the openings within the mesh screens 30 and 46 are smaller than about 350 microns, and advantageously smaller than about 300 microns.
According to one embodiment, the outer surface of the inner wall 40 of the cup 14 has an outwardly extending support rib 52 and the outer wall 42 has a corresponding, inwardly extending support rib 54 . Just above the support rib 54 on the inner surface of the outer wall 42 , is a groove 56 .
The inner surface of the inner wall 40 of the cup 14 has an inwardly extending outlet tube stop or support rib 60 . As well, as shown in FIG. 2 e , the inner surface of the inner wall 40 of the cup 14 , below the outlet tube stop 60 , has an inwardly extending step or liner support rib 71 , for supporting the cup 14 on the liner 70 , as described below.
Advantageously, on the outer surface of the outer wall 42 of the cup 14 , just below the top edge of the outer wall 42 is an outwardly extending bead 62 . Alternatively, the bead 62 could instead be a series of beads 62 (not shown).
In order to use the desiccant cup within the accumulator 10 , loose desiccant (not shown) is placed in the cup 14 . The lid 16 is then placed within the cup 14 . When the lid 16 is lowered within the cup 14 , the inner boundary 22 of the lid rests against a top surface of the support rib 52 of the inner wall 40 , and the peripheral boundary 20 of the lid 16 rests against a top surface of the support rib 54 of the outer wall 42 of the cup 14 . As well, the bead 36 on the outer surface 34 of the lid 16 snaps within the groove 56 of the outer wall 42 of the cup 14 to secure the lid 16 in place.
The lid 16 may be further secured to the cup 14 through a number of techniques known to those skilled in the art. One such technique is ultra-sonic welding. One weld (not shown) attaches the inner surface of the inner boundary 22 of the lid 16 to the outer surface of the inner wall 40 of the cup 14 . Another weld attaches the outer surface 34 of the lid 16 to the inner surface of the inner wall 40 of the cup 14 .
When the desiccant cup 14 has been filled with desiccant, such as synthetic zeolite or sol-gel silica, for example, and after the lid 16 has been secured to the cup 14 , the cup may be placed within the accumulator 10 . The particular configuration of the desiccant cup 14 and lid 16 described above may be accommodated by the accumulator 10 of the type shown in FIG. 3 . As shown in FIG. 3 , the accumulator 10 has an inner liner 72 , which fits within the accumulator 10 . The liner 72 incorporates a central support (not shown) for the cup 14 , which support terminates in an upwardly extending, open, generally circular terminal portion, forming a hole within the terminal portion. The terminal portion of the liner 72 has a diameter sufficient to support the bottom surface of the liner support rib 71 of the inner wall 40 of the cup 14 . The liner 72 may also incorporate a groove 74 in its inside surface.
The desiccant cup 14 is placed on top of the terminal portion of the liner 72 . In that position, the bead 62 on the exterior surface of the outer wall 42 of the cup 14 snaps into the groove 74 on the inside surface of the liner 72 , to help secure the cup 14 in position and to prevent passage of particles between the outer wall 42 of the cup 14 and the inside surface of the liner 72 .
When the cup 14 is in position within the liner 70 , an outlet tube 80 is placed inside the inner wall 40 of the cup 14 , the outlet tube being supported by the upper surface of the outlet tube stop 60 .
Preferably, the elements of the liner 72 , the cup 14 and the lid 16 are adapted to fit together so that particles larger than 350 microns cannot pass from above the lid 16 to below the cup 14 .
The cup 14 and the lid 16 could be manufactured from any number of materials known to those skilled in the art including nylon, polyester, and polypropylene materials suitable for use in environments where refrigerant and oil are present. As suggested above, the cup 14 and the lid 16 may be formed by injection molding.
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 practised otherwise than as specifically described herein.
Of course, there are many other possible configurations to allow a lid and a cup for a desiccant to fit together. There are also many different configurations to allow a desiccant container to fit within an accumulator or receiver/dryer. One example of a configuration different from those described above is shown in the alternate embodiment of FIGS. 2 f , 2 g , 2 h and 3 b.
In the earlier embodiment shown in FIG. 2 a , the lid 16 fits within the circumference of the cup 14 . However, as shown in the alternate embodiment of a desiccant container 99 of FIGS. 2 f and 3 b , the circumference of a lid 100 rests on top of the circumference of a cup 102 .
A cross-sectional view of the desiccant container 99 of this alternate embodiment, in place within a liner 104 , is shown in FIG. 3 b . The lid 100 has an extension portion 106 extending away from a top portion of the lid 100 . A v-shaped projection portion 108 projects downwardly from the extension portion 106 . To help keep the lid 100 in position on the cup 102 , a groove 112 is located along a top surface of the cup 102 . After the lid 100 is placed on top of the cup 102 , the lid 100 may be ultrasonically welded to the cup 102 .
The desiccant container 99 is secured within the liner 104 by sliding the desiccant container 99 past a detent 116 , which detent 116 projects inwardly from the liner 104 .
As can also been seen from FIG. 3 b , lower portions of the cup 102 have downward, v-shaped projections 118 , which fit within corresponding v-shaped grooves 122 located within the liner 104 .
As shown in FIG. 3 b , the liner 104 incorporates a projecting support 124 . When the outlet tube 80 (not shown in FIG. 3 b ) is in place, the outlet 80 rests on top of the projecting support 124 .
This alternate embodiment omits a number of elements present in the earlier embodiments described above. For example, the outlet tube stop 60 (as shown in the earlier embodiment of FIG. 2 d ) and the liner support rib 71 of the inner wall 40 of the cup 14 (as shown in FIG. 2 e ) have been omitted. As well, the integral bead 36 on the lid 16 of the earlier embodiment of FIG. 2 c has been omitted. The groove 56 of the outer wall 42 of the cup as shown in the earlier embodiment of FIG. 2 d has been omitted. The bead 62 around the outer wall 42 of the cup 14 (as shown in FIG. 2 d ) has been omitted. Similarly, the groove 74 on the inside surface of the liner (as shown in FIG. 3 a ) has been omitted.
As noted above, many other possible embodiments are also within the scope of above teachings. For example, it is possible to design a desiccant container without distinguishable lid and cup portions.
As another example, although the embodiments described above relate to a desiccant container 12 having two integral mesh screens 30 and 46 , the desiccant container 12 could contain a single integral mesh screen, either 30 or 46 . Instead of the other integral mesh screen, a technique already known by those skilled in the art could be used to provide filtering (such as using a separate filtering device).
Many other modifications and/or variations are also possible. For example, there are many different techniques known to those skilled in the art for fitting parts of containers together and for securing containers within other objects. Therefore, for example, techniques different from those described herein could be used to secure the lid 16 to the cup 14 , to achieve a similar result. Various features of the desiccant container 12 have been described as being generally circular (such as the lid 16 , the inner boundary 22 of the lid 16 , the inner wall 40 of the cup 14 , the outer wall 42 of the cup 14 , etc.). However, different configurations could also be used. For example, in the embodiment of FIGS. 2 b and 2 d , the lid 16 has an opening 24 which is centered with respect to the outer boundary 20 . Similarly, the opening within the inner wall 40 of the cup 14 is centered with respect to the outer wall 42 . However, both the opening 24 of the lid 16 and the opening within the inner wall 40 of the cup 14 could be off center.
The configuration of the desiccant container 12 has been described herein to be adapted to the particular accumulator 10 and liner 72 , described above. However, the basic features of the desiccant container 12 could be adapted for other types and configurations of accumulators, with or without liners and for other purposes (outside of the context of air conditioning systems for vehicles). In other words, the embodiments described above relate to air conditioning systems in vehicles. However, the desiccant containers described herein could be used in air conditioning systems outside of the context of vehicles, and could be used outside of the context of air conditioning systems entirely.
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A desiccant container for use in an accumulator or a receiver/dryer of a vehicle includes at least one integral mesh screen for preventing small particles from passing therethrough. Preferably, the container includes two integral mesh screens, one forming an upper surface of the desiccant container and the other forming a lower surface of the desiccant container. By incorporating integral mesh screens, the container need not include separate filters.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 12/980,653, filed Dec. 29, 2010 (now published as US 2011/0089251) which is a continuation of U.S. patent application Ser. No. 12/546,209, filed Aug. 24, 2009 (now issued as U.S. Pat. No. 8,006,915) which is a continuation of U.S. patent application Ser. No. 10/577,718, filed May 2, 2006 (now issued as U.S. Pat. No. 7,594,614), which is a national stage of PCT/CA03/01683 filed Nov. 3, 2003.
TECHNICAL FIELD
[0002] The present invention relates, in general, to high-pressure waterjets for cleaning and cutting and, in particular, to high-frequency modulated waterjets.
BACKGROUND OF THE INVENTION
[0003] Continuous-flow high-pressure waterjets are well known in the art for cleaning and cutting applications. Depending on the particular application, the water pressure required to produce a high-pressure waterjet may be in the order of a few thousand pounds per square inch (psi) for fairly straightforward cleaning tasks to tens of thousands of pounds per square inch for cutting and removing hardened coatings.
[0004] Examples of continuous-flow, high-pressure waterjet systems for cutting and cleaning are disclosed in U.S. Pat. No. 4,787,178 (Morgan et al.), U.S. Pat. No. 4,966,059 (Landeck), U.S. Pat. No. 6,533,640 (Nopwaskey et al.), U.S. Pat. No. 5,584,016 (Varghese et al.), U.S. Pat. No. 5,778,713 (Butler et al.), U.S. Pat. No. 6,021,699 (Caspar), U.S. Pat. No. 6,126,524 (Shepherd) and U.S. Pat. No. 6,220,529 (Xu). Further examples are found in European Patent Applications EP 0 810 038 (Munoz) and EP 0 983 827 (Zumstein), as well as in US Patent Application Publications US 2002/0109017 (Rogers et al.), US 2002/0124868 (Rice et al.), and US 2002/0173220 (Lewin et al.).
[0005] Continuous-flow waterjet technology, of which the foregoing are examples, suffers from certain drawbacks which render continuous-flow waterjet systems expensive and cumbersome. As persons skilled in the art have come to appreciate, continuous-flow waterjet equipment must be robustly designed to withstand the extremely high water pressures involved. Consequently, the nozzle, water lines and fittings are bulky, heavy and expensive. To deliver an ultra-high-pressure waterjet, an expensive ultra-high-pressure water pump is required, which further increases costs both in terms of the capital cost of such a pump and the energy costs associated with running such a pump.
[0006] In response to the shortcomings of continuous-flow waterjets, an ultrasonically pulsating nozzle was developed to deliver high-frequency modulated water in non-continuous, virtually discrete packets, or “slugs”. This ultrasonic nozzle is described and illustrated in detail in U.S. Pat. No. 5,134,347 (Vijay) which on Oct. 13, 1992. The ultrasonic nozzle disclosed in U.S. Pat. No. 5,134,347 transduced ultrasonic oscillations from an ultrasonic generator into ultra-high frequency mechanical vibrations capable of imparting thousands of pulses per second to the waterjet as it travels through the nozzle. The waterjet pulses impart a waterhammer pressure onto the surface to be cut or cleaned. Because of this rapid bombardment of mini-slugs of water, each imparting a waterhammer pressure on the target surface, the erosive capacity of the waterjet is tremendously enhanced. the ultrasonically pulsating nozzle cuts or cleans is thus able to cut or clean much more efficiently than the prior-art continuous-flow waterjets.
[0007] Theoretically, the erosive pressure striking the target surface is the stagnation pressure, or ½.rho.v.sup.2 (where ρ represents the water density and v represents the impact velocity of the water as it impinges on the target surface). The pressure arising due to the waterhammer phenomenon, by contrast, is ρcv (where c represents the speed of sound in water, which is approximately 1524 m/s). Thus, the theoretical magnification of impact pressure achieved by pulsating the waterjet is 2 c/v. Even if air drag neglected and the impact velocity is assumed to approximate the fluid discharge velocity of 1500 feet per second (or approximately 465 m/s), the magnification of impact pressure is about 6 to 7. If the model takes into account air drag and the impact velocity is about 300 m/s, then the theoretical magnification would be tenfold.
[0008] In practice, due to frictional losses and other inefficiencies, the pulsating ultrasonic nozzle described in U.S. Pat. No. 5,154,347 imparts about 6 to 8 times more impact pressure onto the target surface for a given source pressure. Therefore, to achieve the same erosive capacity, the pulsating nozzle need only operate with a pressure source that is 6 to 8 times less powerful. Since the pulsating nozzle may be used with a much smaller and less expensive pump, it is more economical than continuous-flow waterjet nozzles. Further, since waterjet pressure in the nozzle, lines, and fittings is much less with an ultrasonic nozzle, the ultrasonic nozzle can be designed to be lighter, less cumbersome and more cost-effective.
[0009] Although the ultrasonic nozzle described in U.S. Pat. No. 5,154,347 represented a substantial breakthrough in waterjet cutting and cleaning technology, further refinements and improvements were found by the Applicant to be desirable. The first iteration of the ultrasonic nozzle, which is described in U.S. Pat. No. 5,154,347, proved to be sub-optimal because it was used in conjunction with pre-existing waterjet generators. A need therefore arose for a complete ultrasonic waterjet apparatus which takes full advantage of the ultrasonic nozzle.
[0010] It also proved desirable to modify the ultrasonic nozzle to make it more efficient from a fluid-dynamic perspective, to be able to clean and remove coatings more efficiently from large surfaces, and to be more ergonomic in the hands of the end-user.
[0011] Accordingly, in light of the foregoing deficiencies, it would be highly desirable to provide an improved ultrasonic waterjet apparatus.
SUMMARY OF THE INVENTION
[0012] An aspect of the present invention provides an ultrasonic waterjet apparatus including a generator module which has an ultrasonic generator for generating and transmitting high-frequency electrical pulses; a control unit for controlling the ultrasonic generator; a high-pressure water inlet connected to a source of high-pressure water; and a high-pressure water outlet connected to the high-pressure water inlet. The ultrasonic waterjet apparatus further includes a high-pressure water hose connected to the high-pressure water outlet and a gun connected to the high-pressure water hose. The gun has an ultrasonic nozzle having a transducer for receiving the high-frequency electrical pulses from the ultrasonic generator, the transducer converting the electrical pulses into vibrations that pulsate a waterjet flowing through the nozzle, creating a waterjet of pulsed slugs of water, each slug of water capable of imparting a waterhammer pressure on a target surface.
[0013] Preferably, the transducer is piezoelectric or piezomagnetic and is shaped as a cylindrical or tubular core.
[0014] Preferably, the gun is hand-held and further includes a trigger for activating the ultrasonic generator whereby a continuous-flow waterjet is transformed into a pulsated waterjet. The gun also includes a dump valve trigger for opening a dump valve located in the generator module.
[0015] Preferably, the ultrasonic waterjet apparatus has a compressed air hose for cooling the transducer and an ultrasonic signal cable for relaying the electrical pulses from the ultrasonic generator to the transducer.
[0016] For cleaning or de-coating large surfaces, the ultrasonic waterjet apparatus includes a rotating nozzle head or a nozzle with multiple exit orifices. The rotating nozzle head is preferably self-rotated by the torque generated by a pair of outer jets or by angled orifices.
[0017] An advantage of the present invention is that the ultrasonic waterjet apparatus generates a much higher effective impact pressure than continuous-flow waterjets, thus augmenting the apparatus' capacity to clean, cut, deburr, de-coat and break. By pulsating the waterjet, a train of mini slugs of water impact the target surface, each slug imparting a waterhammer pressure. For a given pressure source, the waterhammer pressure is much higher than the stagnation pressure of a continuous-flow waterjet. Therefore, the ultrasonic waterjet apparatus can operate with a much lower source pressure in order to cut and deburr, to clean and remove coatings, and to break rocks and rock-like substances. The ultrasonic waterjet apparatus is thus more efficient, more robust, and less expensive to construct and utilize than conventional continuous-flow waterjet systems.
[0018] Another aspect of the present invention provides an ultrasonic nozzle for use in an ultrasonic waterjet apparatus. The ultrasonic nozzle includes a transducer for converting high-frequency electrical pulses into mechanical vibrations that pulsate a waterjet flowing through the nozzle, creating a waterjet of pulsed slugs of water, each slug of water capable of imparting a waterhammer pressure on a target surface. The nozzle has a rotating nozzle head or multiple exit orifices for cleaning or de-coating large surfaces.
[0019] Another aspect of the present invention provides an ultrasonic nozzle for use in an ultrasonic waterjet apparatus including a transducer for converting high-frequency electrical pulses into mechanical vibrations that pulsate a waterjet flowing through the nozzle, creating a waterjet of pulsed slugs of water, each slug of water capable of imparting a waterhammer pressure on a target surface, the transducer having a microtip with a seal for isolating the transducer from the waterjet, the seal being located at a nodal plane where the amplitude of standing waves set up along the microtip is zero.
[0020] Another aspect of the present invention provides related methods of cutting, cleaning, deburring, de-coating and breaking rock-like materials with an ultrasonically pulsed waterjet. The method includes the steps of forcing a high-pressure continuous-flow waterjet through a nozzle; generating high-frequency electrical pulses; transmitting the high-frequency electrical pulses to a transducer; transducing the high-frequency electrical pulses into mechanical vibrations; pulsating the high-pressure continuous flow waterjet to transform it into a pulsated waterjet of discrete water slugs, each water slug capable of imparting a waterhammer pressure on a target surface; and directing the pulsated waterjet onto a target material. Depending on the desired application, the ultrasonically pulsed waterjet can be used to cut, clean, de-burr, de-coat or break.
[0021] Where the application is cleaning or de-coating a large surface, the ultrasonic waterjet apparatus advantageously includes a nozzle with multiple exit orifices or with a rotating nozzle head.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:
[0023] FIG. 1 is a schematic side view of an ultrasonic waterjet apparatus having a mobile generator module connected to a hand-held gun in accordance with an embodiment of the present invention;
[0024] FIG. 2 is a schematic flow-chart illustrating the functioning of the mobile generator module;
[0025] FIG. 3 is a schematic showing the functioning of the ultrasonic waterjet apparatus;
[0026] FIG. 4 is a top plan view of the mobile generator module;
[0027] FIG. 5 is a rear elevational view of the mobile generator module;
[0028] FIG. 6 is a left side elevational view of the mobile generator module;
[0029] FIG. 7 is a cross-sectional view of an ultrasonic nozzle having a piezoelectric transducer for use in the ultrasonic waterjet apparatus;
[0030] FIG. 8 is a side elevational view of the ultrasonic nozzle mounted to a wheeled base for use in cleaning or decontaminating the underside of a vehicle;
[0031] FIG. 9 is a cross-sectional view of an ultrasonic nozzle showing the details of a side port for water intake and the disposition of a microtip for modulating the waterjet;
[0032] FIG. 10 is a side elevational view of a microtip in having the form of a stepped cylinder;
[0033] FIG. 11 is a cross-sectional view of a multiple-orifice nozzle for use in a second embodiment of the ultrasonic waterjet apparatus;
[0034] FIG. 12 is a schematic cross-sectional view of a third embodiment of the ultrasonic waterjet apparatus having a rotating nozzle head which is rotated by the torque generated by two outer jets;
[0035] FIG. 13 is a cross-sectional view of a rotating ultrasonic nozzle having angled orifices;
[0036] FIG. 14 is a cross-sectional view of a variant of the rotating ultrasonic nozzle of FIG. 13 ;
[0037] FIG. 15 is a cross-sectional view of another variant of the rotating ultrasonic nozzle of FIG. 13 ;
[0038] FIG. 16 is a cross-sectional view of an ultrasonic nozzle having an embedded magnetostrictive transducer;
[0039] FIG. 17 is a schematic cross-sectional view of a magnetostrictive transducer in the form of cylindrical core;
[0040] FIG. 18 is a cross-sectional view of an ultrasonic nozzle with a magnetostrictive cylindrical core;
[0041] FIG. 19 is a cross-sectional view of an ultrasonic nozzle with a magnetostrictive tubular core;
[0042] FIG. 20 is a schematic cross-sectional view of a rotating twin-orifice nozzle with a stationary coil; and
[0043] FIG. 21 is a schematic cross-sectional view of a rotating twin-orifice nozzle with a swivel.
[0044] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.
DETAILED DESCRIPTION
[0045] FIG. 1 illustrates an ultrasonic waterjet apparatus in accordance with an embodiment of the present invention. The ultrasonic waterjet apparatus, which is designated generally by the reference numeral 10 , has a mobile generator module 20 (also known as a forced pulsed waterjet generator). The mobile generator module 20 is connected via a high-pressure water hose 40 , a compressed air hose 42 , an ultrasonic signal cable 44 , and a trigger signal cable 46 to a hand-held gun 50 . The high-pressure water hose 40 and the compressed air hose 42 are sheathed in an abrasion-resistant nylon sleeve. The ultrasonic signal cable 44 is contained within the compressed air hose 42 for safety reasons. The compressed air is used to cool a transducer, which will be introduced and described below.
[0046] The hand-held gun 50 has a pulsing trigger 52 and a dump valve trigger 54 . The hand-held gun also has an ultrasonic nozzle 60 . The ultrasonic nozzle 60 has a transducer 62 which is either a piezoelectric transducer or a piezomagnetic transducer. The piezomagnetic transducer is made of a magnetostrictive material such as a Terfenol™ alloy.
[0047] As illustrated in FIG. 2 , the mobile generator module 20 has an ultrasonic generator 21 which generates high-frequency electrical pulses, typically in the order of 20 kHz. The ultrasonic generator 21 is powered by an electrical power input 22 and controlled by a control unit 23 (which is also powered by the electrical power input, preferably a 220-V source). The mobile generator module also has a high-pressure water inlet 24 which is connected to a source of high-pressure water (not illustrated but known in the art). The high-pressure water inlet is connected to a high-pressure water manifold 25 . A high-pressure water gage 26 connected to the high-pressure water manifold 25 is used to measure water pressure. A dump valve 27 is also connected to the high-pressure water manifold. The dump valve 27 is actuated by a solenoid 28 which is controlled by the control unit 23 . The dump valve is located on the mobile generator module 20 , instead of on the gun, in order to lighten the gun and to reduce the effect of jerky forces on the user when the dump valve is triggered. Finally, a high-pressure water pressure gage and switch 29 provides a feedback signal to the control unit.
[0048] Still referring to FIG. 2 , the mobile generator module 20 also has an air inlet 30 for admitting compressed air from a source of compressed air (not shown, but known in the art). The air inlet 30 connects to an air manifold 31 , an air gage 32 and an air-pressure sensor and switch 33 for providing a feedback signal to the control unit. The control unit also receives a trigger signal through the trigger signal cable 46 . The control unit 23 of the mobile generator module 20 is designed to not only ensure the safety of the operator but also to protect the sensitive components of the apparatus. For instance, if there is no airflow through the transducer, and water flow through the gun, then it is not possible to turn on the ultrasonic generator.
[0049] As shown in FIG. 2 , the mobile generator module 20 has a high-pressure water outlet 40 a , a compressed air outlet 42 a and an ultrasonic signal output 44 a which are connected to the hand-held gun 50 via the high-pressure water hose 40 , the compressed air hose 42 and the ultrasonic signal cable 44 , respectively.
[0050] FIG. 3 is a schematic diagram of the wiring and cabling of the ultrasonic waterjet apparatus 10 . The compressed air hose is rated for 100 psi and carries within it the ultrasonic signal cable which is rated to transmit high-frequency 3.5 kV pulses. The air hose and ultrasonic signal cable are plugged connects with the transducer in the gun. The high-pressure water hose is rated to a maximum of 20,000 psi and is connected to the gun but downstream of the transducer as shown. The trigger signal cable, designed to carry 27 VAC, 0.7 A signals, links the trigger and the generator module.
[0051] As shown in FIG. 3 , the ultrasonic waterjet apparatus 10 has several safety features. All the electrical receptacles are either spring-loaded or locked with nuts. As mentioned earlier, the water and air hoses are sheathed in abrasion-resistant nylon to withstand wear and tear. Further, in the unlikely event that an air hose is severed by accidental exposure to the waterjet, the voltage in the ultrasonic signal cable is reduced instantaneously to zero by the air pressure sensor and switch.
[0052] FIGS. 4 , 5 and 6 are detailed assembly drawings of the mobile generator module 20 showing its various components. The mobile generator module 20 has an air filter assembly 34 for protecting the transducer from dust, oil and dirt. The solenoid 28 is coupled to a pneumatic actuator assembly 35 for actuating the dump valve. The pneumatic actuator assembly includes a pneumatic valve 35 a , an air cylinder 35 b , an air cylinder inlet valve 35 c , an air cylinder outlet valve 35 d . The mobile generator module 20 further includes a water/air inlet bracket 36 , a water/air outlet bracket 37 , a pipe hanger 38 , the water pressure switch 29 , the air pressure switch 33 and a water/air pressure switches bracket 39 .
[0053] With reference to FIG. 7 , the ultrasonic nozzle 60 of the ultrasonic waterjet apparatus 10 uses a piezoelectric transducer or a piezomagnetic (magnetostrictive) transducer 62 which is connected to a microtip 64 , or, “velocity transformer”, to modulate, or pulsate, a continuous-flow waterjet exiting a nozzle head 66 , thereby transforming the continuous-flow waterjet into a pulsated waterjet. The ultrasonic nozzle 60 forms what is known in the art as a “forced pulsed waterjet”, or a pulsated waterjet. The pulsated waterjet is a stream, or train, of water packets or water slugs, each imparting a waterhammer pressure on a target surface. Because the waterhammer pressure is significantly greater than the stagnation pressure of a continuous-flow waterjet, the pulsated waterjet is much more efficient at cutting, cleaning, de-burring, de-coating and breaking.
[0054] The ultrasonic nozzle may be fitted onto a hand-held gun as shown in FIG. 1 or may be installed on a computer-controlled X-Y gantry (for precision cutting or machining operations). The ultrasonic nozzle may also be fitted onto a wheeled base 70 as shown in FIG. 8 . The wheeled base 70 has a handle 72 and a swivel 74 and twin rotating orifices 76 . The wheeled base of FIG. 8 can be used for cleaning or decontaminating the underside of a vehicle.
[0055] The continuous-flow waterjet enters through a water inlet downstream of the transducer as shown in FIG. 7 . As shown in FIG. 7 and FIG. 9 , the water enters the ultrasonic nozzle 60 though a side port 80 which is in fluid communication with a water inlet 82 . The water does not directly impinge on the slender end of the microtip 64 , which is important because this obviates the setting up of deleterious transverse oscillations of the microtip. Transverse oscillations of the microtip disrupt the waterjet and may lead to fracture of the microtip.
[0056] Although the microtip may be shaped in a variety of manners (conical, exponential, etc.), the preferred profile of the microtip is that of a stepped cylinder, as shown in FIG. 10 , which is simple to manufacture, durable and offers good fluid dynamics. The microtip 64 is preferably made of a titanium alloy. Titanium alloy is used because of its high sonic speed and because it offers maximum amplitude of oscillations of the tip. As shown in FIG. 10 , the microtip 64 has a stub 67 and a stem 65 . The stub 67 is female-threaded for connection to the transducer. The stem 65 is slender and located downstream so that it may contact and modulate the waterjet. Also shown in FIG. 10 is a flange 69 located between the stub 67 and the stem 65 . The flange 69 defines a nodal plane 69 a . As the sound waves travel downstream (from left to right in the FIG. 10 ), and are reflected at the tip, a pattern of standing waves are set up in the microtip 64 . At the nodal plane 69 a , the amplitude of the standing waves is zero and therefore this is the optimum location for placing an O-ring (not shown) for sealing the high-pressure water. The O-ring is hard-rated at 85-durometer or higher.
[0057] As shown in FIG. 7 , the ultrasonic nozzle 60 has a single orifice 61 . A single orifice is useful for many applications such as cutting and deburring various materials as well as breaking rock-like materials. However, for applications such as cleaning or de-coating large surface areas, a single orifice only removes a narrow swath per pass. Therefore, for applications such as cleaning and removing coatings such as paint, enamel, or rust, it is useful to provide a second embodiment in which the ultrasonic nozzle has a plurality of orifices. An ultrasonic nozzle 60 with three orifices 61 a is shown in FIG. 11 . The microtip has three prongs for modulating the waterjet as it is forced through the three parallel exit orifices. The triple-orifice nozzle of FIG. 11 is thus able to clean or de-coat a wider swath than a single-orifice nozzle. As shown in FIG. 11 , a nut 60 a secures the multiple-orifice nozzle to a housing 60 b . FIG. 11 shows how the microtip 64 culminates in three prongs 64 a , one for each of the three orifices 61 a.
[0058] In a third embodiment, which is illustrated in FIG. 12 , the ultrasonic nozzle 60 has a rotating nozzle head 90 which permits the ultrasonic nozzle 60 to efficiently clean or de-coat a large surface area. The rotating nozzle head 90 is self-rotating because water is bled off into two outer jets 92 . The bled-off water generates torque which causes the outer jets 92 to rotate, which, in turn, cause the rotating nozzle head 90 to rotate. In this embodiment, the bulk of the waterjet is forced through one or two angled exit orifices 91 . Depending on the material to be cleaned, the outer jets may or may not contribute to the cleaning process. An acoustically matching swivel 94 is interposed between the transducer and the rotating nozzle head. The swivel 94 is designed to not only withstand the pressure but also acoustically match the rest of the system to achieve resonance. The swivel 94 may or may not have a speed control mechanism, such as a rotational damper, for limiting the angular velocity of the rotating nozzle head.
[0059] As shown in FIGS. 13 , 14 , and 15 , self-rotation of the rotating nozzle head 90 may be achieved by varying the angle of orientation of the exit orifices 91 . As the waterjet is forced out of the exit orifices, a torque is generated which causes the rotating nozzle head 90 to rotate. A rotational damper in the swivel 94 may be installed to limit the angular velocity of the rotating nozzle head 90 . The configurations shown in FIGS. 13 , 14 and 15 are particularly useful in confined spaces. For cleaning and de-coating large surfaces, it is also possible to use a single oscillating nozzle.
[0060] For underwater operations, the piezomagnetic, transducer is used rather than the piezoelectric which cannot be immersed in water. The piezomagnetic transducer 62 can be packaged inside the nozzle 60 unlike the piezoelectric transducer. The piezomagnetic transducer uses a magnetostrictive material such as one of the commercially available alloys of Terfenol™. These Terfenol-based magnetostrictive transducers are compact and submergible in the nozzle 60 as shown in FIG. 16 . Whereas the piezoelectric transducer produces mechanical oscillations in response to an applied oscillating electric field, the magnetostrictive material produces mechanical oscillations in response to an applied magnetic field (by a coil and bias magnet as shown in FIG. 17 ). However, for reliable operation, it is important to keep the magnetostrictive material below the Curie temperature and always under compression. While the compressive stress can be applied by the end plates shown in FIG. 17 , cooling it to keep the temperature below the Curie point, particularly for the uses described herein, requires one of several different techniques, depending on the application.
[0061] FIG. 17 shows one assembly configuration for a magnetostrictive transducer 62 . A Terfenol™ alloy is used as a magnetostrictive core 100 . The core 100 is surrounded concentrically by a coil 102 and a bias magnet 104 as shown. A loading plate 106 , a spring 107 and an end plate 108 keep the assembly in compression.
[0062] For short-duration applications, which do not require rotating nozzle heads, the configuration shown in FIG. 16 is adequate. In this configuration, the transducer is cooled by airflow just as in the case of a piezoelectric transducer (e.g. by compressed air being forced over the transducer).
[0063] For long period of operation, or for operating in a rotating configuration, this type of airflow cooling is not a viable solution. The configurations shown in FIGS. 18 , 19 , 20 and 21 can be adopted for any demanding situation. As illustrated in FIG. 18 , the Terfenol rod is cooled by high-pressure water flowing through an annular passage. As illustrated in FIG. 19 , on the other hand, a Terfenol is shaped as a tube 100 a to further enhance cooling. The Terfenol tube is placed within the coil 102 and bias magnet 104 , as before. The configurations shown in FIGS. 18 and 19 can be used for non-rotating multiple-orifice configurations.
[0064] For rotating nozzle heads incorporating two or more orifices, the configurations illustrated in FIGS. 20 and 21 are more suitable. As shown in FIGS. 20 and 21 , high-pressure water is forced through an inlet 82 , pulsated and then ejected through two exit orifices 76 . Each exit orifice has its own microtip 64 , or “probe”, that is vibrated by the magnetostrictive transducer 62 . In FIG. 20 , the nozzle head 66 is rotated while the coil 102 remains stationary. In FIG. 21 , the nozzle is rotated using a swivel 74 as described earlier. As a result, the pulsed waterjet is split into two jets for efficiently cleaning or de-coating a large surface area.
[0065] The embodiment(s) of the invention described above is (are) intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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An ultrasonic waterjet apparatus has a mobile generator module and a high-pressure water hose for delivering high-pressure water from the mobile generator module to a hand-held gun with a trigger and an ultrasonic nozzle. An ultrasonic generator transmits high-frequency electrical pulses to a piezoelectric or magnetostrictive transducer which vibrates to modulate a high-pressure waterjet flowing through the nozzle. The waterjet exiting the ultrasonic nozzle is pulsed into mini slugs of water. The ultrasonic waterjet apparatus may be used to cut and de-burr materials, to clean and de-coat surfaces, and to break rocks. The ultrasonic waterjet apparatus performs these tasks with much greater efficiency than conventional continuous-flow waterjet systems because of the repetitive waterhammer effect. A nozzle with multiple exit orifices or a rotating nozzle may be provided in lieu of a nozzle with a single exit orifice to render cleaning and de-coating large surfaces more efficient.
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STATEMENT OF GOVERNMENT RIGHTS
This invention was made with government support under U.S. Navy contract #N00039-08-C-0022 awarded by The U.S. Navy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates to the field of radio receiver systems and methods, and more particularly to receivers which are tolerant of high levels of in-band interference.
BACKGROUND OF THE INVENTION
Radio receivers are well known. Typically, systems are designed to avoid strong interferors in the received band, or provide sufficient dynamic range in the bandwidth of the receiver to tolerate both the interferor and the signal of interest.
In order to avoid interference, the antenna and/or receiver may be designed to reject signals having particular frequency characteristics. Likewise, transmissions with defined temporal constraints may be filtered. Further, directional antennas or antenna arrays may provide spatial discrimination. These methods work to avoid interference if a signal of interest may be distinguished from an interferor by spatial, temporal or spectral characteristics. On the other hand, in many cases, interferors cannot be so distinguished.
It thus is also possible to remove interference. If the interferor is not coincident with the signal of interest, a filter may be applied to block the interferor. This possible solution requires that the interferor be sufficiently predictable that a filter may be provided, and that the filter be sufficiently precise to avoid distortion or degradation of the signal of interest. Where the interferor and signal of interest overlap, a filter is difficult or impossible to employ.
A second method of removing interferors is to provide active signal cancellation. In this case, a model of the interfering signal is created, which is then subtracted from the received signal. This requires that a sufficiently accurate representation of the interfering signal be created, and precisely matched in amplitude and phase with the actual interferor. Where the interferor is modulated, this technique must tolerate the modulated waveform, or model the modulation in real time.
See, for example, U.S. Pat. Nos. 7,362,257, 7,359,465, 6,574,270, 6,570,909, 6,501,788, 7,349,505, 7,349,504, 7,336,930, 7,333,420, 7,295,597, 7,292,552, and U.S. Patent Applications 20030053526, 20020172173, and 20020051433, each of which are expressly incorporated herein by reference.
Active noise cancellation is employed in various fields, such as audio. As the frequency of the interferor to be canceled increases, the difficulty in matching the phase of the signal also increases. If the phase mismatch is more than 90 degrees, the cancellation system can actually increase the interference. Likewise, as the bandwidth of the interferor increases, the difficulty in matching the phase delay across the entire band increases in difficulty. Thus, while interference cancellation has been deployed in various systems, its adoption at radio frequencies, for complex interferors, has been limited. See, e.g., Gardner, W. Agee, B., “Two-stage adaptive noise cancellation for intermittent-signal applications”, IEEE Transactions on Information Theory, 26(6):746-750 (November 1980).
SUMMARY OF THE INVENTION
The present invention provides a self-calibrating, two stage interference cancellation architecture for mitigating interference present in a wideband receiver, and especially which avoids saturation of the receiver, or even damage to the receiver, by strong interferors.
In sensitive radio frequency receivers, the use of input protection devices may cause undesired distortion of the input, or loss of sensitivity. Therefore, a strong signal is passed directly to a sensitive input device, which may have limited input capacity.
One aspect of the present invention provides an active protection scheme for the input stage of a radio frequency receiver, in which signals which would overload the electronic input stages are cancelled. In this case, cancellation need not be limited to interferors, though in the case of high amplitude signals of interest, it is generally preferred to reduce gain, since this will often reduce the influence of interferors without increasing complexity. Since this cancellation is performed prior to amplification or other active processing of the received signal, the cancellation signal is an analog signal. Typically, the cancellation signal is generated by a digital signal processor, which is then converted to an analog signal which is summed (subtracted) with the incoming signal. Alternately, if the electronic input stages are differential, the cancellation signal may be presented as a common mode signal which is removed through a differential amplification process. In either case, the net result is to pass a signal to the electronic input stages which is within the capacity of those stages to handle, wherein the signal may still retain partial interference and even possible distortion from the first cancellation process. In a second stage of interference cancellation, interferors present in the electronically processed signal, generally prior to digitization, are removed from the signal. In this second stage, a residual interference signal, and possibly components resulting from the first stage cancellation process, are removed, leaving a representation of the received signal absent the interferors. In some cases, it may be desired to inject a signal into the receive signal chain, and this may be intentionally done by controlling the first and/or second stage cancellation signals. Likewise, in some cases, it may be desired to remove a signal which is not a true “interferor”.
The two stage architecture provides an advantage in that the first stage is adapted to avoid irreversible distortion of the signal of interest while maintaining an amplitude of the interferor below a saturation or damage level for the input circuitry.
In a digital receiver according to embodiments of the present invention, there is an amplification of a received signal, followed by digitization of the amplified signal. The digitizer, on the other hand, has different saturation and possible damage issues than the analog amplification circuitry. Therefore, the second stage circuitry is directed at a different task than the first: to modify the signal which has successfully passed through the analog input stages, to remove signal components which would disrupt the digitization or later signal processing.
Typically, the first and second stage interference cancellation are controlled together, in a coordinated fashion. For example, in a linear and non-distorting signal processing chain, a digital signal representing the interference signal is generated as a multi-bit parallel representation. The high order bits are used to generate the first stage interference cancellation signal, while the low order bits, with appropriate scaling, are used to generate the second stage interference cancellation signal.
According to another embodiment, a model of an interfering signal is defined in a digital processor. The model is then used to generate two separate analog signals of appropriate precision, serving as respective first and second stage interference cancellation signals. In this case, the first stage signal has a high amplitude, and, for example, suffers from a predictable distortion, such as an intermodulation distortion. The second stage signal is generated based on the same model as the first stage, and also a model of the analog input components and the residual signal entering the analog-to-digital converter. The second stage interference cancellation signal therefore represents the residual interference which is not cancelled by the first stage signal, and intermodulation of signals, especially of the residual interferor and the signal of interest. Of course, other distributions of function are contemplated.
According to a preferred embodiment of the invention, a model of an interfering signal, for example a co-site interferor for which the data which generates the transmitted waveform is available, is used to generate a corresponding signal which is subtracted from a received signal. In particular, the invention provides a two-stage interference cancellation system, having a first stage which precedes active circuits within the receiver, and thereby reduces signal overload and permits high gain, and a second stage which is provided after amplification of the difference signal resulting from the first stage.
After the second stage, the interferor is substantially cancelled, and the signal may be directly digitized or further processed.
Since the first stage occurs prior to amplification or other processing, the cancellation signal is established to reduce the level of the resulting signal such that it does not saturate or damage remaining components of the system, and since there is a second stage, the cancellation does not have to be complete. Further, by reducing the interferor amplitude prior to passing through non-linear processing elements, such as semiconductor amplifiers, the level of intermodulation distortion is decreased.
Typically, the first stage cancellation signal represents a model of the interfering signal, which may be, for example, a representation of the source data for that signal and an interference signal path model, which for example can account for transmitter distortion, multipath, and the like. On the other hand, the second stage can be adaptively driven based on the downstream signal, less dependent on the interfering signal per se, since the output of the second stage is within the dynamic range of the receiver, permitting digital processing of the resulting signal after the second stage. Therefore, the first stage seeks to grossly cancel the interfering signal, while the second stage addresses residual components. Generally, the second stage accepts signals which are within the operating range of the circuit technology, but possibly outside the saturation range of the receiver, and produces a signal within the operating range of the receiver. The first stage, since it precedes active components, has a much larger operating range with respect to received signals, without damage or substantial distortion.
In one embodiment of the invention, the model of the interfering signal may represent the sum of multipath transmitted signals, each with its own gain and delay factors. The model may also incorporate intermodulation products of strong interfering signals, derived for example from nonlinear components in the transmit chain.
FIG. 1 shows a block diagram of an embodiment of the invention. This system represents a broadband receiver comprising components that may incorporate multiple device technologies and multiple operating temperatures. The multi-stage architecture enables one to select the optimum technology and temperature for each component. For example, as described in more detail below, the hybrid technology hybrid temperature (HTHT) receiver of FIG. 1 may have having room temperature semiconductors, high temperature superconductors and cooled semiconductors, and low temperature superconductors as part of an integrated system. In this architecture, the decimated output of an analog-to-digital converter (ADC) is cross-correlated with a digital-RF transmit signal in a digital correlator. This cross-correlation specifies the time delay and gain characteristic of co-site interference carried to the receiver. The correlation output is iteratively used to adjust the gain of the cancellation signal until high precision interference rejection is achieved.
The gain of the cancellation signal is digitally modeled in a look-up table. The data in the lookup table(s) may be derived from various sources, for example from a transmitter or feedback from the receiver, or both. The lookup table is, in a preferred embodiment, used to drive the second stage interference cancellation stage, and possibly the first interference cancellation stage. For example, the lookup table is used to drive a digital-to-analog converter (DAC) to generate the second stage, or fine cancellation signal, which in turn is subtracted from the first modified signal derived from the first stage (coarse) cancellation stage. The subtraction technique is, for example a magnetic flux subtractor, though other known techniques may be employed.
In some cases, such as multipath interference, the interferor can be modeled as a “fractal” or wavelet or self-similar pattern which is repeated in time or space, with a relatively simple variation between instances. In this case, a look-up table can be used to describe the basic form of the signal, with a parametric variation applied to describe the separate instances. Thus, in the case of a multipath interferor, a lookup table can describe the earliest occurrence of a signal, and may be updated adaptively, and a set of parameters describing delay and gain for each later instance used for cancellation.
The cancellation signal for the first stage cancellation signal generator may be derived directly from a transmitter-derived signal. The second stage cancellation signal may also be driven from the lookup table, or alternately or additionally, may be derived from a feedback loop within the receiver. The difference arises due to the fact that the first stage signal must generally be defined before the receiver settles, and therefore a feedback architecture, especially during startup, is problematic. On the other hand, the second stage cancellation signal may be required to avoid distortion, but in some cases, a signal usable for at least defining cancellation parameters may be available before the final second stage interference cancellation parameters are established. For example, a less sensitive or more tolerant digitizer may be provided and employed during startup. Likewise, the signal to be generated for the second stage interference cancellation may not be readily apparent from the information used to derive the first stage interference cancelling signal. Thus, while during an initialization phase, the first and second stage interference cancellation signals may be derived from a common transmit reference signal or other library reference signal, after the system is started, a feedback signal (other than the gain and delay adjustments discussed above) may be advantageously employed to define the signal parameters.
The data within the lookup table may be up-dated periodically, and therefore may be generated by slower computational components than the cancellation circuitry itself. These slower computational components may be, for example, silicon-based digital signal processors operating at room temperature or cryogenic temperatures, but not necessarily superconducting temperatures.
The gain adjustment to null the interference signal, is typically performed digitally, by adjusting the magnitudes of data in the lookup table, though this can also be adjusted digitally after the table, or as an analog gain adjustment. The phase relationship of the lookup table data and the signal may be determined using an autocorrelator, which will produce an output representing a delay and a gain factor between the signal and table data. The clocking or index of the lookup table may then be adjusted to assure maximum cancellation. A genetic or Monte Carlo algorithm may be implemented to ensure that the phase and amplitude (or more generally, time delay and gain factor) are optimally determined.
In a preferred embodiment, a self-calibration procedure is implemented which consists of an adaptive algorithm that is used to modify the gain in the look-up table (LUT). In this embodiment, interference reduction of greater than 60 dB is demonstrated in a system model.
A preferred embodiment of the interference cancellation architecture provides a two-stage hybrid temperature, hybrid technology (HTHT) scheme with a coarse canceller at high temperature, and a fine canceller at low temperature. Since the current from the input is coupled to the quantizer via a step-up current transformer, the quantizer potentially sees a much higher current, directly proportional to the turns ratio of the transformer.
The choice of turns ratio is influenced by the required mutual inductance and secondary inductance of the transformer; the values establish the current sensitivity and noise floor respectively of the analog-to-digital converter (ADC). For example, assuming a transformer turns ratio of ten, and an interference signal amplitude before the transformer of 200 mA, 2 Amperes of current will flow through the quantizer. In a worst case scenario, the first stage cancellation signal will add in-phase with the interference signal, resulting in 4 Amperes of current through the quantizer. In the absence of a current limiting device, such high currents may permanently damage the electronic device. It is difficult to place an on-chip current limiter at the low temperature superconducting (4 Kelvin) stage, and hence, it is preferred to perform the subtraction in a high temperature stage, either at 70 Kelvin stage using HTS (high temperature superconductor) materials or at room temperature. A current limiter technology may be employed similar to that disclosed in Mathias Noe, Michael Steurer, “High-temperature superconductor fault current limiters: concepts, applications, and development status”, Supercond. Sci. Technol. 20 R15-R29 (2007), expressly incorporated herein by reference.
Thus, another reason for the two-stage architecture is because a current limiter is required before the sensitive receiver system, and this is preferably implemented at higher temperatures than the low temperature superconducting circuits which implement a preferred receiver. However, this high temperature stage interference canceller may not sufficiently cancel the interferor to permit direct processing, and hence a second stage canceller operating at low temperature superconducting temperatures may also be provided. For example, a delta-sigma digital to analog converter may have insufficient dynamic range and bandwidth to fully cancel the interferor in the initial stage.
It is therefore an object to provide a receiver, comprising an input adapted to receive an analog signal, such as an antenna, antenna array, or cable; a first combiner adapted to combine the analog signal with a first signal to produce a first combined signal, such as a resistive combiner, electrostatic coupler, a flux subtractor, or the like; an overload protection device adapted to selectively block the first combined signal if it represents an overload condition, to produce an overload protected signal; a second combiner adapted to combine the overload protected signal with a second signal to produce a second combined signal, such as a resistive combiner, electrostatic coupler, a flux subtractor, or the like; and a saturable detector, adapted to detect information within the second combined signal. This system therefore isolates overload conditions from the second combiner and saturable detector, which may be, for example, superconducting devices which are relatively intolerant of high power signals which must be dissipated.
It is another object to provide a communication system, comprising a first electronic subsystem adapted to generate a first digital representation associated with an interfering signal, the first digital representation being adjusted in time delay and gain factor and converted to a first analog representation and subtracted from a received signal comprising an information signal having an amplitude, forming a first difference signal wherein interference from the interfering signal is at least partially cancelled; an amplifier adapted to amplify the first difference signal; a second electronic subsystem adapted to generate a second digital representation associated with a residual signal comprising at least one of a residual interfering signal and a residual component of the first analog representation present in the difference signal, the second digital representation being adjusted in time delay and gain factor and converted to a second analog representation and subtracted from the first difference signal, forming a second difference signal wherein interference from the residual signal is at least partially cancelled; and a detector adapted to produced a response to the second difference signal at a data rate, to thereby represent the information signal, wherein said detector has at least one of: a saturation level, wherein in response to a presented signal having an amplitude below the saturation level, a detector output represents a concurrent state of the presented signal, and in response to a presented signal having an amplitude above the saturation level, the detector output is dependent on a state of a plurality of temporally spaced states of the presented signal, wherein said communication system is tolerant of an interfering signal having an amplitude sufficient to produce a presented signal to the detector above the saturation level, thereby interfering with detection of the information signal, and a dynamic range, wherein a ratio of the power of the interfering signal and the power of the information signal is in excess of the dynamic range, thereby interfering with detection of the information signal.
It is a still further object to provide a receiver, comprising: an input adapted to receive an analog signal having an information content having a first signal power and an interference content having a second signal power; a first canceller, adapted to cancel a portion of the second signal power without substantially attenuating the first signal power, and to produce a first modified signal comprising a residual interference content and the information content; an overload protection device adapted to selectively block the first modified signal if it exceeds a threshold; a second canceller, adapted to cancel at least a portion of the residual interference content to reduce a residual signal power thereof, to produce a second modified signal; and a detector, adapted to: detect the information content within the second modified signal; and produce an adaptation signal for control of at least the second canceller, wherein the first canceller is adapted to introduce a signal component into the first modified signal exceeding the threshold. The overload protection device may comprise a superconducting component, for example having a critical current density which is exceeded by an overload condition, and which therefore self-limits the current passing through the element. Of course, other configurations and implementations of the overload element may be employed. The receiver may include at least one of an analog amplifier, a digital amplifier, an analog filter, a digitizer, and a transformer. The at least one of the analog amplifier, digital amplifier, analog filter, digitizer, transformer, overload protection device, and saturable detector may operate at a cryogenic temperature below about 100 K.
It is another object to provide a system and method to detect a radio frequency signal-of-interest in an input signal, that also includes at least one interference signal, comprising: generating a digital reference signal corresponding to the at least one interference signal in at least a waveform, a magnitude and a delay; converting the digital reference signal to a corresponding analog coarse cancellation signal; combining the input signal with the analog coarse cancellation signal in a coarse combiner to generate a coarse residue signal, wherein the interference signal is substantially cancelled and the signal-of-interest is substantially maintained; generating a fine cancellation signal, corresponding to a residual interference signal in the coarse residue in at least a waveform, a magnitude and a delay; combining the coarse residue signal with the fine cancellation signal in a fine combiner, to generate a fine residue signal, wherein the residual interference signal is substantially cancelled and the signal of interest is substantially maintained; and digitizing the fine residue signal and detecting the signal-of-interest.
Another object provides a system adapted to detect a radio frequency signal-of-interest in an input signal, that also includes at least one interference signal, comprising: a coarse cancellation signal generator, producing a digital reference signal corresponding to the at least one interference signal in at least a waveform, a magnitude and a delay, which is converted to a corresponding analog coarse cancellation signal; a coarse combiner, adapted to combine the input signal with the analog coarse cancellation signal to generate a coarse residue signal, wherein the interference signal is substantially cancelled and the signal-of-interest is substantially maintained; a fine cancellation signal generator, producing a fine cancellation signal corresponding to a residual interference signal in the coarse residue in at least a waveform, a magnitude and a delay; a fine combiner, adapted to combine the coarse residue signal with the fine cancellation signal, to generate a fine residue signal, wherein the residual interference signal is substantially cancelled and the signal of interest is substantially maintained; and a digitizer adapted to digitize the fine residue signal from which the signal-of-interest is detectable.
The fine cancellation signal may be an analog signal generated based on a second digital reference signal.
The method may further comprise digitally correlating the digitized fine residue signal with the second digital reference signal; and using the time-averaged digital correlation output to provide an adaptive feedback control of at least one of the magnitude and delay of the fine cancellation signal.
The system may further comprise a digital correlator adapted to correlate the digitized fine residue signal with the second digital reference signal; and an adaptive feedback control, using the time-averaged digital correlation output, to provide of at least one of the magnitude and delay of the fine cancellation signal.
An iterative algorithm may be applied to adjust at least one of the magnitude and delay of the fine cancellation signal, in order to reduce the time-averaged digital correlation output toward zero.
The digital reference signal may be is provided by the source signal of an interference signal transmitter.
At least one of the analog coarse cancellation signal and the fine cancellation signal may comprise a linear combination of plurality of representations of a signal having respectively different magnitudes and delays.
The at least one interference signal may comprise multipath interference, and wherein the analog coarse cancellation signal comprises a plurality of representations of the digital reference signal differing in respective magnitude and delay.
The fine residue signal may be digitized using a superconducting analog to digital converter.
The fine cancellation signal may be generated based on a digital lookup table which is adaptively updated.
At least a portion of a power of the coarse residue signal may be restricted from the fine combiner by a limiter when the power of the coarse residue signal exceeds a threshold.
The fine residue signal may be digitized with a digitizer having a dynamic range, the dynamic range being insufficient to detect the signal of interest in the input signal, wherein the magnitude and delay of the digital reference signal and the fine cancellation signal are adjusted such that the dynamic range of the digitizer is sufficient to detect the signal-of-interest remaining in the fine residue signal.
The fine combiner may comprise a transformer with at least three coils. The transformer may comprise a superconducting component.
The analog coarse cancellation signal may be produced the by analog filtering an oversampled digital pulse train.
At least one of the coarse cancellation signal and the fine cancellation signal may be selectively delayed using a discrete digital time delay.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a self-calibrating two-stage hybrid temperature hybrid technology interference cancellation architecture.
FIG. 2 shows a block diagram of a model for a two-stage HTHT interference cancellation architecture.
FIG. 3 shows a representation of an on-chip flux subtractor, which consists of a transformer having a 12 turn primary coil coupled to a washer type secondary, with two washers connected in parallel to reduce the effective secondary inductance.
FIG. 4 shows a block diagram of a low complexity transmit signal cancellation test chip including flux subtractor and PMD ADC.
FIG. 5 shows a layout of a PMD ADC with a single junction quantizer, including a flux subtractor.
FIGS. 6A and 6B show graphs of a power spectrum of coarse and fine cancellation signals before lowpass filtering; the power in fine cancellation signal shown in FIG. 6B is 44.5 dB lower than the coarse cancellation signal shown in FIG. 6A .
FIGS. 7A-7E show power spectra of a transmit signal ( FIG. 7A ), interference signal ( FIG. 7B ), cancellation signal ( FIG. 7C ), coarse residue ( FIG. 7D ) and fine residue ( FIG. 7E ), showing that the fine interference residue carried to the receiver is a very small part of the original interference signal.
FIG. 8A shows a power spectrum of transmit interference before cancellation and the desired input signal (Left).
FIG. 8B shows the power spectrum of the receiver's decimated output after interference cancellation (Right).
FIG. 9 shows a flow chart describing the adaptive algorithm used for interference cancellation.
FIG. 10 shows a power spectrum of transmit interference before cancellation and the desired input signal.
FIG. 11 shows a Power spectrum of the receiver's decimated output with zero gain implemented in the LUT.
FIG. 12 shows a power spectrum of the receiver's decimated output with a gain of +3 implemented in the LUT.
FIG. 13 shows a power spectrum of the receiver's decimated output with a gain of +2.375 implemented in the LUT.
FIG. 14 shows Iterative changes in the LUT gain by the Self-calibrating mechanism to reduce interference cancellation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Two-Stage Hybrid Temperature Hybrid Technology Cancellation Architecture
The two stage hybrid temperature hybrid technology (HTHT) architecture as shown in FIG. 1 seeks to accomplish two significant goals:
Provide a high precision cancellation with greater than 80 dB reduction of high power interference in the 0-30 MHz band.
Nulling the bulk of the interference in a coarse canceller at a high temperature stage. This facilitates employing a current limiting device to protect the quantizer from being permanently damaged by any high power currents that may result in event of unsuccessful cancellation.
One of the advantages of the two-stage cancellation architecture is the increased flexibility in tuning the gain of the cancellation signal. The increased flexibility comes from the fact that the total gain of the amplifier chain, in the coarse and fine cancellation paths, can be independently adjusted to change their respective outputs on a coarse and fine grid respectively. More specifically, the very high gain implemented on the coarse cancellation path, proportionally amplifies relatively smaller changes in the Look-Up Table (LUT) values, producing much larger changes in the coarse output. While this high gain enables subtracting the bulk of the interference, it limits finer changes, thereby allowing residual interference to be carried to the receiver. Although the residual interference is much smaller compared to the original interference, it can significantly reduce the dynamic range of the receiver. By subtracting a high precision, low power, fine cancellation signal in the second stage canceller, a greater mitigation of co-site interference can be achieved. The low gain amplifiers on the fine cancellation path enable generation of this high precision, low power, fine cancellation signal. The ability to manipulate the gains of the on-chip digital amplifiers, by changing their respective rail voltages, provides a possibility to adaptively control the rail voltages by means of the correlator output. Such programmability greatly enhances the possible precision of interference cancellation.
The architecture of FIG. 1 may be described in greater detail as follows. This represents a system wherein a sensitive radio-frequency receiver 100 may unintentionally receive part of the signal from a radio-frequency transmitter 200 , located in close proximity at the same site. In a real-world application, every effort would be made to shield the receive antenna 102 from the transmit antenna 240 , but since the transmit power may be many orders of magnitude greater than the sensitivity of the receiver, even a very small co-site coupling a from the transmit antenna to the receive antenna may tend to saturate the sensitive receiver. Let us represent the desired RF receive signal 145 at the detector 150 as S R , and the RF transmit signal 190 before amplification as S T . If the amplifier gain due to transmit amplifiers 202 , 210 , and 215 is given by a factor G 1 , the signal 235 transmitted by transmit antenna 240 is given as G 1 S T . Further, the signal 105 received by receive antenna 102 can then be expressed as S R +αG 1 S T . The second term here is likely to be much larger than the first, possibly saturating or damaging the detector 150 , and greatly reducing the useful dynamic range of the detector. In order to provide the greatest flexibility in cancelling the interference signal component αG 1 S T from the receive signal, FIG. 1 shows a two stage interference canceller comprised of a coarse interference canceller 250 and a fine interference canceller 275 . The coarse canceller and the fine canceller represent separately optimized amplifier chains for the same transmit signal S T , wherein a cancellation signal is combined with the receive signal in an appropriate subtractor module. In each canceller, the gain factor and time delay may be adjusted in order to provide the greatest reduction in the presence of the interference signal S T in the receive signal 145 at the detector 150 .
Consider first the coarse cancellation system. The coarse subtractor 115 is the first component in the receive chain after the receive antenna 102 , and provides for wideband combination of analog signals from the antenna and the coarse canceller 250 . It is identified as a subtractor, but of course an additive RF combiner will function in the same way, provided that the phase of the cancellation signal is properly reversed. Passive RF combiners are well known in the prior art, and may include, for example, transformers and Wilkinson combiner/splitters. Assume that the coarse canceller has access to the transmit signal S T from the transmitter, and that the gain factor in the amplifier chain for the coarse canceller (comprised of amplifiers 265 and 260 ) is given by G 2 , where typically G 2 <<G 1 . Then the coarse cancellation signal 110 is given as G 2 S T , and the output of the coarse subtractor 115 may be given as a receive signal with a reduced interferor S R +(αG 1 -G 2 )S T . We emphasize here that this is a simplified shorthand expression, and represents an attempt to match both gain and time delay factors in the interference signal S T . So it is not sufficient simply to set the gain factor G 2 in the coarse canceller equal to αG 1 to provide complete interference cancellation. Further, complete cancellation is not necessary (or even desirable) in the coarse canceller; the major requirement is only to reduce the interference power to the level wherein the sensitive precision components of the detector and fine canceller can work effectively. As part of the coarse processing stage, the coarse subtractor may be followed by a saturable power limiter 120 , which may for example be a current limiter. This may also be combined with an analog bandpass filter that defines the band of interest. Such a limiter is important in protecting the components further downstream from high RF powers, in particular from transients when the system is first initiated or the transmitter is turned on. In addition, an optional component may be a subsequent low-noise amplifier LNA 125 , to provide additional sensitivity to the receiver. Since we are focusing here on the relative power of signal and interference, we will ignore the gain factor associated with the LNA, though it is apparent that the gain can be accounted for.
Following the optional LNA 125 , the next component is the fine subtractor 140 , which combines the reduced interference signal 130 with the fine cancellation signal 135 from the fine canceller 275 . The fine canceller also has access to the transmit signal S T , and let us assume a gain factor G 3 from amplifiers 290 and 295 . Since much of the interference has already been cancelled, one typically has G 3 <<G 2 . The condition that G 3 =αG 1 -G 2 represents the ideal matching of both gain and time delay (phase) of fine cancellation signal 135 and reduced interference signal 130 , to yield a difference signal 145 from the fine subtractor 140 of only S R , the desired receive signal.
In the embodiment shown in FIG. 1 , both the receiver 100 and the transmitter 200 represent full digital RF systems, wherein the signals are processed in full digital format all the way to RF. This requires that frequency shifting is carried out using digital multipliers rather than analog mixers, and that conversion between analog and digital is carried out at high radio frequencies. This has a particular advantage in dealing with a very broad signal band which covers an octave or more in frequency, such as is present over the high-frequency (HF) signal band that covers the range from 2-30 MHz. A Digital RF™ system such as that in FIG. 1 could cover the entire HF band, in a way that a conventional analog system with only a digital baseband processor could not. We note that FIG. 1 does indeed include a conventional digital baseband processor 170 that could incorporate standard operations such as modulation/demodulation (MODEM) and coding/decoding (CODEC and INFOSEC). Further, the identifications of the baseband receive signal 165 and baseband transmit signal 175 are intended to imply a set of in-phase and quadrature (I and Q) or other conventional two-phase signals, even if local oscillators are not explicitly shown.
The sensitive detector 150 in the receiver 100 is a broadband analog-to-digital converter, that may, for example, be a broadband delta-sigma modulator, or a delta modulator, or a phase-modulation-demodulation (PMD) converter. The digital downconverter 155 is a digital multiplier, where the digital local oscillator is not explicitly shown. In the transmitter 200 , the digital upconverter 180 is a similar digital multiplier, also with an unshown digital local oscillator. In general, the Digital RF™ signal from the digital upconverter may represent a mulibit signal. The conversion from a multibit Digital RF™ signal to an analog signal is integrated with the amplification process in several components shown in FIG. 1 . The digital encoder 185 may convert from a multibit Nyquist rate digital signal to an oversampled single-bit signal that may in turn be converted to a pulse-width modulated signal 190 , with a low frequency spectrum that represents the signal to be transmitted S T . This PWM signal may then be amplified in a digital amplifier 202 , and analog amplifier 210 , and a high-power amplifier (HPA) 215 to achieve the needed gain factor of G 1 . This may still consist of pulses, so that a low-pass filter 230 is needed to generate the final analog signal 235 with amplitude G 1 S T that is broadcast from the transmit antenna 240 . FIG. 1 also allows for a digital equalizer 195 that generates a predistorted digital-RF transmit signal 205 , that can correct for nonlinear distortion present in the transmit amplifier chain (particularly the HPA) with a predistorter feedback signal 220 that may permit the equalizer to respond dynamically.
The transmit chains for the coarse canceller 250 and the fine canceller 275 are similar to those in the transmitter 200 , except that the output power levels are substantially reduced, so that an HPA is not necessary. These include a digital encoder ( 255 and 285 ), a digital amplifier ( 260 and 290 ), an analog amplifier ( 265 and 295 ), and an analog filter ( 270 and 300 ). The cancellers also have digital time delay adjustments for dynamic phase matching ( 250 and 280 ), and the fine canceller also includes a dynamic gain adjustment module 277 . The gain adjustment module may include, for example, a digital lookup table (LUT) with entries that can be dynamically adjusted with input from a waveform comparator 160 . This waveform comparator may be a digital correlator that cross-correlates the baseband receive signal 165 with the baseband transmit signal 175 , to detect the presence of the transmit signal in the receive signal. The feedback from the correlator 160 is designed to adjust the gain (and possibly the phase) in the fine canceller 275 in order to dynamically minimize the amplitude of the transmit signal in the receive signal. Alternatively, a similar correlation could be carried out between the RF receive and transmit signals directly, rather than at baseband.
It is important to point out that the two-stage interference approach described in FIG. 1 is not limited to co-site interference from a co-located transmitter. For example, in some military applications, the interfering signal might be an enemy jamming signal. If the interfering signal is of a form that can be digitally synthesized, perhaps out of a selection of library waveforms, then coarse and fine cancellation signals can be generated and adjusted similar to that in FIG. 1 .
While the architecture outlined in FIG. 1 may be carried out using components in various device technologies, a preferred embodiment of FIG. 1 may be implemented using superconducting devices for some components. Since superconducting components typically operate at cryogenic temperatures below about 100 K, a preferred embodiment may also comprise an integrated cryogenic system that combines superconductors and cooled semiconductors to obtain improved system performance. Such a hybrid technology, hybrid temperature (HTHT) system may obtain functionality that cannot easily be achieved with any single technology on its own.
In a preferred embodiment of the receiver 100 in FIG. 1 , the ADC modulator 150 and digital downconverter 155 may be implemented using superconducting Josephson junctions, based on rapid-single-flux-quantum (RSFQ) logic. The most advanced technology for RSFQ circuits is comprised of Josephson junctions based on the element niobium (Nb) and operating at a temperature of 4 K. Complex digital circuits with clock rates of 40 GHz and above are possible in this technology. The same Nb technology would be appropriate for the digital-RF components of the transmitter, namely the digital upconverter 180 , the digital encoder 185 , the dynamic digital equalizer 195 , and the feedback ADC 225 , and similarly for the canceller components: the digital LUT 277 , digital delays 280 and 250 , and digital encoders 255 and 285 . In addition, the digital amplifiers 202 , 260 , and 280 might be implemented, at least in part, using superconducting components at 4 K. Finally, the low-loss analog properties of superconducting Nb could also be used for the fine subtractor 140 as a “flux subtractor”, and for the analog filter 300 .
A cryocooler with a cooling stage designed for deep cryogenic temperatures such as 4 K also typically has available cooling power at an intermediate temperature of 40-80 K. Such an intermediate temperature may be used in a preferred implementation for the low-noise operation of cooled semiconductor amplifiers, as well as for high-temperature superconducting analog components such as filters and transformers. For example, in the receiver 100 of FIG. 1 , the coarse subtractor 115 , the current limiter 120 , and the LNA 125 could operate in this intermediate temperature regime. Further, transmit and canceller components that would benefit from cryogenic operation at an intermediate temperature include amplifiers 210 , 265 , and 290 , as well as analog filter 270 . The digital correlator 160 could operate at room temperature if it processes the baseband signal, or at 4 K in superconducting technology if it compares the digital-RF waveforms directly.
Model for the Two-Stage Hybrid Temperature Hybrid Technology Interference Cancellation Architecture
FIG. 2 shows a more detailed architecture of a receiver system 100 and a co-site transmitter 200 , together with coarse canceller 250 and fine canceller 275 , that were used in a Simulink™ (Mathworks) simulation of a system similar to that in FIG. 1 . Similar label numbers are used in both figures where appropriate. The transmit architecture consists of a k-bit baseband signal 175 , sampled at a frequency of Fs. The following second order Hogenauer digital interpolation filter 182 inserts extra data points and effectively increases the sampling rate. The n-bit output of the digital interpolation filter is further processed by a second order delta-sigma (ΔΣ) modulator 188 (acting as digital encoder 185 in FIG. 1 ) that converts the output to a single-bit or multi-bit ΔΣ code. A chain of amplifiers with increasing gain (GT 1 210 and GT 2 215 ) is used to boost the signal power to the required transmit signal level, followed by filtering in low-pass (Butterworth) filter 230 , then broadcast with transmit antenna 240 . A fraction of the transmit power 245 is coupled from transmitter 200 to receiver 100 , and combined with the desired input signal to generate the receive signal+interference 105 . This combined signal 105 is coupled to the coarse subtractor 115 , where it is combined with the signal generated by the coarse canceller 250 . The receiver 100 in FIG. 2 includes the coarse subtractor 115 , the fine subtractor 140 , and components that implement a low-pass superconducting ADC. These include a current to flux converter 151 with a flux pump 152 , a delta modulator 154 , an ADC clock 157 with a vernier timing adjustment and a two-channel synchronizer 158 , a digital doubler 159 , a differential code converter 161 , an offset 162 , and a decimation filter 163 . The data can now be fed to a baseband digital correlator (not shown) for further processing. A band-limited white noise component 153 is provided in the model of the receiver, to simulate noise coupled into the receiver,
On the cancellation path in FIG. 2 , the output of the transmit interpolation filter 182 is passed to both a coarse canceller 250 and a fine canceller 275 , each of which may be implemented as a magnetic flux subtractor. A very high static gain implemented in the coarse cancellation path subtracts the bulk of the high power interference. The coarse canceller is placed, for example, at a higher temperature stage than the fine canceller. This eases implementation of a current limiting device, which, in case of unsuccessful cancellation, prohibits large currents from flowing through to the quantizer. Each canceller also includes the same delta-sigma modulator and amplifiers as for the transmit signal.
A lookup table (LUT 277 ) on the fine cancellation path is used to adjust the gain of the fine cancellation signal. To reduce the LUT complexity, m MSBs from the n-bit interpolation word are used to produce m+2 MSBs, where the 2 additional bits are of higher significance; the rest of n-m LSBs are left unchanged. In other words, the LUT provides a gain of up to 4. The combined N-bits are processed by the ΔΣ modulator 288 . The inability to change n-m LSBs in the LUT produces an error which is further amplified ( 290 ) by a small gain (GC 3 ) in the fine cancellation path. By reducing the gain in this path, the resulting error in the cancellation signal is greatly reduced.
In contrast, the very high gain inherent in a single-stage cancellation architecture proportionally amplifies the errors in the LUT, thereby resulting in a very large residual interference being carried to the receiver. The required precision in a single stage cancellation architecture to minimize this residual signal is difficult to achieve and may increase system cost and/or complexity, or may simply not be achievable.
On-Chip Flux Subtractor
The current carrying capability of the transformers and the quantizer will determine the amount of cancellation that can be performed on-chip, i.e., in the second stage of interference cancellation. FIG. 3 shows a flux subtractor structure ( 140 ) that can be used for on-chip second-stage fine interference cancellation. Each transformer consists of a 12 turn primary coil coupled to a single-turn washer type secondary coil. The effective secondary inductance of each transformer is reduced by connecting two washers in parallel. The secondary coils of the two transformers are connected in series. The subtraction is performed by reversing the polarity of one transformer, such that it couples current in the opposite direction with reference to the other transformer. The inputs are the receive signal+interference 130 and the cancellation signal 135 , and two outputs are shown, each with the cancelled signal that represents the desired received signal 145 . In the preferred embodiment, this flux subtractor is implemented using superconducting Nb technology, and designed to operate at a cryogenic temperature about 4 K.
Low Pass Phase Modulation-Demodulation Analog-to-Digital Converter with Flux Subtractor
The radio frequency interference cancellation design of a preferred embodiment includes a test chip that includes an integrated flux subtractor, the physical medium dependent analog-to-digital converter with a single junction quantizer, and an 18-bit digital decimation filter. FIG. 4 shows the schematic diagram of such a test chip, and FIG. 5 shows the full integrated circuit layout of such a chip implemented in superconducting Nb technology. This test chip does not include the digital cross correlator that would be present in a fully adaptive embodiment shown schematically in FIGS. 1 and 2 .
The schematic in FIG. 4 is designed to perform a stand-alone test of parts of the architecture of the fine cancellation stage shown in FIGS. 1 and 2 . In particular, it is designed to show how a properly designed flux subtractor 140 (such as that in FIG. 3 ) may enable the substantial cancellation of a relatively large interference signal deliberately added to the receiver. A test exciter 201 plays the role of a transmitter 200 in FIG. 1 , generating an interference signal αG 1 S T . This is combined with a weak desired receive signal S R , and the combined receive signal+unwanted transmit signal 105 with amplitude S R +αG 1 S T is fed to the flux subtractor 140 . The other input to flux subtractor 140 comes directly from the test exciter, with a manual module 276 at room temperature, to adjust the gain and phase of this test interference signal. The output of the flux subtractor circuit is fed to a superconducting ADC modulator 150 on the same chip, followed by digital downconversion and digital processing to obtain the power spectrum of the signal. If the adjustment is optimized, the peak associated with the interferor should be greatly suppressed, permitting the desired receive signed 145 to be measured with high dynamic range.
The test chip in FIG. 5 shows the layout of a superconducting integrated circuit, 1 cm across, comprised of a superconducting flux subtractor 140 as in FIG. 3 , a phase-modulation-demodulation ADC 150 , and a digital filter 156 that decreases the output data rate. Digital output amplifiers 157 send the multibit difference signal out to room-temperature digital signal processors for analysis of the power spectrum. Preliminary tests of the flux subtractor have confirmed basic operation.
Simulation of Hybrid Temperature Hybrid Technology Architecture
Two simulations based on the architecture of FIG. 2 were carried out and are described below. In the first simulation, ideal matching of the transmit signal to the cancellation signal was assumed, and the results are shown in FIGS. 6-8 . The two stage interference cancellation architecture was shown to enable more than 80 dB reduction of high power interference in the 0-30 MHz band, and is 40 dB better than a comparable single-stage cancellation architecture. Simulation results show a 55 dB SNR and 56 dB SFDR for a 9.7 MHz input signal in 58 MHz bandwidth and in the presence of 31 dBm high power interferors at 25 MHz. The second simulation describing a self-calibrating dynamic two stage interference cancellation architecture is shown later in FIGS. 9-14 .
For simulation purposes, a 2-bit baseband transmit signal was employed, sampled at 125 MHz. An additional bit is used as a sign bit. Thus the baseband signal amplitude is restricted between ±4. For the ease of simulation, an 8-bit interpolation filter (excluding the sign bit) was employed. 4 MSBs of the interpolation filter are passed to the 6-bit LUT, resulting in a 10-bit combined output. The output of the superconductor digital amplifier is assumed to be 10 mV at 50 Ohm load, which translates into 200 μA of maximum current output. The number to current converter in FIG. 2 appropriately scales the output of the LUT such that the maximum possible LUT output is mapped to 200 μA of current. The outputs are processed by a second order ΔΣ modulator. Again for simplicity of simulation, a 1-bit quantizer is assumed. This results in the modulator being sampled at 2 N ·Fs, equal to 128 GHz. Although such high sampling frequencies are not possible with current fabrication technology, a multi-bit quantizer (q-bit) may be used in the implementation, thereby reducing the sampling frequency by a factor of 2 (q-1) . For example, a 4-bit quantizer would reduce the sampling frequency to 128/8=16 GHz, which is well within current capabilities using RSFQ technology available from Hypres Inc. (Elmsford, N.Y.).
On the transmit signal path, a 108 dB cumulative amplification following the on-chip superconductor amplifier is assumed to model a 7.88 kW transmitter. The output is lowpass filtered with a third order Butterworth filter with its passband edge at 317 MHz. A small fraction of the transmit power (1.73%) is coupled to the receiver, resulting in high power interference signal. For the selected signal amplitude, interference of 31.5 dBm is carried to the receiver.
On the coarse cancellation path, a static gain of 72.7 dB is implemented to subtract the bulk of the interference in a coarse canceller at a high temperature stage. On the fine cancellation path, a gain of 8.2 dB is accomplished in the lookup table which is further amplified by a 20 dB gain in the output amplifier. FIGS. 6A and 6B show the power spectra of the coarse and fine cancellation signal, respectively. Both the signals are lowpass filtered with filter parameters the same as that on the transmit signal path. As seen, the interference is reduced by more than 36 dB in the fine cancellation stage.
As can be seen from FIGS. 7A-7E , which plots the power spectra of the transmit signal ( FIG. 7A ), interference signal ( FIG. 7B ), the digitally generated cancellation signal ( FIG. 7C ), the interference residue after the coarse cancellation stage ( FIG. 7D ), and the interference residue after the fine cancellation stage ( FIG. 7E ) which is carried to the receiver, a fraction of transmit signal is coupled to the receiver in form of interference. As is evident, a significant reduction of interference is achieved from the two-stage cancellation architecture. Thus, the two-stage cancellation architecture achieves greater than 80 dB reduction of high power interference and is 40 dB better than the single-stage cancellation architecture.
On the receiver side, the phase modulation-demodulation analog-to-digital converter (ADC) with a single junction quantizer is used as a lowpass, high dynamic range analog-to-digital converter. The lower sideband of the analog-to-digital converter is set to 30 μA. A 9.7 MHz sinusoid serves as the input signal. Since the ADC is a flux quantizing ADC, the current to flux converter serves as the input transformer that converts the input current to magnetic flux. The ADC is sampled at 30 GHz with a decimation ratio of 256 giving an output sample rate of 117 MHz. FIG. 8A shows the spectrum of the desired input signal and transmit interference before cancellation, whereas FIG. 8B shows the output spectrum of the receiver's decimated output after interference cancellation. The tallest peak in the receiver output spectrum corresponds to the input signal at 9.7 MHz, whereas the peak at 25.23 MHz corresponds to the transmit interference. As can be seen from FIG. 8B , the transmit interference is reduced by 80 dB. The spur free dynamic range (SFDR) of the ADC is 56.38 dB whereas the signal to noise ratio (SNR) is 55.89 dB in a 58 MHz bandwidth.
Simulation Model for the Self-Calibrating Two-Stage Hybrid Temperature Hybrid Technology Interference Cancellation Architecture
A second simulation was carried out for a preferred embodiment of an adaptive, dynamic self-calibrating two-stage interference cancellation architecture. The static gain in the LUT may be adjusted manually or automatically to achieve high precision cancellation. In a static system subject to co-site interference, manual calibration may be acceptable, while in dynamic environments, automatic calibration may be preferred. Hence, the static cancellation architecture is largely insensitive to the environmental changes which necessitate periodic calibration of the delay and gain of the cancellation signal. The self-calibrating architecture dynamically adjusts the gain of the cancellation signal to compensate for any changes in the interference. The self-calibration mechanism digitally cross-correlates the baseband transmit signal with the receiver's decimated output and uses an adaptive algorithm to change the gain in the LUT. The process iterates until high precision cancellation is obtained.
Cross-Correlation
Cross correlation is a standard method of estimating the degree to which two series are correlated. For two series x(i) and y(i) where i=0, 1, 2 . . . N−1, the cross correlation r at delay d is defined as
r
(
d
)
=
∑
i
[
(
x
(
i
)
-
mx
)
*
(
y
(
i
-
d
)
-
my
)
]
∑
i
[
(
x
(
i
)
-
mx
)
2
∑
i
[
(
y
(
i
-
d
)
-
my
)
2
Where, mx and my are the means of the corresponding series.
If x(i) and y(i) are similar series that are in phase with one another, then the correlation function r will be positive. If they are out of phase, the correlation will be negative. If they are uncorrelated, then r will tend toward 0 if the averaging time T is long enough. The phase delay time d can be adjusted to change the relation of correlated signals between fully in-phase to fully out-of-phase.
Self-Calibration Algorithm
FIG. 9 shows a flow chart describing the adaptive algorithm used for interference cancellation in a preferred embodiment shown in the simulation. In FIG. 9 , “positive” is abbreviated “+ve” and “negative” is abbreviated “−ve”. The goal of the adaptive algorithm is to adjust the gain in the LUT such that the mean of correlation between the decimated output of the receiver and the baseband transmit signal is driven towards zero. A zero mean signifies that the two signals are uncorrelated implying the interference is minimum. However, for a non-zero mean, the gain of the cancellation signal needs to be modified to achieve precise cancellation. A negative mean signifies additional gain required in the cancellation signal, whereas, a positive mean signifies the necessity to attenuate the cancellation signal. To start, the upper LUT gain is initialized to the maximum possible gain that can be implemented in the LUT. Similarly, the lower LUT gain is initialized to a negative number corresponding to the maximum possible attenuation that can be implemented in the LUT. The current value of the LUT gain is selected to be the arithmetic mean of the upper and lower LUT gains. For the current LUT gain, if the correlation mean is positive and lower than any previous positive correlation mean, the current LUT value becomes the ‘Lower LUT Gain’. Similarly, for the current LUT gain, if the correlation mean is negative and higher than any previous negative correlation mean, the current LUT value becomes the ‘Upper LUT Gain’. The next value of the LUT gain is again selected to be the arithmetic mean of the upper and lower LUT gains. Thus, the algorithm iteratively reduces the window between the upper and lower LUT gain, in the process optimizing the LUT gain such that the mean of correlation tends to zero. Practically it is very difficult to achieve a perfect zero mean. Hence, the algorithm iteratively optimizes the gain until a correlation mean sufficiently close to zero is achieved.
Simulation Results
On the receiver side, the phase modulation-demodulation analog-to-digital converter (ADC) with a single junction quantizer is used as a lowpass, high dynamic range analog-to-digital converter. The lower sideband of the analog-to-digital converter is set to 30 μA. A 9.7 MHz sinusoid serves as the input signal. Since the ADC is a flux quantizing ADC, the current to flux converter serves as the input transformer that converts the input current to magnetic flux. The ADC is sampled at 30 GHz with a decimation ratio of 256 giving an output sample rate of 117.18 MHz. On the coarse cancellation path, a static gain of 71.05 dB is implemented to subtract the bulk of the interference in a coarse canceller at a high temperature stage. On the fine cancellation path, a gain/attenuation of up to 4 times in amplitude or 12 dB can be accomplished in the LUT. This gain in the LUT is further amplified by a 49.8 dB gain in the output amplifier. Both the signals are lowpass filtered with filter parameters the same as those on the transmit signal path.
As seen in the power spectrum shown in FIG. 10 , the transmit interference is 30 dB higher than the desired receive signal. The baseband transmit signal is at an input frequency of 25.23 MHz, sampled at 117.18 MHz, further interpolated by a factor of 8, and followed by an oversampled sigma-delta modulator. For a meaningful correlation between the receiver's output and the baseband transmit signal, it is important that the sum of the desired input signal and co-site interference does not exceed the slew rate limit of the ADC. Thus, in case of high power interference it is essential to attenuate the input so that the ADC is not saturated. On successful interference cancellation, the full desired signal can be reapplied.
The upper LUT gain and lower LUT gain are initialized to +4 and −4 respectively. Thus, the current LUT gain which is the arithmetic mean of the upper and lower LUT gains is zero. FIG. 11 shows the power spectrum of the receiver's decimated output. The interference peak is reduced by about 15 dB by the static gain implemented in the coarse cancellation path. However, a significant interference is carried to the receiver. The cross-correlation between the decimated output of the ADC and the baseband transmit signal has a mean value of −0.0027, resulting in a correlation mean of −0.0019. A negative mean signifies that additional gain is required to amplify the cancellation signal to match the interference. Hence the lower LUT gain is now modified to 0 with the upper LUT gain being +4. Thus, the current value of LUT gain is set to +2. The power spectrum in FIG. 12 shows a further reduction in the interference peak at 25.23 MHz, with a correlation mean of −0.0019. An improved negative correlation mean further modifies the lower LUT gain to +2 while the upper LUT gain remains at +4. Consequently, the gain in the LUT for the next iteration is set at +3.
The power spectrum in FIG. 12 shows a further reduction in the interference peak at 25.23 MHz, with a correlation mean of +0.0022. An improved positive correlation mean signifies lowering the gain in the LUT. Consequently, the upper LUT gain is modified to +3, whereas the lower LUT gain remains unchanged at +2. Thus, the gain in the LUT for the next iteration is set at +2.5.
The iteration process continues with the mean of correlation being +0.0007 for a gain of 2.5. The LUT gain is further modified to 2.25 resulting in a negative correlation mean of −0.0004, necessitating an increase in the LUT gain. Thus, the LUT gain is set to 2.375.
The correlation mean is now 0.00019, sufficiently close to zero. The algorithm stops the optimization process on getting sufficiently close to zero. FIG. 13 shows the power spectrum of the ADC's decimated output. As can be seen, greater than 60 dB reduction of the interference peak has been achieved. The signal to noise ratio (SNR) of the ADC is 31 dB in a 59 MHz bandwidth.
Due to the limited dynamic range of the LUT, some of the LSB's of the interpolation filter are uncorrected. This in turn reflects as an error which is amplified by the gain on the fine cancellation path. Thus, for a given number of bits in the LUT, the precision of cancellation is a function of the gain on the fine cancellation path. This gain on the fine cancellation path is determined by the variations in the level of interference. For minor variations in the interference, the gain on the fine cancellation path can be lower. Consequently, further reduction of the interference can be achieved, up to the 80 dB reduction shown in the first ideal simulation.
FIG. 14 shows the iterative sequence of changes in the LUT gain to achieve high precision interference cancellation. For any further deviation of the correlation mean from zero, the adaptive algorithm springs back in action and readjusts the gain in the LUT, to minimize the interference. The successful implementation of the self-calibration mechanism makes the architecture robust and insensitive to environmental changes and other factors that may vary the interference magnitude.
The correlator may be implemented in a high speed superconductor technology, for example, integrated into the same superconducting device as a flux subtractor for the fine signal cancellation and the analog to digital convertor. However, an important deduction of this simulation results is the ability to correlate the outputs at low speed. This implies that the correlation no longer needs to be in the superconductor domain and can be easily moved to room temperature. Moreover, this permits implementation of highly sophisticated adaptive algorithms, including multi-bit correlation, that permit lower convergence time of the algorithm. Likewise, the correlator may reside close to the analog to digital convertor at superconducting temperatures, with room temperature electronics interfacing with this device.
A self-calibrating two-stage interference cancellation architecture has been designed, modeled and simulated. The self-calibrating mechanism cross-correlates the receiver's decimated output with the baseband transmit signal and iteratively adjusts the gain of the cancellation signal to minimize the interference. For a 31.5 dBm interferor at 25.23 MHz, the simulation shows greater than 60 dB reduction of the interference peak. For a 9.7 MHz input signal, signal-to-noise ratio of 31 dB is achieved in 58 MHz bandwidth.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
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A radio frequency receiver subject to a large in-band interferor employs active cancellation with coarse and fine cancellation signals, each with a respective radio frequency combiner, in order to increase the effective dynamic range of the receiver for weak signals of interest. One or both can be digitally synthesized. This is particularly applicable for co-site interference, whereby the interfering transmit signal is directly accessible. A similar system and method may also be applied to external interferors such as those produced by deliberate or unintentional jamming signals, or by strong multipath signals. An adaptive algorithm may be used for dynamic delay and gain matching. In a preferred embodiment, a hybrid technology hybrid temperature system incorporates both superconducting and semiconducting components to achieve enhanced broadband performance.
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[0001] This application claims priority from Japanese Patent Application No. 2003-205384 filed on Aug. 1, 2003, which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a signal processing apparatus, and more particularly to an apparatus for transmitting image data and audio data after storing temporarily the image data and the audio data in a memory.
[0004] 2. Related Background Art
[0005] Recently, the development of a computer interface for connecting a personal computer (hereinafter referred to as a PC) and peripheral equipment has advanced, and Universal Serial Bus (USB), Institute of Electrical and Electronic Engineers (IEEE) 1394 and the like have been frequently used as typical bus standards.
[0006] These computer interfaces are used for transferring digital data of a still image, a moving image and the like, all recorded by a digital camera or a digital video camera into a storing medium such as a memory card. Moreover, the above-mentioned interfaces have lately begun to be used for streaming, in which images and sound from a storing medium such as a charge coupled device (CCD) or a tape are reproduced while being transferred to a PC side, in addition to the transfers of a still image file and a moving image file, both stored in the storage medium.
[0007] A video class interface is generally used for the streaming in accordance with USB. The video class interface is prescribed in a specification of “Universal Serial Bus Device Class Definition for Video Devices”. There are Motion Joint Photographic Experts Group (MJPEG), a digital video (DV) format, Moving Picture Experts Group (MPEG) and the like as the formats of images the transfer methods of which are prescribed.
[0008] Moreover, when streaming is performed by means of the video class interface, both of an isochronous transfer and a bulk transfer can be used. However, for keeping the continuity of images and sounds and for producing a situation in which a PC can easily identify the timing of a frame change of images, the isochronous transfer is generally used.
[0009] In case that the MJPEG format is selected as a subtype (or a moving image transferring format in a video class interface), an audio class interface is used independently of the video class interface when streaming in which audio data is added to images is performed, because the transfer of sounds is not prescribed by the video class interface. In the following, the data transfers of the video class and the audio class, both used for streaming in accordance with the MJPEG format, will be described.
[0010] First, an audio data transfer in the USB audio class is described.
[0011] In an asynchronous transfer, a data transfer is performed in synchronization with a start of frame (SOF), which is transmitted from a USB host to a device at a fixed period. In the audio class, a camera side is required to surely transmit a fixed amount of data at every reception of a data transmission request, which is transmitted from a PC at a fixed interval on the basis of an SOF.
[0012] The data transmission request from the PC is based on a clock on the PC side. On the other hand, the camera side produces audio data on the basis of a clock generated by the camera side itself in place of the clock of the PC. When the frequencies of both of the clocks are quite the same, there are no problems. Actually, an error surely exists between them. Consequently, the amount of data generated per unit time on the camera side and the amount of data read per unit time by the PC differ from each other slightly.
[0013] The data to be transferred at the time of streaming is buffered by an audio storing memory for a fixed period of time. Owing to the error between the writing clock and the reading clock, an interval between a data write position and a data read-out position in the audio storing memory changes in proportion to the elapse of the time of the streaming. When the interval is out of a fixed range, a buffer overrun or a buffer underrun occurs, and transfer data breaks down.
[0014] Next, a moving image data transfer in the USB video class is described.
[0015] Also in the USB video class, the PC transmits a data transmission request to the camera side at a fixed interval on the basis of an SOF similarly to the case of the audio class. However, differently from the case of the audio class, the amount of the data to be transmitted is adjusted to the clock on the camera side.
[0016] FIG. 19 is a view showing the transfer timing of video data. Data transmission requests from the PC are based on an SOF, and are always transmitted to the camera side at a fixed period. On the other hand, the camera side which received the transmission requests does not always transmit video data but transmits video data of one frame upon receiving a clock generated at every frame by the camera side itself. It is sufficient for the PC side to update a display frame at every new reception of video data of one frame. By this method, the buffer overrun and the buffer underrun do not occur in the video data storing memory of the camera side.
[0017] Until now, the transfers in accordance with the audio class and the video class in the USB have been severally described. In the following, the streaming of a sound and a moving image in a class formed by the combination of the aforementioned two classes will be described.
[0018] At the time of performing the streaming of a moving image and a sound in a digital video camera or the like, a moving image pickup apparatus for generating moving image data and an audio pickup apparatus for generating audio data are severally driven by clocks different from each other.
[0019] Generally, a digital video camera is equipped with a mechanism for preventing deviation in synchronization between an image and a sound, which deviation is caused by using different clocks to generate an image and a sound respectively.
[0020] However, in the case where the USB video class is used for the transfer of moving image data and the USB audio class is used for the transfer of audio data at the time of streaming, the moving image data and the audio data are transferred in accordance with different methods. Consequently, a problem of the deviation in synchronization occurs.
[0021] That is, as described above, the amount of the data to be transferred is determined on the basis of the clock on the PC side in the USB audio class. On the other hand, the amount of the data is determined on the basis of the clock on the camera side in the USB video class. Consequently, a phenomenon in which a sounds runs too fast or too late against an image occurs owing to an error between the both clocks. Moreover, the deviation becomes larger as time elapses, and at last the above-mentioned overrun or the underrun of the audio data storing buffer occur to break down the streaming.
[0022] A technique related to the above-mentioned problem is described in Japanese Patent Application Laid-Open No. 2000-21081.
[0023] The invention described in the Japanese patent application adopts the following method. That is, a host (PC) and a device (camera) count the number of clocks generated between continuous two synchronization signals (SOF) and the number of received data, and feed back the counted numbers to determine the transmission amount of data.
[0024] However, such a method has a problem that processing is complicated.
SUMMARY OF THE INVENTION
[0025] The present invention aims to solve such problems.
[0026] Another object of the present invention is to correct a synchronous deviation between audio data and moving image data, which deviation is caused at the time of streaming of a sound and a moving image.
[0027] For achieving such objects, according to an aspect of the present invention, a signal processing apparatus of the invention includes: input means for inputting a moving image signal and an audio signal corresponding to the moving image signal; first storing means; second storing means; write control means for writing the moving image signal into the first storing means in accordance with a first timing signal and writing the audio signal into the second storing means in accordance with the first timing signal; communication means for reading out the moving image signal from the first storing means in accordance with the first timing signal, reading out the audio signal from the second storing means in accordance with a second timing signal having a frequency different from that of the first timing signal, and transmitting the read-out moving image signal and the read-out audio signal to an external device through a transmission path; and read-out control means for changing a read-out position of the audio signal to a predetermined read-out position to be determined according to a write position of the audio signal, in case that a difference between the write position and the read-out position of the audio signal in the second storing means reaches a predetermined value.
[0028] The further objects and the features of the present invention other than the ones described above will be apparent on the basis of the detailed description of the preferred embodiments of the invention in the following with the attached drawings being referred to.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a view showing a connection between a digital video camera and a PC to which the present invention is applied;
[0030] FIG. 2 is a block diagram showing a configuration of the digital video camera and the PC, to which the present invention is applied;
[0031] FIG. 3 is a view showing the state of the buffering of audio data;
[0032] FIG. 4 is a view showing a configuration for the control of an audio storing memory;
[0033] FIG. 5 is a flowchart showing the read-out control of audio data;
[0034] FIG. 6 is a block diagram showing a configuration of a digital video camera and a PC, to which the present invention is applied;
[0035] FIG. 7 is a view showing the state of the buffering of audio data;
[0036] FIG. 8 is a view showing a configuration for the control of an audio storing memory;
[0037] FIG. 9 is a flowchart showing the read-out control of audio data;
[0038] FIG. 10 is a block diagram showing a configuration of a digital video camera and a PC, to which the present invention is applied;
[0039] FIG. 11 is a view showing a configuration for the control of an audio storing memory;
[0040] FIG. 12 is a flowchart showing the read-out control of audio data;
[0041] FIG. 13 is a view showing a configuration for the control of an audio storing memory;
[0042] FIG. 14 is a flowchart showing the read-out control of audio data;
[0043] FIG. 15 is a view showing a configuration for the control of an audio storing memory;
[0044] FIG. 16 is a flowchart showing the read-out control of audio data;
[0045] FIG. 17 is a block diagram showing a configuration of a digital video camera and a PC, to which the present invention is applied;
[0046] FIG. 18 is a view showing a configuration for the control of an audio storing memory; and
[0047] FIG. 19 is a view showing a state of transmission of audio data and image data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[heading-0048] Embodiment 1
[0049] In the following, a first embodiment of the present invention will be described. In the present embodiment, the present invention is applied to a case where moving image data and audio data both captured by a digital video camera are transferred to a PC connected to the video camera with a USB while the PC side reproduces received data.
[0050] As shown in FIG. 1 , a USB host (PC) 200 and a digital video camera 100 equipped with a USB terminal are connected to each other with a USB cable. Video data and audio data, both obtained by the digital video camera 100 , are transferred to the USB host (PC) 200 through the USB cable and reproduced by the USB host (PC) 200 . Incidentally, the USB video class and the USB audio class are used for transferring moving image data and audio data, respectively.
[0051] FIG. 2 is a view showing the system configuration of the digital video camera 100 and the USB host (PC) 200 .
[0052] The digital video camera 100 includes a camera controller 101 , a moving image pickup apparatus 102 , a moving image storing memory 103 , an audio pickup apparatus 104 , an audio storing memory 105 , an audio storing memory monitoring setting apparatus 106 , a USB controller 107 , a packetizing apparatus 108 , a USB receiving buffer 109 and a USB transmission buffer 110 .
[0053] The camera controller 101 supplies operation clocks to the moving image pickup apparatus 102 and the audio pickup apparatus 104 to operate them at suitable timing.
[0054] The moving image pickup apparatus 102 converts an object image to digital data in accordance with an instruction received from the camera controller 101 and writes the converted digital data into the moving image storing memory 103 . The audio pickup apparatus 104 samples sounds in accordance with an instruction received from the camera controller 101 and writes the sampled sounds as digital data into the audio storing memory 105 .
[0055] The moving image storing memory 103 and the audio storing memory 105 are severally a ring buffer of the first-in and first-out system, and each buffers moving image or audio data for a fixed period of time.
[0056] The packetizing apparatus 108 reads out moving image data from the moving image storing memory 103 in accordance with an instruction received from the USB controller 107 and divides the read-out moving image data into USB packets to store the USB packets into the USB transmission buffer 110 . Moreover, the packetizing apparatus 108 similarly reads out audio data from the audio storing memory 105 and divides the read-out audio data into USB packets to store the USB packets into the USB transmission buffer 110 .
[0057] The USB controller 107 stores the moving image data stored in the moving image storing memory 103 and the audio data stored in the audio storing memory 105 into the USB transmission buffer 110 by issuing an instruction to the packetizing apparatus 108 at the time of receiving a data transmission request from the USB host 200 though the USB receiving buffer 109 , and informs the audio storing memory monitoring setting apparatus 106 of the reception of the data transmission request.
[0058] On the other hand, the USB host (PC) 200 includes a USB transmission buffer 201 , a USB receiving buffer 202 , a USB controller 204 , a reproduced data buffer 207 , a reproduction mechanism 206 , a video output apparatus 203 and an audio output apparatus 205 .
[0059] The USB controller 204 is arranged to supply clocks for a streaming operation of the USB host 200 . The USB controller 204 stores a data transmission request into the USB transmission buffer 201 at a fixed time interval and supplies reproduction timing to the reproduction mechanism 206 .
[0060] The USB transmission buffer 201 transmits the data transfer requests stored by the USB controller 204 to the digital video camera 100 . The USB receiving buffer 202 stores the reception data received from the digital video camera 100 into the reproduced data buffer 207 . The reproduced data buffer 207 is of the first-in and first-out system and stores reproduced data for a fixed period of time. The reproduction mechanism 206 receives a clock from the USB controller 204 , and then reads out reproduction data from the reproduced data buffer 207 to convert the read-out reproduction data into a video signal and an audio signal. The reproduction mechanism 206 then outputs the converted video signal and the audio signal to the video output apparatus 203 and the audio output apparatus 205 , respectively. The video output apparatus 203 outputs the video signal received from the reproduction mechanism 206 as an image. The audio output apparatus 205 outputs the audio signal received from the reproduction mechanism 206 as a sound.
[0061] In the following, the operation of the audio storing memory monitoring setting apparatus 106 will be described.
[0062] FIG. 4 is a view showing the surrounding configuration of the audio storing memory 105 .
[0063] The audio storing memory 105 is of the ring buffer system and holds a data read-out position (address) r and a data write position w in a fixed memory area. At the time of data writing, subject data is written at the data write position w, and the data write position is shifted backward. Moreover, at the time of data reading, data is read out from the data read-out position r, and the data read-out position r is shifted backward.
[0064] When both of the data write position w and the data read-out position r reach the rearmost position of the memory area, the data write position w and the data read-out position r are returned to the top of the memory area.
[0065] The above-mentioned circulations of the data write position w and the data read-out position r in the fixed memory area realizes the buffer of the first-in and first-out system.
[0066] In the present embodiment, as shown in FIG. 3 , the data read-out position r is moved to an ideal data read-out position r′ at the point of time when the magnitude of the deviation of the data read-out position r from the ideal data read-out position r′ in the audio storing memory 105 , which deviation is caused by an error between the clocks of the digital video camera 100 and the USB host (PC) 200 , exceeds an allowable deviation amount α.
[0067] FIG. 3 is a view showing a state of data in the audio storing memory 105 . The ideal read-out position r′ in the audio storing memory 105 can be determined on the basis of an ideal value a′ of the data amount subjected to buffering by the audio storing memory 105 .
[0068] For preventing the occurrence of any synchronous deviations of sounds and dynamic images at the time of streaming, it is necessary to keep the amount of the audio data buffered by the audio storing memory 105 to be constant. Consequently, the ideal value a′ of the audio data amount to be buffered is to be the data amount subjected to buffering at the time of a start of streaming. When the data read-out position r and a data write position w are known, the data amount a subjected to buffering can be obtained. Conversely, an ideal data read-out position r′ can be determined to the present data write position w on the basis of the ideal value a′ of data amount to be subjected to buffering.
[0069] That is, when the audio storing memory monitoring setting apparatus 106 is informed of a reception of data transmission request from the USB controller 107 , the audio storing memory monitoring setting apparatus 106 executes the processing shown in the flowchart of FIG. 5 .
[0070] First, on the basis of the present data write position w, the audio storing memory monitoring setting apparatus 106 determines an ideal data read-out position r′ of the case where only the ideal value a′ of the data amount to be subjected to buffering is buffered (step S 501 ). Next, the audio storing memory monitoring setting apparatus 106 determines an allowable range D of data reading on the basis of the ideal data read-out position r′ and a fixed range a (step S 502 ). Then, the audio storing memory monitoring setting apparatus 106 judges whether the read-out position r is within the allowable range D or not (step S 503 ). When the read-out position r does not exist within the allowable range D, the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the ideal data read-out position r′ (step S 504 ).
[0071] As described above, according to the present embodiment, when the read-out position in the audio storing memory 105 is shifted to exceed the predetermined allowable range D from the ideal read-out position, the read-out position is forcibly moved to the ideal read-out position. Consequently, the breakdown of data owing to an error between the writing clock and the reading clock can be prevented.
[heading-0072] Embodiment 2
[0073] Next, a second embodiment will be described.
[0074] The first embodiment adopts a method of correcting the data read-out position when the data read-out position in the audio storing memory is out of the allowable range. The present embodiment corrects the data read-out position synchronously to a timing of some trigger from an external connection destination.
[0075] The configuration of the present embodiment is basically the same as the one of the first embodiment. The connection of the digital video camera and the USB host of the present embodiment is the one shown in FIG. 1 , and the configuration of them is the one as shown in FIG. 6 . Similarly to the first embodiment, the USB video class is used for the transfer of moving image data, and the USB audio class is used for the transfer of audio data.
[0076] In the USB video class used in the present embodiment, a function of getting an image as a still image into the PC 200 as the USB host at an arbitrary point of time during streaming in accordance with an instruction from the PC 200 is also defined.
[0077] For using the still image getting function, the digital video camera 100 of the present embodiment is equipped with a still image pickup apparatus 111 and a still image storing memory 112 . The still image pickup apparatus 111 converts an object image into digital data in response to an instruction of the camera controller 101 . Moreover, the still image storing memory 112 is for buffering still image data until the still image data is transferred to the packetizing apparatus 108 .
[0078] An operation of getting a still image into the PC 200 is performed in accordance with the following procedure.
[0079] First, the getting operation of the still image is started by an instruction for getting a still image, provided by a user's operation of the reproduction mechanism 206 operating on the USB host (PC) 200 . Then, a still image getting request is transmitted to the digital video camera 100 through the USB controller 204 and the USB transmission buffer 201 . On the side of the digital video camera 100 , the still image getting request is transmitted to the USB controller 107 through the USB receiving buffer 109 .
[0080] The USB controller 107 , which has received the still image getting request, issues a still image getting instruction to the camera controller 101 and reports the reception of the still image getting request to the audio storing memory monitoring setting apparatus 106 (the details thereof will be described later). The camera controller 101 , which has received the still image getting request, outputs an instruction to the still image pickup apparatus 111 to generate still image data and delivers the still image data to the packetizing apparatus 108 through the still image storing memory 112 . The packetizing apparatus 108 packetizes the still image data to store the packetized still image data into the USB transmission buffer 110 similarly to the cases of the moving image data and audio data.
[0081] The still image data stored in the USB transmission buffer 110 is transmitted to the USB host 200 to be further transmitted to the reproduction mechanism 206 through the USB receiving buffer 202 and the reproduced data buffer 207 . When the reproduction mechanism 206 receives the still image data, the reproduction mechanism 206 outputs the received still image data to the video output apparatus 203 for a fixed period of time. Moreover, when the reproduction mechanism 206 gets the still image, the reproduction mechanism 206 uses a file I/O 208 provided in the USB host (PC) 200 , to save the gotten still image as a file.
[0082] In the present embodiment, the reproduction mechanism 206 generates a shutter sound as an electronic sound at the time of the getting of the still image.
[0083] Because transferred audio data is discontinuous at the time of a correction of the data read-out position in the audio storing memory 105 , an unpleasant sound such as a noise is sometimes generated in reproduced sounds.
[0084] For solving this problem, the present embodiment takes the following consideration. That is, the present embodiment performs the correction of the audio data read-out position at the timing of the generation of the shutter sound at the time of the getting of a still image to prevent the unpleasant sound from being heard by a user.
[0085] In the following, the operation of the audio storing memory monitoring setting apparatus 106 at the time of the getting of a still image will be described. Similarly to FIG. 3 , FIG. 7 is a view showing a state of the audio storing memory 105 . FIG. 8 is a view showing the configuration of the main part of the audio storing memory 105 . FIG. 9 is a flowchart showing the operation of the audio storing memory monitoring setting apparatus 106 .
[0086] When the USB controller 107 , which has received a still image getting request, informs the audio storing memory monitoring setting apparatus 106 of the reception of the still image getting request (step S 901 ), the audio storing memory monitoring setting apparatus 106 determines on the basis of the present data write position w, an ideal data read-out position r′ of the case where only an ideal value a′ of data amount to be subjected to buffering is buffered (step S 902 ). Then, the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the determined ideal data read-out position r′ (step S 903 ).
[heading-0087] Embodiment 3
[0088] Next, a third embodiment will be described.
[0089] The second embodiment enables the evasion of an unpleasant noise at the time of resetting by performing the resetting of the data read-out position of the audio storing memory by taking advantage of interruption of a streaming reproduction during the operation of getting a still image. The present embodiment minimizes the unpleasant feeling of a user owing to a noise by performing the resetting at the timing when the volume of a sound becomes smaller than a predetermined threshold value.
[0090] The configuration of the present embodiment is basically the same as the one of the first embodiment. The connection of the digital video camera and the USB host of the present embodiment is the one shown in FIG. 1 , and the configuration of them is the one as shown in FIG. 10 . Only different points from the first embodiment are described in the following.
[0091] FIG. 11 is a view showing the configuration of the main part of the audio storing memory monitoring setting apparatus 106 of the present embodiment. FIG. 12 is a flowchart showing the processing of the audio storing memory monitoring setting apparatus 106 . When the audio storing memory monitoring setting apparatus 106 is informed of a reception of a data transmission request from the USB controller 107 , the audio storing memory monitoring setting apparatus 106 determines on the basis of the present data write position w, an ideal data read-out position r′ of the case where only an ideal value a′ of data amount to be subjected to buffering is buffered (step S 1201 ). Next, the audio storing memory monitoring setting apparatus 106 judges whether the volume of audio data stored at the present data read-out position r is small enough or not (step S 1202 ). When the volume is small enough, the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the determined ideal data read-out position r′ (step S 1203 ).
[heading-0092] Embodiment 4
[0093] Next, a fourth embodiment will be described.
[0094] The fourth embodiment is based on the same idea as the one of the third embodiment. However, the position at which the audio data to be used for the judgment of whether the resetting of the data read-out position is performed or not is obtained differs from that of the third embodiment.
[0095] The configuration of the present embodiment is basically the same as the one of the third embodiment. The connection of the digital video camera and the USB host of the present embodiment is the one shown in FIG. 1 , and the configuration of them is the one as shown in FIG. 10 . Only different points from the third embodiment are described in the following.
[0096] FIG. 13 is a view showing the configuration of the main part of the audio storing memory monitoring setting apparatus 106 . FIG. 14 is a flowchart showing the processing of the audio storing memory monitoring setting apparatus 106 .
[0097] When the audio storing memory monitoring setting apparatus 106 is informed of a reception of a data transmission request from the USB controller 107 , the audio storing memory monitoring setting apparatus 106 determines an ideal data read-out position r′ on the basis of the present data write position w (step S 1401 ). Next, the audio storing memory monitoring setting apparatus 106 judges whether the volume of audio data stored at the ideal data read-out position r′ is small enough or not (step S 1402 ). When the audio storing memory monitoring setting apparatus 106 judges that the volume is small enough, the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the ideal data read-out position r′ (step S 1403 ).
[heading-0098] Embodiment 5
[0099] Next, a fifth embodiment will be described.
[0100] The fifth embodiment obtains the audio data to be used for the judgment of whether the resetting of the data read-out position is performed or not from both of the present data read-out position r and the ideal data read-out position r′.
[0101] The configuration of the present embodiment is basically the same as the one of the third embodiment. The connection of the digital video camera and the USB host of the present embodiment is the one shown in FIG. 1 , and the configuration of them is the one as shown in FIG. 10 . Only different points from the third embodiment are described in the following.
[0102] FIG. 15 is a view showing the configuration of the main part of the audio storing memory monitoring setting apparatus 106 . FIG. 16 is a flowchart showing the processing of the audio storing memory monitoring setting apparatus 106 .
[0103] When the audio storing memory monitoring setting apparatus 106 is informed of a reception of a data transmission request from the USB controller 107 , the audio storing memory monitoring setting apparatus 106 determines an ideal data read-out position r′ on the basis of the present data write position w (step S 1601 ). Next, the audio storing memory monitoring setting apparatus 106 judges whether the volume of audio data stored at the present data read-out position r is small enough or not (step S 1602 ). When the volume is small enough, the audio storing memory monitoring setting apparatus 106 further judges whether the volume of each audio data stored at the ideal data read-out position r′ is small enough or not (step S 1603 ). When the audio storing memory monitoring setting apparatus 106 judges that the volume is small enough at the step S 1603 , the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the ideal data read-out position r′ (step S 1604 ).
[heading-0104] Embodiment 6
[0105] Next, a sixth embodiment will be described.
[0106] The second embodiment performs the resetting of the data read-out position of the audio storing memory by taking advantage of the interruption of a streaming reproduction during the operation of getting a still image. The present embodiment forcibly performs the resetting of the data read-out position at every fixed period of time by means of a timer.
[0107] The configuration of the present embodiment is basically the same as the one of the first embodiment. The connection of the digital video camera and the USB host of the present embodiment is the one shown in FIG. 1 , and the configuration of them is the one as shown in FIG. 17 . Only different points from the first embodiment are described in the following.
[0108] Even when the USB controller 107 receives a data transmission request, the USB controller 107 does not inform the audio storing memory monitoring setting apparatus 106 of the fact of the reception. The digital video camera 100 includes a timer 111 . The timer 111 outputs a timing signal to the audio storing memory monitoring setting apparatus 106 at every fixed period of time.
[0109] When the audio storing memory monitoring setting apparatus 106 receives a timing signal from the timer 111 , the audio storing memory monitoring setting apparatus 106 controls the read-out position of the audio storing memory 105 as follows.
[0110] FIG. 18 is a view showing the configuration of the main part of the audio storing memory monitoring setting apparatus 106 of the present embodiment. When the audio storing memory monitoring apparatus 106 receives a timing signal, the audio storing memory monitoring setting apparatus 106 determines an ideal data read-out position r′ on the basis of the present data write position w, and the audio storing memory monitoring setting apparatus 106 moves the data read-out position r to the ideal data read-out position r′.
[0111] According to each embodiment described above, a synchronous deviation between audio data and moving image data generated at streaming of a sound and a moving image can be corrected without using any complicated circuits.
[0112] Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.
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A signal processing apparatus includes: a write controller for writing an input moving image signal into a first memory in accordance with a first timing signal and writing an input audio signal into a second memory in accordance with the first timing signal; a communication unit for reading out the moving image signal from the first memory in accordance with the first timing signal, reading out the audio signal from the second memory in accordance with a second timing signal having a frequency different from that of the first timing signal, and transmitting the read-out moving image signal and the read-out audio signal to an external device; and a read-out controller for changing a read-out position of the audio signal to a predetermined read-out position to be determined according to a write position of the audio signal, in case that a difference between the write position and the read-out position of the audio signal is a predetermined value.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method for analyzing DNA information in the fields of clinical diagnosis and life science, and a device therefor.
[0002] As the progress in the technology of DNA analysis, recently, significant attention has been focused on the analysis of information of DNA/RNA sequence in the fields of clinical diagnosis and life science. In the field of life science, for example, advances have been made for determining the whole nucleotide sequence of a variety of animal and plant DNAs, as illustrated by the Human Genome Project. Thus, the coding region of a novel protein and the regulatory site of the expression thereof have been analyzed gradually, involving also the elucidation of pathogenic genes such as oncogenes and the like.
[0003] In the field of clinical diagnosis, alternatively, the introduction of the technology of DNA analysis has been accelerated toward the identification of a variety of etiology and laboratory tests, on the basis of the fruitful results of these research works. The diagnosis of infectious diseases including viral hepatitis type C and AIDS (acquired immunodeficiency syndrome) due to HIV (human immunodeficiency virus) infection is one example of the fields for which the introduction of DNA diagnosis has been highly desired because of the high detection sensitivity required therefor and because of the relation between the infectious performance of these viruses (retroviruses) and the DNA/RNA polymorphism. For the laboratory tests of tumor cells, which are now depending on empirical pathological diagnosis, and for the tests of HLA (human leukocyte antigen) type with the sample number rapidly increasing from the demand of the registration at the myeloid bank, the introduction of the technology of DNA analysis has been expected, which can give accurate and precise information.
[0004] A great progress has been made recently in the DNA analysis technology desired in such fields, wherein a method for separating slight difference in DNA sequence utilizing the difference in the conformation of a single-stranded DNA during electrophoresis has been developed, in addition to the conventional DNA sequencing and hybridization methods. As introduced in Genomics, Vol. 5, pp. 874-879, 1989, for example, the method designated as SSCP (Single Strand Conformation Polymorphisms) has been drawing attention as a technique for detecting even a single base substitution at a high sensitivity. The separating method detects the difference in sequence by detecting the difference in the conformation as the difference in the mobility on gel electrophoresis, with attention focused on the finding that leaving DNA, normally composed of a pair of complementary double strands, in the state of a single strand, typically, the single-stranded DNA autonomously associates by itself within the molecule under appropriate conditions (ion strength, temperature and the like) and form certain conformation specific to the sequence, which conformation varies depending on the sequence.
[0005] The method detects the difference in DNA at a high sensitivity, but because electrophoresis is employed in the process of separation, such a long period of time should be required for the separation that a high throughput is realized with much difficulty. The selection of the conditions for efficiently reflecting the difference in DNA sequence over the difference in the mobility on electrophoresis involves tough works. Still furthermore, the method is hardly automated, and additionally, the method involves another drawback in requiring the separation in some case under a plurality of conditions so as to thoroughly separate the whole polymorphism.
[0006] A method called denaturant gradient gel electrophoresis for detecting slight difference in DNA sequence is also proposed, but because the method also employs electrophoresis, it has the same drawbacks as described above.
[0007] It has been known that the difference between the denaturing conditions of a double-stranded DNA with a completely complementary sequence and the conditions of a double-stranded DNA with an almost complementary but not completely complementary sequence can be detected as the difference in absorbance change when such double-stranded DNA is denatured into a single-stranded DNA (melting curve) (for example, see I. V. Razlutuskii, L. S. Shlyakhtenko and Yu. L. lyubchenko: Nucleic Acids Research, Vol. 15, No. 16, pp. 6665-6676 (1987)). Furthermore, it has been known that the type of a single-stranded RNA forming conformation (hair pin, stem, loop structure, etc.) can be detected and identified by the change in the absorbance when the base pairing of the single-stranded RNA is denatured (melting curve) (for example, see L. G. Laing and D. E. Draper: J. Mol. Biol. (1994) 237, 560-576).
[0008] According to these methods, no electrophoresis procedure is required after a sample is collected, so that these methods are advantageous in that the procedures are simple and the measurements are easily carried out as optical measurement, with higher reliability.
[0009] Additionally, a technique is proposed, comprising optically measuring and detecting the phenomenon that when a double-stranded DNA having a completely complementary sequence and a double-stranded DNA having a nearly completely but not completely complementary sequence are denatured, the fluorescent energy transfer induced by two types of fluorophors individually labeling each of the complementary strands is eliminated, thereby detecting the difference in the sequences of the two types of DNAs not completely complementary (Japanese Patent Laid-open No. Hei 7-31500). Because no electrophoresis procedure is then required after a sample is collected, the same advantage is brought about as described in the aforementioned example.
[0010] However, it is only sequence compositions (GC contents, etc.) or deletion/insertion of bases that these methods can detect. The identification of detailed difference in sequence, particularly DNA polymorphism including single-base substitution, is substantially difficult by these methods. These methods require to carry out the regulation of denaturing conditions at such an extremely low rate that the methods have been hardly applicable to the detection and determination at a high throughput.
[0011] Furthermore, no examination has been made about direct optical analysis of DNA polymorphism including single-base substitution in a single-stranded DNA.
SUMMARY OF THE INVENTION
[0012] In order to overcome the problem, in accordance with the present invention, the melting curve of the conformation of a single-stranded DNA is directly detected, whereby a more precise and practical method of signal processing is provided along with a device therefor with a simplified structure.
[0013] For separation and analysis of a single-stranded DNA of a target DNA region including a heterozygote type having more than two DNA types in one cell, the method of the present invention comprises memorizing the melting curves of all known types of polymorphism (template curves), comparing the signal curve of a sample with such single template curve or with all the curves prepared via linear binding of a plurality of the template curves in combination, and determining that the DNA type, namely the sequence characteristics of the measured single-stranded DNA fragment, is defined as a combination of the template curves providing that the RMS between the signal curve and the combination is the smallest below a given value.
[0014] For the DNA analysis by PCR for clinical diagnosis, the sequence information of the target DNA fragment together with the amount of the PCR product, should be obtained. Therefore, the present invention is designed advantageously so as to bring about simultaneously all the information mentioned above via the quantitative measurement of the melting curve.
[0015] By designing that a sample holding means which hold the sample and regulates the sample temperature should be a means with a larger surface/volume ratio, the denaturing rate gets faster for measurement. Consequently, it has been found that the melting curve of a single-stranded DNA during the temperature elevation for resolving the conformation draws a different curve from the melting curve during the temperature decrease for forming the conformation, which indicates the presence of hysteresis. By processing the data with a signal processing means identical to what has been described above, DNA polymorphism with single-base substitution can be analyzed.
[0016] It has been found that, as an intercalating agent, such as ethidium bromide which can sift the fluorescent wave length after intercalating to the DNA base pairing, is intercalated, the intensity of the fluorescence emitted from the interaction of the single-stranded DNA with the intercalating agent during the irradiation of the excitation beam changes corresponding to the denaturation of the single-stranded DNA. Therefore, by measuring the intensity and processing the data with a signal processing means identical to what has been described above, the sequence information of the single-stranded DNA fragment can be yielded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a block diagram of the structure of a detector of a first example in accordance with the present invention;
[0018] FIGS. 2 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0101 of DNA in the exon 2 of the HLA-DQA1 region;
[0019] FIGS. 3 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0102 DNA in the exon 2 of the HLA-DQA1 region;
[0020] FIGS. 4 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0103 DNA in the exon 2 Of the HLA-DQA1 region;
[0021] FIGS. 5 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0301 DNA in the exon 2 of the HLA-DQA1 region;
[0022] FIGS. 6 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0401 DNA in the exon 2 of HLA-DQA1 region;
[0023] FIGS. 7 ( a ) and ( b ) are graphs of the absorbance data and differential absorbance data obtained from the temperature differentiation of the absorbance data, representing the melting curve of a single-stranded DNA of the known type DQA1*0601 DNA in the exon 2 of HLA-DQA1 region;
[0024] [0024]FIG. 8 is a graph of the derivative of the melting curve of the type DQA1*0301, after fitting with the Gaussian distribution curves.
[0025] [0025]FIG. 9 is a graph of the derivative of the melting curve of a heterozygote sample of the types DQA1*0102 and DQA1*0301, representing the characteristic parameters of the curve;
[0026] [0026]FIG. 10 is graphs of another analysis example of a heterozygote DNA;
[0027] [0027]FIG. 11 depicts a measurement example of the hysteresis curve of a melting curve;
[0028] [0028]FIG. 12 depicts the schematic chart of the process flow of an example in accordance with the present invention;
[0029] [0029]FIG. 13 depicts the schematic view of the structure of the detector of the first example in accordance with the present invention;
[0030] [0030]FIG. 14 depicts the detailed structure of the spectroscopic cell of an example in accordance with the present invention;
[0031] [0031]FIG. 15 depicts the block diagram of an example of the structure of a detector for detecting the fluorescence of the DNA and the intercalating agent;
[0032] [0032]FIG. 16 is a graph of the melting curve via the fluorescence from HLA-DQA1*0101 and HLA-DQA1*0102.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] The present invention will now be illustrated hereinbelow in one example.
[0034] [0034]FIG. 1 is a block diagram of the fundamental structure of the DNA analyzer in accordance with the present invention. Ultraviolet ray (of a wave length of 260 nm) from light source 1 is divided into two beams at optical system 2 , which are then individually incident into sample part 4 and control part 5 , both being placed in cell holder 6 . Thereafter, the individual beams collimated with optical systems (not shown) are detected with photomultiplier 7 , and are then passed through amplifier 9 and processed with analytical signal processing device 10 . The cell holder 6 can control the temperatures of the sample part 4 and the control part 5 , following the temperature profiles programmed optionally with temperature regulator 8 . Temperature control can be done at an optional rate of temperature increase or decrease. The temperature in the cell holder 6 is measured with a temperature sensor (not shown), and input to the feedback temperature regulator 8 and the signal processing device 10 simultaneously. Because it is required that the temperature of some sample should be controlled within the range from −20° C. to 100° C., the cell holder 6 should have such a structure that dry air flows from the bottom of each sample holding cell 4 and 5 to the top thereof so as to prevent the occurrence of bedewing on the surface of the both cells.
[0035] The control part 5 is arranged, so as to correct the absorption of a buffer solution dissolving a sample at the sample part 4 and the absorption of the sample cell to determine the net DNA absorption. This is a routine technique in the spectrometry, and the data in examples described below are all through the correction.
[0036] Using the device described above, DNA polymorphism analysis will be illustratively described hereinbelow.
[0037] In the present Example, single-stranded DNA of HLA (human leukocyte antigen) class II: DQA1 region was amplified using asymmetric-PCR method from genomic DNA extracted from human blood cells. Then, the DNA polymorphism analysis (DNA typing) of the region was carried out.
[0038] By the standard procedure, a DNA sample solution with the extracted genomic DNA, a PCR buffer solution containing a final 10 mM concentration of Tris-HCl (pH 8.3), 50 mM KCl, 1.5 mM MgCl 2 , 0.02% gelatin, and 200 μM of each of deoxyribonucleotide triphosphates (dATP, dCTP, dGTP, and dTTP), 2.5 U Taq polymerase, 20 pmol of each of the two types of primers GH 26 and GH 27 corresponding to the HLA-DQA1 region to be analyzed (Ulf B. Gyllensten and Henry A. Erlich; Proceedings of the National Academy of Sciences of USA, Vol. 85, pp. 7652-7656, October 1988) were mixed together in a test tube, followed by overlaying mineral oil on the mixture. The PCR cycling condition was 27 cycles of 94° C. (1 minute), 57° C. (1.2 minute) and 72° C. (1 minute) in this order.
[0039] Using {fraction (1/100)} of the reaction product, asymmetric PCR was done. The asymmetric PCR solution was almost the same as described for PCR, except that the amounts of the primers were modified such that GH 26 was 10 pmol and GH 27 was 1 pmol. The PCR cycling condition was 15 cycles of 94° C. (1 minute), 57° C. (1.2 minute) and 72° C. (1 minute) in this order.
[0040] The reaction product was desalted and concentrated with a microfilter (Microcon™30, manufactured by Grace Japan), which was then dissolved in the TNE buffer (10 mM Tris-HCl, 1 mM EDTA (pH 8.3), 30 mM NaCl). The resulting product was defined as a sample solution.
[0041] In the present Example, asymmetric PCR was used for preparing a single-stranded DNA, but other methods may be used as well, including a method comprising PCR amplifying a double-stranded DNA and thereafter digesting one single-stranded DNA with λ exonuclease (λ exonuclease method) and a method comprising PCR amplification in the state where either one of the PCR primers is immobilized on membrane and thereafter washing off the single-stranded DNA not immobilized on the membrane while elevating the temperature to the melting temperature (membrane method). Although the membrane method requires to immobilize a predetermined primer on membrane, the method can prepare a single-stranded DNA at a high purity in a simple manner. Additionally, the method is suitable for automation.
[0042] Placing the sample solution at the sample part 4 while placing the TNE buffer as the control solution at the control part 5 , the sample temperature was once decreased to 0° C. Subsequently, the temperature was elevated to 60° C. at an elevation rate of 1° C./min.
[0043] FIGS. 2 to 7 ( a ) and ( b ) depict the melting curves of the single-stranded DNAs of the known six types (DQA1*0101, DQA1*0102, DQA1*0103, DQA1*0301, DQA1*0401, DQA1*0601; The WHO Nomenclature Committee for Factors of the HLA System, 1989, Immunogenetics, 31: 131-140, 1990) of the HLA-DQA1 region DNA (242 bp or 239 bp), as absorbance data and differential absorbance data by temperature (the data of the other two types, i.e. DQA1*0201 and DQA1*0501, were not shown herein because the inventors could not obtain their homozygote samples). In the figures (b), only differential absorbance data are shown. One base is different between the types DQA1*0101 and DQA1*0102; three bases are different between the types DQA1*0101 and DQA1*0103; and two bases are different between the types DQA1*0102 and DQA1*0103. Twenty-seven bases are different between the types DQA1*0101 and DQA1*0301. The types DQA1*0401 and DQA1*0601, by three bases shorter than the other types, have the sequences difference in 20 bases or more from the sequence of DQA1*0101, but only one base is different between these types DQA1*0401 and DQA1*0601.
[0044] Still further, the individual figures (a) and (b) depict the results of the analysis of the same samples, but the figure (a) depicts the results of the analysis obtained until the application of the priority of the present invention, while the figure (b) depicts the results of the analysis relatively recently obtained. The reason that the two figures do not completely agree with each other although the figures depict the analysis results of the same samples resides in the difference in the skill of analytical procedures and the data correction adopted for making up for the unskilled analytical procedures. The fact does not mean that the analysis has no reproducibility.
[0045] The figures show that groups with very different sequences, for example, a group of DQA1*0101-DQA1*0103 (type 1), a group DQA1*0301 (type 3) and a group of DQA1*0401 and DQA1*0601 (short type), have distinctively different characteristics in their melting curves. It is also shown that the type difference such as the difference in one base or two bases (for example, DQA1*0101-DQA1*0103, DQA1*0401, DQA1*0601), can be detected as a marked difference.
[0046] [0046]FIG. 8 depicts the derivative of the melting curve of the type DQA1*0301, fitting with the Gaussian distribution functions. As apparently shown in FIG. 8, the melting curve of the type DQA1*0301 can be satisfactorily fitted with the superposition of two types of Gaussian curves.
[0047] In other words, this indicates that by preparing the melting curves of the known DNA-type and comparing the melting curve of a sample DNA with the melting curves of these known DNA type as the templates, the type of sample DNA can be identified. Furthermore, by fitting the Gaussian curve to the melting curve, these identification can be carried out numerically and more efficiently.
[0048] Table 1 collectively shows the amplitude (a), peak location (mean; μ) and range (standard deviation; σ) of a plurality of the Gaussian curves fitted to the derivatives of the melting curves of the known six types depicted in FIGS. 2 to 7 .
TABLE 1 Number of DNA type terms a μ σ DQA1*0101 1 0.0026 18 10 2 0.0012 37 9 DQA1*0102 1 0.0026 19.0 11 2 0.001 36.0 9 DQA1*0103 1 0.0025 20 12 2 0.0013 34 39 DQA1*0301 1 0.0017 17 7 2 0.0012 29 11.5 DQA1*0401 1 0.0037 26 10 2 0.0015 29 5.5 DQA1*0601 1 0.0037 26 10 2 0.0014 33 5.5
[0049] The number of terms in the Gaussian functions used for fitting is defined as a number where fitting error is saturated at minimum. As shown in the Table, the derivative of a melting curve corresponding to one of the types can be represented by its characteristic parameters (a, μ, σ). Comparing the melting curve of an unknown DNA (type) with the melting curves of these known types of DNA polymorphism as the templates via the comparison with the parameters shown in Table 1, not only the procedure can be done through automatic computer processing but also strict comparison can be realized through the mathematical process.
[0050] For the mathematical process, comparing a freshly measured and input signal curve with one of the known melting curves preliminarily prepared or with all the curves preliminarily prepared by linearly binding a plurality of the template curves in combination, a template curve with the least statistical error or a combination of the template curves that give the linearly bound curve with the least statistical error should be defined as the sequence characteristics of a single-stranded DNA fragment prepared from the sample double-stranded DNA fragment.
[0051] [0051]FIG. 9 depicts the derivative of the melting curve of a heterozygote sample of 0102 and 0301(representing DQA1*0102 and DQA1*0301), together with the characteristic parameters of the curve. In such heterozygote sample, the derivative is represented as the superposition of templete curves of the individual DNA type, which indicates that typing can be carried out on the principle of spectral analysis.
[0052] On the basis of the results of FIG. 9, Table 2 summarizes the parameters of the individual DNA types. More specifically, if a heterozygote DNA has the parameter values of μ (peak location) and σ(standard deviation), being almost the same as those represented as the regression values shown in Table 2, the heterozygote DNA is of a heterozygote of two DNA types deduced from the values.
TABLE 2 Regression Regression DNA μ values σ values types μ1 16.9 σ1 6.89 0301 μ2 19.0 σ2 11.0 0102 μ3 28.9 σ3 11.5 0301 μ4 35.9 σ4 9.0 0102
[0053] In the present Example, a satisfactorily accurate melting curve could be generated in a practical sense, at a temperature elevation rate of 5° C./min at maximum. In this case, the analysis time is about 10 minutes per sample, achieving speeding up by 20 fold or more compared with the conventional DNA sequencing and SSCP method (4 hours or more).
[0054] [0054]FIG. 10 depicts another analysis example of a heterozygote DNA based on FIGS. 2 ( a ) to 7 ( b ). In the present Example, the melting curves of the eight types of DNA type in the HLA-DQA1 exon 2 region (242 p or 239 bp (3-bp depletion)) as the templates for individual sense strands should be measured preliminarily. The measured heterozygote curve from a sample agrees well with the synthetic curve of the template 0101 represented to the DQA1*0101 and the template 0102 represented to the DQA1*0102 (RMS=0.00008). Consequently, it is indicated that the sample can be identified as the heterozygote DNA of the two.
[0055] For the polymorphism analysis, it is necessary to determine to which type the DNA type of an analytical sample belongs and/or whether the DNA type is novel or not. Also, essentially, a heterozygote sample having a plurality of DNA types should be isolated and analyzed. In the present Example, however, accurate identification of a DNA type can be carried out in a smooth manner using a signal processor comprising memorizing the melting curves corresponding to all known types of polymorphism (template curves), comparing a freshly measured and input signal curve with one of a plurality of the template curves or with all the curves preliminarily prepared by linearly binding a plurality of the template curves in combination, and determining that a combination of the template curves that give the least RMS below a given value is the DNA type (namely, sequence characteristics) of the measured single-stranded DNA fragment. Furthermore, combinations with larger probabilities can be output in the order of smaller RMS.
[0056] As to the results shown in FIG. 10, the merit of this procedure is shown in Table 3.
[0057] The combination with the least final error represents an accurate heterozygote combination, and the value of the error is almost the same as (rather smaller than) the reproducibility error in the measurement of the melting curve 5 times. Table 3 shows the reproducibility error and RMS of an accurate combination (the combination marked with double circles in the Table), along with the RMSs of some of the combinations with less error among the remaining combinations. For a heterozygote combination of sequences different by one base from each other, the DNA type with the highest probability of erroneous judgment is a homozygote type of each of the individual DNA types originally constituting the heterozygote type. As apparently shown in Table 3, it is indicated that significant difference is present between accurate and inaccurate judgments.
TABLE 3 cf. Hetero (DQA1*0101/0102) DNA types Error (RMS) × 10 −4 ⊚ 0101/0102 hetero 0.74 0101 homo 1.28 0102 homo 1.55 0101/0103 hetero 2.56 0101/0201 hetero 4.5 Reproducibility error 0.8
[0058] By substantially uniformly regulating the temperature of samples at a high speed, the dynamic response of the conformation of a single-stranded DNA fragment of some sample to the temperature change was identified in a range above 10° C./min of temperature elevation or decrease. More specifically, it was identified that during the denaturing and forming of the conformation (during temperature elevation and decrease, respectively), the melting curve drew a hysteresis curve (1→2→3→4→5→6→2→3→4→5→ . . . ) as shown in FIG. 11. Specific to the difference in sequence such as the substitution, depletion or insertion of bases, the hysteresis curve varies depending on the sample. This indicates that the method is not only applicable to the change in the absorbance but also to the hysteresis curve of the absorbance, wherein more accurate determination of such type at a higher speed can be done by comparing a measured hysteresis curve with the template hysteresis curves in the same manner as in the case of the signal processing method.
[0059] In such manner, the measurement of a sample was completed within one minute (for 50 seconds) at maximum speed, to generate a hysteresis curve at two cycles of temperature elevation and decrease. The hysteresis curve varies depending on the rate of temperature elevation. Therefore, if the rate of temperature elevation is set at an appropriate level depending on the type, an effective hysteresis curve corresponding to the DNA type can be produced. Thus, the DNA analysis can be effected on the basis of the dependency of the hysteresis curve on the rate of temperature elevation.
[0060] Then, examples of a device for DNA analysis are shown in FIGS. 12 and 13, for continuously carrying out a flow system from PCR as a preliminary treatment to the melting curve measurement.
[0061] [0061]FIG. 12 depicts the schematic chart of the process flow; FIG. 13 depicts the schematic view of the device structure; and FIG. 14 depicts the detailed structural view of the spectroscopic cell.
[0062] The reaction process progresses through the processes (a) to (g) shown in FIG. 12. As shown in (a), PCR is carried out in PCR cell 600 immobilizing oligonucleotide A 602 as a PCR primer on porous filter membrane 601 on the bottom of the PCR cell. In the PCR cell 600 , extracted and purified genomic DNA is placed as a sample, which is then mounted in the device of FIG. 13. As shown in (b) as the PCR progresses, a double-stranded DNA (PCR product) corresponding to the sample DNA is generated in the manner such that the single strand on the solid phase is fixed at one end on the filter membrane 601 . The denaturing of the double-stranded DNA separates a free single-stranded DNA in the liquid phase as shown in (d) from the single-stranded DNA fixed at one end on the filter membrane (solid phase) as shown in (c). Dissolving the single-stranded DNA of the liquid phase in a buffer solution for measurement, and transferring the DNA solution into a spectroscopic cell, the temperature of the spectroscopic cell is controlled to regulate the state of a single-stranded DNA in the liquid phase (in the denatured state) as shown in (e) and the formation of the conformation as shown in (f). As shown in (g), the absorbance is measured through the spectroscopic cell, to prepare a melting curve.
[0063] [0063]FIG. 13 depicts the schematic view of the device structure. As described below, after transferring a PCR solution, a washing buffer and a spectroscopic buffer through gates 705 , 706 of sample pretreatment cell 700 into PCR cell 600 , the PCR cell 600 is regulated at a given heat cycle. Porous filter 601 immobilizing primer A is placed in the PCR cell 600 . In the sample pretreatment cell 700 , the treatments (a) to (d) described in FIG. 12 are carried out.
[0064] On the porous filter 601 inside the PCR cell 600 is immobilized oligonucleotide A (10 pmol) as a PCR primer, and then, the extracted and purified genomic DNA (100 ng) is placed as a sample in PCR solution tank 701 . Gas is transferred through gas source 707 and valves 723 , 722 , 721 into the PCR solution tank 701 , while the PCR solution (50 μl) is transferred through valves 725 , 724 into the PCR cell 600 . In this case, the PCR solution was made of a mixture solution of primer (oligonucleotide ) B (10 pmol), 10 nmol each of deoxyribonucleotide triphosphates (DNTP: dATP, dCTP, dGTP, dTTP) and a heat-resistant DNA polymerase (Taq polymerase) (1 unit) in a buffer solution containing 50 mM KCl, 10 mM Tris-HCl (pH 8.3), 1.5 mM MgCl 2 , gelatin of 0.001% (as a final concentration).
[0065] In this state, PCR is performed while regulating the temperature of the PCR cell 600 in hot air or cold air. The PCR cycling condition is 25 cycles of 94° C. for 30 minutes, 55° C. for 1 minute 72° C. for 30 seconds and in this order. The total reaction time was 50 minutes. The time period required for the PCR is possibly shortened as short as about 20 minutes, by making the cell shape into a thinner form and enlarging the surface/volume ratio. By closing the valves 724 , 728 , the vaporization of the reaction solution at higher temperatures could be made substantially zero.
[0066] After the termination of the reaction, gas is fed from gas source 707 through valves 722 , 723 into a washing or spectroscopic buffer tank, while the washing buffer flows through valves 726 , 725 , 724 onto the filter 601 for washing the filter 601 several times, to wash off the remaining primer and the residual dNTP. The liquid waste is disposed through valve 728 into liquid waste tank 703 . PCR product remains on the filter 601 . If unwanted matters which cannot pass through the filter 601 may possibly remain, gas may be fed through valve 728 from gas source 708 , while liquid waste is disposed through valve 724 into liquid waste tank 709 . As shown in FIG. 12( b ), all of these motions are driven under the conditions where double strands are on the porous filter 601 in the solid phase state.
[0067] Introducing subsequently a final washing solution (serving as the spectroscopic buffer) into the PCR cell, and then inducing the inside of the PCR cell 600 into a melting state by raising the temperature, the solution flows from the PCR cell 600 toward the outlet 705 by using the gas source 708 . More specifically, as shown in FIG. 12( d ), a single-stranded DNA in the liquid phase is collected and then transferred into spectroscopic cell 300 . In the present Example, as a washing buffer, use was made of TNE buffer (20 μl; 10 mM Tris-HCl, 1 mM EDTA (pH 8.3), 30 mM NaCl). After introducing and measuring the sample in the spectroscopic cell 300 , the sample is disposed in the liquid waste tank 704 by the flow of the washing buffer through valves 726 , 727 into the cell. Consequently, the sample is disposed after such measurement while the inside of the spectroscopic cell is washed. Instead of the liquid waste tank 704 , then, a fraction collector may be placed to recover the sample after the measurement.
[0068] In the device structure aforementioned, the ratio of the numbers of the PCR cell 600 and the number of the spectroscopic cell 300 was 1:1, but attaching a plurality of PCR cells through valves to a single spectroscopic cell, the reaction products may be introduced sequentially into the spectroscopic cell for measurement.
[0069] Alternatively, by directly supplying a biological cell sample such as blood as a sample material into PCR cell 600 , carrying out the extraction of a sample DNA by a known method, and subsequently carrying out the aforementioned DNA typing, the system from extraction to analysis may be made consistent. However, the overall structure of such system may possibly be more complex.
[0070] [0070]FIG. 14 is the figure of a structural example of the spectroscopic cell 300 employed in FIG. 13, wherein the side view is on the left side and the cross sectional view on the right side is a view in line A-A of the side view in the arrow direction.
[0071] The spectroscopic micro-cell 300 in the present Example is made of quartz glass and black quartz glass; the window of the light path is made of quartz (transparent) glass, and the remaining parts of the cell box in a rectangular parallelepiped with the upper top open are made of black quartz glass. On the upper top are internally arranged spacers of black quartz glass, while leaving the flow gates 303 on both the sides. Therefore, a sample solution holding part of a square shape, with a light path of a 10 mm length and a cross section of a 1.4 mm×1.4 mm-square shape, is formed below the spacers. A temperature sensor 301 is slightly projected toward the sample solution holding part at the central part of the spacers. As shown (inserted) with the broad arrow in the figure, the spectroscopic micro-cell 300 is placed internally inside temperature regulator 302 to regulate the temperature of a sample solution.
[0072] In the present embodiment, the cell wall is made of black quartz glass with a thickness of about 1 mm, because the glass has far less reflection stray light with a relatively high thermal conductivity and a substantially great strength; for the cell material, a material with less reflection stray light and an excellent thermal conductivity is suitable. Another example is aluminum alloy coated with platinum black and TiN (titanium nitride). In the cell of the present Example, temperature sensor 301 is embedded in temperature regulator 302 to measure the sample temperature at the central location of the light path. Therefore, the cell can regulate the temperature of samples at a high efficiency. Additionally, the cell can measure the temperature at a high precision. Furthermore, compared with general commercially-available spectroscopic cells, the cell of the present Example has such a larger surface/volume ratio of 2800 that the cell can realize the temperature increase or decrease at the rate of from 0.1° C./min to 5° C./sec.
[0073] Finally, description will now be made of an example by means of ethidium bromide, wherein the fluorescence from a sample DNA and the intercalating agent is detected to prepare the melting curve.
[0074] [0074]FIG. 15 depicts the block diagram of an example of a detector structure to detect the fluorescence from the DNA and the intercalating agent. Ultra-violet ray (of a wave length of 260 nm) from light source 801 passes through a filter and optical system 802 such as lens, to be incident into sample 804 placed in sample holder 805 . Via the presence of ethidium bromide intercalated with the sample DNA, fluorescence of 590 nm is emitted, which is then collimated with the optical system 807 followed by detection with photoelectric converter 808 . The signal is thereafter processed through amplifier 805 at analytical signal processing means 810 . The sample holder 805 can regulate the sample temperature following the temperature profile optionally programmed with temperature regulator 806 . Temperature regulation can be preset optionally at a rate of temperature increase or decrease from 0.1° C./min to 2° C./sec. Temperature can be regulated within the range of −20° C. to 100° C. by an electronic heating-cooling means using Peltier effect.
[0075] In the present Example, the cell may be adapted for signal processing and preventing the occurrence of bedewing on the cell surface, as is described in the foregoing examples.
[0076] When determining the melting curve by means of the fluorescence from the intercalating agent, the fluorescence intensity decreases as the conformation of a single-stranded DNA is denatured. This is because the fluorescence emitted from the ethidium bromide intercalated with the base pairs forming the conformation is not any more emitted since the intercalation is eliminated as the conformation is denatured. The problem of reproducibility was noticed at an earlier stage, including the change of the fluorescence intensity depending on the concentration of ethidium bromide, but using the melting curve standardized on the fluorescence intensity at the lowest limit temperature, the reproducibility between samples could be secured.
[0077] [0077]FIG. 16 depicts the melting curve of HLA-DQA1*0101 and HLA-DQA1*0102 by means of fluorescence. In the same manner as in the case of absorbance, a single-base substitution could be identified. The data in FIG. 16 are measured at a concentration {fraction (1/50)} fold that of the case of absorbance. By using fluorescence, sensitivity was improved by 10 fold to 100 fold (precision in measuring melting curve=improvement of S/N ratio).
[0078] As in the case of absorbance, signal processing is carried out on the comparison with template curves. Consequently, all samples were accurately analyzed.
[0079] In accordance with the present invention, some examples have been described insofar, but the applicable range of the present invention is not limited to these examples. A method comprising analyzing the melting curve of a single-stranded DNA, thereby producing the information of the DNA sequence, as well as a device therefor, is within the scope of the present invention.
[0080] By using the method and device in accordance with the present invention as has been mentioned insofar, DNA information at least at minimum required for clinical diagnosis and DNA tests, namely the presence or absence of a target sequence, the level thereof if present and the sequence characteristics thereof, can be obtained. The overall process from the pretreatment to the recovery of DNA information and the analysis thereof can be completed, for a short period, by the simple device structure and procedures.
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The object of the present invention is to provide a method capable of analyzing the presence or absence of a target DNA sequence, the level and sequence characteristics thereof at a high sensitivity, and a device therefor, wherein the overall process from pretreatment to the recovery of DNA information and the analysts thereof can be completed in a speedy fashion by the simple device structure and procedures.
Therefore, by preparing a single-stranded DNA fragment of a target DNA region, detecting the change in the absorbance of the single-stranded DNA sample while changing the denaturing condition of the conformation of the single-stranded DNA fragment by a denaturing condition regulatory means, and analyzing the curve of the change in the absorbance over the modification in the denaturing condition, the sequence information of the single-stranded DNA, namely the target DNA, can be generated in a rapid and simple manner.
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BACKGROUND
[0001] 1. Field
[0002] The present invention relates generally to powered knives, such as those commonly used in meat processing plants. More specifically, embodiments of the present invention concern a rotary knife with a blade housing having a high-grip connection.
[0003] 2. Discussion of Prior Art
[0004] Powered rotary knives that are used in the meat processing industry for dressing an animal carcass are known in the art. The process of dressing the carcass normally involves the removal of meat and fat from various bones as well as cutting various bones. Powered rotary knives enable workers to perform this process with great efficiency.
[0005] Turning to FIGS. 1-4 , one such prior art rotary knife K includes a handle H, a blade housing BH, an annular blade B, a pinion housing PH, and a pinion cover C. The blade B is rotatably supported by the blade housing BH. As is customary, the blade housing BH is releasably clamped between the pinion housing PH and pinion cover C. The blade housing BH and pinion cover C each present grooved surfaces S that frictionally engage one another when the blade housing BH is clamped into position. The frictional engagement between grooved surfaces S restricts relative movement between the blade housing BH and the pinion cover C when the blade housing BH is secured. Reliable securement of the blade housing BH is important to maintain uniform and smooth rotating engagement between the blade B and blade housing BH. Movement of the blade housing BH relative to pinion cover C out of the secured position can cause excessive wear and/or malfunction of the blade housing BH, blade B, or both.
[0006] It has been found that prior art rotary knives suffer from certain deficiencies. For instance, the high-speed rotational movement of the annular blade, which is ideal for quickly and efficiently processing meat, causes the cutting edge of the annular blade to quickly become dull and require frequent sharpening or replacement. As a result, conventional rotary knives suffer from problems associated with knife maintenance. For example, the grooved surfaces S can become worn over time so as to lose frictional engagement (e.g., due to repeated knife assembly and disassembly for blade sharpening and replacement and/or due to the blade housing being too loosely or firmly clamped into the operating position). Thus, because the illustrated frictional connection provided by grooved surfaces S between the blade housing BH and pinion cover C is prone to wear, such wear can result in unintended relative movement between the blade housing BH and pinion cover C that causes excessive wear and/or malfunction of the blade housing BH, blade B, or both.
SUMMARY
[0007] The following brief summary is provided to indicate the nature of the subject matter disclosed herein. While certain aspects of the present invention are described below, the summary is not intended to limit the scope of the present invention.
[0008] Embodiments of the present invention provide a rotary knife that does not suffer from the problems and limitations of the prior art knives set forth above.
[0009] A first aspect of the present invention concerns a rotary knife that broadly includes a handle, a rotatable annular blade, an expandable blade housing, and a housing support. The expandable blade housing is configured to removably support the blade. The blade housing is movable relative to the handle between a blade-securing condition, in which the blade housing securely supports the blade for rotational operation, and a relatively expanded blade-releasing condition, in which the blade housing permits removal and installation of the blade relative to the blade housing. The housing support is coupled to the handle and supports the housing on the handle in the blade-securing and blade-releasing conditions. The support and housing include interengaging surfaces that contact one another when the housing is in the blade-securing condition, with at least one of the interengaging surfaces including an applied high-friction coating so as to enhance frictional engagement between the housing and support and thereby restrict inadvertent expansion of the housing to the blade-releasing condition.
[0010] A second aspect of the present invention concerns a pinion cover for a rotary knife, wherein the knife includes a rotatable annular blade removably supported by an expandable housing that is at least in part clamped between the pinion cover and a pinion housing member to releasably retain the housing in a blade-securing condition. The pinion cover broadly includes a generally arcuately shaped body. The body presents a radially outwardly facing clamping face that is configured to be in an opposing relationship with the pinion housing. The clamping face is configured to contact at least a portion of the housing. The clamping face includes an applied high-friction coating so as to enhance frictional engagement with the at least a portion of the housing and thereby restrict inadvertent expansion of the housing out of the blade-releasing condition.
[0011] A third aspect of the present invention concerns a method of refurbishing a rotary knife, wherein the knife includes a rotatable annular blade removably supported by an expandable housing element that is at least in part clamped between clamping elements to releasably retain the housing element in a blade-securing condition, with each clamping element cooperating with the housing element to define interengaging surfaces that contact one another when the housing element is in the blade-securing condition. The knife refurbishing method broadly includes the steps of preparing at least one of the elements to receive a high-friction coating thereon; and applying a high-friction coating to the at least one of the elements such that the high-friction coating at least partly defines the corresponding interengaging surface, with the high-friction coating serving to enhance frictional engagement between the elements and thereby restrict inadvertent expansion of the housing out of the blade-securing condition.
[0012] Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] Preferred embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:
[0014] FIG. 1 is an upper perspective of a prior art rotary knife including a handle, a blade housing, an annular blade rotatably mounted in the blade housing, and a housing support that secures the blade housing to the handle, with the housing support including a pinion housing and a pinion cover;
[0015] FIG. 2 is a fragmentary cross section of the prior art rotary knife taken along line 2 - 2 in FIG. 1 , showing a radially inwardly facing engagement surface of the blade housing and a radially outwardly facing engagement surface of the pinion cover, with the engagement surfaces each presenting a plurality of spaced apart grooves to enhance frictional engagement between the surfaces;
[0016] FIG. 3 is an enlarged fragmentary perspective of the pinion cover shown in FIGS. 1 and 2 , showing the grooved engagement surface of the pinion cover;
[0017] FIG. 4 is an enlarged fragmentary perspective of the blade housing shown in FIGS. 1 and 2 , showing the grooved engagement surface of the blade housing;
[0018] FIG. 5 is an upper perspective of a rotary knife constructed in accordance with a preferred embodiment of the present invention, with the rotary knife including a handle, a blade housing, an annular blade rotatably mounted in the blade housing, and a housing support that secures the blade housing to the handle, with the housing support including a pinion housing and a pinion cover;
[0019] FIG. 6 is a fragmentary cross section taken along line 6 - 6 in FIG. 5 , showing a radially inwardly facing surface of the blade housing and a radially outwardly facing surface of the pinion cover each including a high-friction coating applied to the underlying substrate, with the surfaces being in frictional engagement with one another;
[0020] FIG. 7 is an exploded fragmentary perspective of the rotary knife shown in FIGS. 5 and 6 ;
[0021] FIG. 8 is an exploded fragmentary perspective of the rotary knife similar to FIG. 7 but taken from an opposite side of the knife;
[0022] FIG. 9 is an enlarged fragmentary perspective of the pinion cover shown in FIGS. 5-8 , showing the high-friction coating of the pinion cover; and
[0023] FIG. 10 is an enlarged fragmentary perspective of the blade housing shown in FIGS. 5-8 , showing the high-friction coating of the blade housing.
[0024] The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Turning initially to FIG. 5 , a rotary knife 20 is constructed in accordance with a preferred embodiment of the present invention. The illustrated rotary knife 20 is particularly well suited for use in meat processing facilities, although other knife applications are entirely within the ambit of the present invention. The illustrated rotary knife 20 is preferably pneumatically powered by a pressurized air source (not shown), e.g., an air compressor. However, the principles of the present invention are equally applicable where the rotary knife is driven by alternative external power sources, such as sources that transmit power through hydraulic power or electrical power. The rotary knife 20 broadly includes a handle 22 , an expandable split blade housing 24 , a rotating annular blade 26 , a pinion housing 27 , and a pinion cover 28 .
[0026] The handle 22 includes a grip housing 30 . The grip housing 30 has a generally cylindrical shape and extends between a proximal connector end 34 and a distal end 36 . The proximal end 34 is configured for quick connection to a pneumatic supply (not shown) or alternative power source. The grip housing 30 further presents an internal passage that houses a pneumatic motor (not shown).
[0027] Turning to FIGS. 5-10 , the pinion housing 27 , pinion cover 28 , and fasteners preferably cooperatively provide a housing support that supports the blade housing 24 relative to the handle 22 . In particular, the pinion housing 27 and pinion cover 28 serve as clamping components that clamp and thereby support the blade housing 24 . However, as will be described in greater detail, the illustrated housing support could be alternatively configured without departing from the scope of the present invention.
[0028] The pinion housing 27 is preferably fixed to the grip housing 30 at the distal end 36 and includes an arcuate clamping surface 38 , a pinion-receiving socket 40 , and holes 42 . The arcuate clamping surface 38 defines a laterally extending rib 44 for positioning the blade housing 24 , as will be discussed (see FIG. 7 ). The socket 40 is sized to receive and permit rotation of a drive pinion 46 . The drive pinion 46 is interconnected with and is rotatably powered by the pneumatic motor.
[0029] The expandable split blade housing 24 is substantially unitary and can be flexed so as to expand and contract between a blade-securing condition and a relative expanded blade-releasing condition. The blade housing 24 is annular and includes adjacent ends 48 , an annular ring 50 , and a flange 52 . The blade housing 24 preferably presents a pinion-receiving opening 54 defined between the ends 48 . The blade housing 24 also preferably presents arcuate inner and outer housing surfaces 56 , 58 , with the outer housing surface 58 facing in a radially outward direction and the inner housing surface 56 facing oppositely to the outer housing surface 58 in a radially inward direction. The arcuate outer housing surface 58 defines a circumferential outer housing groove 60 that generally extends laterally along the flange 52 . The outer housing surface 58 also presents axial slots 62 (see FIG. 8 ). The inner housing surface 44 defines circumferential rib segments 64 and a circumferential inner housing groove 66 (see FIGS. 7 and 8 ). The inner housing groove 66 serves as a race for rotatably supporting the blade 26 as will be discussed. Between the ends 48 , the inner housing groove 66 extends substantially along the perimeter of the ring 50 .
[0030] While the illustrated blade housing 24 preferably includes the single inner housing groove 66 , it is consistent with the principles of the present invention for the blade housing 24 to include an alternative groove configuration for rotatably supporting the blade 26 , e.g., an alternative number of grooves or an alternative groove shape. Preferred features of such alternative blade housing and groove constructions are disclosed in U.S. Pat. No. 8,037,611, issued Oct. 18, 2011, entitled ROTARY KNIFE WITH BLADE BUSHING, and U.S. application Ser. No. 13/283,324, filed Oct. 27, 2011, entitled ROTARY KNIFE WITH MECHANISM FOR CONTROLLING BLADE HOUSING, both of which are incorporated in their entirety by reference herein.
[0031] The handle 22 , blade housing 24 , pinion housing 27 , and pinion cover 28 are preferably manufactured from a tempered steel to resist oxidation and corrosion within the adverse environment of a slaughterhouse. However, the principles of the present invention are equally applicable where the handle 22 , blade housing 24 , pinion housing 27 , and pinion cover 28 include other metallic or non-metallic materials such as brass, aluminum, or stainless steel.
[0032] In the illustrated embodiment, the blade housing 24 also preferably includes a high-friction coating 68 applied to the substrate housing material along the flange 52 . Preferably, the inner housing surface 56 of the blade housing 24 includes the coating 68 . Also, the coating 68 is preferably a single material layer that is applied in sections adjacent to each end 48 . As defined herein, a high-friction coating refers to a coating applied to the surface of a substrate (e.g., where the coating is adhered to the substrate surface) so that when the combined substrate and coating frictionally engages another surface, the resulting coefficient of friction is greater than the coefficient of friction associated with frictional engagement between the substrate surface and the another surface. As will be discussed, the coating 68 is most preferably designed to frictionally engage another coating applied to the pinion cover 28 .
[0033] It is also within the scope of the present invention where the blade housing 24 includes, either entirely or partly, an outermost material layer for other purposes, such as corrosion resistance, aesthetic qualities, or other performance requirements. For instance, the blade housing 24 could have a layer of brass, aluminum, or stainless steel that is suitable for surface-to-surface engagement with the blade 26 . In this manner, such an outermost layer, whether coated, adhered, or otherwise secured onto the base material, may provide an optimal surface for low-friction bearing engagement with the blade 26 .
[0034] The blade housing 24 is attached to the pinion housing 27 by arranging the outer housing surface 58 in engagement with the clamping surface 38 so that the ribs 44 are positioned within the outer housing groove 60 and the drive pinion 46 is aligned with the pinion-receiving opening 54 . As will be discussed, the pinion cover 28 and fasteners 70 secure the blade housing 24 to the pinion housing 27 and permit adjustable clamping of the blade housing 24 between the pinion housing 27 and pinion cover 28 .
[0035] Turning to FIGS. 7 and 8 , the annular blade 26 is preferably unitary and is substantially continuous around its circumference. The blade 26 includes a blade wall 72 and a ring gear 74 extending from the blade wall 72 for mating with the drive pinion 46 . The blade wall 72 presents a sharp cutting edge 76 and an arcuate outer blade groove 78 . The blade 26 is preferably rotatably mounted in the blade housing 24 by positioning the rib segments 64 in sliding engagement within the outer blade groove 78 .
[0036] If desired, the blade 26 may be alternatively configured to include other types of edges. For example, instead of the sharp edge 76 , the blade 26 could alternatively include an abrasive edge (e.g., with a surface that is gritted), a bristled edge, or a brush-type shredding edge. Similar to the blade housing 24 , it is consistent with the principles of the present invention for the blade 26 to include an alternative groove configuration, such as an alternative number of grooves or an alternative groove shape.
[0037] The blade 26 is preferably manufactured from tempered steel. However, similar to the handle 22 , blade housing 24 , pinion housing 27 , and pinion cover 28 , the principles of the present invention are applicable where the blade 26 includes other metallic or non-metallic materials, such as brass, aluminum, or stainless steel. Alternatively, the blade 26 , either entirely or partly, may include an outermost layer of brass, aluminum, or stainless steel that is suitable for surface-to-surface engagement with the blade housing 24 . In this manner, such an outermost layer, whether coated, adhered, or otherwise secured onto the base material, may provide an optimal surface for low-friction bearing engagement. However, the outermost layer may be included for other purposes, such as corrosion resistance, aesthetic qualities, or other performance requirements. It will also be appreciated that the blade 26 could be mounted within the blade housing 24 using an annular bushing to restrict wear of the blade 26 and/or blade housing 24 . Embodiments of a rotary knife with preferred features of an annular blade bushing are disclosed in the above-incorporated '611 patent and '324 application.
[0038] The pinion cover 28 preferably includes a unitary body with a curved wall 80 and internally-threaded bosses 82 that are integrally formed with the wall 80 . The wall 80 includes a pair of oppositely positioned tab ends 84 . The pinion cover 28 also preferably includes a high-friction coating 86 . The illustrated coating 86 is preferably a single material layer applied continuously from one tab end 84 to the other tab end 84 . Thus, the pinion cover 28 presents a clamping surface 88 that faces in a radially outward direction and includes the coating 86 .
[0039] The coatings 68 , 86 are preferably formed with a liquid epoxy and discrete aluminum oxide particles interspersed within the epoxy to provide a gritted coating surface. However, it is also within the scope of the present invention where an alternative coating is used, e.g., to provide a suitable coefficient of friction. For instance, an alternative synthetic resin could be used to form the coatings 68 , 86 . Also, discrete grit particles made from an alternative material, such as silicon carbide or diamond, could be employed with the epoxy. For some aspects of the present invention, the coatings 68 , 86 could also be devoid of grit particles.
[0040] Again, the illustrated coatings 68 , 86 each preferably comprise a single layer of the combined epoxy and particles. However, it is within the ambit of the present invention where multiple layers of epoxy and particles are applied to form the coatings 68 , 86 . For instance, it may be necessary to adjust the thickness dimensions T 1 ,T 2 of the coatings 68 , 86 , e.g., where the thickness dimension T is increased to compensate for wear of the corresponding substrate (see FIG. 6 ). While the thickness dimensions T 1 ,T 2 are preferably substantially the same, the coatings 68 , 86 could have different thicknesses without departing from the scope of the present invention.
[0041] The coatings 68 , 86 are preferably applied to the respective underlying substrate. Prior to application of coatings 68 , 86 , one or more steps are preferably required to prepare the substrate surface (e.g., so that adhesion is maximized between the substrate and coating). Preferably, the substrate surface is prepared by cleaning the surface (e.g., with a solvent), then abrading the surface, and then cleaning the abraded surface again. Preparation of the surface might also involve complete or partial removal of any previous coating layers. However, preparation of the substrate surface could involve just one of the foregoing steps. Furthermore, it will be appreciated that other preparatory steps could be required before coating application. The process of abrading the substrate surface is preferably done using sandpaper with a grit size that ranges from about one hundred (100) grit to about four hundred (400) grit. However, the substrate surface could be roughened by techniques other than abrasion, e.g., by etching the substrate surface, without departing from the scope of the present invention.
[0042] Application of coatings 68 , 86 is preferably done manually, although the principles of the present invention are applicable where a machine is employed to apply the coatings. For application of a single coating layer, the coating material is initially mixed. In particular, grit particles and epoxy are preferably mixed to provided the illustrated coating material. The mixed coating material is then applied to the prepared substrate surface in a coating layer. The applied coating layer is then allowed to set prior to use of the single coating layer and substrate.
[0043] To form the coatings 68 , 86 by applying multiple coating layers, coating material is mixed, a first coating layer is then applied to the prepared substrate surface, and the first applied coating layer is then allowed to set. Each subsequent coating layer is applied to the previous coating layer after the previous coating layer has set. Each subsequent coating layer is then allowed to set prior to application of another coating layer or use of the combined coating and underlying substrate.
[0044] Application of the high-friction coatings to the corresponding substrate is preferably intended to be performed as part of a knife refurbishment process, as will be described further. However, it is also within the scope of the present invention where the coatings are applied as part of the original knife component manufacturing process.
[0045] The pinion housing 27 and pinion cover 28 are shiftable relative to each other and preferably used to removably attach and support the blade housing 24 relative to the handle 22 . In particular, fasteners 70 preferably extend through holes 42 in the pinion housing 27 , along openings 90 presented by the flange 52 , and are threaded into the threaded holes presented by the bosses 82 so that the blade housing 24 is clamped between the pinion cover 28 and the pinion housing 27 . With the pinion housing 27 and pinion cover 28 holding the blade housing 24 in clamping engagement, further tightening of the fasteners 70 serves to increase the gripping force applied to the blade housing 24 by the pinion housing 27 and pinion cover 28 .
[0046] Similarly, with the pinion housing 27 and pinion cover 28 in clamping engagement, loosening of the fasteners 70 serves to decrease the applied gripping force. Thus, the secured blade housing 24 can be disassembled from the knife 20 by loosening the fasteners 70 and shifting the pinion cover 28 away from the pinion housing 27 . Such disengagement of the pinion housing 27 and pinion cover 28 permits removal of the blade housing 24 therefrom. Subsequently, the removed blade housing 24 can be selectively expanded from the blade-securing condition to the blade-releasing condition to permit removal of blade 26 from the blade housing 24 .
[0047] Blade housing removal may accompany one or more of various knife maintenance procedures. For instance, blade housing removal may be followed by application of the illustrated coatings 68 , 86 . Alternatively, blade housing removal may be followed by sharpening of the removed blade, followed by reinstallation of the sharpened blade. Yet further, blade housing removal could be followed by installation of another blade, such as an entirely new annular blade.
[0048] In any event, the blade to be installed in the knife 20 can be rotatably mounted in the expanded blade housing 24 following any application and setting of coatings 68 , 86 . The blade is inserted by expanding the blade housing from the blade-securing condition to the blade-releasing condition, positioning the blade in rotatable engagement with the inner housing surface 56 , and returning the blade housing 24 to the blade-securing condition. After blade insertion, the blade housing 24 can be secured between the pinion housing 27 and pinion cover 28 . Securement of the blade housing 24 includes the steps of positioning the flange 52 between the pinion housing 27 and pinion cover 28 , with the outer housing surface 58 adjacent the clamping surface 38 and the inner housing surface 56 adjacent the clamping surface 88 . The fasteners 70 are then inserted through the pinion housing 27 , threaded into the pinion cover 28 , and tightened so as to clamp the blade housing 24 in place.
[0049] With the blade housing 24 secured relative to the handle 22 , the clamping surface 38 of pinion housing 27 is preferably opposed to and interengaged with the outer housing surface 58 . Also, the clamping surface 88 of pinion cover 28 is preferably opposed to and interengaged with the inner housing surface 56 . Furthermore, the clamping surfaces 38 , 88 are preferably opposed to each other.
[0050] In this manner, the fasteners 70 hold the pinion housing 27 and pinion cover 28 in clamping engagement with the blade housing 24 . However, for some aspects of the present invention, the pinion cover 28 could be constructed so as not to be used to secure the blade housing 24 . For instance, the blade housing 24 could simply be secured to the pinion housing 27 with fasteners.
[0051] Preferably, the coatings 68 , 86 frictionally engage one another when the pinion housing 27 and pinion cover 28 are clamped to and secure the blade housing 24 . Also, the pinion cover 28 preferably substantially covers the drive pinion 46 while permitting intermeshing engagement between the drive pinion 46 and the blade 26 .
[0052] While the knife 20 is preferably constructed so that the pinion cover 28 is separate from the blade housing 24 , it is also within the scope of the present invention where the pinion cover 28 is provided as part of the blade housing 24 and/or pinion housing 27 .
[0053] The illustrated knife 20 preferably includes both of the illustrated coatings 68 , 86 so that the coatings 68 , 86 cooperatively provide a high coefficient of friction between the pinion cover 28 and blade housing 24 . However, for some aspects of the present invention, the knife 20 could be provided with only one of the coatings 68 , 86 . For example, the knife 20 could have only the coating 86 on the pinion cover 28 , with the coating 86 being in frictional engagement with the substrate of the flange 52 .
[0054] It is also within the ambit of the present invention where the coatings 68 , 86 are alternatively positioned to frictionally hold the blade housing 24 in the desired position. For instance, the coatings 68 , 86 could be applied to the pinion housing 27 to define at least part of the curved clamping surface 38 and to the blade housing 24 to define at least part of the outer housing surface 58 . In this manner, the coatings 68 , 86 could provide direct frictional engagement between the blade housing 24 and the pinion housing 27 . Also, the clamping surfaces 38 , 88 and housing surfaces 56 , 58 could all include coatings to provide additional frictional engagement.
[0055] In operation, the knife 20 is preferably maintained by periodic refurbishment of interengaging surfaces of the pinion housing 27 and the blade housing 24 . It is to be understood that knife refurbishment can involve not only re-coating of a surface that has previously been provided with the coating material but also newly applying the coating material to a new or used knife component. For example, the blade housing BH and pinion cover C of the knife K shown in FIGS. 1-4 may have one or more coating layers applied thereto once the grooved surfaces S have become worn. In any case, surface refurbishment is initiated by removing the blade housing 24 and blade 26 from the pinion housing 27 . Removal of the blade housing 24 and blade 26 preferably exposes the clamping surfaces 38 , 88 and the inner and outer housing surfaces 56 , 58 . Consequently, blade housing removal also serves to expose surfaces for application of coatings 68 , 86 .
[0056] Prior to the coating application, knife refurbishment continues by preparing the underlying substrate surfaces of the blade housing 24 and pinion cover 28 . As described, such preparation preferably involves a desired sequence of cleaning and abrading the surface. Coating material is then mixed and prepared. The mixed coating material is then applied to the prepared surfaces to form a coating layer. The coating layer is then allowed to set. Once the coatings are set, the blade housing 24 is secured to the handle 22 by the pinion housing 27 and the pinion cover 28 with fasteners 70 .
[0057] The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0058] The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
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A rotary knife includes a handle, a rotatable annular blade, an expandle blade housing, and a housing support. The blade housing is movable relative to the handle between a blade-securing condition, in which the blade housing securely supports the blade for rotational operation, and a relatively expanded blade-releasing condition, in which the blade housing permits removal and installation of the blade relative to the blade housing. The housing support is coupled to the handle and supports the housing in the blade-securing and blade-releasing conditions. The support and housing include interengaging surfaces that contact one another in the blade-securing condition, with at least one of the interengaging surfaces including an applied high-friction coating.
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[0001] This is a continuation of U.S. Ser. No. 11/946,243, filed Nov. 28, 2007, which is a continuation of U.S. Ser. No. 11/216,918, filed Aug. 31, 2005, which are each hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to circuit design tools generally and, more particularly, to a timing violation debugging capability inside a place-and-route tool.
BACKGROUND OF THE INVENTION
[0003] Very often in late design stages of an integrated circuit, small timing and crosstalk violations are fixed manually as no tools currently exist to implement the fixes. The violations are commonly caused by constraint changes and functional changes before and during place-and-route operations. To keep the performance results of the integrated circuit consistent through the place-and-route operations, and the rest of the design development, manual interactions are often limited to only the violated parts. To find the best place to implement changes during the place-and-route operation, having all related information available in a bundled form is desirable. The related information includes areas of highest and lowest resistance of a net, highest and lowest capacitance to adjacent nets and the availability of faster, slower and different driver strength cell types for the current cells within the design. In addition, an automatic ability to write out engineering change order (ECO) files, when needed, or implement fixes on the circuit networks, where possible, during the place-and-route operations is also desirable.
[0004] Current approaches to implementing the fixes involve manual interactions of the engineers. The engineers have to find a correct solution by reading documentation and datasheets about the cells. A considerable amount of experience with the place-and-route operations is often helpful. However, the manual interactions consume significant time reading the large reports and are prone to human errors. Furthermore, a large number of different software tool licenses must be obtained to acquire the various tools used to analyze different aspects of the circuit design.
SUMMARY OF THE INVENTION
[0005] The present invention concerns a storage medium for use in a computer to develop a circuit design. The storage medium recording a software tool that may be readable and executable by the computer. The software tool generally comprises the steps of (A) receiving a first user input that identifies a specific cell of a plurality of existing cells in the circuit design, the specific cell having a timing characteristic, (B) generating a replacement display corresponding to the specific cell, the replacement display comprising a plurality of alternate cells suitable to replace the specific cell, each of the alternate cells having a different value associated with the timing characteristic of the specific cell, (C) receiving a second user input that identifies a replacement cell of the alternate cells and (D) automatically generating a first engineering change order to replace the specific cell with the replacement cell.
[0006] The objects, features and advantages of the present invention include providing a timing violation debugging capability inside a place-and-route tool that may (i) display timing violations and crosstalk violations from inside the place-and-route tool, (ii) display sources of the timing violations and the crosstalk from inside the place-and-route tool, (iii) display the timing violations and the crosstalk violations in a compressed format, (iv) help reduce a turnaround time for debugging small timing violations and small crosstalk violations inside application specific integrated circuit designs, (v) help reduce an amount of time spend fixing the violations and/or (vi) automatically generate engineering change orders to fix and/or reduce selected violations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other objects, features and advantages of the present invention will be apparent from the following detailed description and the appended claims and drawings in which:
[0008] FIG. 1 is a block diagram of an example implementation of a system is shown in accordance with a preferred embodiment of the present invention;
[0009] FIG. 2 is a flow diagram of an example method for developing a circuit design;
[0010] FIG. 3 is a diagram of an example main display;
[0011] FIG. 4 is a flow diagram of an example method for handling timing violations;
[0012] FIG. 5 is a diagram of an example violation display;
[0013] FIG. 6 is a diagram of an example layout display;
[0014] FIG. 7 is a diagram of an example timing display;
[0015] FIG. 8 is a diagram of an example replacement display;
[0016] FIG. 9 is a flow diagram of an example method for handling network violations;
[0017] FIG. 10 is a diagram of an example network display;
[0018] FIG. 11 is a diagram of an example buffer display;
[0019] FIG. 12 is a flow diagram of an example method for handling crosstalk violations;
[0020] FIG. 13 is a diagram of an example crosstalk display; and
[0021] FIG. 14 is a diagram of an example drive cell display.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIG. 1 , a block diagram of an example implementation of a system 100 is shown in accordance with a preferred embodiment of the present invention. The system (or apparatus) generally comprises a circuit (or module) 102 , a circuit (or module) 104 , a circuit (or module) 106 and a circuit (or module) 108 . The circuit 102 may be referred to as storage medium. The storage medium 102 may be implemented as a memory such as a hard drive, Flash memory, optical drive or the like. The storage medium 102 may be readable and writeable to and from the circuit 104 .
[0023] The circuit 104 may be referred to as a processor circuit. The processor circuit 104 may be operational to read data and software programs (or tools or modules) from the storage medium 102 , execute the software and write data back to the storage medium 102 . The processor circuit 104 may receive user input data from the circuit 106 and may present user output data to the circuit 108 .
[0024] The circuit 106 may be referred to as a user input device. The user input device 106 may include one or more mechanisms for the user to enter selections and other information into the system 100 . The user input device 106 may include, but is not limited to, a keyboard and a mouse.
[0025] The circuit 108 may be referred to as a display device. The display device 108 may include one or more mechanisms for presenting information from the system 100 to the user. The display device 108 may include, but is not limited to, a visual display, a printer and one or more audio speakers.
[0026] A general purpose of the system 100 is to bundle all relevant information for a circuit design layout debug inside a place-and-route tool executed by the processor circuit 104 . The relevant information may be related to any kind of network (or “net” for short) or cell. The information may be shown to the user in a compressed form on a display. Showing the information to the user from the place-and-route tool generally eases the work of debugging the circuit design during place-and-route related cleanup operations. The debugging may be useful in late design stages to fix one or more remaining timing violation and/or one or more crosstalk violations quickly and easily.
[0027] The storage medium 102 may store multiple software tools (or programs) and multiple electronic files. The software tools generally comprise a static timing analysis (STA) tool (or program) 120 , a delay calculation tool (or program) 122 , an extraction tool (or program) 124 , an operating system (or program) 128 and a place-and-route tool (or program) 130 . The electronic files generally comprise a design database (or file) 132 , a technology library (or file) 134 , a name mapping file 136 , a crosstalk result file 138 , a delay violation result file 140 , an extraction file 142 , a final engineering change order (ECO) file 146 and an intermediate ECO file 148 . Other software tools and files may be stored in the storage medium 102 to meet the criteria of a particular application.
[0028] The STA tool 120 and the delay calculation tool 122 are known in the art. The extraction tool 124 may be operational to extract information from the circuit design and present the information in a standard parasitic exchange (SPEF) format and/or a detailed standard parasitic format (DSPF). The extraction tool 124 is known in the art.
[0029] The place-and-route tool 130 generally comprises a place-and-route core module (or program) 150 , an ECO module (or program) 152 , a debug module (or program) 154 and a graphical user interface (GUI) module (or program) 156 . The place-and-route tool 130 may be operational to read and/or write to the various files 132 - 148 . Communication may also be provided between the place-and-route tool 130 and the operating system 128 to transfer information to and from the user via the user input device 106 and the display device 108 .
[0030] The place-and-route core module 150 may be operational to perform conventional place-and-route operations. For example, the place-and-route core module 150 may automatically place multiple cells of the circuit design within a die layout constraint and route multiple nets between the pins (or interfaces) of the cells.
[0031] The ECO module 152 may be operational to automatically generate one or more intermediate ECOs based on changes indicated by the user through the various graphical user interfaces (displays or windows) initiated by the debug module 154 . The intermediate ECOs may be written to the intermediate ECO file 148 and/or temporarily stored in a memory of the processor 104 . Upon receipt of a user command, the ECO module 152 may be operational to read the intermediate ECOs from the intermediate ECO file 148 and generate a final ECO containing all of the selected changes. The final ECO may be written to the final ECO file 146 .
[0032] The debug module 154 may be operational to walk the user through a sequence of displays useful in debugging performance violations found in the circuit design. The debug module 154 may generate output information in an information signal (e.g., I/O INFO) containing the types of data to be presented to the user and containing the types of user inputs to be presented to the user. The output information may be transferred to the GUI module 156 for formatting. Input information in the signal I/O INFO carrying the user selections may be received back to the debug module 154 .
[0033] The GUI module 156 may be operational to arrange the output information in a plurality of formats suitable for a plurality of display screens (or “display” for short) to the user. The various formats may result in a series of calls and transfers to the operating system 128 to cause graphical user interfaces (e.g., displays or windows) to be presented by the display device 108 . The GUI module 156 may also receive a plurality of selections from the user through the user input device 106 via the operating system 128 . The user selections may be passed back to the debug module 154 as the input information.
[0034] Referring to FIG. 2 , a flow diagram of an example method 160 for developing a circuit design is shown. The method (or process) 160 generally comprises a step (or block) 162 , a step (or block) 164 , a step (or block) 166 , a step (or block) 168 , a step (or block) 170 , a step (or block) 172 , a step (or block) 174 , a step (or block) 176 and a step (or block) 178 . The method 160 may begin with the execution of the STA tool 120 , the delay calculation tool 122 and the extraction tool 124 in the step 162 . Results from the STA tool 120 and the delay calculation tool 122 may be stored in the delay violation results file 140 . Results from the extraction tool 124 may be stored in the SPEF/DSPF extraction file 142 .
[0035] In the step 164 , the performance violations in the crosstalk results file 138 , the delay violation results file 140 , the SPEF/DSPF file 142 may be read into the place-and-route tool 130 . Data from the name mapping file 136 and the design database 132 may also be read into the place-and-route tool 130 . Resistance values and capacitance values may be available from the SPEF/DSPF file 142 . Additionally the place-and-route tool 130 may read the timing violations such as setup timing violations, hold time violations and ramp time violations, generally available from the delay violation results file 140 . Network crosstalk violations may be available from the crosstalk results file 138 . Other violations and performance information may be generated internally by the place-and-route module 150 and made available to the debug module 154 .
[0036] The debug module 154 may determine if any timing violation data exists to show to the user. If yes, the debug module 154 may command the GUI module 156 to generate and present user option information to cause a main display to be created by the display device 108 in the step 168 . If not, the debug module 154 may command the GUI module 156 to generate and present information to cause a message to be presented to the user stating that no violations were found.
[0037] FIG. 3 is a diagram of an example main display 180 is shown. The main display 180 may implement a graphical user interface that allows the user to select from among several different actions for the place-and-route tool 130 to perform. The main display 180 generally comprises an open violation list button (or input) 182 , a write ECO button (or input) 184 and a close button (or input) 186 . Selection of the close button 180 by the user (e.g., the CLOSE path from the step 170 ) may cause the debug module 154 to save all relevant data and end the current debugging operations.
[0038] Selection of the open violation list button 182 by the user (e.g., the LIST path from step 170 ) may cause the debug module 154 to assemble a list of all performance violations available to the place-and-route tool 130 . The method 160 may proceed to the list operations ( FIG. 4 ) through the block 172 .
[0039] Selection of the write ECO button 186 by the user (e.g., the WRITE path from the step 170 ) may cause the debug module 154 to command the ECO module 152 to generate a final ECO for the current debugging session. The ECO module 152 may respond to the ECO command by reading any intermediate ECOs stored in the intermediate ECO file 148 and/or temporarily in a memory of the processor 104 in the step 174 . The ECO module 152 may combine the intermediate ECOs to generate the final ECO and store the final ECO in the final ECO file 146 in the step 176 . The final ECO may then be displayed and/or printed through the display device 108 .
[0040] Referring to FIG. 4 , a flow diagram of an example method 190 for handling timing violations is shown. The method (or process) 190 generally comprises the block 172 , a step (or block) 192 , a step (or block) 194 , a step (or block) 196 , a step (or block) 198 , a step (or block) 200 , a step (or block) 202 , a step (or block) 204 , a step (or block) 206 , a step (or block) 208 , a step (or block) 210 , a step (or block) 212 , a step (or block) 214 and the block 178 .
[0041] In the step 192 , the debug module 154 may generate violation information suitable for generating a GUI displaying all of the performance violations available to the place-and-route tool 130 . The debug module 154 may also generate layout information suitable for generating a GUI displaying some or a portion of a layout view of the circuit design in the step 192 . The layout view may be implemented as a frame view. A frame view is generally an abstract layout view of one or more cells and one or more nets of circuit showing pins, contacts and blockage areas in various fabrication layers. The violation GUI and the aggressor GUI may be displayed to the user in the step 194 .
[0042] Referring to FIG. 5 , a diagram of an example violation display (GUI) 220 is shown. The violation display 220 may be implemented as a two-dimensional table. Different types of timing violations and signal integrity violations, along with associated performance values may be disposed along a first axis (e.g., an x-axis) of the table. The violation display 220 generally shows various kinds of violations ordered from the largest violations to the smallest violations. Cell names/pin names associated with the violations may be displayed. The timing values may be the results from the delay calculation tool 122 and the STA tool 120 . The crosstalk nets may be victim nets or the aggressor nets listed in the crosstalk calculation report file 138 .
[0043] Each of the violations and values may be disposed in a separate column. A second axis (e.g., a y-axis) of the table may contain a legend row and at least one additional row for the violations. The total number of rows may vary with a maximum number of violations in a most-used column. Examples of the timing violations include a setup time, a hold time, a ramp time (covering both ramp up and ramp down), overdrive, and out of characterization range violations. A setup time generally refers to an amount of time a signal is specified to remain valid before a clock edge use to sample the signal. A hold time generally refers to an amount of time a signal is specified to remain valid after a clock edge used to sample the signal. A ramp time generally refers to an amount of time a signal is specified to ramp up from a starting level to an ending level and/or an amount of time a signal is specified to ramp down from a starting level to an ending level. An example of a signal integrity violation is a crosstalk violation. Crosstalk generally referred to an amount of noise induced on a victim net by one or more neighboring aggressor nets and/or crossing nets. The noise may be transferred between nets due to capacitance coupling and/or inductive coupling. In other embodiments, the place-and-route tool 130 may be configured to display other signal integrity violations, such as ground bounce, noise, electromigration and the like.
[0044] Referring to FIG. 6 , a diagram of an example layout display (GUI) 222 is shown. The layout display 222 generally comprises one or more cells (e.g., CELL 1 , CELL 2 and CELLA) and one or more nets (e.g., NET 1 -NET 6 and NETA) connecting the cells. The layout display 222 may show each individual cell and network as either normal or highlighted. In the example illustrated, CELL 1 and CELL 2 are highlighted (e.g., bold, color or flashing) while CELLA is shown as normal. Likewise, NET 1 -NET 4 and NETA are shown highlighted while NET 5 and NET 6 are shown as normal.
[0045] Returning to FIG. 4 , in the step 196 , the place-and-route tool 130 may receive a user input selecting a particular timing violation or a particular crosstalk violation presented in the violation display 220 . The place-and-route tool 130 generally differentiates between the timing violations and the crosstalk violations. If any crosstalk violation is selected (e.g., user places a mouse cursor over the appropriate cell in the table and left clicks), the method 190 may proceed to the crosstalk operations ( FIG. 12 ) through the block 200 .
[0046] If any timing violation is selected, the debug module 154 may generate timing information in the step 198 suitable to cause a timing GUI to be displayed to the user via the display device 108 . The debug module 154 may also be operational in the step 198 to highlight the associated cells and/or nets shown in the layout GUI 222 . The timing GUI may be displayed and the layout GUI 222 may be altered to incorporate the highlighting in the step 202 . In selecting a particular cell or a particular net to fix (e.g., CELLA/PINA), the debug module 154 may highlight a complete path related to the violated pin (e.g., CELLA/PINA) and highlight in another way (e.g., flashing) the areas in the path that may be the real violators.
[0047] Referring to FIG. 7 , a diagram of an example timing display (GUI) 230 for a setup timing violation is shown. The timing display 230 may be implemented as a two-dimensional table. The table is generally a shortened (e.g., compressed) form of the reports from the STA tool 120 and the delay calculator tool 122 . A path name legend, a net name legend, a delay legend and a ramp time legend may be disposed along a first axis (e.g., an x-axis) of the table. The cell names/pin names and net names in the path may be disposed along a second axis (e.g., a y-axis). The timing delay values and ramp time values may be displayed in respective columns. Timing displays for hold time violations and for ramp time violations may be similar to the timing display 230 for the setup timing violation.
[0048] Looking at the values in the timing display 230 suggests some areas of improvement may be possible. In a first example, the delay of CELL 2 may be high compared with CELL 1 , assuming that the same cell type is used in both CELL 1 and CELL 2 . In a second example, the delay of NET 2 may be high relative to the delay of NET 1 . Selecting one of the net table cells (e.g., NET 2 ) in the timing display 230 may cause the place-and-route tool 130 to proceed with a set of network operations ( FIG. 9 ) through the block 206 . By clicking on one of the path table cells (e.g., CELL 2 /PINA−CELL 2 /PINZ) inside the report in the step 204 , a new replacement GUI window may be generated in steps 208 and 210 that shows a list of the alternative cells, available in the technology library 134 with related values (e.g., size, input capacitance, etc.).
[0049] Referring to FIG. 8 , a diagram of an example replacement display (GUI) 232 for alternate cells is shown. The replacement display 232 may be implemented as a two-dimensional table. A cell name legend, a delay legend and a ramp time, setup time and/or hold time legend may be disposed along a first axis (e.g., an x-axis) of the table. The available alternate cell names may be disposed along a second axis (e.g., a y-axis). The performance values of the cells may be displayed in respective columns.
[0050] The place-and-route tool 130 may receive a selection of a particular alternate cell from the user in the step 212 that may fix or reduce the violation. The ECO module 152 may respond to the selection by automatically generating and storing an intermediate ECO in the step 214 . The intermediate ECO may be stored in the intermediate ECO file 148 and/or temporarily in a memory of the processor 104 . The method 190 may then return to the main display via the block 178 .
[0051] Referring to FIG. 9 , a flow diagram of an example method 240 for handling network violations is shown. The method (or process) 240 generally comprises the block 206 , a step (or block) 242 , a step (or block) 244 , a step (or block) 246 , a step (or block) 248 , a step (or block) 250 , a step (or block) 252 , a step (or block) 254 , a step (or block) 256 and the block 178 .
[0052] If the place-and-route tool 130 receives a user input selecting a particular net from the violation display 220 in the step 204 ( FIG. 4 ), the debug tool 154 may change the layout information in the step 242 to highlight the net in the layout display 222 . The debug tool 154 may also generate network information in the step 242 to cause a network display (GUI) 260 to be shown to the user via the display device 108 in the step 244 . The network display 260 generally shows information about the particular net that may be relevant to fixing the selected network violation.
[0053] Referring to FIG. 10 , a diagram of an example network display (GUI) 260 is shown. The network display 260 may be implemented as a two-dimensional table. The network information shown in the network table generally comprises a net length, a total resistance, an area of highest and lowest resistance, a total capacitance and an area of highest and lowest capacitance to adjacent nets and to metal (used for fulfilling the technology density criteria). The resistance and capacitance values may be provided from the extraction tool 124 . The net length may be generated by the place-and-route core module 150 . Selecting one of the network characteristic items in the step 246 inside the table of the network display 260 may cause the method 240 to transfer to as associated area inside the place-and-route core module 150 in the step 248 where the selected network characteristic may be modified.
[0054] A last table cell in the network display 260 may have a user input button having a legend (e.g., INSERT BUFFER). User selection of the INSERT BUFFER button may instruct the debug module 154 to generate buffer information in the step 250 . The buffer information generally results in the presentation a buffer display 262 to the user in the step 252 .
[0055] Referring to FIG. 11 , a diagram of an example buffer display (GU) 262 is shown. The buffer display may be implemented as a two-dimensional table. The buffer table may show a listing of buffers (e.g., inverting pairs and non-inverting devices) and respective parameters available from the technology library 134 . The available buffers may be used to correct hold time violations, ramp timing violations and/or other cell timing violations.
[0056] Returning to FIG. 9 , the place-and-route tool 130 may receive a user selection of a particular buffer/inverter pair in the step 254 . The ECO module 152 may then generate and store and intermediate ECO in the intermediate ECO file 148 and/or temporarily in a memory of the processor 104 for the particular buffer in the step 256 . Optional manual fixes involving insertions or deletions of fill metal may also be performed by using the functionality of the place-and-route core module 150 . The method 240 may then return to the main display 180 via the block 178 .
[0057] Referring to FIG. 12 , a flow diagram of an example method 270 for handling crosstalk violations is shown. The method (or process) 270 generally comprises the block 200 , a step (or block) 272 , a step (or block) 274 , a step (or block) 276 , a step (or block) 278 , a step (or block) 280 , a step (or block) 282 , a step (or block) 284 , a step (or block) 286 , a step (or block) 288 , a step (or block) 290 , a step (or block) 292 and the block 178 .
[0058] Fixing crosstalk violations may be initiated by the user selecting a particular net from the network table in the network display 260 . The debug module 154 may then generate crosstalk information in the step 272 associated with the selected net. The crosstalk information may be used to generate a new crosstalk display window and update the layout display 222 in the step 274 .
[0059] Referring to FIG. 13 , a diagram of an example crosstalk display (GUI) 300 is shown. The crosstalk display 300 may be implemented as a two-dimensional table. The crosstalk table generally comprises a list of up to a predetermined maximum number (e.g., 5) of the largest aggressor nets that contribute to the crosstalk in the selected victim net (e.g., NETA). The list may include, but is not limited to, a driving cell, a length of parallel routing and which layer is used by each of the aggressor nets. In a parallel (simultaneous) operation in the step 272 , the debug module 154 may update the layout information to highlight the victim net (e.g., NETA) in one color (e.g., red or bold) and the aggressor nets (e.g., NET 3 and NET 4 ) in another color (e.g., green or dashed) in the layout display 222
[0060] Returning to FIG. 12 , the user may select a particular DRIVING CELL table cell in the VICTIM NET line in the network table in the step 276 . The debug module 154 may respond to the selection by generating stronger drive cell information related to the selected driving cell in the step 278 . The stronger drive cell information may be used to generate a drive cell display in the step 280 .
[0061] Referring to FIG. 14 , a diagram of an example drive cell display (GUI) 302 is shown. The drive cell display 302 may be implemented as a two-dimensional table. The drive cell table generally lists various alternate cell types and the relative characteristics available in the technology library 134 . For a victim net, the alternate drive cells may be stronger drive cells than the current drive cell used in the circuit design for driving the victim net.
[0062] Returning to FIG. 12 , the user may select one of the stronger drive cells to replace the current drive cell in the step 282 . The ECO module 152 may respond to the stronger drive cell selection by generating an intermediate ECO in the step 284 . The intermediate ECO may be stored in the intermediate ECO file 148 and/or temporarily in the memory of the processor 104 .
[0063] If the user selects a DRIVING CELL input in an AGGRESSOR NET line from the crosstalk display in the step 276 , the debug module 154 may generate weaker drive cell information related to the selected drive cell in the step 286 . The weaker drive cell information may be used to generate the drive cell display 302 to the user in the step 288 . The drive cell display 302 created from the weaker drive cell information may have a similar format as created from the stronger drive cell information (see step 278 ). However, the weaker drive cell information generally lists the available drive cells from the technology library 134 having weaker cell types than the selected aggressor net. Upon receipt of a user selection for an alternate weaker drive cell in the step 290 , the ECO module 152 may generate an intermediate ECO in the step 292 to replace the current drive cell of the selected aggressor net. The intermediate ECO may be stored in the intermediate ECO file 148 and/or temporarily in the memory of the processor 104 as part of the step 292 . The user may also be given an option to change the routing of the nets by moving away (rerouting) the victim net from the aggressor nets or the other way round. Net rerouting may be an optional task that may be performed by using the functionality of the place-and-route core module 150 . Afterwards, the method 270 may return to the main display 180 via the block 178 .
[0064] The function performed by the flow diagrams of FIGS. 2 , 4 , 9 and 12 may be implemented using a conventional general purpose digital computer programmed according to the teachings of the present specification, as will be apparent to those skilled in the relevant art(s). Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will also be apparent to those skilled in the relevant art(s).
[0065] The present invention may also be implemented by the preparation of ASICs, FPGAs, or by interconnecting an appropriate network of conventional component circuits, as is described herein, modifications of which will be readily apparent to those skilled in the art(s).
[0066] The present invention thus may also include a computer product which may be a storage medium including instructions which can be used to program a computer to perform a process in accordance with the present invention. The storage medium can include, but is not limited to, any type of disk including floppy disk, optical disk, CD-ROM, magneto-optical disks, ROMs, RAMS, EPROMs, EEPROMs, Flash memory, magnetic or optical cards, or any type of media suitable for storing electronic instructions. As used herein, the term “simultaneously” is meant to describe events that share some common time period but the term is not meant to be limited to events that begin at the same point in time, end at the same point in time, or have the same duration.
[0067] While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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A storage medium for use in a computer to develop a circuit design. The storage medium recording a software tool that may be readable and executable by the computer. The software tool generally includes the steps of (A) receiving a first user input that identifies a specific cell of a plurality of existing cells in the circuit design, the specific cell having a timing characteristic, (B) generating a replacement display corresponding to the specific cell, the replacement display comprising a plurality of alternate cells suitable to replace the specific cell, each of the alternate cells having a different value associated with the timing characteristic of the specific cell, (C) receiving a second user input that identifies a replacement cell of the alternate cells and (D) automatically generating a first engineering change order to replace the specific cell with the replacement cell.
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BACKGROUND OF THE INVENTION
The electric vehicle is regaining popularity. Because of pollution from the combustion engine, federal and state governments are seeking alternative power systems for the automobile and other vehicles. One of the leading candidates is the battery-powered vehicle, which utilizes electricity stored in batteries.
Although battery-powered vehicles are clean, quiet and efficient, they face a number of obstacles to acceptance. One obstacle is the short time-life of the vehicle's charged batteries. While there have been advances in power storage and charge duration, the time-life cycle of a battery-based vehicle is only about two hours. Therefore, a battery-powered vehicle cannot go for more than two hours without recharging. Another obstacle to acceptance is the inconvenience to the user in having to continually plug into a power source.
Because of the batteries short time-life the driver needs to manually plug and unplug the vehicle every time it is used. If the driver fails to plug in the vehicle, then the driver may find the car insufficiently recharged for the next use. This practical issue of everyday use must be answered, if there is to be any significant widespread use of the electric automobile.
SUMMARY OF THE INVENTION
The invention supplies an in-vehicle electrical device with electricity from an off-vehicle power supply. The electrical device is connected to an in-vehicle electrical plug. The power supply comprises an electrical outlet supplying the off-vehicle power and an indicator for indicating the outlet's location. Also attached to the vehicle is a locator for automatically seeking and locating the outlet based on signals detected from the indicator and then connecting the plug to the outlet.
The invention supplies electricity to a recharger used to recharge batteries in a battery-powered vehicle. An arm mechanism is attached to the vehicle and moveable relative to the vehicle. At the distal end of the arm is an electrical plug protected by a retractable sheath and electrically connected to the recharger. While not in use, the arm and plug are retracted to a secure position. A docking station is located remote from the vehicle. The docking station contains an electrical outlet electrically connected to an electrical power supply. The docking station emits light distinguishable from background light and contains a conical passageway, which leads from the face of the docking station to the outlet for guiding the plug to the outlet. A docker is attached to the vehicle and is in electrical communication with the arm mechanism. The docker contains optical sensors tuned to the light emitted by the docking station. Software instructions move the arm mechanism to seek the outlet, calculate the position of the outlet, move the arm mechanism to connect the plug to the outlet, and establishes a communication link with the docking station. A power controller remote from the vehicle is in electrical communication with the docking station. The power controller contains an authorizer for establishing a communication link with the docker and determining whether the vehicle is approved for receiving electricity, an activator controlling the power supplied to the outlet, and a meter and accounter for measuring the energy used by the vehicle for billing purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a preferred embodiment of the invention.
FIG. 2 is a schematic sectional view of electrical plug 30 of FIG. 1.
FIG. 3 is a section taken along lines II--II of the electrical plug 30 of FIG. 2.
FIG. 4 is a section taken along lines III--III of the electrical plug 30 of FIG. 2.
FIG. 5 is a schematic sectional view of electrical plug 30 of FIG. 1 with the protective sheath 32 retracted.
FIG. 6 is a schematic sectional view of electrical outlet 20 of FIG. 1.
FIG. 7 is a section taken along lines IV--IV of the electrical outlet 20 of FIG. 6.
FIGS. 8a-8c show a view of the docking function.
FIG. 9 is a block diagram of the power controller 70 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment shown in FIG. 1, a battery-powered vehicle 10 is equipped with an in-vehicle recharger 15 for recharging the batteries 18. The vehicle's recharger converts household level, 115 V, alternating current (AC) to the appropriate direct current (DC) necessary to recharge that particular vehicle's batteries. The recharger 15 may be preinstalled by the vehicle manufacturer or the recharger 15 may be an aftermarket add-on. The preferred embodiment of the present invention automatically connects the in-vehicle recharger 15 to an off-vehicle AC power supply 80.
The off-vehicle power supply 80 consists of an AC power source 85, a power controller 70, and a docking station 50. The power source 85 generates the household level, 115 V, AC electricity used by the off-vehicle power supply. The use of 115 VAC electricity is preferred in this embodiment to take advantage of existing in-vehicle recharging systems and to promote use of the invention. The power controller 70, as explained in detail below, is responsible for controlling the power connection to the docking station 50. The docking station 50 is preferably stationary and contains an electrical connector outlet 20.
The non-vertically faced docking station 50 shown in FIG. 1 is a preferred embodiment. Although the docking station face 53 is shown to be non-vertical, the face 53 may be configured at any suitable angle, including vertically. Leading inward from the face 53 to the outlet 20 is a substantially conical or concave passageway 52. The passageway 52 aids in guiding the connection between the plug 30 and the outlet 20 by physically funneling the plug 30 toward the outlet 20. Thus, the passageway 52 corrects errors in alignment between the plug 30 and outlet 20.
In the preferred embodiment, the docking station 50 is configured similar to a curb in appearance. In the curb configuration, the center axis 25 of outlet 20 is located approximately a distance Z2 above the road surface 100. By locating the outlet 20 at a known vertical position, the process of locating the outlet 20 is simplified. In addition, the docking station 50 emits a homing beacon 57 to aid the location process. In the preferred embodiment, the homing beacon 57 is visible light generated by a suitable light source such as LED 51, which is mounted within the outlet 20. To reduce the possibility of damage to the LED 51, the LED 51 is mounted on the side of the outlet 20 away from the docking station face 53 with the homing beacon 57 projected through the plug opening. The use of visible light has an additional benefit in allowing the vehicle operator to quickly locate docking stations, especially at night. To limit human and machine confusion between the homing beacon 57 and other light sources (e.g. headlights, sunsets, and reflections), the LED 51 generates a known frequency response. Preferably, the LED 51 emits light from the blue end of the visible light spectrum. As a further visual aid, the homing beacon 57 is energized only when the power controller 70 is operable.
The in-vehicle components are depicted within the dashed line representing the vehicle 10. A servo motor 42 drives gearbox 44 in response to commands issued by docker 60. Attached to the gearbox 44 is a mechanical arm 45 with a male plug 30 attached to the distal end of the arm 45 opposite the gearbox 44 by means of a retaining collar 43 or other suitable means.
The gearbox 44 allows movement of the plug 30 along three axis, the Y-axis running parallel to the nearest edge of the vehicle 10, the X-axis running perpendicular to the nearest edge of the vehicle 10, and the Z-axis running vertically. During vehicle operation or when no recharging is occurring, the gearbox 44 stores the plug 30 in a single secure location, preferably at one extreme along the Y-axis, Y1, and at a height, Z1, above the road surface 100. The secure location protects delicate in-vehicle components from road hazards.
To recharge the batteries, the docker 60 needs to locate the docking station 50 and connect the plug 30 to the outlet 20. Servo motor 42 causes the gearbox 44 to lower the arm 45 and plug 30 to a position, Z2, above the road surface 100. That is, the arm 45 and plug 30 are aligned parallel to the road surface 100 at a vertical distance, Z2, equal to the vertical distance of the outlet 20 above the road surface 100. The servo motor 42 then moves the gearbox 44 and, thus, plug 30 along the Y-axis. While the gearbox 44 is in motion, photodetectors 46,48 positioned on the gearbox 44 scan for an indicator signal (i.e. the LED light 57) from LED 51 in the docking station 50 and communicate any detections to docker 60.
If the docker 60 does not detect the homing beacon 57 before the gearbox 44 reaches the far reach along the Y-axis, Y2, then the docker 60 instructs the servo motor 42 to stop movement. The docker then instructs the servo motor 42 to move the plug 30 and arm 45 in the X-Z plane such that the photodetectors 46,48 are tilted 45 degrees toward the road surface. In this orientation, the photodetectors 46,48 can also detect a docking station 50 not conforming to the preferred curb configuration embodiment. The docker 60 next instructs the servo motor 42 to reverse the gearbox's 44 motion along the Y-axis. If the docker 60 fails to detect the homing beacon before the gearbox 44 returns to the initial position along the Y-axis, Y1, then the docker 60 commands the servo motor 42 to return the plug 30 to the secure position.
If the docker 60 detects the docking station's homing beacon 57, then the docker 60 stops the servo motor 42 from moving the gearbox 44 further along the Y-axis. The docker 60 analyzes the signal from the homing beacon 57 and commands the gearbox 44 to adjust the angle of arm 45 in the X-Y and X-Z planes until the arm 45 and plug 30 are aligned directly opposite the homing beacon. In addition to azimuth adjustments, motion in the X-Y plane may require movement of the gearbox 44 along the Y-axis. From this aligned position, the docker 60 instructs the gearbox 44 to extend the arm 45 toward the homing beacon. The gearbox 44 is gimbal mounted such that physical contact between the 30 and the docking station passageway 52 causes the gearbox 44 to move within the physical constraints imposed by passageway 52.
When the servo motor 42 has projected the plug 30 into the outlet 20, the contact between sheath 32 and outlet 20 stops the forward motion of the sheath 32. However, as the servo motor 42 continues to project the plug 30 forward, a male electrical connector 31 (shown in FIG. 2) projects beyond the sheath 32 and is forced into a female electrical connector 21 (shown in FIG. 6). A clutch 41 disengages the gearbox 44 when a significant physical resistance to the projection of the plug 30 occurs, causing the plug 30 to stop projecting and preventing damage to the plug 30, gearbox 44, and servo motor 42. Thus, the clutch 31 stops projecting the plug 30 when the plug 30 is seated within the outlet 20.
The docker 60 detects an electrical connection after the servo motor 42 halts movement by sensing the change in impedance between the male connector 31 and the sheath 32. If an electrical connection exists, the dock®r 60 transmits a code identifying the vehicle through the plug 30 and outlet 20 to the power controller 70. The code is preferably the vehicle identification number (VIN) or any other unique, manufacturer-supplied code. In addition, the code may contain recharging parameters, such as current requirements, to be used by the power controller 70 to optimize the recharging procedure. The power controller 70 retransmits the received code back to the docker 60 through the outlet 20 and plug 30. If the docker 60 receives the same code it transmitted then the electrical connection is complete and the docker 60 transmits an acknowledgement signal through the plug 30 and outlet 20 to the power controller 70. If the docker 60 did not receive the same code it transmitted then it causes the servo motor 42 to remove the plug 30 from the outlet 20 and attempt to reinsert the plug 30 into the outlet. The power controller detects the removal of plug 30 from outlet 20 by sensing the change in impedance across the outlet 20 and, consequently resets. If the docker 60 fails to establish a connection after three attempts the docker alerts the vehicle operator that recharging did not occur.
Upon receiving the acknowledgement signal from the docker 60, the power controller 70 determines whether the vehicle is authorized to obtain electricity from the docking station 50. The power controller 70 may authorize any vehicle to use the docking station 50 or may limit use to a specific list of vehicles. If the vehicle is authorized, then the power controller 70 transmits an acknowledgement signal through outlet 20 and plug 30 to the docker 60. The power controller then causes electricity to be supplied to the outlet 20. If the vehicle is not authorized, the power controller 70 transmits a nonacknowledgement signal through the outlet 20 and plug 30 to the docker 60 and does not supply electricity to the outlet.
Upon receiving an acknowledgement signal from the power controller 70, the docker 60 performs any necessary switching to permit the receipt of AC electricity. Upon receiving a nonacknowledgement signal from the power controller 70, the docker 60 instructs the servo motor 42 to disconnect the plug 30 from the outlet 20 and return the plug 30 to the secure position. In either event, the docker 60 signals the vehicle operator of the success or failure of the authorization.
FIG. 2 shows the structure of the plug 30 in detail. Male connector 31 is a standard BNC-type connector encased in a plastic housing 35. A metallic protective sheath 32 and insulating plastic endpiece 36 encase the distal end of the plug housing 35 and protect the male connector 31 from damage. The forward force of the plug 30 causes the male connector 31 to project beyond the endpiece 36 by compressing springs 34a, 34c and sliding the sheath 32 along conductive metal rails 37a, 37c. Conductive wires 38,39 carry the electric current from the plug to the recharger 15. Wire 39 carries the positive current and is connected to male connector 31. Wire 38 carries the negative current and is connected to at least one rail 37a in contact with the sheath 32. The wires 38,39 exit the proximal end of the plastic housing 35. Retaining collar 43 attaches the proximal end of the plastic housing 35 to the distal end of the arm 45 by mating with the housing threads 33.
FIG. 3 shows a section view of the plug 30 taken along line II--II of FIG. 2. In particular, the view shows the shape of the rails 37a-d. The rails 37a-d contain a wedge-shaped groove and the sheath 32 contains a matching wedge-shaped projection. Thus, the rails 37a-d operate as a track upon which the sheath 32 rides when retracted.
FIG. 4 shows a section view of the plug 30 taken along lines III--III of FIG. 2. For the sake of clarity, the springs 34a-d are excluded from FIG. 4. As seen from this view the rails 37a-d are rectangular-shaped without a wedge groove because the proximal ends of the rails 37a-d are capped to prevent the sheath 32 from detaching from the plug housing 35. This section of the sheath 32 has a matching rectangular-shaped channel. Thus, the sheath 32 can retract as shown in FIG. 5 because the sheath's 32 rectangular channel can move along the full length of the rails 37a-d. However, the section of sheath 32 with a wedge-shaped projection within the channel cannot move beyond the rectangular-shaped end of the rails 37a-d.
The structure of the outlet 20 is shown in FIG. 6 Positive current is supplied through conducting wire 29 to the metallic female connector 21. The female connector 21 is encased within an electrical insulating divider 23. Negative current is supplied through conducting wire 28 to the metallic outlet wall 22. The wall 22 is separated from the connector 21 by the insulating divider 23. The wall 22 is shaped to match the plug sheath 32. FIG. 7 shows the section view along line IV--IV of FIG. 6.
FIGS. 8a-8c the process of connecting the plug 30 to the outlet 20. In FIG. 8A, a plug makes contact with the passageway 52. Further pressure on the plug causes motion toward the outlet 20. FIG. 8B shows the plug funneled into position directly aligned with the outlet. Further force pushes the plug into the matching outlet. FIG. 8C shows the plug 30 engaging the outlet 20. To disconnect, the plug is pulled straight out of the outlet.
FIG. 9 shows the structure of the power controller 70. AC power is supplied by a power source 85. To power the LED and internal electronics, the AC electricity is converted to DC electricity by rectifier circuit 76. The activator 72 passes DC electricity to the docking station LED 51 only if all components of power controller 70 are operational. Authorizer 71 establishes communications with the docker 60 through wire 29 connected to the outlet connector 21 and verifies the vehicle's identity. If the authorizer 71 identifies the vehicle, a signal is sent to the activator 72. Activator 72, in response to the signal from authorizer 71, energizes AC electricity to the plug 20. The activator 72 contains a Ground Fault Interrupt (GFI) circuit breaker 75 to shut off the electric supply to outlet 20 if a current spike occurs. The current flows through accounter 73 and meter 74. The meter 74 monitors the energy used by the vehicle. Accounter 73 notes the energy usage by the charging vehicle for accounting and billing purposes. While the vehicle is recharging, the current flow through meter 74 and accounter 73 drops as the recharger 15 restores the batteries' electrical charge. Upon removal of the plug 30 from the outlet 20, the current flow becomes zero. When accounter 73 detects a drop in energy usage below a predetermined level, the accounter 73 signals the activator 72 to disconnect the power. The predetermined level may be computed based on the recharging parameters transmitted by the docker 60 or may default to a standard value.
Although the invention has been particularly shown and described with reference to a preferred embodiment 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.
As described, the invention supplies AC electricity through outlet 20 to be compatible with currently produced electric vehicles, which are equipped with vehicle specific rechargers. However, an alternative embodiment could supply either AC or DC electricity by including a recharger as part of power controller 80. A remote recharger would be desirable if manufacturers cease equipping electric vehicles with rechargers. The recharging parameters transmitted from the vehicle to the power controller may contain DC power requirements. The power controller could then supply the vehicle-specific DC voltage and current to the vehicle.
The invention has been described relative to a battery-powered vehicle, however the invention has applications beyond that use. The invention is also useful for gasoline and diesel vehicles as well. These vehicles could use the docking station to recharge their batteries or to supply electricity while the engine is off. Thus, a parked vehicle could operate ventilation and cooling systems using electricity supplied by the docking station.
In the curb configuration, the outlet need not be located at a known height, Z2, above the road surface. For example, the outlet opening may be configured parallel to the docking station face (i.e. the outlet's axis is perpendicular to the face). In that case, the arm and plug would be projected at an angle perpendicular to the docking station face. Similarly, an in-ground docking station in which the passageway 52 is below the ground may be desirable.
The LED need not be positioned so light projects through the opening in the female connector. The LED could be configured on the face side of the female connector. For example, the LED could be built into the outlet on the face side of the insulating divider 23 without affecting the operation of the docker.
For simplicity, the LED has been described as generating blue light. However, the LED need not generate a single peak frequency response. The LED could generate an easily distinguishable signature comprising several frequency peaks. Only one of the generated wavelengths need be in the visible light spectrum.
Although the power controller is shown to be physically separate from the docking station, it need not be. While that embodiment is appropriate for a network of docking stations, a home unit could have all power controller features integrated into the docking station. In any event, some features might be more conveniently located within the docking station.
A particular power controller may not require all the above-mentioned features. For example, the power controller could be operated by a coin operated meter. In that case, all properly connected vehicles would be automatically authorized and recharging would stop when the coin meter expires.
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The invention supplies electricity to a recharger used to recharge batteries in a battery-powered vehicle. An arm mechanism is attached to the vehicle and moveable relative to the vehicle. At the distal end of the arm is an electrical plug protected by a retractable sheath and electrically connected to the recharger. A docking station located remote from the vehicle, emitting light and containing a conical passageway for guiding the plug to the outlet. A docker attached to the vehicle, containing optical sensors tuned to the light emitted by the docking station. Software instructions move the arm mechanism to seek the outlet, calculate the position of the outlet, and move the arm mechanism to connect the plug to the outlet. Software instructions activate the electrical supply to the outlet if the vehicle is authorized to receive electricity.
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FIELD OF THE INVENTION
The present invention relates generally to electrical and RF connectors, and more specifically relates to both connectors for use at an interface between the end of a fiber optic cable and a photodetector or a light transmitting device, or in the former converting light from the cable into an electrical signal, and for the latter converting an electrical signal into an optical signal for transmission over the fiber optic cable, and also relates to a fiber node including such connectors.
BACKGROUND OF THE INVENTION
Optical transmission of television and data signals has been rapidly expanded for use in television, and telecommunication systems. In cable television systems, fiber optic cable is now being employed in many systems from the point of transmission of television and data signals to the subscriber's premises. The use of coaxial cable for television and telecommunication systems is rapidly being replaced by the use of fiber optic cables because optical signals travel greater distances and require less repeater amplification than electrical signals transmitted via coaxial cable. Fiber optic signal distribution systems are also immune to electromagnetic interference either as ingress or egress.
As one example of usage of fiber optic cables in cable television systems, such cables consist of numerous single optical fibers, each capable of carrying a full spectrum of television and data information services. It is possible to allocate each fiber in a fiber optic cable at the subscriber end of a distribution system to an individual subscriber. Typically, a male connector is attached to the end of each fiber to enable the fibers to be connected to terminal equipment in a subscriber's home or business. The terminal equipment permits bi-directional communication between a subscriber and the cable television provider. In this example, the terminal equipment converts optical signals from the provider into electrical radio frequency signals for use by the subscriber, and also converts the electrical signals generated by the subscriber or the subscriber's equipment into optical signals for transmission over the optical cable to the provider.
Known terminal equipment typically employs an optical to RF interface connector configured for direct attachment to a printed circuit board within the housing of the terminal equipment. The fiber optic cable at the subscriber's end typically has a male connector attached to it, whereby the connector in a portion of the associated fiber optic cable must be passed through a hole in the housing of the terminal equipment, and plugged into the female optical to RF interface connector mounted on the printed circuit board. Interconnecting the terminal end of a fiber optic cable to a subscriber's terminal equipment is time consuming, and sometimes involves coiling of the fiber optic cable within the housing of the terminal equipment, that may attenuate the optical signal, or in a worse case may interrupt the signal, all of which increases the installation time to insure proper operation. The present inventors recognize that there is a need in the art for improved optical to RF interface connectors and connection systems.
SUMMARY OF THE INVENTION
One embodiment of the invention is an optical to RF interface connector that includes a housing or shell having a back portion configured for retaining a light detector device or light/laser transmitter device, and a front portion configured for receiving and securing to a terminating connector mounted on an end of a fiber optic cable, for permitting optical signals to pass between the fiber optic cable and the light detector or light/laser transmitter. The housing or shell is further configured for pressing a back portion into the housing of an associated electrical device. The electrical leads of the light detecting or light transmitting device protrude from the back portion of the shell in a manner facilitating connection of the leads to a printed circuit board located within the housing of the associated electrical device. In another embodiment of the invention, at least two of the inventive optical to RF interface connectors are press fit into the housing of a fiber node or optical to RF media conversion unit, whereby one of the connectors retains a light transmitter for optically transmitting broadband signals back to the optical cable system of a cable television provider, whereas the other connector retains a light detecting device for the reception of broadband signals from the fiber optic cable as transmitted from the cable system provider. In yet another embodiment of the invention, the fiber node or bi-directional RF/optical converter includes means for electrically operating the light transmitting device to convert electrical signals to optical signals for transmission through the fiber optic cable connected to the optical to RF interface output connector, and means for operating the light detecting device to convert optical signals from a fiber optic cable connected to the optical to RF interface input connector into electrical signals, whereby a diplex filter is used to bi-directionally couple electrical output and input signals between a bi-directional RF connector of the converter, and the means for operating the light transmitting device, and means for operating the light detecting or receiving device, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present invention are described below with reference to the drawings, in which like items are identified by the same reference designation, wherein:
FIG. 1 is a pictorial view looking toward a front portion of an optical to RF interface connector for one embodiment of the invention;
FIG. 2 is a front elevational view of the connector of FIG. 1 ;
FIG. 3 is a back elevational view of the connector of FIG. 1 ;
FIG. 4 is a bottom plan view of the connector of FIG. 1 ;
FIG. 5 is a top plan view of the connector of FIG. 1 ;
FIG. 6A is a pictorial view looking toward a back portion of the connector of FIG. 1 , for a first embodiment of the invention;
FIG. 6B is a pictorial view looking toward a back portion of the connector of FIG. 1 , for a second embodiment of the invention;
FIG. 6C is a pictorial view looking toward a back portion of the connector of FIG. 1 , for a third embodiment of the invention;
FIG. 7 shows a pictorial view looking toward the front of a known optical receiving or electrical transmitting device packaged in either one of the TO-18, TO-46, or TO-52 “top hat” packaging configuration;
FIG. 8A shows a pictorial view looking toward the front or “top hat” end of TO-56 packaging configuration for a known optical transmitting or receiving device;
FIG. 8B shows a bottom view (absent the electrical leads) of the packaging configuration of FIG. 8A ;
FIG. 9 shows a longitudinal cross-sectional view taken along 9 - 9 of FIG. 1 , for one embodiment of the invention;
FIG. 10 shows a top view of a fiber node or optical to RF media conversion device incorporating at least two of the connectors of FIG. 1 , for another embodiment of the invention;
FIG. 11 shows a pictorial view looking toward the back of the device of FIG. 10 , showing the mounting of the optical to RF interface connectors;
FIG. 12 shows a pictorial view looking toward the front of the device of FIG. 10 ;
FIG. 13 shows a bottom plan view of the device of FIG. 10 ;
FIG. 14 shows a block schematic diagram of the electronic circuitry for the device of FIG. 10 ;
FIG. 15 shows a pictorial view looking toward a front portion of an optical to RF interface connector for a second embodiment of the invention;
FIG. 16 is a pictorial view looking toward a back portion of the connector of FIG. 15 ;
FIG. 17 is a pictorial view looking toward a front portion of an optical to RF interface connector for a third embodiment of the invention; and
FIG. 18 is a pictorial view looking toward a back portion of the connector of FIG. 17 for the third embodiment of the invention;
FIG. 19 is a pictorial view looking toward a front portion of a female optical to RF interface connector for mating with a male ST fiber optical cable termination connector for an alternative embodiment of the present invention; and
FIG. 20 is a pictorial view looking toward a rear portion of the connector of FIG. 19 .
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , a pictorial view looking toward the front left side of the present connector 2 is shown for a first embodiment of the invention. In this embodiment, the female connector is configured for receiving an ST style male connector, the latter being a male fiber optic cable connector that is known in the art. The protrusions 4 and an open slot 6 provide for the bayonet interlocking configuration with the male ST connector at the end of a fiber optic cable (not shown). The protrusions 4 and open slot 6 are formed in a frontmost cylindrical segment 8 , having a front face 3 with a beveled inside edge 5 , and a hole 18 , as shown. The inside diameter of hole 18 of the initial portion of the cylindrical segment 8 is dimensioned for snugly receiving the outermost portion of the male ST connector (not shown) to be received by the connector 2 . As will be described in greater detail below, a ferrule located at the frontmost portion of the standard ST male optical fiber connector is received in hole 18 of connector 2 . The hole 18 has a back face 10 , that has a centrally located hole 20 . The cylindrical segment 8 terminates to a back cylindrical segment 12 that includes a flat portion 14 for providing a D-configuration. In the preferred embodiment, segment 12 , is knurled on its cylindrical portion, as shown. The back cylindrical segment 12 has a larger outside diameter than a frontmost cylindrical segment 8 of connector 2 , as shown. The back circumferential edge 16 is beveled, with the back cylindrical segment 12 being otherwise configured for press fitting into a D-hole (not shown) of the housing of an electrical optical device. Use of the D-hole configuration, along with the flattened portion 14 of segment 12 , insures that the connector 2 is properly oriented when press fit into the housing, to insure that the leads of an electrical optical device retained in the segment 12 are optimally aligned to facilitate connection of the leads from the device (not shown) to a printed circuit board or other electrical termination within the housing (not shown) of the electro-optical device (not shown). This configuration will be discussed in greater detail below.
A front elevational view of the present connector 2 is shown in FIG. 2 . As previously explained, the hole 18 in the frontmost segment 8 receives a portion of the male ST connector, and the hole 20 of the reduced inside diameter segment 10 is sized to receive the center ferrule of the male ST connector (not shown). Note that the front edge of the hole 20 includes a beveled surface 21 proximate its interface with the backwall 10 of hole 18 .
In FIG. 3 , a back elevational view of the connector 2 is shown. A beveled edge 22 is provided on a back portion or edge of the cylindrical segment 12 , as previously mentioned. Proceeding inward from the beveled edge 22 , a flat band like circular face or portion 24 is shown, followed by a hole 26 , followed by a flat ring-like portion 28 (back face of hole 26 ), followed by countersunk hole 30 having a cylindrical sidewall 27 defining the sides thereof, and a backwall 29 , terminating to the center hole 20 which extends through to the reduced inside segment 10 in the frontmost portion or segment 8 . As will be shown in greater detail below, the countersunk hole 30 , and its backwall 28 are configured for receiving and press fitting therein an electro-optical device having a top-hat configuration, as will be described in greater detail below. Bottom and top plan views of the connector 2 are shown in FIGS. 4 and 5 , respectively.
A pictorial view looking toward the back of the connector 2 is shown in FIG. 6A , for one embodiment of the invention. In another embodiment of the invention, as shown in FIG. 6B , a slotway 32 is included in a portion of a sidewall 23 of the countersunk hole 26 for insuring proper alignment of an optical device to be press fitted therein to, such as TO-18, TO-46, and TO-52 top-hat shells as known in the art. A pictorial view looking toward the front of such a top-hat electrical optical device 33 is shown in FIG. 7 . The shell includes a tab 34 protruding from a collar-like portion 36 , and a frontmost cylindrical portion 38 extending from the top 36 . A circular window 40 is included at the top of a stub-like cylindrical portion 38 , for providing for the passage of a lightbeam either from the device in the case of a light transmitting device, or to the device in the case of a light receiving device, for example. Three electrical leads 42 are shown in this example protruding from the bottom of the device, which as previously explained, are typically electrically connected to a printed circuit board, or some other component within the housing of the electro-optical device to which the present connector 2 is press fit.
In another embodiment of the invention, as FIG. 6C , three elongated semicircular protrusions 44 are axially aligned and spaced apart on the sidewall 23 of the hole 26 for ensuring proper alignment of an electro-optical receiving or transmitting device that is housed within a TO-56 shell. A pictorial view looking toward the front of a optical device 35 housed in TO-56 shell is shown in FIG. 8A to include a pair of electrical leads 46 , a collar-like portion 48 , a cylindrical stud-like portion 50 extending from the collar 48 , the latter having an optical window 52 in the top center portion thereof for permitting the passage of light. The collar 48 includes three semicircular grooves 54 spaced apart about its circumference, as shown in the back view of FIG. 8B . When the device 35 of FIGS. 8A and 8B , as housed in a TO-56 top-hat shell, in this example, is press fit into the connector 2 , the grooves 54 align with the semicircular protrusions 44 (see FIG. 6C ), for ensuring that the associated optical device 35 is properly aligned, thereby ensuring that electrical leads 46 can be connected within the housing without interference with one another. The optical device alignment mechanisms shown in the embodiments of the invention of FIGS. 6B and 6C are not meant to be limiting, and the back portion of the connector 2 can be configured for receiving optical electrical devices contained within other housing or shell configurations.
FIG. 9 is a partial cross-sectional view of the connector 2 of FIG. 1 taken along 9 - 9 . In this example, an optical device 56 having electrical leads 58 protruding from the bottom thereof is shown installed within the connector 2 , wherein the retention is via press fit in the preferred embodiment, as previously described. In other embodiments of the invention, the optical device 56 can be secured by other than press fitting, such as the use of appropriate epoxies, and other adhesive materials, for example. Note that in the example given, the connector 2 is press fit into a D-hole of the enclosure or housing 60 of the electro-optical apparatus.
With further reference to the cross section of connector 2 shown in FIG. 9 , various important dimensional features are shown. Dimension “A” determines the depth of an electro-optical transmitting or receiving device 56 that is predetermined for the top-hat shell thereof. The dimension “B” is predetermined for controlling the depth of the electro-optical device 56 within connector 2 . Dimension “C” is the inside diameter of the hole 30 , which is predetermined for permitting press fitting of the collar or flange portion 62 of device 56 into hole 30 . Dimension “D” represents the innermost and minimum diameter of the inward hole 26 of connector 2 for receiving the flange or collar portion 62 of electro-optical transmitting or receiving device 56 . Dimension “E” represents the length of the hole 20 necessary for receiving the optical fiber ferrule sleeve of the male ST connector (not shown) to be mated to the connector 2 of the present invention. Dimension “F” is the inside diameter of hole 20 necessary for snugly but slidingly receiving the ferrule of the mating ST male connector. Note that dimensions “A,” “B,” and “E” determine the distance required such that the receiving or transmitting end of the optical fiber within the ferrule sleeve of the mating male connector, and the light receiving or transmitting electro-optical device 56 are in physical contact.
The above-described embodiments of the invention are not meant to be limiting. The dimensions “A” through “F,” and the length and configuration of the frontmost cylindrical segment 8 of connector 2 can all be modified for accommodating different types of electro-optical transmitting and receiving devices 56 , and for mating with many other male terminating connectors at the ends of fiber optic cables, other than ST male connectors. As will be described below, other known optical cable terminating connectors that can be mated with by changing the configuration of a connector 2 include MT/RJ, SC, SC/APC, E-2000, O-C, FC, FC/APC, LC, and LC/APC all of which are known in the art. Note that the acronym “APC” stands for Angle-polished Physical Contact.
The present connector 2 , through the use of press fit into the housing of an electro-optical apparatus or device, is suitable for radio frequency interference (RFI) sealing of the housing, and moisture sealing, where the housing is used for an outdoor environment. The present inventors have developed an engineering prototype for a “fiber node” 64 (also known as an “optical to RF media conversion unit,” or “a bi-directional RF/optical converter”) that utilizes the present connectors 20 for facilitating the connection of fiber optic cables thereto. More specifically, the present inventors have designed a fiber node 64 to have many unique features, including the use of the subject inventive connectors 2 for eliminating the requirement of passing a fiber optic cable with its connector through a hole in the housing of the device 64 to mate with a female connector mounted upon a PC board, or otherwise within the employer of the housing 60 of the fiber node 64 apparatus. As shown in FIG. 10 , a top view of the fiber node 64 includes at one end a leftmost one of the present connectors 2 for providing a “REV Fiber Out” port 66 fiber interface with a laser transmitting device representing electro-optical device 56 of FIG. 9 , for transmission of the optically modulated reverse CATV spectrum along a fiber optic cable connected to the associated connector 2 , as previously described. The rightmost connector 2 represents a fiber optic port “FWD Fiber In” port 68 for providing a fiber optic interface for the reception of the optically modulated forward CATV spectrum from a fiber optic cable terminated to the port 68 for coupling optical signals to a light receiving device representing electro-optical device 56 of FIG. 9 . Four F-type coaxial connectors are associated with ports 72 , 74 , 76 , and 78 , respectively. Port 72 provides a reverse spectrum test point (Rev TP). Port 74 provides a DC power termination, for in this example receiving 12 volts. Also in this example, the reverse spectrum frequency ranges from 5 to 42 MHZ. Port 76 provides a termination for a forward spectrum test point (Fwd TP) for a spectrum signal frequency range of 52-870 MHZ. Lastly, port 78 provides a “DC/RF” termination for both interfacing bi-directional RF signals to a user, and receiving DC power from a known adapter device that combines DC power and RF signals on a single coaxial cable. Also shown as provided on the top of the fiber node 64 , are a light emitting diode (LED) 80 that is activated to emit light to indicate that the light transmitting optical device 56 is active at port 66 , and another LED 82 activated to indicate that optical signals are being received at port 68 by an optical or light receiving device employed for the electro-optical device 56 . Test points 84 , 86 , and 88 are included in this example between LEDS 80 and 82 , as shown. One volt per milliwatt of optical power is provided at test point 84 for checking the power level of the signals being transmitted, which is proportional to the optical signal strength thereof. Test point 86 provides a common ground for the test points 84 and 88 . Test point 88 provides for a measure of the DC bias level, which is proportional to the optical signal strength of the optical signals being received at port 68 . Note also that the housing 60 includes left side and right side mounting flanges 90 , and 92 , respectively, each having open elevated slots 94 , 96 , respectively, for facilitating the positioning of the housing 60 on a flat mounting surface (not shown).
In FIG. 11 , a back view of the fiber node 64 is shown. Note that the housing is formed from appropriate metal material, in this example. A ground termination device 89 is provided along a side portion of the housing proximate port 72 , as shown in this example. A front view of the fiber node 64 is shown in FIG. 12 . A bottom view thereof is shown in FIG. 13 . A bottom cover plate 98 is secured to the bottom of fiber node 64 in a manner hermetically sealing the components contained within the housing from the elements, via a known sealing technique such as using appropriate gasket material and adhesives or solder.
A block schematic diagram is shown in FIG. 14 for the fiber node 64 in this embodiment of the invention. The fiber node 64 provides a bi-directional RF and optical converter device or apparatus that includes a printed circuit board 103 mounted within the fiber node housing 60 , in this example, via four grounding screws 120 located at each corner of the printed circuit board 103 , as shown and at other locations where grounding of the circuit to the housing is necessary. A laser diode 100 is secured within a connector 2 at port 66 , whereas a photodiode 102 is secured within the associated connector 2 at port 68 . The photodiode 102 converts optical input signals into electrical signals which are connected to input terminals of a receive control circuit 114 , and an amplifier 118 . The receive control circuit 114 provides power to LED 82 for indicating that signals are being received, and also delivers a voltage proportional to the optical power to the test point 88 . The output of amplifier 118 is connected to the input of a directional coupler 116 . The directional coupler couples electrical input signals to the forward receive test point port 76 , and also to a diplex filter 112 . Electrical signals are also bi-directionally coupled between the diplex filter 112 and port 78 , the latter providing bi-directional RF signal flow between a subscriber and the cable system provider. The diplex filter 112 also has an output connected to a directional coupler 106 for delivering electrical RF output signals from directional coupler 106 to port 72 providing a reverse transmit test point, and also to the input of a laser driver 104 . The laser driver 104 is connected to a transmit control circuit 108 , and also to laser diode 100 ; in this example, for converting the reverse RF output signals to optical signals, for transmission to the cable provider. The transmit control 108 also provides an output to LED 80 for indicating times that reverse RF output signals are being transmitted. The transmit control 108 also delivers a voltage proportional to the transmitted optical power to test point 84 .
With reference to FIGS. 15 and 16 , a second embodiment of the invention is for providing in this example a rectangular configured optical to RF interface connector 104 for mating with SC, LC E2000, MTRJ, and MU male fiber optic cable termination connectors. The frontmost segment of the connector 104 for this second embodiment of the invention is a substantially rectangular shell or enclosure 106 including an interface keyway or slot 108 cut through the shell from the open front face 110 toward the rear portion of the shell 106 , as shown. The shell 106 has a hollow cavity 112 , and a back wall 114 that has a cylindrical optical fiber ferrule guide 116 protruding therefrom into the interior of the cavity 112 , as shown. The through hole 118 of the optical ferrule guide 116 , similar to the hole 20 shown in FIG. 9 for the connector of the first embodiment of the invention, passes through to the back cylindrical segment 118 to permit light to travel between the electro-optical device 56 mounted within the back cylindrical segment 118 , in substantially the same manner as shown in FIG. 9 for the first embodiment of the invention. As in the previous embodiment, the flat portion 120 in the back cylindrical segment 118 serves as a press-fit orientation key. The remaining round outside portion of cylindrical segment of 118 is narrowed in the preferred embodiment of invention. An O-ring seal 122 is provided around the innermost portion of the back cylindrical segment 118 , as shown. Otherwise, the back cylindrical segment 118 of this alternative embodiment is substantially similar to the back cylindrical segment 12 of the first embodiment of the invention, as shown in FIG. 9 .
A third embodiment of the invention is shown in FIGS. 17 and 18 for an optical to RF interface connector configured for mating with male FC, and SMA Optical fiber termination connectors. More particularly, the connector includes a threaded frontmost cylindrical segment 124 that is provided with a connector interface keyway 126 cut into its front edge, as shown. A cylindrical optical fiber ferrule guide 128 is centrally located within the cylindrical segment 124 , as shown, and serves the same purpose as the ferrule guide of the second embodiment of the invention (see FIG. 15 ). A back cylindrical segment 130 is included as shown, with the rounded portion narrowed to provide better press-fit retention, and also configured with a flat portion 132 serving as a press-fit orientation key. The back cylindrical portion 130 has a greater outside diameter than the frontmost threaded cylindrical segment 124 , in this example. A circular flange 134 is located between the frontmost threaded cylindrical segment 124 and the back cylindrical portion 130 , as shown. The flange 134 has a greater outside diameter than the back cylindrical portion 130 . The configuration of the back portion 130 is substantially the same as that of the back portion 118 of the second embodiment of the invention shown in FIG. 16 , which each include inner ring seal 122 .
With reference to FIGS. 19 and 20 , an alternative embodiment of the invention for providing a female optical to RF interface connector for mating with a male ST fiber optical cable termination connector includes a frontmost cylindrical portion 8 that is configured in substantially the same manner as shown in FIGS. 1 through 6A . The back cylindrical portion 130 is configured in substantially the same manner as that shown for the embodiments of FIGS. 17 and 18 .
The various embodiments of the present invention provide a connector that relative to the prior art increases the interface reliability for the fiber optic cable connection, and reduces insertion loss by eliminating the necessity to loop a portion of fiber optic cable around the inside perimeter of the housing of a device, and by providing a direct electrical connection from the connector to the printed circuit board or other electrical components housed within the enclosure of the particular fiber optic device. Also, the alternative connector embodiments of the invention all permit the use of smaller enclosures or housings for the associated electro-optical devices, and further insure an RF seal to meet the requirements of Electromagnetic Interference suppression greater than 120 dB. Also particularly the press-fit connector embodiments insure a pressure tight seal between the connector and the housing of the associated device for preventing moisture migration into the interior of the housing. A yet further another advantage of the present invention in its various embodiments is that the alternative connector embodiments provide for optimum heat sinking of the active optical component mounted within the connector, whereby heat can pass from the optical component to the connector, and therefrom to the housing or enclosure of the associated device, thereby temperature stabilizing the optical component.
Although various embodiments of the invention have been shown and described, they are not meant to be limiting. Those of skill in the art may recognize certain modifications to these embodiments, which modifications are meant to be covered by the spirit of the appended claims. For example, the press fit configuration of connectors of the various embodiments of the invention can alternatively be screw-in type mounting by configuring the back portion to be externally threaded. Also, said connector embodiments can be made from any suitable metallic material such as nickel or tin plated brass, for example.
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An optical to RF interface connector has a cellular housing that has a back most portion configured for press fitting into a hole of the housing of an electro-optical apparatus, with the hole and back most portion of the shell being key to one another to insure proper orientation of the connector. The press fitting is further configured for providing both an RF seal, and moisture seal. The frontmost portion of the connector shell is configured for securely coupling to an optical interface male connector that is attached to an end of a fiber optic cable. The innermost portion of a connector shell is further configured for receiving and retaining therein either a auto detector or light detecting device for converting optical signals received from the fiber optic cable into electrical signals for processing, or is light transmitting device for converting electrical signals into optical signals for transmission over the associated fiber optic cable. A light mark is provided between within the connector shell between the light detecting transmitting device and a optical fiber terminating end of the male connector for permitting the passage of optical signals therebetween. The back most portion of the connecter shell is further configured for receiving the light detecting or transmitting device in an augmentation associated with the key position of the back most portion of press fit into the electro optical apparatus housing, for insuring that electrical leads of the light transmitting or light receiving device do not interfere with one another in being connected either to a printed circuit board or other termination within the housing of the associated apparatus.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for pre-cleaning parts, which are made of plastic and to which foreign bodies to be removed are stuck, as part of a recycling process, more particularly for removing foreign bodies disposed on parts made of plastic, preferably for removing labels, dirt, etc. disposed on used plastic bottles such as PET bottles.
The invention further relates to an apparatus for applying the method of the invention.
2. Description of Related Art
Equipment and methods for treating plastic waste (e.g., PET bottles) are known from practical experience. Here, any dirt is removed usually by subjecting the plastic waste to a wet-washing process.
Even a hot-washing process is often required with the addition of cleaning chemicals such as caustic soda solution, NaOH, etc. Here, the washing medium is constantly reconditioned, which results in high outlay and considerable environmental pollution if the washing medium is discharged as waste water on completion of the washing process.
One particular problem is the impurities or foreign bodies disposed on plastic bottles such as the so-called PET bottles. For recycling the PET bottles, it is necessary to remove the labels that are made of a different material than the bottles and are mostly printed. They are often made of PVC and can be removed only with difficulty in a conventional washing plant. Moreover, other foreign bodies such as stones, glass, small pieces of metal, etc. that are not collected by an overband magnetic separator remain stuck to the PET bottles. These foreign bodies must also be removed from the plastic to be recycled.
Furthermore, it is significant that the foreign bodies stuck to the PET bottles are often abrasive components. If these abrasive components are not removed before the comminution or grinding process of the PET bottles, they result in a considerable amount of wear of the mill. Furthermore, any residual content of the bottles must be removed since the sticky sugared water results in disturbances during the further processing and recycling. Moreover, residual liquid in the bottles stresses the wastewater treatment plants.
The object underlying the present invention is therefore to specify a method and an apparatus for pre-cleaning parts made of plastic as part of a recycling process, as a result of which it is possible to recycle plastic without any problems. The invention aims to reduce the contamination of the water cycle to a minimum.
SUMMARY OF VARIOUS EMBODIMENTS
As for the method of the invention, the object mentioned above is achieved according to the invention by the features of various method embodiments described herein. Accordingly, the generic method is characterized in that the foreign bodies are removed from the parts by applying mechanical stress to the parts.
As for the apparatus of the invention, the above object is achieved by the features defined in various apparatus embodiments described herein. Accordingly, the generic apparatus is characterized by a housing comprising a chamber for receiving the parts, means for applying mechanical stress to the parts, means for separating the foreign bodies released from the parts, and means for discharging the foreign bodies and parts onto separate paths being provided in the chamber.
One finding according to the invention is that it is easily possible to remove the foreign bodies stuck to the plastic parts to be recycled by applying mechanical stress to the parts. If the parts are stressed purely mechanically, it is not required to prewash the parts with steam, which consumes excessive energy. Furthermore, it is essential to the method of the invention that the removal of the foreign bodies is carried out without first comminuting the parts or PET bottles. Accordingly, the mill is not stressed by abrasive foreign bodies. Quite the contrary, the parts made of plastic are stressed mechanically according to the method of the invention without an upstream comminution of the plastic parts in such a way that the foreign bodies, no matter of what type, are detached from the plastic parts.
The movement of the plastic parts inside the apparatus results in the development of friction of the plastic parts against each other and against the machine parts and this friction likewise brings about or at least promotes a release of impurities.
In a very advantageous manner, the foreign bodies are removed from the parts or the PET bottles exclusively mechanically. The mechanical stress can mean a deformation of the parts so that the foreign bodies are detached from the parts due to the deformation of the same. More particularly, it is feasible for the parts to be deformed by bending, compressing and/or stretching processes, as a result of which the foreign bodies are detached from the parts.
In principle, it is also possible for the foreign bodies to be removed from the parts by the additional action of a liquid or steam, the parts being subjected to a mechanical action in either case. It is also feasible for the foreign bodies to be removed from the parts by the additional action of heat or cold in order to promote the detachment of the foreign bodies from the parts.
Very advantageously, the foreign bodies are knocked off effectively from the parts or PET bottles. In doing so, the foreign bodies can be comminuted, which promotes a separation of the foreign bodies from the parts to be recycled.
If there is any residual liquid in the bottles to be recycled, it would be advantageous to allow the liquid to drain off from the bottles. For this purpose, the parts or bottles could be at least slightly scored or cut as part of the application of mechanical stress, but not comminuted. The advantage of scoring the parts is that any liquid located in the bottles travels outwardly without the risk of prematurely comminuting the PET bottles, which would consequently make it difficult to separate the PET material from the foreign bodies.
After being collected, the parts or bottles to be recycled are usually compacted into bales and compressed accordingly. The material to be recycled is supplied in this form to the recycling process. For purposes of the pre-cleaning process of the invention, the bale is disintegrated and the parts are isolated and supplied in isolated form to the pre-cleaning process. Accordingly, the foreign bodies are removed after a disintegration of the bale or isolation of the parts, which promotes the pre-cleaning process very considerably.
Furthermore, it is very advantageous if the foreign bodies are removed over a pre-definable retention time and/or pre-definable stress intensity. Both parameters are adjustable and can be adjusted and optimized in dependence of each other as far as possible and in dependence of the material or the degree of soiling.
Basically, it cannot be ruled out that small portions of the PET bottles are cut off from the same during the pre-cleaning process and are separated together with the foreign bodies even though it is exclusively the foreign bodies that are to be separated. It is advantageous in this respect if the foreign bodies detached and separated from the parts are supplied together with plastic portions to a repeat separation process, in which the remaining plastic portions of the PET bottles are separated again and supplied to the recycling process. The actual dirt, i.e., the foreign bodies detached from the bottles such as labels, metal, etc. is then disposed of or supplied to a further recycling process.
It should be noted at this point that the actual recycling process follows the method of the invention, the parts or bottles freed of foreign bodies being preferably supplied by means of a conveyor to the further recycling process that is then carried out in a known manner per se.
The apparatus of the invention comprises a housing comprising a chamber for receiving the parts or PET bottles, means for applying mechanical stress to the parts, means for separating the foreign bodies released from the parts, and means for discharging the foreign bodies and parts onto separate paths being provided in the chamber.
In other words, the mechanically detached foreign bodies are supplied, for example, by means of a perforated plate having holes of a suitably defined diameter to a conveyor located below the housing or the chamber as far as possible. The foreign bodies could travel here by means of a conveyor screw to a repeat separation process carried out in a cyclone, for example. Here, the foreign bodies are again separated from the residual plastic portions that are then supplied again to the recycling process.
The chamber used for the pre-cleaning process could be in the form of a centrifugal device or a drum. A rotor comprising stress-applying means is provided in the housing or in the chamber. Basically, it is advantageous if the rotor disposed inside rotates relative to the housing. A reverse function is also feasible.
The stress-applying means could be of various forms. For example, they can be in the form of bars, vanes, paddles or the like. It is also feasible for the stress-applying means to comprise blades, and the bars, vanes, paddles or the like can be equipped, at least in part, with blades that serve for scoring the plastic parts or the PET bottles. It should be noted at this point that it is very advantageous if the parts or PET bottles are not comminuted as part of the pre-cleaning process. Accordingly, the blades must be configured such that the bottles are at the most scored, but not cut up.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
There are different possibilities of implementing and developing the teaching of the present invention to advantage. For this purpose, reference should be made to the following explanation of a preferred exemplary embodiment of the invention with reference to the drawings. Generally preferred design forms and developments of the teaching of this invention have also been described in conjunction with the explanation of the preferred exemplary embodiment of the invention with reference to the drawings, in which:
FIG. 1 shows an exemplary embodiment of the apparatus of the invention in a diagrammatic side-vi
FIG. 2 shows the item shown in FIG. 1 in a diagrammatic top view,
FIG. 3 shows the separation of any residual plastic portions from the foreign bodies in a diagrammatic side-view, and
FIG. 4 a diagrammatically represents the sequence of the method of the invention in a first variant,
FIG. 4 b diagrammatically represents the sequence of the method of the invention in a second variant,
FIG. 5 shows an exemplary embodiment of a rotor equipped with tools in a diagrammatic side-view,
FIG. 6 shows the item shown in FIG. 5 in a diagrammatic front view, and
FIG. 7 shows a tool of the rotor disposed on a holding plate in a diagrammatic view that is enlarged in comparison to FIGS. 5 and 6 .
DETAILED DESCRIPTION
FIG. 1 shows an exemplary embodiment of an apparatus of the invention in a diagrammatic side-view, which apparatus is taken as the basis for describing the method of the invention.
The exemplary embodiment selected here involves the recycling of so-called PET bottles that are supplied, preferably in isolated form, to the apparatus of the invention. The bottles are supplied by means of a feed chute 1 in the exemplary embodiment shown in FIG. 1 . Instead of providing a feed chute, a forced feed system comprising one or more conveyor screws could be provided in order to promote throughput. Furthermore, the forced feed system, for example, the so-called screw-feed system, is suitable more particularly in the rotor variant that is shown in FIGS. 5 and 6 and that functions very effectively on the basis of a forced feed system.
It should be noted that the apparatus of the invention works ideally in a dry process stage namely due to the constructive features described hereinafter.
The apparatus shown in FIG. 1 comprises a housing 2 comprising a chamber located therein. A rotor 3 that is equipped with shovels 4 or tools 11 is disposed inside the housing 2 or in the chamber. Dirt located on the PET bottles or foreign bodies located on the same, for example, labels are knocked off effectively by the shovels 4 or the tools 11 .
The foreign bodies that are knocked off travel by way of a perforated plate 5 onto or into a screw conveyor 6 and are supplied from here to an additional process of separation.
The PET bottles freed of the foreign bodies are transported from the apparatus or the housing 2 onto a conveyor belt 7 and are supplied from here to a further recycling process.
The foreign bodies detached from the PET bottles travel by means of the screw conveyor 6 into a separator 8 that is independent thereof and that comprises a zigzag channel and a cyclone 10 . Here, residual plastic portions that have been accidentally knocked off from the PET bottles are separated from the foreign bodies and supplied to the conveyor belt 7 so that these parts are also available for the recycling process. As shown in the representation of FIG. 3 , the remainder, i.e., the labels and the dirt or the foreign bodies are then supplied to a waste station 9 and a process of separation can be carried out here also.
FIG. 4 a diagrammatically represents the sequence of the method of the invention, the parts or the PET bottles to be recycled being supplied in an isolated form to the apparatus of the invention and thus to the housing 2 . The rotor 3 comprising the shovels 4 is disposed in the housing 2 , as suggested in FIG. 4 a.
Labels, dirt, etc. that have been knocked off from the PET bottles preferably travel through the perforated plate 5 by means of a screw conveyor 6 to an additional separator 8 that can operate by means of gravitational force. Plastic portions separated from the labels and dirt can be supplied to the recycling process.
The PET bottles freed of the foreign bodies are conveyed from the housing 2 onto the conveyor belt 7 and from here to the further recycling process. As mentioned above, the foreign bodies released travel together with the residual plastic portions by means of the screw conveyor 6 to the additional separator 8 , from where the residual plastic portions are likewise supplied after an additional process of separation to the conveyor belt 7 and thus to the recycling process.
Preferably, the released foreign bodies are supplied in the conventional manner by means of a cyclone 10 to a waste station 9 , where a cleanly sorted separation is likewise possible, but not strictly necessary.
It should be noted at this point that the apparatus of the invention can be without a screen or a perforated plate, in which case the fractionation is carried out inside a closed drum or inside a closed housing 2 made of imperforated sheet metal. Downstream of the apparatus or the housing 2 , a separation into a usable fraction and an unusable fraction would then take place namely in order to separate the bottles from labels or dirt here.
It is also feasible to arrange a screening machine downstream of the apparatus instead of a converting air separation, which screening machine is suctioned for the removal of the so-called light fraction. Such a device can comprise a hood above the screening machine, and a ventilation hood connection is provided in the hood. Lastly, the screening machine here can also be a type of air separator comprising an automatic extraction system.
FIG. 4 b diagrammatically represents a possible sequence of the method of the invention in a second variant, in which the PET bottles containing dirt, labels or the like are supplied to the apparatus of the invention, namely to the housing 2 , in which there is disposed a rotor 3 comprising suitable tools 11 . The rotor 3 rotates relative to the housing 2 . Basically, a relative movement between the rotor 3 and the housing 2 is necessary, no matter which component rotates actively in doing so.
Inside the housing 2 that is also referred to as the outer drum, labels and caps are separated from the actual PET bottle without disturbing or knocking off the bottle head, in which case a separation of the cap from the bottle neck would be possible only with considerable effort or would not be possible at all.
In any case, the comminuted material travels from the apparatus or the housing 2 into a separator 8 that is understood to mean a separation stage and that can operate by means of gravitational force, for example.
As for the rotor 3 disposed in the housing 2 , it is essential that the rotor 3 together with its tools 11 (see FIGS. 5 , 6 , and 7 ) and the outer drum or the housing 2 be able to remove labels and caps from the containers or PET bottles without disturbing the bottle necks in doing so. This is of particular significance especially because a destruction of the bottle necks would result in a loss of material in the recycling process since the bottle necks would have to be separated together with the caps.
Preferably, the outer drum or the housing 2 is rotationally fixed, and the rotor 3 rotates. The reverse kinematics is also feasible. As a rule, the axles of the housing 2 or the outer drum and the rotor 3 are disposed so as to be coaxial. An eccentric arrangement of the rotor 3 inside the housing 2 is feasible and can even be advantageous in order to define zones, in which the bottles are acted upon with varying intensity inside the housing 2 .
The separator 8 or the separation stage shown in FIG. 4 b serves for separating the isolated labels even upstream of the screening machine or the screen so that only the actual bottle material together with the caps is supplied to the screen.
FIG. 5 shows an exemplary embodiment of a rotor 3 in a diagrammatic side-view, and the manner in which the rotor 3 can be arranged in the housing 2 or in the outer drum formed by the housing 2 . In the exemplary embodiment selected in FIG. 5 , the rotor 3 has an angular cross-section, but it can also have a circular periphery, if required.
FIG. 5 clearly shows that the rotor 3 comprises attachment strips 13 that, in pairs, serve for mounting the tools 11 disposed on holding plates 12 . The tools 11 are disposed in such a way that they define a spin and thus a conveying direction during a rotation of the comminuted goods in a defined direction. In the exemplary embodiment shown in FIG. 5 , the rotational direction is understood to mean the clockwise direction.
The rotor 3 shown in FIG. 5 rotates relative to the housing 2 , and the housing 2 or the outer drum formed by the housing 2 is rotationally fixed. The axles of the rotor 3 and the housing 2 are disposed so as to be coaxial.
FIG. 6 shows the item shown in FIG. 5 in a front view, in which the angular shape of the rotor 3 and the stepped design of the tools 11 are revealed very clearly. FIG. 6 also clearly shows that the tools 11 are mounted on holding plates 12 that are in turn seated on the attachment strips 13 . The holding plates 12 are preferably screwed onto the attachment strips 13 . A replacement of the individual tools 11 or holding plates 12 is possible at all times.
FIG. 7 is a detailed and enlarged view of a holding plate 12 comprising a tool 11 disposed thereon, which tool 11 is disposed at an angle and this results in the conveying direction of the material during the rotation of the rotor 3 .
The stress-applying means, namely the tools 4 , 11 , provided in the housing 2 or on the rotor 3 can be mounted on the rotor 3 so as to be stationary or so as to be adjustable in terms of position and angle in order to be able to influence the retention time of the parts to be treated in the apparatus. More particularly, the stress-applying means can be mounted on the rotor 3 so as to be rigid or movable in a tangential direction.
The rotor 3 itself can be disposed in the housing 2 or in the drum so as to be centric or eccentric relative to the drum axle, the drum or the housing 2 being designed so as to be cylindrical or conical relative to the rotational axis of the rotor 3 .
It is likewise feasible for the inner side of the drum or the housing 2 to be equipped with elements that influence the trajectory of the parts added.
The inlet of material into the apparatus, i.e., the housing 2 is preferably disposed so as to be tangential to the peripheral movement of the rotor 3 in the rotational direction of the rotor 3 .
The outlet of material from the apparatus or the housing 2 is preferably oriented so as to be tangential to the peripheral movement of the rotor 3 in the rotational direction of the rotor 3 .
It should be further noted that the apparatus of the invention serves not only for the mere treatment of parts, but also performs an additional function, namely that of disintegrating bales and briquettes and it combines this function with its actual function.
In order to avoid repetitions, reference should be made to the general portion of the description and the attached claims for additional preferred embodiments of the teaching of the invention.
In conclusion, it should be pointed out expressly that the above exemplary embodiment of the teaching of the invention merely serves for discussing the teaching claimed without restricting it to said embodiment.
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The invention relates to a method for pre-cleaning parts made of plastic as part of a recycling process, wherein foreign bodies to be removed adhere to the parts, in particular for removing foreign bodies on parts made of plastic, preferably for removing labels, dirt, etc. on used plastic bottles, said method being characterized in that the foreign bodies are removed from the parts by mechanically loading the parts. A device for applying the method is characterized by a housing ( 2 ) having a chamber for accommodating the parts, means ( 3, 4, 11 ) for mechanically acting upon the parts and means for separating the foreign bodies released from the parts and for discharging the foreign bodies and parts onto separate paths being provided in the chamber.
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CROSS-REFERENCE TO PRIOR APPLICATIONS
This is a Non Provisional U.S. Application of a provisional application, claiming the benefit of U.S. Provisional Application No. 61/040,998, filed Mar. 31, 2008.
FIELD OF THE INVENTION
The present invention relates to pharmaceutical compositions containing naratriptan and a compound selected from the group consisting of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED and methods of using such compositions for treating migraine headaches.
BACKGROUND OF THE INVENTION
Migraine typically begins with mild to moderate pain that increases in severity over several hours to reach peak severity. The painful phase of the migraine attack persists for 6 to 12 hours in most migraine patients. For those with migraines, the two most important features of migraine medications are providing quick relief and effectively decreasing pain. Migraine patients are dissatisfied with the amount of time to obtain pain relief after taking migraine medication. One group of very effective migraine pain relievers are triptans. The onset of relief or action of the triptans is measured by the rapid time to peak blood concentration (T max ). Migraine patients reported relief of migraine related disability within 2 hours after dosing with a triptan. Migraine patients need rapid relief from their pain and desire a faster time to headache relief. (see Dawn A. Marcus, M.D., “Establishing a Standard of Speed for Assessing the Efficacy of the Serotonin 1B/1D Agonists (Triptan)” Arch Neurol /Volume 58, June 2001 available on www.archneurol.com)
Naratriptan has been marketed under the trade name Amerge® by Glaxo Wellcome in the U.S. in tablets (2.5 mg) for oral administration. Naratriptan is a member of the drug class known as scrotonin (5HT) agonists and has been used as a pharmaceutical agent to successfully treats acute migraines. Naratriptan tablets are well absorbed, with about 70% oral bioavailability. Following administration of a 2.5 mg tablet orally, the peak concentrations are obtained in 2 to 3 hours. During a migraine attack, absorption was slower, with a T max of 3 to 4 hours.
Because migraine patients desire to return back to their daily task in life within a short time after taking migraine medication, there is a need to have rapid, complete relief of migraine pain within less than 2 hours after drug administration. So far, various efforts to improve the peak concentrations of Naratriptan have failed.
SUMMARY OF THE INVENTION
The present invention provides a pharmaceutical composition for treating migraines in a subject with a shortened lime period for the onset of maximum peak concentration, comprising of: (a) naratriptan or its salt thereof, (b) at least one compound selected from the group consisting of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED and (c) optionally, a pharmaceutically acceptable excipient.
The present invention also provides a tablet for rapid onset of therapeutic effects in treating migraines comprising of a (1) about 0.1 mg to about 100 mg of naratriptan, and (2) from about 10 mg to about 500 mg of at least one of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED.
The present invention further provides a method of treating migraine headaches, comprising the step of administering the pharmaceutical composition which contains (a) naratriptan or its salt thereof, (b) at least one compound selected from the group consisting of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED and (c) optionally, a pharmaceutically acceptable excipient, in a subject in need of such a treatment, wherein said pharmaceutical composition, upon oral administration, takes at least 20% less time to reach T max in comparison to administering naratriptan alone.
The contents of the patents and publication cited herein and the contents of documents cited in these patents and publications are hereby incorporated herein by reference to the extent permitted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the mean plasma concentrations of naratriptan in rats following a single oral administration of naratriptan (10 mg/kg) alone or in combination with one of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED (200 mg/kg).
DETAILED DESCRIPTION OF THE INVENTION
The term “about” or “approximately” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within 1 or more than 1 standard deviations, per practice in the art. Alternatively, “about” with respect to pharmaceutical compositions can mean a range of up to 10%, preferably up to 5%.
The phrase “pharmaceutically acceptable” refers to compounds or compositions that are physiologically tolerable and do not typically produce an allergic or similar untoward reaction, such as gastric upset, dizziness and the like, when administered to a mammal.
As used herein, the term “treat” or “treating” includes one or more of the following: (a) arresting, delaying the onset (i.e., the period prior to clinical manifestation of a disorder) and/or reducing the risk of developing or worsening a disorder; (b) relieving or alleviating at least one symptom of a disorder in a mammal, including for example, hypercalcemia; or (c) relieving or alleviating the intensity and/or duration of a manifestation of a disorder experienced by a mammal including, but not limited to, those which are in response to a given stimulus (e.g., pressure, tissue injury or cold temperature). The term “treat” also includes prophylactically preventing, curing, healing, alleviating, relieving, altering, remedying, ameliorating, improving, or affecting a condition (e.g., a disease), the symptoms of the condition, or the predisposition toward the condition.
The term “bioavailability” refers to the rate and extent to which the active ingredient or active moiety is absorbed from a drug product and becomes systematically available.
The term “2-HPOD” refers to 8-(2-hydroxyphenoxy)octyldiethanolamine and pharmaceutically acceptable salts. 8-(2-hydroxyphenoxy)octyldiethanolamine has the following chemical structure:
The term “2-HPHM” refers to 6-(2-hydroxyphenoxy)hexylmorpholine and its pharmaceutically acceptable salts. 6-(2-hydroxyphenoxy)hexylmorpholine has the following chemical structure:
The term “4-BPED” refers to 2-(4-phenoxyphenyl)ethyldiethanolamine its pharmaceutically acceptable salts. 2-(4-phenoxyphenyl)ethyldiethanolamine has the following chemical structure:
The term “4-BPED” refers to 2-(biphen-4-yl)ethyldiethanolamine and its pharmaceutically acceptable salts. 2-(biphen-4-yl)ethyldiethanolamine has the following chemical structure:
The term “2-PPED” refers to 2-(2-phenoxyphenyl)ethyldiethanolamine and its pharmaceutically acceptable salts. 2-(2-phenoxyphenyl)ethyldiethanolamine has the following chemical structure:
The term “AUC 0-last ” refers to area under the curve to the last quantifiable time point. The term “C max ” refers to peak plasma concentration. C max is the maximum absorption of the Naratriptan into the mammal's blood stream. The term “T max ” refers to mean time-to-peak concentrations. A shorter T max correlates with a more rapid onset of action and quicker pain relief in mammals.
In one embodiment of the present invention, a naratriptan salt is used in the pharmaceutical composition. Such salt includes hydrochloride, hydrobromide, mesylate, acetate, trifluoroacetate, propionate, fumarate, tartrate, citrate, phosphate, succinate, bisulfate, and besylate salts.
In another embodiment of the present invention, the pharmaceutical composition contains naratriptan and one of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED in a weight ratio from about 1:100 to about 1:5, preferably from about 1:75 to about 1:4, more preferably from about 1:50 to about 1:2 and the most preferably from about 1:50 to about 1:1.
In another embodiment of the present invention, the method of treating migraine headaches achieves T max in a subject, upon oral administration of the pharmaceutical composition, in at least 20% less time in comparison to administering naratriptan alone, preferably in at least 40% less time, more preferably in at least 50% less time, more preferably in at least 60% less time, more preferably in at least 70% less time, more preferably in at least 75% less time and the most preferably in at least 80% less time.
In the present invention, the delivery system is the pharmaceutical formulations which may be in the form of a liquid or solid. Liquid formulations may be water-based. The absorption enhancer was dissolved in deionized water. 10 N NaOH solution was used to help dissolving acid form carriers. HCl was added to lower pH of the absorption enhancer stock solution if the pH was higher than 7.4. Naratriptan powder was added to the absorption enhancer solution 5 minutes before dosing. The final concentration of drug was 10 mg/ml, and the final concentration of carrier was 200 mg/ml for the study.
The following examples are given as specific illustrations of the invention. It should be understood, however, that the invention is not limited to the specific details set forth in the examples. All parts and percentages in the examples, as well as in the remainder of the specification, are by weight unless otherwise specified.
Example 1
The study was conducted in fasted adult male Sprague-Dawley rats (n=5 for each group as seen in FIG. 1 ). Naratriptan is also designated Nar. Naratriptan was administered alone to rates orally as a control. For oral dosing, single solutions were administrated at time 0, in the following manner: (a) each absorption enhancer carrier (200 mg/kg) in combination with Nar (10 mg/kg) was administered orally to rats; and (b) Nar (10 mg/kg) alone was administered orally to rats. Blood samples were collected by retro-orbital bleed under CO 2 anesthesia pre-dosing (0 minute), and 5, 15, 30, 40, 50, 60, 120 and 240 minutes after dosing. In the control study, where Naratriptan (10 mg/kg) alone was administered to rats, mean peak concentrations were achieved at 27 minutes post-dose. In the administration of Nar/2-HPOD combination, mean peak Naratriptan plasma concentration was observed at 13 minutes post-dose as opposed to 27 minutes as seen following Naratriptan alone. In the administration of Nar/2-HPHM combination, mean peak Naratriptan plasma concentration was observed at 12 minutes post-dose as opposed to 27 minutes as seen following Naratriptan alone. Both, the Nar/2-HPOD and Nar/2-HPHM combination took approximately ½ the time of Naratriptan alone. In the administration of Nar/4-PPED combination, mean peak Naratriptan plasma concentration was observed at 7.5 minutes post-dose as opposed to 27 minutes as seen following Naratriptan alone. Also the mean C max value of the Nar/4-PPED combination was approximately 2-fold higher compared to that obtained following Naratriptan alone. In the administration of Nar/4-BPED combination, mean peak Naratriptan plasma concentration was observed at 9 minutes post-dose as opposed to 27 minutes as seen following Naratriptan alone. In the administration of Nar/2-PPED combination, mean peak Naratriptan plasma concentration was observed at 28 minutes post-dose approximately the same lime as seen following Naratriptan alone. However, the mean C max value of the Nar/2-PPED combination was significantly higher than as seen following Naratriptan alone. The testing data are shown in the following table.
AUC last
C max
Group
(min * ng/ml)
(ng/ml)
T max (min)
Naratriptan alone (10 mg/kg)
62851
1052
27.0
Naratriptan/2-HPOD (10 mg/kg)
73568
1315
13.0
Naratriptan/2-HPHM (10 mg/kg)
26815
1095
12.0
Naratriptan/4-PPED (10 mg/kg)
52453
933
7.5
Naratriptan/4-BPED (10 mg/kg)
57857
940
9.0
Naratriptan/2-PPED (10 mg/kg)
43725
1357
28.0
The principles, preferred embodiments, and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art, without departing from the spirit of the invention.
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The present invention relates to pharmaceutical compositions containing Naratriptan, a compound selected from the group consisting of 2-HPOD, 2-HPHM, 4-PPED, 4-BPED and 2-PPED, and optionally, a pharmaceutically acceptable excipient.
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This application claims the benefit of U.S. Provisional Application No. 60/947,135, filed on Jun. 29, 2007, the entire contents of which are incorporated herein by reference.
FIELD
A connector that fluidly connects a first fluid system to a second fluid system for performing processing operations, for example charging, evacuation and/or testing, on the second fluid system.
BACKGROUND
A connector is often used to connect an external fluid system, for example charging, evacuation and/or testing equipment, to a second fluid system, for example manufacturing, test, or processing equipment. Once the connection is made and any valves are opened, fluid can flow through the connector either into the second fluid system or from the second fluid system depending on the processing operation being performed.
Connectors are typically designed with one connection interface that enables the connector to be able to connect to the second fluid system in only one way. This means that a typical connector cannot be used to connect to fluid systems that require different connection interfaces on the connector.
Further, conventional connectors are provided with one actuator for actuating the connectors, for example a manual or pneumatic/hydraulic actuator. However, one actuator is not necessarily appropriate for every connection to be made. For example, with manual and pneumatic/hydraulic connector actuation, the connection forces are hard to control which may prevent use of those types of actuators when connecting to a delicate or fragile fluid system. Further, space constraints may limit or prevent use of certain type of actuators.
SUMMARY
A modular connector system is described that permits changes to the connector, for example changes in the type of connection interface that is used and/or changes in the type of actuator that is used to actuate the connector. By making parts of the connector changeable, the connector can be changed so as to be able to connect to different fluid systems. This eliminates the need to have separate connectors for different fluid systems.
In one embodiment, a modular connector system for connecting a first fluid system to a second fluid system includes a connector body having a connector end and an actuator end, and a plurality of connector units. Each connector unit includes a connection mechanism that detachably connects the respective connector unit to the connector end of the connector body. The connection mechanisms of the connector units connect the connector units to the connector end in the same manner, thereby allowing the different connector units to connect to the connector body.
The modular connector system can also include a plurality of actuator units, each of which includes a connection mechanism that detachably connects the respective actuator unit to the actuator end of the connector body. The connection mechanisms of the actuator units can connect the actuator units to the actuator end in the same manner thereby allowing the different actuator units to connect to the connector body.
Any type of detachable connection between the connector body and the connector units and/or actuator units can be used if found suitable. One form of detachable connection described herein comprises threads.
In an embodiment, the connector body includes a generally hollow sleeve having a connector end and an actuator end, with threads at the connector end that enable connection to a connector unit and threads at the actuator end that enable connection to an actuator unit. A piston is slidably disposed within the sleeve so that the piston and the sleeve can move relative to one another.
Each actuator unit can be comprised of an actuation mechanism, and a connection mechanism that detachably connects the respective actuator unit to an actuator end of a connector body. The connection mechanisms connect the actuator units to the actuator end in the same manner.
Each connector unit can comprise means for connecting to the fluid system, and a connection mechanism that detachably connects the respective connector unit to a connector end of a connector body. The connection mechanisms connect the connector units to the connector end in the same manner.
The modular connector system can also include a flexible drive to interconnect the connector body and a connector unit. The flexible drive can include an elongated, hollow flexible tube with a first end and a second end, a connection mechanism at the first end of the tube for detachably connecting the tube to the connector body, and a connection mechanism at the second end of the tube for detachably connecting the tube to the connector unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details are explained below with the help of the examples illustrated in the attached drawings in which:
FIG. 1 is a top view of a modular connector in accordance with one exemplary embodiment.
FIG. 2 is a longitudinal cross-sectional view of the modular connector of FIG. 1 taken along line 2 - 2 .
FIG. 3 is a perspective view of a connector body used in the modular connector system.
FIG. 4 is a longitudinal cross-sectional view of the connector body.
FIG. 5 is a cross-sectional view of the portion contained in area 5 from FIG. 2 showing the connector unit in detail.
FIG. 6 is a cross-sectional view of the actuator unit from FIG. 2 .
FIGS. 7-12 illustrate alternative embodiments of connector units of the modular connector system.
FIGS. 13-16 illustrate alternative embodiments of actuator units of the modular connector system.
FIGS. 17-24 illustrate various embodiments of a flexible drive interconnecting the connector body and various connector units.
FIG. 25 illustrates an embodiment without an integrated actuator unit fixed to the connector.
DETAILED DESCRIPTION
A modular connector system is described that permits one or more parts of a connector to be changed to permit use of the connector with different fluid systems. As described herein, the connector system includes at least one connector body, a plurality of connector units that are each individually connectable to the connector body, a plurality of actuator units that are each individually connectable to the connector body, and optionally at least one flexible drive that is designed to interconnect the connector body to the connector units. However, alternative connector systems are possible, including those where the connector units can be changed but the actuator unit that is used is fixed, the actuator units can be changed but the connector unit that is used is fixed, the connector body can be changed but the connector unit and the actuator unit are fixed, and various other combinations.
In its simplest form, a modular connector that is produced from the modular connector system includes a connector body, an actuating means for actuating the modular connector, and a means to connect the modular connector to a fluid system for performing processing operations, for example charging, evacuation and/or testing, on the fluid system. The actuating means can be an actuator unit, for example an actuator unit described herein. The means to connect can be a connector unit, for example a connector unit described herein. In certain embodiments, the modular connector can include a flexible drive between the connector body and the means to connect.
With reference initially to FIG. 1 , an embodiment of a modular connector 10 is illustrated that can fluidly connect a first fluid system (not shown) to an interface 100 of a second fluid system for performing processing operations, for example charging, evacuation and/or testing, on the second fluid system. The first fluid system to which the modular connector 10 is attached can be, for example, a source of air or helium for testing. The second fluid system to which the modular connector 10 is intended to connect can be, for example, a fluid reservoir. However, the modular connector 10 can be used with other fluid systems in which a connector is used to fluidly connect a first fluid system to a second fluid system.
The modular connector 10 includes a connector body 12 , an actuating means in the form of an actuator unit 14 for actuating the connector, and a means to connect in the form of a connection unit 16 . With reference to FIG. 2 , the actuator unit 14 connects to the connector body 12 in a detachable manner to allow a different actuator unit to be connected to the connector body for actuating the connector 10 . Likewise, the connection unit 16 connects to the connector body 12 in a detachable manner to allow a different connection unit to be connected to the connector body for connecting to the interface 100 .
With reference to FIGS. 3 and 4 , the connector body 12 includes a generally hollow, tubular sleeve 20 having an externally threaded back or actuator end 22 and an externally threaded front or connector end 24 . The threads form means by which the actuator unit 14 and connection unit 16 connect to the connector body. The back end 22 and front end 24 of the sleeve 20 are both open. The sleeve 20 also includes an elongated slot 26 formed therethrough.
The connector body 12 also includes an actuation piston 30 that is slideably disposed within the sleeve 20 to permit relative sliding movement between the piston 30 and the inside surface of the sleeve 20 . The actuation piston 30 includes an internal axial passageway 60 extending through the front end thereof, and a radial passage 62 connected to the axial passageway 60 . As shown in FIGS. 1 and 2 , a threaded fitting 64 is threaded into the radial passage 62 and forms a means to connect to the first fluid system. The slot 26 in the sleeve 20 accommodates rearward and forward movements of the fitting 64 as the piston 30 moves axially, and the fitting 64 protruding through the slot 26 limits rotational movement of the piston 30 . Further, the rear of the piston 30 includes an internally threaded hollow portion 66 at the rear of the actuation piston 30 which engages with the actuator unit 14 in a manner discussed below.
Turning now to FIG. 5 , the connection unit 16 includes a tube 70 that is threaded within the axial passageway 60 of the piston and extends beyond the end of the sleeve 20 and the piston 30 . Due to the threaded engagement between the tube 70 and the piston 30 , axial movement of the piston 30 results in corresponding axial movement of the tube 70 . A seal 72 is provided to seal between the outer circumference of the tube 70 and the interior of the passageway 60 to prevent fluid leaks. The tube 70 includes an internal flow passage 74 that communicates with the rear of the passageway 60 and with the radial passage 62 to form a fluid flow passage between the tube 70 and the fitting 64 .
The connection unit 16 further includes a cap 80 that is threaded onto the threaded front end 24 of the sleeve 20 . The cap 80 includes a central opening 82 through which the tube 70 passes. At the point where the tube 70 extends past the cap 80 , the tube 70 includes a reduced diameter section 84 that extends to the front end of the tube 70 . A washer 86 is slid over the reduced diameter section 84 , followed by a tubular seal 88 , and another washer 90 . The washer 86 , the seal 88 and the washer 90 are retained on the tube 70 by a lock ring 92 .
Actuation of the piston 30 is achieved using the actuator unit 14 . With reference to FIG. 6 , the actuator unit 14 in this embodiment includes an actuation mechanism in the form of an electric actuator 34 , and a connection mechanism that detachably connects the actuator unit to the threaded end 22 of the connector body 12 .
The connection mechanism of the actuator unit 14 includes an internally threaded hexagonal nut 32 that can thread onto the back end 22 of the sleeve 20 of the connector body 12 . The electric actuator 34 in this embodiment takes the form of an electric motor having a drive shaft 36 connected to a suitable reduction mechanism 38 , for example a gear box, to increase torque. The electric motor can be connected to any suitable source of electricity, for example a 120V source or to one or more batteries. The reduction mechanism 38 is fixed to the nut 32 via a flange 40 that is integral with the nut 32 and screws 42 that extend through the flange 40 and into threaded receptacles on the reduction mechanism 38 . The electric motor is preferably a two-way motor to allow forward and reverse rotation of the drive shaft 36 .
The reduction mechanism 38 includes an output 44 that is fixed to a screw drive 46 for rotating the screw drive 46 . As shown in FIG. 2 , the screw drive 46 extends into the hollow portion 66 at the rear of the actuation piston 30 . A drive nut 48 is threaded onto the screw drive 46 . The exterior surface of the nut 48 is threaded and is screwed into the hollow portion 66 of the piston 30 . The nut 48 also includes a radial flange 52 on the rear end thereof that engages the rear of the piston 30 . When the actuator unit 14 is mounted in position, and when the screw drive 46 is rotated, the drive nut 48 is driven in a forward direction toward the connection mechanism 16 or driven in a rearward direction away from the connection mechanism 16 . Since the nut 48 is fixed to the piston 30 , the piston 30 moves with the nut 48 in either the forward or rearward direction.
As shown in FIG. 6 , thrust washers 54 are disposed on either side of a flange 56 at the rear of the screw drive 46 within the nut 32 . The thrust washers 54 prevent transfer of thrust to drive gears in the reduction mechanism 38 . In addition, a drive support washer 58 is provided between the flange 52 and the thrust washers 54 , disposed around the screw drive 46 within the nut 32 .
To achieve connection with the interface 100 , the projecting end of the tube 70 is inserted into the end of the interface 100 . The electric motor is then activated to rotate the screw drive 46 in the appropriate direction to cause the piston 30 to be actuated axially rearwardly. This retracts the tube 70 into the connector 10 , which causes the seal 88 to be compressed between the washers 86 , 90 , due to engagement between the washer 86 and the cap 80 . As the seal 88 is compressed, it expands in diameter, and seals against the inner diameter of the interface 100 . Processing can then occur through the connector 10 , with fluid being able to flow through the connector between the first and second fluid systems. Disconnection is achieved by activating the motor to actuate the piston 30 forwardly to release the compression on the seal 88 , returning the connection unit 16 to its original state.
When connected, the connection unit 16 in this embodiment seals with the fluid system interface 100 . There is no gripping ability provided by the connection unit 16 other than the friction of the seal 88 against the inner diameter of the fluid system interface.
Other connection units can be used with the modular connector system. Examples of alternative connection units are illustrated in FIGS. 7-12 in which the same reference numerals indicate elements that are similar to those described above.
In FIG. 7 , the connection unit 120 that seals and grips with the interface 100 is illustrated. The connection unit 120 is similar in construction and operation to the non-modular connection mechanism disclosed in U.S. Pat. No. 5,343,798 which is incorporated herein by reference in its entirety.
The unit 120 comprises a tube 122 that is threaded within the axial passageway of the piston 30 and extends beyond the end of the sleeve 20 and the piston 30 similar to the tube 70 . Due to the threaded engagement between the tube 122 and the piston 30 , axial movement of the piston 30 results in corresponding axial movement of the tube 122 . A seal 124 is provided to seal between the outer circumference of the tube 122 and the interior of the passageway to prevent fluid leaks. The tube 122 includes an internal flow passage 125 similar to the internal passage 74 .
The connection unit 120 further includes a cap 126 that is threaded onto the threaded front end 24 of the sleeve 20 . The cap 126 includes a central opening through which the tube 122 passes. A washer 128 is disposed over the tube, followed by a plurality of split collets 130 , a wedge 132 , and a seal 134 . The end of the tube 122 includes a flange 136 that retains the elements on the tube 122 . In addition, a resilient ring 138 surrounds the collets 130 to bias the collets to the position shown in FIG. 7 .
In use, the end of the connection unit 120 is inserted into the interface 100 . When the tube 122 is pulled rearwardly, the seal 134 is compressed and expands into engagement with the inner surface of the interface 100 to seal with the interface. In addition, the collets 130 are ramped outward by the wedge 132 into engagement with the inner diameter to grip with the interface 100 .
FIG. 8 shows a connection unit 140 that grips and seals with internal threads of an interface 102 . The connection unit 140 is similar in construction and operation to the non-modular connection mechanism disclosed in U.S. Pat. No. 5,788,290 which is incorporated herein by reference in its entirety. The sleeve 20 includes a modified piston 142 that is axially moveable in the sleeve 20 . The connection unit 140 includes a sleeve 144 that threads onto the threaded end 24 of the sleeve 20 . A hollow tube 146 is connected by threads to the piston 142 and extends into the sleeve 144 . A seal 148 is provided around the tube 146 to seal with the inner diameter of the sleeve 144 . The unit 140 also includes a plurality of split collets 150 that are pivotally connected to the end of the tube 146 , and a resilient ring 152 is disposed around the collets 150 to bias the collets. A pin 154 is disposed inside the collets 150 , and includes a tapered front end 156 . The pin 154 is supported by a cross-member 158 that is connected to the sleeve 144 via a retaining mechanism 159 . The front ends of the collets 150 are slideable on the outside of the pin 154 .
In FIG. 8 , the connection unit 140 is shown in its default, activated state. To activate the connection unit, the collets 150 are pushed outward over the end 156 of the pin 154 by the piston 142 and tube 146 . This permits the ends of the collets 150 to collapse under the bias of the ring 152 to a reduced diameter, allowing the end of the connection unit to be inserted into the interface 102 . The collets 150 are then retracted by pulling the piston and the tube toward the connector. As this occurs, the pin 154 causes the collets to expand outward back to the position shown in FIG. 8 so that the outside of the collets grip with the threads on the interface 102 . At the same time, the interface 102 seals against the end face of the sleeve 144 .
FIG. 9 shows a connection unit 160 that is designed to seal with the outer diameter of an interface 104 . The outer diameter can be smooth or it can have threads. There is no gripping ability provided by the connection unit 160 other than the friction of the seal against the outer diameter of the interface 104 .
The connection unit 160 includes a sleeve 162 that threads onto the threaded end 24 of the sleeve 20 . A seal 164 is disposed inside the sleeve 162 , sandwiched between two washers 166 , 168 . The washer 166 is movable axially within the sleeve 162 . In use, the interface 104 is inserted into the connection unit 160 . The piston 30 is advanced axially to push the washer 166 . This compresses and extrudes the seal 164 against the outer diameter of the interface 104 .
FIG. 10 shows a connection unit 180 that grips and seals with the interface 104 . The connection unit 180 is similar in construction and operation to the non-modular connection mechanism disclosed in U.S. Pat. No. 5,507,537 which is incorporated herein by reference in its entirety. The connection unit 180 includes a sleeve 182 that threads onto the threaded end 24 of the sleeve 20 . A hollow tube 184 is connected by threads to a modified piston 186 and extends partially into the sleeve 182 . A seal 188 is disposed inside the sleeve 182 , sandwiched between the end of the tube 184 and a washer 190 . A plurality of split collets 192 are disposed inside the front end of the sleeve 182 , with outer surfaces 194 of the collets 192 being sloped. A wear ring 196 is disposed between the outer surface of the collets 192 and the inner surface of the sleeve 182 so as to reduce the wear on the collets and the sleeve.
In use, the interface 104 is inserted into the connection unit 180 . The piston 186 is advanced axially to push against the seal 188 . This compresses and extrudes the seal 188 against the outer diameter of the interface 104 . At the same time, the collets 192 are ramped inward onto the outer diameter to grip the interface 104 .
FIGS. 11A-E show a connection unit 200 that is configured to seal with an interface 106 and to grip onto the interface 106 which is externally threaded or includes another feature that can be used for gripping, for example a bead, barb, bump, etc.
With reference to FIG. 11A , which shows the connection unit 200 in a default position, the connection unit 200 includes a sleeve 202 , and a lock ring 204 is threaded onto the threaded end 24 of the sleeve 20 . The lock ring 204 is disposed between a shoulder 206 on the sleeve 202 and a retainer 208 secured to the rear of the sleeve. A hollow tube 210 is threaded into a modified piston 212 and extends into the sleeve 202 . A plurality of collets 214 are pivotally secured to the end of the tube 210 , and a resilient biasing member 216 ( FIG. 11B ), for example a o-ring, biases the collets outward.
In addition, a sealing piston 218 is disposed inside the end of the tube 210 and inside the collets 214 . A main seal 220 is secured to the end of the piston 218 for sealing engagement with the interface 106 . Further, a plurality of push pins 222 extend through the end of the tube 210 and are engaged with the rear of the piston 218 and the end 24 of the sleeve 20 .
FIG. 11B shows the connection unit 200 in an open position, with the front ends of the collets 214 advanced axially by the piston 212 from the front end of the sleeve 202 which remains stationary with the sleeve 20 . The biasing force provided by the biasing member 216 causes the collets 214 to pivot open to facilitate insertion of the interface 106 . In addition, the front end of the tube 210 advances relative to the pins 222 to a position adjacent the rear side of the piston 218 . This permits the interface 106 to be inserted a maximum distance into the connection unit 200 .
FIG. 11C illustrates the start of connection. The interface 106 is inserted up to the main seal 220 and the piston 212 starting to be pulled back into the connector. The interior of the collets 214 are threaded. As a result, during connection as the collets close over the threads on the interface 106 , the threads may not exactly align. This can cause the interface 106 to back off the seal 220 slightly, for example up to ½ a thread, to match threads. The push pins 222 do not provide any function during the start of connection.
FIG. 11D illustrates the connector in mid connection. The piston 212 continues to draw the tube 210 , collets 214 , interface 106 and the sealing piston 218 into the sleeve 202 and the sleeve 20 . When the push pins 222 contact the end 24 of the sleeve 20 , the movement of the sealing piston 218 is stopped.
FIG. 11E illustrates the connector at full connection. As connection continues between FIGS. 11D and 11E , the push pins 222 continue to stop movement of the sealing piston 218 . As the interface 106 continues to be drawn into the connector, the interface 106 seals tightly against the main seal 220 . A seal 224 is provided that seals between the sealing piston 218 and the interior of the tube 210 . The seal 224 of the sealing piston 218 provides a larger sealing diameter than the main seal 220 so when under pressure, the sealing piston will generate a greater seal against the interface 106 .
FIG. 12 shows a connection unit 230 that grips and seals with an interface 108 . The connection unit 230 is similar in construction and operation to the non-modular connection mechanism disclosed in U.S. patent application Ser. No. 11/671,747 which is incorporated herein by reference in its entirety. The connection unit 230 has a semi-cylindrical nest 232 that includes a flange 234 that is configured to grip over a thread or another feature on the interface 108 . The nest 232 is threaded onto the threaded end 24 of the sleeve 20 . A seal 236 is disposed at the end of a piston 238 configured to seal with an internal diameter of the interface 108 .
In use, the interface 108 is inserted into the nest 232 so that the flange 234 grips over the threads or other feature on the interface. The piston 238 is then actuated forward into the interface 108 so that the seal 236 seals against the inner diameter of the interface 108 .
Connection units other than those described and illustrated herein can be used, provided they are found suitable for modularity.
As should be apparent, the connector units described above share a common connection mechanism, for example threads, that detachably connects the respective connector unit to the connector end of the connector body and connect the connector units to the connector end in the same manner.
To further enhance modularity, other actuator units can be used with the modular connector system. Examples of alternative actuator units are illustrated in FIGS. 13-16 in which the same reference numerals indicate elements that are similar to those described above.
FIGS. 13 and 14 provide a top view and a cross-sectional side view, respectively, of a manually activated actuator unit 300 shown connected to the back end 22 of the connector body 12 .
The actuator unit 300 includes an internally threaded hexagonal nut 302 that can thread onto the back end 22 of the sleeve 20 of the connector body 12 . The rear end of the nut 302 is slotted and a temporary force squeeze handle 304 is pivotally attached to the nut 302 by a pin 306 for providing a temporary compression motion. A piston 308 is threaded into the hollow portion 66 of the actuation piston 30 to fix the piston 308 to the piston 30 . The rear end of the piston 308 is engaged with the squeeze handle 304 .
When the squeeze handle 304 is squeezed in the direction of the arrow, the piston 308 and piston 30 are pushed forward to actuate the connector unit. When the handle 304 is released, the pistons 30 , 308 are biased by a suitable biasing means, for example a coil spring 310 , back to their position shown and the handle 304 returned to its original position.
FIG. 15 is a cross-sectional side view of a manually activated actuator unit 320 shown connected to the back end 22 of the connector body 12 which is only partially illustrated. The actuator unit 320 includes an internally threaded hexagonal nut 322 that can thread onto the back end 22 of the sleeve 20 of the connector body 12 . The rear end of the nut 322 is slotted and a flip handle 324 is pivotally attached to the nut 322 by a pin 326 . A piston 328 is threaded into the hollow portion of the actuation piston 30 to fix the piston 328 to the piston 30 . The rear end of the piston 328 is engaged with the flip handle 324 .
The flip handle 324 provides a constant compression force. FIG. 15 illustrates the deactivated or default position. When the handle 324 is rotated up or down, the piston 328 and the piston 30 are pushed forward to actuate the connector unit. When the handle 324 is rotated back to the position shown in FIG. 15 , the pistons 30 , 328 are biased by a suitable biasing means, for example a coil spring acting between the connector body 12 and the piston 30 , back to their position.
FIG. 16 is a cross-sectional side view of a pneumatic/hydraulic activated actuator unit 330 shown connected to the back end 22 of the connector body 12 which is only partially illustrated. The actuator unit 330 includes an internally threaded hexagonal nut 332 that can thread onto the back end 22 of the sleeve 20 of the connector body 12 . The nut 332 includes a fluid port 334 for pneumatic/hydraulic fluid. An o-ring 336 is disposed around a modified piston 338 that functions similarly to the piston 30 . The piston 338 has a circumferential channel 340 that receives the o-ring 336 .
In use, pressurized fluid, for example air or hydraulic fluid, is introduced through the port 334 and acts on the rear of the piston 338 . This pushes the piston 338 to actuate the connection unit. The force applied to the piston 338 can be a constant force if a constant fluid pressure is applied, or momentary if the fluid pressure is reduced. When air is used as the pressurized fluid, a spring may be used to bias the piston 338 back to the deactivated position. When hydraulic fluid is used, a biasing spring can be used to bias the piston back to the deactivated position, or withdrawal of the hydraulic fluid can cause the piston to pull back due to suction.
In certain case, the modular connector is used in tight spaces that make it difficult for both the connection unit and the actuator unit to be located in that space. Therefore, a flexible drive, examples of which are illustrated in FIGS. 17-24 , can be provided between the connector body and the connection unit.
FIG. 17 illustrates a flexible drive 400 between the connector body 12 and the connection unit 16 illustrated in FIG. 5 . The flexible drive 400 includes a flexible external sleeve 402 having a cap 404 at one end that is threaded onto the front end 24 of the sleeve 20 . The opposite end 406 of the sleeve 402 is externally threaded and the cap 80 of the connection unit 16 is threaded onto the end 406 . The sleeve 402 can be made of a suitable flexible material, for example an elastomer.
A flexible, hollow shaft 410 is disposed inside the sleeve 402 . One end 412 of the shaft 410 is fixed to the piston 30 by threads, while the other end 414 of the shaft 410 is fixed to the tube 70 of the connection unit 16 . The shaft 410 includes a flow passage 416 to allow fluid to flow therethrough from the connection unit 16 to the connector body 12 . The shaft 410 is movable relative to the sleeve 402 to enable the shaft 410 to be pushed or pulled by the piston 30 to actuate the connection unit 16 . For example, when the piston 30 is actuated backward, the piston 30 pulls the shaft 410 backward, which retracts the tube 70 to actuate the connection unit 16 as described above.
FIG. 18 illustrates a flexible drive 430 similar in construction and function to the flexible drive 400 . One end of the drive 430 is connected to the connector body 12 in the same manner as the flexible drive 400 , while the opposite end is connected to the connection unit 120 illustrated in FIG. 7 . The drive 430 includes a flexible external sleeve 432 and a hollow, flexible shaft 434 movable inside the sleeve 432 , with the shaft 434 defining a flow passage 436 for fluid.
The flexible drives in FIGS. 17 and 18 can be used with any connection unit, including any connection unit described herein, which is activated by pushing or pulling of the shaft.
FIG. 19 illustrates a flexible drive 450 that utilizes hydraulic actuation. The flexible drive 450 is connected between the connector body 12 and the connection unit 140 illustrated in FIG. 8 . The flexible drive 450 includes a flexible external sleeve 452 having a cap 454 at one end that is threaded onto the front end 24 of the sleeve 20 . The opposite end 456 of the sleeve 452 is externally threaded and the sleeve 144 of the connection unit 140 is threaded onto the end 456 .
A flexible, hollow shaft 460 is disposed inside the sleeve 452 . One end 462 of the shaft 460 is disposed inside the piston 30 , while the other end 464 of the shaft 460 is fixed to the tube 146 of the connection unit 140 . The end 464 of the shaft 460 is formed into a piston 466 that is fixed to the tube 146 and is slideable within the end 456 of the sleeve 452 . O-rings 468 , 470 are provided to seal between the tube 146 and the piston 466 , and between the piston 466 and the sleeve 452 , respectively. The shaft 460 includes a flow passage 472 to allow fluid to flow therethrough between the connection unit 140 and the connector body 12 . In addition, a space 474 is provided between the sleeve 452 and the shaft 460 for hydraulic fluid
In addition, the front end of the piston 30 is modified with an exterior channel to receive an o-ring 476 for sealing with the interior of the sleeve 20 , and an interior channel 478 to receive an o-ring for sealing with the exterior of the end 462 . Thus, an enclosed hydraulic chamber is defined between the front end of the piston 30 , the space 474 , and the rear end 480 of the piston 466 .
When the piston 30 is actuated in a forward direction, the volume of the hydraulic chamber is reduced which increases the pressure of the hydraulic fluid. The fluid then pushes on the rear end 480 of the piston 466 , which actuates the tube 146 to activate the connector as described above for FIG. 8 .
FIG. 20 illustrates a flexible drive 500 that is similar in construction and function to the flexible drive 450 , and that is connected between the connector body 12 and the actuation unit 160 described above in FIG. 9 .
FIG. 21 illustrates a flexible drive 510 that is similar in construction and function to the flexible drive 450 , and that is connected between the connector body 12 and the actuation unit 180 described above in FIG. 10 .
FIG. 22 illustrates a flexible drive 520 that is similar in construction and function to the flexible drive 450 connected between the connector body 12 and the actuation unit 200 described in FIGS. 11A-E .
FIG. 23 illustrates a flexible drive 530 that utilizes hydraulic activation but where the processing fluid exits from the connection unit through the forward end of the flexible drive 530 . The flexible drive 530 includes a hollow, flexible hydraulic line 532 that contains hydraulic fluid. One end of the line 532 is connected by a cap 534 to the end 24 of the sleeve 20 . The front end of the piston 30 is modified with an exterior channel to receive an o-ring 536 for sealing with the interior of the sleeve 20 .
The opposite end of the line 532 is of enlarged size and includes a threaded fitting 538 secured thereto for passage of process fluid. The line 532 is connected to the connection unit 180 described in FIG. 10 . A piston 540 is disposed within the enlarged end of the line 532 , with the piston secured to the tube 184 . O-rings 542 , 544 are provided forwardly of the fitting 538 to seal between the piston 540 and the tube 184 , and between the piston 540 and the interior of the line 532 . In addition, an o-ring 546 is provided to seal between the rear of the piston 540 and the interior of the line 532 . In addition, radial flow passages 548 are formed in the piston 540 and fluidly connect the hollow interior of the tube 184 with the fitting 538 to permit processing fluid to flow.
In use, actuation of the piston 30 in a forward direction decreases the volume of the hydraulic chamber, causing the hydraulic fluid to push on the rear of the piston 540 thereby forcing the piston, and the tube 184 , forward to activate the connection unit 180 as described above in FIG. 10 .
FIG. 24 illustrates a flexible drive 560 that is similar in construction and function to the flexible drive 530 , but which is connected to the connection unit 160 described above in FIG. 9 .
The flexible drives of FIGS. 19-24 can be used with any connection unit, including any connection unit described herein, which is suitable for being activated by the hydraulic activation that is described.
FIG. 25 illustrates an embodiment of a connector 600 that includes the connector body 12 , and a connection unit, for example connection unit 16 . In FIG. 25 , the same reference numerals indicate elements that are similar to those described above in FIGS. 1-6 . The connector 600 is similar to the connector 10 described above, except that the electric motor 34 and the reduction mechanism 38 are not connected to the connector 600 . Instead, the connector 600 is provided with an interface to which a drive mechanism connects to actuate the connector. With this embodiment, the drive mechanism can stay with a station while the connector 600 moves down an assembly line connected to the interface of the second fluid system. At the end of the assembly line, another drive mechanism can be provided to remove the connector 600 from the second fluid system.
The interface of the connector 600 includes a screw drive shaft 602 connected to the drive nut 48 . The shaft 602 extends rearwardly to a free end 604 that is suitably shaped for engagement by a drive mechanism. A clutch mechanism 606 is fixed to the rear of the nut 32 via the flange 40 . The clutch mechanism 606 resists unwanted loosening of the connector 10 while traveling down the assembly line.
In use of the connector 600 , a drive mechanism (not shown) at a station is connected to the connector 600 . The drive mechanism connects to the nut 32 and to the free end 604 of the shaft 602 . Engagement with the nut 32 prevents rotation of the nut and connector during rotation of the shaft 602 . The drive mechanism then rotates the shaft 602 to actuate the drive nut 48 and the connection unit 16 as described above for FIGS. 1-6 .
The invention may be embodied in other forms without departing from the spirit or novel characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is 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 intended to be embraced therein.
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A modular connector system that permits changes to the connector, for example changes in the type of connection interface that is used and/or changes in the type of actuator that is used to actuate the connector. By making parts of the connector changeable, the connector can be changed so as to be able to connect to different fluid systems. This eliminates the need to have separate connectors for different fluid systems.
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BACKGROUND OF THE INVENTION
The invention relates to an automatic coffeemaker comprising, in a housing, a fixed body which comprises a cylinder closed, on the one hand, by a cover and, on the other hand, by a ferrule traversed by a rotating shaft connected to motor means, and in which are provided openings, an opening for passage of the grind adapted for the introduction of a quantity of ground coffee, a feed opening for liquid adapted to introduce a quantity of hot water from a water heater, an outlet passage for the infusion, and an opening for ejection of the grounds.
The invention concerns more particularly a coffeemaker of this type in which said cylinder is so arranged as to enclose a cylindrical infusion chamber delimited at its ends, on the one hand, by a cover and, on the other hand, by the front surface of a piston which is slidably mounted in the cylinder thanks to translatory drive means fixed for rotation with said shaft, and which can occupy at least two positions, either a rest position in which the piston is retracted from the opening of the passage for the grind, permitting the flow of said grind into the chamber, or a packing position in which the opening of the passage for the grind being closed, the piston packs the grind below the ejection opening against the cover.
In known machines of this type, the ground coffee is introduced into the infusion chamber which is then sealed. The piston packs the grind. Hot water is then passed through the grind, then when the infusion is produced, it is removed by the infusion outlet opening, while the grounds are ejected. To perform this cycle, recourse is had to complicated and costly mechanisms of little reliability at this time.
Moreover, these machines permit producing only an infusion of the "espresso" type, the volume of the infusion chamber being constant at the time of infusion, and the pressure exerted by the piston being also continuously constant.
SUMMARY
The invention has for its object to simplify the existing mechanisms, and to provide an apparatus which is particularly simple, reliable and inexpensive.
According to the invention, a tubular jacket is slidably mounted within the cylinder by means of an actuating device connected to the shaft, the piston being itself slidably mounted in the jacket, and comprises an opening provided in its lateral wall, the jacket being adapted to occupy two positions, either a filling position in which the jacket comes into abutment against the cover and closes the outlet opening for the grounds, in which the opening coincides with the opening of the passage for the grind, and in which the piston passes from its rest position to its packing position, or an ejection position in which the jacket closes the opening for passage of the grind, leaving free the ejection opening for the grounds, and in which after ejection of the grounds, the piston passes from its packing position to its rest position, the different positions being differentiated from each other by a selector of the number of turns of rotation of the rotating shaft.
Thanks to the single and simultaneous control by the shaft of the translatory drive means for the piston and of the device for actuating the jacket, it suffices to impart to the shaft a certain number of turns to obtain automatically all the defined positions of the jacket which comprise a complete cycle for preparation of coffee. This combination body, jacket and piston permits obtaining a compact block easy to make by molding and whose pieces are adapted to be assembled automatically by mass production without the need for adjustment of these various pieces relative to each other.
According to another characteristic of the invention, the piston can moreover occupy an intermediate packing position between the rest position and the packing position in which the piston partially packs the grind above the ejection opening for the grounds, so as to obtain a pressure in the infusion chamber lower than for the normal packing position.
Thus, by adjusting the number of rotative turns of the shaft, the user can selectively produce from the same quantity of coffee, either a coffee of the "espresso" type in which the piston moves directly to the end of its path corresponding to the packing position, so as to increase the pressure in the infusion chamber, or a coffee of the "American" type in which the piston stops before its packing position, in its intermediate position, producing a lower pressure in the infusion chamber, then continues to the packing position permitting then the extraction from the grounds of all the infusion.
The characteristics and advantages of the invention will be further apparent from the description which follows, by way of example, with reference to the accompanying drawing, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a view in vertical cross section of a coffeemaker according to the invention showing particularly an infusion cylinder comprising a piston in rest position and a jacket in filling position;
FIG. 2 is a view analogous to that of FIG. 1 in which the translatory drive means of the piston and the actuating device of the jacket are shown in elevation;
FIG. 3 is a view analogous to that of FIG. 2 in which the piston is shown in elevation, and illustrating the piston in the intermediate packing position and the jacket in its filling position;
FIG. 4 is a view analogous to FIG. 3 in which the actuating device of the jacket is shown in cross section, and illustrating the position in an ejection position;
FIG. 5 is a view analogous to FIG. 2 in which the jacket is shown in elevation, and illustrates, when the jacket is in ejection position and the piston in packing position, the means for expulsion of the grounds;
FIG. 6 is a cross sectional view of the closure in its open condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The automatic coffeemaker as shown in FIGS. 1 to 5 comprises, in a housing 1 (shown schematically in broken lines in FIGS. 1 and 2), a fixed body 2 which comprises a cylinder 3 closed on the one hand by a cover 4 and on the other hand by a ferrule 5 traversed by a rotatable shaft 6 connected to motorized means 7 (schematically shown in broken lines in FIGS. 1 and 2). Openings are provided in the body 2: an opening 8 for passage of the grind adapted for the introduction of a quantity of ground coffee M by a grinding distributor 9 known per se (shown in FIGS. 1 and 2) associated with a reservoir 10, a liquid feed opening 11 adapted be introduce a quantity of hot water from a water heater 12 (shown schematically in broken line in FIGS. 1 and 2), a passage 13 for evacuation of the infusion, and an opening 14 for ejection of the grounds G. The cylinder 3 is so arranged as to enclose a cylindrical infusion chamber 15 delimited at is ends, on the one hand, by the cover 4 and, on the other hand, by the front face 16 of a piston 17 which is slidably mounted in the cylinder 3 thanks to translatory driving means 18 integral in rotation with said shaft 6.
According to the invention, a tubular jacket 19 is slidably mounted within cylinder 3 by means of an actuating device 20 connected to the shaft 6, the piston 17 being itself slidably mounted in the jacket 19, such that the side wall of the jacket 19 delimits the infusion chamber 15 at its periphery. An annular sealing joint 22 is disposed between the piston 17 and the jacket 19. The actuating device 20 for the jacket 19 comprises a rotating cam 23, constituted by a helicoidal groove in which rides a finger 24 secured to the jacket 19. The jacket 19 comprises an opening 25 provided in its side wall.
As is better seen in FIG. 2, the translatory drive means 18 of the piston comprise a double thread screw 26 mounted rotatably in the body 2 and whose axis is parallel to the direction of movement of the piston 17, said screw 26 comprising at least two helicoidal paths 27, 28, a so-called pressure path 27 and a so-called retraction path 28, which are wound in the opposite direction from each other and are connected by rounded portions 29 at their respective ends so as to constitute together an endless path for a shoe 30 which is movably mounted in the piston 17. The shoe 30 comprises two parts, a cylindrical part 31 mounted rotatably in a corresponding opening 32 (FIGS. 3 and 4) of the side wall 33 of the piston 17 and an oval part 34 with rounded ends adapted to be displaced along one of the paths 27, 28. In the described embodiment, there are chosen preferably four helicoidal paths, namely two pressure paths 27 and two retraction paths 28, and two shoes 30, disposed on opposite sides of the side wall 33 of the piston 17 and each adapted to follow a respective one of the pressure paths 27 or retraction paths 28. The pressure paths 27 and the retraction paths 28 preferably have the same pitch.
The piston 17 can occupy at least two positions, either a rest position (FIG. 1 and 2) in which the piston 17 is retracted from the opening 8 for passage of the grind, permitting flow of said grind M into the chamber 15, or a packing position (FIGS. 4 and 5) in which the opening 8 for passage of the grind being closed, the piston 17 packs the grind M against the cover 4 above the ejection opening 14. Continuous rotation of the screw 26 in the same direction effects displacement of the piston 17 alternately from one position toward the other.
Thus, when the screw 26 turns, each shoe 30 traverses first the corresponding pressure path 27, bringing the piston 17 from its rest position (FIGS. 1 and 2) to its packing position (FIGS. 4 and 5), then turns about a rounded portion 27, pivots in the opening 32 of the side wall 33 of the piston 17, and follows then the corresponding retraction path 28, which effects movement of the piston 17 from its packing position (FIGS. 4 and 5) to its rest position (FIGS. 1 and 2).
The jacket 19 can occupy two positions, either a filling position (FIGS. 1, 2, 3 and 4) in which the jacket 19 comes into abutment against a portion of the cover 4 and closes the opening 14 for ejection of the grounds, wherein the opening 25 coincides with the opening 8 for passage of the grind, and in which the piston 17 passes from its rest position (FIGS. 1 and 2) to its packing position (FIG. 4), or an ejection position (FIG. 5) in which the jacket 19 closes the opening 8 for passage of the grind, leaving free the opening 14 for ejection of the grounds, and in which after ejection of the grounds G, the piston 17 moves from its packing position (FIG. 5) to its rest position. The continuous rotation of the cam 23 in the same direction effects displacement of the jacket 19 alternately from one position toward the other.
The various positions of the jacket and of the piston are defined relative to each other by a selector 35 (schematically shown in broken lines in FIGS. 1 and 2) of the number of rotative turns of the rotatable shaft 6. The selector 35 can be preferably an electronic control device for the motorized means, known per se, comprising a turn counter and controlling incidentally the grind distributor 9 and the water heater 12.
As shown in FIG. 3, the piston 17 can moreover occupy a packing position intermediate between the rest position and the packing position in which the piston 17 packs partially the grind M above the opening 14 for ejection of the grounds, so as to obtain a pressure in the infusion chamber 15 lower than for the normal packing pressure.
This position is defined by the selector 35 which stops the rotation of the shaft 6 before the piston 17 is at the end of its path (packing position).
Thus the user can chose to make with the same quantity of grind M either a coffee of the "espresso" type or a coffee of the "American" type.
For an "American" coffee, the selector 35 by means of the shaft 16 brings the piston 17 to its intermediate position, which permits obtaining a lower pressure in the infusion chamber 15, then the piston 17 continues its translation to occupy its packing position, there is then drainage of the cake of grounds G, so as to extract all the aroma from the coffee.
For an "espresso" coffee, the selector 35 causes the piston 17 to advance directly to its packing position, the pressure in the infusion chamber 15 is then raised so as to produce foam on the infusion.
As better shown in FIG. 2, the actuating device 20 for the jacket 19 comprises two parts, namely a part 36 in which the pitch of the groove 23 is small such that the jacket 19 passes slowly from its ejection position toward its filling position, and another portion 37 in which the pitch of the groove 23 is large so that the jacket 17 passes rapidly from its ejection position to its filling position.
As is better seen in FIGS. 1 to 4, the actuating device 20 for the jacket 19 and the translatory drive means 18 of the piston 17 are constituted by two distinct members, fixed in rotation with each other by means of a resilient member 38, preferably of the Boudin spring type, interposed between the shaft 6 and the translatory drive mans 18 of the piston 17, so as to permit in the packing position a very slight displacement d of the piston 17 toward its rest position when the volume of grind M is too great in the infusion chamber 15.
In the case of introduction of a volume of grind M greater than the normal volume, the spring 38 permits a slight recoil d of the screw 26 and of the piston 17 and therefore the volume of the infusion chamber 15 slightly increases. Thus the spring 38 compensates the difference of volume.
Moreover, the spring 38 permits after infusion a slight drainage of the grounds G by causing the piston 17 to advance slightly, and thus compensates the difference of volume existing between the grind M and the grounds G.
As shown in FIGS. 1 and 5 and in particular in FIG. 6, the piston 17 comprises a longitudinal liquid feed channel 39 whose outlet 40 opens on the front face 16 of piston 17 and is provided with a filter 41, and whose inlet 42 is connected to the water heater 12. The inlet 42 comprises a safety closure 43, whose condition depends on the relative position of piston 17 relative to the jacket 19 so as to occupy either "closed" condition in which it closes the inlet 42 (FIG. 5) when the jacket occupies its ejection position and the piston 17 its packing position, or an "open" condition in which it frees said inlet 42 (FIGS. 1 and 6) when the jacket 19 occupies its filling position and the piston 17 its rest position.
The closure 43 is carried by the piston 17 and comprises a tubular box 44 passing through the side wall 21 of the jacket 19 and whose bottom 45 contains the inlet 42 of the channel 39 and whose other end 46 is closed by a plug 47. The plug 47 has a central conduit 48 whose inlet 49 is connected to the end of a water inlet tube 50 and whose outlet 51 is located facing a pin valve 52 that is movable in translation. The pin valve 52 has for this purpose at least one prong 53 which is in gripping relation with a helicoidal ramp 54 provided on the plug 47. Said tube 50 is connected by its other end to a control member 55 which is fixed for rotation with a side wall 21 of the jacket 19 such that the rotation of plug 47 will be effected by displacement of the jacket 19 relative to the piston 17.
The rotation control member 55 is constituted by an extension of the side wall of the jacket 19 and which comprises a hole 56 elongated in the direction of translation of the jacket 19 and of a length substantially equivalent to the path of piston 17. The water inlet tube 50 passes with a certain play through the elongated hole 56. When the jacket 19 occupies its filling position and the piston its rest position (FIG. 1), the water inlet tube 50 is substantially perpendicular to the elongated hole 56, and the pin valve 52 is retracted from the outlet 51 of conduit 48. When the piston 17 passes to its packing position (FIG. 4) which corresponds to a travel of about 40 millimeters, the closure 43 follows the movement but as the tube 50 remains perpendicular to the hole 56, it comes into abutment against the edge 57 of the elongated hole 56. When the jacket 19 passes to its ejection position (FIG. 5), which corresponds to a supplemental path of movement of about 40 millimeters, the tube 50 being in abutment against the edge 57, causes the plug 47 to turn by about 45°. The prong 53 of the pin valve 52 rises in the groove 54 of plug 47 which effects the translation of the pin valve 52 toward the outlet 51 of the conduit 48, which it closes.
As is seen more particularly in FIG. 1, the cover 4 is mounted removably on the cylinder 3 and has a central cylindrical boss 58 of a diameter slightly less than that of the jacket 19, boss 58 comprising a passage 13 for evacuation of the infusion whose mouth 59 is provided with a filter 60 carried by the front surface 61 of boss 58, and which comprises on its side surface 62 an annular sealing joint 63 so as to render the infusion chamber 15 sealed between the jacket 19 and the cover 4 when the jacket 19 occupies its filling position.
This removability permits the user to properly clean the infusion chamber 15 and the filters 60 and 41.
As is seen in FIGS. 1 and 5, the expulsion means 64 are associated with the jacket 19 and comprise a wiper 65 mounted pivotally about a fixed transverse axle 66 which is integral with body 2 thanks to means 67, 68 which mutually cooperate with the jacket. The cooperating means are constituted by at least one lug 67, but preferably two lugs mounted on jacket 19 symmetrically relative to each other and adapted each to ride in a corresponding guide 68 of the wiper 65.
The wiper 65 can occupy two positions, namely an inactive position (FIG. 1) to which it is brought when the jacket 19 occupies its filling position and in which it is held away from the infusion chamber 15, and an active position (FIG. 5) to which it is brought when the jacket 19 occupies its ejection position (FIG. 2) and in which it pushes against and sweeps out the grinds G with a movement transverse to the jacket so as to make them pass through the opening 14 for ejection of the grounds.
The jacket 19, the piston 17, the cover 4, the screw 26 and the cam 23 are preferably of plastic, which has the advantage and being mass producible at low cost.
According to the invention, the operation of the coffeemaker proceeds according to the following infusion cycle:
In an initial stage (FIG. 1), the jacket 19 occupies its filling position and the piston 17 its rest position. The closure 43 is in its "open" condition. The expulsion means 64 occupy their inactive position. There is shown, above the opening 8 for passage of the grind, the grind distributor 9 which comprises, for example, a paddle 69 which is connected to motor means 7.
In a filling stage (FIG. 2), the grind distributor 9 dumps a quantity of grind M through the opening 8 for passage of the grind and the opening 25 of the jacket 19, into the infusion chamber 15.
In an intermediate packing stage (FIG. 3), the shaft 6 drives in rotation the screw 26 of the piston 17, which moves toward the intermediate packing position. The infusion chamber 15 is then sealed by the joints 22 and 63 located, on the one hand between the piston 17 and the jacket 19 and, on the other hand, between the boss 58 of cover 4 and the jacket 19. In the case in which the user desires "American" style coffee, the hot water from the water heater 12 controlled by the selector 35 is introduced into the infusion chamber 15 through the feed channel 69 of the piston 17.
In a packing stage (FIG. 4), the shaft 6 continues to drive in rotation the screw 26 of piston 17 which moves toward its packing position.
There will thus be noted two cases:
In the case in which the user wishes "American" style coffee, the grounds G are expressed by the piston so as to extract all the infusion present in the grounds G after the infusion which is produced by intermediate packing.
In the case in which the user desires "espresso" coffee, the grind M is packed and then hot water from the water heater 12 is injected through the feed channel 39 of the piston 17. After infusion, the grind M is slightly expressed by means of spring 38.
In the two cases, the infusion is evacuated through the infusion evacuation passage 13.
Simultaneously, the shaft 6 drives in rotation the actuating device 20 of the jacket 19, which, thanks to the small pitch of the first portion 36 of the device 20, moves very slowly toward its filling position.
In an ejection stage (FIG. 5), thanks to the larger pitch of the second portion 37 of the actuating device 20 of the jacket 19, the jacket moves rapidly toward its filling position.
When moving, the jacket causes the water inlet tube 15 and the lug 47 to pivot, which brings the closure 43 to active position, thus the hot water or the steam can neither leave through the liquid feed channel 39 nor rise through the infusion chamber 15 toward the water heater 12 even though the infusion chamber 15 is no longer sealed.
Simultaneously, the jacket 19 drives the expulsion means 64 to their active position, the pivoting blade 65 bearing on the cake of grounds G so as to eject it through the grounds ejection opening 14.
In a stage of return to the initial stage, the shaft 6 continues to drive in rotation the screw 26 of the piston 17, which returns toward its rest position. Simultaneously, the shaft 6 continues to drive in rotation the actuating device 20 of the jacket 19, causing the jacket to return to its filling position.
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A cylinder (3) is closed, on the one hand, by a cover (4) and, on the other hand, by a ferrule (5) traversed by a rotatable shaft (6). The cylinder (3) is so disposed as to close an infusion chamber (15) delimited by the cover and by a sliding piston (17) driven by a translatory drive (18) integral with the shaft. A jacket (19) is slidably mounted by an actuating device (20) connected to the shaft (6), the piston (17) is itself slidably mounted in the jacket (19), the different positions of the jacket and of the piston being defined relative to each other by a selector (35) of the number of rotations of the shaft. Application particularly for household coffeemaking machines.
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BACKGROUND
A company may use an enterprise network that includes an Internet Protocol Private Branch Exchange (IP PBX) to provide various services, such as telephony, messaging, presence, and video. The company may also use a Session Initiation Protocol (SIP) trunking service to connect to a traditional phone system, such as a Public Switched Telephone Network (PSTN).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating an exemplary environment in which an exemplary embodiment for providing local identity based on a called number may be implemented;
FIGS. 2A-2C illustrate an exemplary scenario in which local identity based on a called number may be provided in the environment depicted in FIG. 1 ;
FIG. 3A is a diagram illustrating an exemplary database;
FIG. 3B is a diagram illustrating exemplary data in the database according to the exemplary scenario depicted in FIGS. 2A-2C ;
FIG. 4 is a diagram illustrating exemplary components of a device that may correspond to one or more of the devices in the environment depicted in FIG. 1 ; and
FIGS. 5A and 5B are flow diagrams illustrating an exemplary process for providing local identity based on a called number.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. Also, the following detailed description does not limit the invention.
According to an exemplary embodiment, a network device receives a call setup message and replaces an existing calling number with a substitute calling number. The network device selects the substitute calling number based on the called number. For example, the substitute calling number may be a local telephone number relative to the called number. In this regard, the called party receiving the call will consider the calling party as having a local presence. Also, the calling party may be billed based on the substitute calling number.
According to an exemplary implementation, the call setup message may be a Session Initiation Protocol (SIP) invite message. According to other implementations, the call setup message may be message based on some other format and/or protocol (e.g., H.323, Extensible Markup Language Protocol (XMPP), Skinny Call Control Protocol (SCCP), Internet Protocol (IP), etc.). According to an exemplary implementation, the substitute calling number may be a screened telephone number (STN) or an unscreened telephone number to be delivered as an Automatic Number Identification (ANI).
FIG. 1 is a diagram illustrating an exemplary environment in which an exemplary embodiment for providing local identity based on a called number may be implemented. As illustrated, environment 100 includes enterprise sites 105 - 1 through 105 -X, in which X>1 (referred collectively as enterprise sites 105 or individually as enterprise site 105 ). Enterprise site 105 includes user devices 110 - 1 through 110 -V, in which V>1 (referred collectively as user devices 110 or individually as user device 110 ). As further illustrated, environment 100 includes an enterprise site 115 that includes a PBX 120 and a customer edge (CE) device 125 . Environment 100 also includes a trunking network (e.g., a SIP trunking network, etc.) deployed over a private IP/Multiprotocol Label Switching (PIP/MPLS) network 130 that includes provider edge (PE) devices 135 - 1 through 135 -S, in which S>1 (referred to collectively as provider edge devices 135 or individually as provider edge device 135 ), a network device 140 , a network device 145 , and a billing device 165 . Additionally, environment 100 includes a public switched telephone network 150 , and customer sites 155 - 1 through 155 -Y, in which Y>1 (referred to collectively as customer sites 155 or individually customer site 155 ) that include user devices 160 - 1 through 160 -W, in which W>1 (referred to collectively as user devices 160 or individually as user device 160 ).
The number of devices and the configuration in environment 100 are exemplary and provided for simplicity. According to other embodiments, environment 100 may include additional devices, fewer devices, different devices, and/or differently arranged devices, than those illustrated in FIG. 1 . Additionally, the number and type of networks in environment 100 are exemplary and provided for simplicity.
According to other embodiments, a single device in FIG. 1 may be implemented as multiple devices and/or multiple devices may be implemented as a single device. A device may be implemented according to a centralized computing architecture, a distributed computing architecture, or a cloud computing architecture. Additionally, a device may be implemented according to one or multiple network architectures (e.g., a client device, a server device, a peer device, or a combination thereof).
Also, according to other embodiments, one or more functions and/or processes described as being performed by a particular device may be performed by a different device, or some combination of devices. Environment 100 may be implemented to include wired and/or wireless connections among the devices illustrated.
Enterprise site 105 is a location associated with a company or a business. User device 110 includes a telephone. For example, the telephone may be implemented as a PBX telephone. According to an exemplary implementation, a user may be able to access PBX 120 , via user device 110 , on-site (e.g., enterprise site 105 ). According to another exemplary implementation, a user may be able to access PBX 120 , via user device 110 , off-site.
Enterprise site 115 is a location associated with a company or a business. PBX 120 includes a device that provides telephone switching service(s). According to an exemplary implementation, PBX 120 is an IP PBX. PBX 120 may serve as a common access point for calls. CE device 125 includes a network device that connects enterprise site 115 to PIP/MPLS network 130 . According to an exemplary implementation, CE device 125 is a customer edge router.
PIP/MPLS network 130 is a PIP/MPLS network. According to an exemplary implementation, PIP/MPLS network 130 includes a trunking network (e.g., SIP, etc.). PE device 135 includes a network device that connects PIP/MPLS network 130 to enterprise site 115 . According to an exemplary implementation, PE device 135 is a provider edge router.
Network device 140 includes a network device that provides a local identity based on a called number service. According to an exemplary implementation, network device 140 includes a device that hosts an application server. According to other implementations, network device 140 may be implemented as another type of network device (e.g., a PBX, a switch, etc.) that is in a call setup path. According to an exemplary implementation, network device 140 may provide a SIP trunking service.
Network device 145 includes a network device that connects PIP/MPLS network 130 to PSTN 150 . According to an exemplary implementation, network device 145 is a gateway device.
Billing device 165 includes a network device that collects and processes billing information. PSTN 150 includes a voice or a telephone network. According to an exemplary implementation, PSTN 150 is a traditional public circuit-switched telephone network.
Customer site 155 is a location associated with a user of user device 160 . User device 160 includes a telephone or other type of telephony device (e.g., a mobile device, etc.).
FIGS. 2A-2C illustrate an exemplary scenario in which local identity based on a called number may be provided in the environment depicted in FIG. 1 . Referring to FIG. 2A , assume that a user of user device 110 - 1 in enterprise site 105 - 1 places a telephone call to a user of user device 160 - 1 in customer site 155 - 1 . In this example, assume that enterprise site 105 - 1 is located in Seattle, Wash., enterprise site 115 is located in Austin, Tex. and customer site 155 - 1 is located Houston, Tex. Also, assume that the user of user device 110 - 1 is calling from 206-555-3456 and that the user of user device 160 - 1 has a telephone number of 713-555-2345.
As illustrated, a call message is transmitted from user device 110 - 1 located in Seattle, Wash. to enterprise site 115 . PBX 120 receives, for example, a call connect message that includes the calling number and the called number. According to an exemplary implementation, if the call connect message is not in a format for PIP/MPLS network 130 , PBX 120 may convert the call connect message to an IP-based message (e.g., a SIP invite message). Alternatively, a gateway (not illustrated) or CE 125 may convert the call message to an IP-based message or other suitable format. In this example, assume that a SIP invite message is transmitted to network device 140 via CE 125 and PE 135 . According to an exemplary implementation, the SIP invite message includes a Diversion header. According to another exemplary implementation, the SIP invite message does not include a Diversion header. According to yet another implementation, the SIP invite message may include another type of header (e.g., a history header, etc.) and/or other data/information field(s), which may be used to carry a billing number. According to this exemplary scenario, it may be assumed that the SIP invite message includes a Diversion header.
Referring to FIG. 2B , network device 140 analyzes the SIP invite message to perform a local identity service. According to an exemplary embodiment, network device 140 inspects the SIP invite message to identify the telephone number of the called party. According to an exemplary implementation, network device 140 identifies information included in the “To” SIP header. According to another implementation, network device 140 may identify information included in the Request-Line-URI that includes the URI of the destination. Network device 140 accesses a database to select an appropriate calling number. An exemplary database is described further below.
FIG. 3A is a diagram illustrating an exemplary database 300 . As illustrated, database 300 includes a “To” header field 305 , a “From” header field 310 , and a “Diversion” header field 315 .
“To” header field 305 indicates a telephone number of the called party. “To” header field 305 may indicate an entire telephone number (e.g. 10 digits) or a portion of a telephone number (e.g., 3 or more digits). “From” header field 310 indicates a telephone number of the calling party. As described further below, the telephone number in “From” header field 310 may serve as the telephone number that the calling party wants to use for the call. Additionally, in instances that, for example, the SIP invite message does not include a Diversion header, the telephone number in “From” header field 310 may be used for billing purposes. “Diversion” header field 315 indicates a telephone number to be used for billing purposes. For example, in instances that, for example, the SIP invite message includes a Diversion header, the telephone number in “Diversion” header field 315 will be used in the Diversion header.
According to other implementations, database 300 may include additional, fewer, and/or different data and/or information fields. For example, according to an exemplary implementation, each record may not include “Diversion” header field. Rather, the telephone number included in “From” header field may serve as both the billing telephone number and the calling party telephone number. Additionally or alternatively, for example, as previously described, according to implementations in which a database is used, depending on the protocols/formats used (e.g., H.323, etc.) suitable data/information fields may store corresponding data/information.
Referring back to FIG. 2B , as previously described, assume that the called telephone number is 713-555-1234. Also, assume that the SIP invite message includes a Diversion header. Network device 140 uses database 300 to select a calling number (e.g., a telephone number to be used in the From header of the SIP invite message) and a billing number (e.g., a telephone number to be used in the Diversion header of the SIP invite message). For example, in FIG. 3B , network device 140 uses the called number as a key for database 300 . For example, network device 140 compares at least 3 digits (e.g., 713, etc.) of the called number (e.g., 713-555-2345) to entries in “To” header fields 305 and identifies record 350 .
Referring to FIG. 2B , network device 140 replaces “2065553456” in the “From” header field of the SIP message with telephone number indicated in the “From” header field 310 of record 350 (e.g., 713300111@abc.com). Additionally, network device 140 replaces the telephone number in the Diversion header with the telephone number indicated in the “Diversion” header field 315 of record 350 (e.g., 7133001111@abc.com). In this example, the telephone numbers in “From” header field 310 and “Diversion” header field 315 of record 350 are the same. However, according to other records (e.g., record 355 ), the telephone numbers may be different and may be a customer preference. Network device 140 transmits the modified SIP message to network device 145 .
In this example, the modified SIP message is received by network device 145 . Referring to FIG. 2C , network device 145 may convert the modified SIP message to a PSTN compatible format. For example, network device 145 may generate and send a Signaling System #7 (SS7) ISDN user part (ISUP) initial address message (IAM) to PSTN 150 . The calling number and the called number are included in the ISUP initial address message. A switch (not illustrated) in PSTN 150 replies with an ISUP address complete message to network device 145 and a voice path is established between the user of user device 110 - 1 and the user of user device 160 - 1 . In this example, assume that the user of user device 160 - 1 has caller ID service. According to such an example, the user of user device 160 - 1 will see that the call originated from “7133001111,” which is a local telephone number. Additionally, as illustrated in FIG. 2C , network device 140 may send billing information to billing device 165 . The company will be charged for the call as if the call is a local call versus long distance. That is, the billing of the call is based on the 713-300-1111 telephone number.
According to other examples, the calling number may be of the same area code or area code and prefix as the called number. Network device 140 may perform a process similar to that described. For example, assume enterprise site 105 -X is located in the same city as customer site 155 -Y. According to an exemplary implementation, network device 140 may access database 300 and substitute telephone numbers in the Diversion and the From headers based on the called number. According to another example, the SIP invite message does not include the Diversion header. Network device 140 may perform a process similar to that described, except that the From header will serve as both the calling party number and the billing number. According to yet another example, the SIP invite message does not include the Diversion header. Network generates a Diversion header and may perform a process similar to that described.
FIG. 4 is a diagram illustrating exemplary components of a device 400 that may correspond to one or more of the devices in environment 100 . As illustrated, according to an exemplary embodiment, device 400 includes a processor 405 , memory/storage 410 storing software 415 , a communication interface 420 , an input 425 , and an output 430 . According to other embodiments, device 400 may include fewer components, additional components, different components, and/or a different arrangement of components than those illustrated in FIG. 4 and described herein.
Processor 405 includes one or multiple processors, microprocessors, data processors, co-processors, application specific integrated circuits (ASICs), controllers, programmable logic devices, chipsets, field-programmable gate arrays (FPGAs), application specific instruction-set processors (ASIPs), system-on-chips (SoCs), central processing units (e.g., one or multiple cores), microcontrollers, and/or some other type of component that interprets and/or executes instructions and/or data. Processor 405 may be implemented as hardware (e.g., a microprocessor, etc.), a combination of hardware and software (e.g., a SoC, an ASIC, etc.), may include one or multiple memories (e.g., memory/storage 410 ), etc.
Processor 405 may control the overall operation or a portion of operation(s) performed by device 400 . Processor 405 may perform one or multiple operations based on an operating system and/or various applications or programs (e.g., software 415 ). Processor 405 may access instructions from memory/storage 410 , from other components of device 400 , and/or from a source external to device 400 (e.g., a network, another device, etc.).
Memory/storage 410 includes one or multiple memories and/or one or multiple other types of storage mediums. For example, memory/storage 410 may include one or multiple types of memories, such as, random access memory (RAM), dynamic random access memory (DRAM), cache, read only memory (ROM), a programmable read only memory (PROM), a static random access memory (SRAM), a single in-line memory module (SIMM), a phase-change memory (PCM), a dual in-line memory module (DIMM), a flash memory, and/or some other type of memory. Memory/storage 410 may include a hard disk (e.g., a magnetic disk, an optical disk, a magneto-optic disk, a solid state disk, etc.), a Micro-Electromechanical System (MEMS)-based storage medium, and/or a nanotechnology-based storage medium. Memory/storage 410 may include drives for reading from and writing to the storage medium.
Memory/storage 410 may be external to and/or removable from device 400 , such as, for example, a Universal Serial Bus (USB) memory stick, a dongle, a hard disk, mass storage, off-line storage, or some other type of storing medium (e.g., a compact disk (CD), a digital versatile disk (DVD), a Blu-Ray® disk (BD), etc.). Memory/storage 410 may store data, software, and/or instructions related to the operation of device 400 .
Software 415 includes an application or a program that provides a function and/or a process. Software 415 may include firmware. Communication interface 420 permits device 400 to communicate with other devices, networks, and/or systems. Communication interface 420 may include a wireless interface and/or a wired interface. Communication interface 420 includes a transmitter, a receiver, and/or a transceiver. Communication interface 420 may operate according to one or multiple protocols, standards, and/or the like.
Input 425 provides an input into device 400 . For example, input 425 may include a keyboard, a mouse, a display, a touchscreen, a touchless screen, a button, a switch, an input port, speech recognition logic, and/or some other type of visual, auditory, tactile, etc., input component. Output 430 provides an output from device 400 . For example, output 430 may include a speaker, a display, a touchscreen, a touchless screen, a light, an output port, and/or some other type of visual, auditory, tactile, etc., output component.
Device 400 may perform processes and/or functions, as described herein, in response to processor 405 executing software 415 stored by memory/storage 410 . By way of example, the instructions may be read into memory/storage 410 from another memory/storage 410 or from another device via communication interface 420 . The instructions stored by memory/storage 410 may cause processor 405 to perform one or more processes described herein. Alternatively, for example, according to other implementations, device 400 may perform one or more processes described herein based on the execution of hardware (processor 405 , etc.), the execution of firmware with hardware, or the execution of software and firmware with hardware.
FIGS. 5A and 5B are flow diagrams illustrating an exemplary process for providing local identity based on a called number. According to an exemplary embodiment, network device 140 performs process 500 . For example, processor 405 may execute software 415 to perform the steps described.
Referring to FIG. 5A , in block 505 , a SIP message is received. For example, network device 140 receives a SIP invite message pertaining to a telephone call. According to an exemplary implementation, the SIP message does not includes a Diversion header. According to another implementation, the SIP message includes a Diversion header.
In block 510 , a called number is identified. For example, network device 140 inspects a To field of the SIP header included in the SIP invite message.
In block 515 , it is determined whether the SIP message includes a Diversion header. For example, network device 140 inspects the SIP message to identify whether a Diversion header is present. According to other implementations, network device 140 may determine whether the SIP message includes a Diversion header based on other factors (e.g., network address of PBX 120 and/or CE 125 , etc.).
If it is determined that the SIP message includes the Diversion header (block 515 -YES), a billing number based on the called number is inserted (block 520 ). For example, network device 140 uses database 300 to select a telephone number for the Diversion header. Network device 140 inserts the selected telephone number in the Diversion header included in the SIP message.
In block 525 , a calling number is inserted. For example, network device 140 uses database 300 to select a telephone number (e.g., a calling party number) based on the called number and/or the billing number. Network device 140 inserts the selected telephone number in the From header of the SIP message.
If it is determined that the SIP message does not include the Diversion header (block 515 -NO), a billing number based on the called number is inserted (block 530 ). For example, network device 140 uses database 300 to select a telephone number for the From header. Network device 140 inserts the selected telephone number in the From header included in the SIP message.
In block 535 , a modified SIP message is forwarded. For example, network device 140 transmits the modified SIP invite message to network device 145 . Network device 145 processes the modified SIP invite message for receipt by PSTN 150 .
Referring to FIG. 5B , in block 540 , billing information based on the billing number or the calling number is sent. For example, network device 140 sends billing information to billing device 165 . Depending on whether the SIP message includes the Diversion header, the billing information is based on the billing number included in the Diversion header or the calling number included in the From header of the SIP message. The call is billed based on the billing number of the calling number.
Although FIGS. 5A and 5B illustrate an exemplary process 500 to provide local identity based on the called number, according to other embodiments, process 500 may include additional operations, fewer operations, and/or different operations than those illustrated in FIGS. 5A and 5B and described herein. For example, although process 500 is described in relation to the Session Initiation Protocol, according to other embodiments, process 500 may include different operations if other protocols and/or formats are used. Additionally, according to other embodiments, PBX 120 or some other network device in a calling path may perform one or more steps of process 500 .
The foregoing description of embodiments provides illustration, but is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Accordingly, modifications to the embodiments described herein may be possible.
The terms “a,” “an,” and “the” are intended to be interpreted to include one or more items. Further, the phrase “based on” is intended to be interpreted as “based, at least in part, on,” unless explicitly stated otherwise. The term “and/or” is intended to be interpreted to include any and all combinations of one or more of the associated items.
In addition, while a series of blocks has been described with regard to the process illustrated in FIGS. 5A-5B , the order of the blocks may be modified according to other embodiments. Further, non-dependent blocks may be performed in parallel. Additionally, other processes described in this description may be modified and/or non-dependent operations may be performed in parallel.
The embodiments described herein may be implemented in many different forms of software, firmware, and/or hardware. For example, a process or a function may be implemented as “logic” or as a “component.” This logic or this component may include hardware (e.g., processor 405 , etc.), a combination of hardware and software (e.g., software 415 ), a combination of hardware and firmware, or a combination of hardware, firmware, and software. The embodiments have been described without reference to the specific software code since software can be designed to implement the embodiments based on the description herein.
In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded as illustrative rather than restrictive.
In the specification and illustrated by the drawings, reference is made to “an exemplary embodiment,” “an embodiment,” “embodiments,” etc., which may include a particular feature, structure or characteristic in connection with an embodiment(s). However, the use of the phrase or term “an embodiment,” “embodiments,” etc., in various places in the specification does not necessarily refer to all embodiments described, nor does it necessarily refer to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiment(s). The same applies to the term “implementation,” “implementations,” etc.
No element, act, or instruction described in the present application should be construed as critical or essential to the embodiments described herein unless explicitly described as such.
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Methods, devices, and storage media provide for receiving a message pertaining to a telephone call set-up; identifying in the message a called telephone number; selecting a calling telephone number based on the called telephone number; replacing a calling telephone number included in the message with the selected calling telephone number; and transmitting the message that includes the selected calling telephone number.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to a vehicle exhaust system, and more particularly to a system and method for cooling exhaust gasses before exiting the vehicle exhaust system.
[0002] Recent emissions regulations for vehicles employing diesel engines limit the amount of soot that the vehicles may emit. The soot is produced as a by-product of the combustion of the diesel fuel and is carried out with the vehicle exhaust. Diesel particulate filters (also called traps) added to the exhaust system limit the soot emissions sufficiently to meet the regulations.
[0003] Diesel particulate filters work by collecting the soot while allowing the exhaust gasses to pass through. As the vehicle operates, then, the soot builds up in the filter. This soot needs to be periodically eliminated from the filter in order to assure that the filter does not become clogged. A clogged filter can potentially cause damage to itself or the engine. The soot that builds up in the filter can be removed through a process called regeneration.
[0004] Regeneration is performed by heating the diesel particulate filter to a high temperature so the soot will burn away, thus cleaning out the filter. However, during regeneration, the heat used to cause the regeneration process causes the exhaust gasses to be expelled out of the tailpipe at higher temperatures than is desirable. Thus, it is desirable to cool the high temperature exhaust gasses—especially those that occur during regeneration—before they are expelled from the exhaust system.
SUMMARY OF THE INVENTION
[0005] An embodiment contemplates an exhaust gas cooler for use with a tailpipe of a vehicle exhaust system. The exhaust gas cooler comprises a cooler housing having a substantially cylindrical shape with an open forward edge, an open rearward edge, and an inner diameter that is adapted to be larger than an exterior diameter of the tailpipe; and a cooler support attached to the cooler housing and adapted to support the cooler housing such that a rearward edge of the tailpipe is located within the cooler housing between the forward and rearward edges of the cooler housing.
[0006] An embodiment contemplates an exhaust system for a vehicle having an engine. The exhaust system may include a tailpipe having an outlet at a rearward edge and having an external diameter adjacent to the rearward edge; and an exhaust gas cooler including a cooler housing having a substantially cylindrical shape with an open forward edge, an open rearward edge, and an internal diameter that is larger than the external diameter of the tailpipe, and a cooler support attached to and supporting the cooler housing such that the rearward edge of the tailpipe is located within the cooler housing between the forward and rearward edges of the cooler housing.
[0007] An embodiment contemplates a method of cooling exhaust gasses produced by a vehicle engine before the exhaust gasses are discharged from a vehicle exhaust system, the method comprising the steps of: providing an exhaust gas cooler around a rearward edge of a tailpipe such that the exhaust gas cooler includes a cooler housing having a rearward edge and a forward edge, with the rearward edge of the tailpipe being located between the rearward and forward edges of the cooler housing; operating the engine, causing the exhaust gasses to flow from an outlet on the rearward edge of the tailpipe; drawing ambient air into the exhaust gas cooler; mixing the exhaust gasses and the ambient air; and expelling an exhaust gas/ambient air mixture out of the rearward edge of the cooler housing.
[0008] An advantage of an embodiment is that the exhaust gas cooler mixes hot exhaust gasses with cooler air, thus lowering the temperature of the exhaust gasses before they are expelled from the exhaust system. This is particularly advantageous for vehicles having a diesel particulate filter that needs to be regenerated from time to time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustration of a vehicle with a diesel engine, and a portion of an exhaust system for the vehicle.
[0010] FIG. 2 is a schematic side view of an exhaust gas cooler and a portion of a tailpipe, without cooler supports shown.
[0011] FIG. 3 is a schematic end view of the exhaust gas cooler and tailpipe, without cooler supports shown.
[0012] FIG. 4 is a section cut, on an enlarged scale, taken along line 4 - 4 in FIG. 3 .
[0013] FIG. 5 is a schematic end view of the exhaust gas cooler and tailpipe, without the cross vane assembly shown.
[0014] FIG. 6 is a schematic end view of the cross vane assembly.
DETAILED DESCRIPTION
[0015] FIG. 1 illustrates a vehicle 10 having an engine, which may be a diesel engine 14 , mounted therein. The diesel engine 14 drives a transmission 16 , which, in turn, drives a vehicle driveline 18 , and, ultimately, vehicle wheels.
[0016] An exhaust system 24 receives exhaust gasses 22 from the diesel engine 14 , treats the exhaust gasses 22 , and directs them into the atmosphere away from the vehicle 10 . More specifically, an exhaust pipe 28 connects at an upstream end to conventional exhaust system hardware (not shown), such as, for example, a turbocharger (not shown), that receives exhaust from exhaust manifolds (not shown) on the engine 14 . The exhaust pipe 28 directs the exhaust gases 22 into a diesel oxidation converter 30 (also known as a diesel oxidation catalyst). The diesel oxidation converter 30 treats the exhaust gases 22 in order to reduce the amounts of certain constituents that will be emitted into the atmosphere. Such constituents may be, for example, carbon monoxide (CO) and unburned hydrocarbons (HC).
[0017] A first intermediate pipe 32 connects to the downstream end of the diesel oxidation converter 30 and directs the exhaust gasses 22 into a diesel particulate filter 34 (also called a diesel particulate trap). The diesel particulate filter 34 is basically a filter for collecting (i.e., trapping) soot (also called diesel particulate matter) from the exhaust in order to minimize the amount of soot in the exhaust gasses 22 . Downstream of the diesel particulate filter 34 is a second intermediate pipe 36 . The second intermediate pipe 36 directs the exhaust gasses 22 into a muffler 38 . Alternatively, the exhaust system 24 has no muffler or second intermediate pipe and the diesel particulate filter 34 directs the exhaust gasses 22 directly into a tailpipe (discussed below). The vehicle and its components discussed above are known to those skilled in the art and so will not be discussed or shown in more detail herein.
[0018] The muffler 38 directs the exhaust flow into an inlet 42 of a tailpipe 40 . The tailpipe 40 includes an outlet 44 . Near the outlet 44 , the tailpipe 40 connects to and supports an exhaust gas cooler 50 . The exhaust gas cooler 50 includes an open rearward edge 52 , which extends rearward past the tailpipe 40 . The open rearward edge 52 is where an exhaust gas/ambient air mixture 26 are emitted into the atmosphere away from the vehicle 10 .
[0019] FIGS. 2-6 illustrate the exhaust gas cooler 50 , and its attachment to the tailpipe 40 in more detail. The exhaust gas cooler 50 includes a generally cylindrical cooler housing 54 having an open forward edge 56 and the open rearward edge 52 . The cooler housing 54 has an internal diameter 55 that is substantially larger than an external diameter 48 of the tailpipe 40 . For example, the internal diameter 55 of the cooler housing 54 may be about one-and-one-half to two-and-one-half times the external diameter 48 of the tailpipe 40 . Because of this difference in diameters, there is an opening 64 on the forward edge 56 all of the way around the tailpipe 40 .
[0020] The tailpipe 40 is coaxial with the cooler housing 54 , and has a tailpipe rearward edge 46 that extends past the cooler housing forward edge 56 in order to create some axial overlap. For example, the rearward edge 46 may extend between about one-quarter and one-half of the way into the cooler housing 54 toward the housing rearward edge 52 .
[0021] The cooler housing 54 may be mounted on and aligned with the tailpipe 40 with cooler supports, which are illustrated in this embodiment as threaded fasteners 60 and corresponding nuts 62 . A first set of nuts 62 may be used to press against the tailpipe 40 , while a second and third set of nuts 62 are adjusted on the fasteners 60 to align and support the cooler housing 54 relative to the tailpipe 40 . Alternatively, the cooler supports may be one or more brackets (not shown) attached between the cooler housing 54 and tailpipe 40 to align and support the exhaust gas cooler 50 relative to the tailpipe. The brackets may be secured between the components by welding, with adhesive, or with fasteners. As another alternative, although not considered as desirable for alignment purposes, the exhaust gas cooler 50 may have cooler supports (not shown) mounted to vehicle structure (not shown) to hold the cooler housing 54 at the proper location and orientation relative to the tailpipe 40 .
[0022] The exhaust gas cooler 50 may also include a cross vane assembly 66 that mounts inside the cooler housing 54 adjacent to the rearward edge 46 of the tailpipe 40 . The cross vane assembly 66 may include four vanes 68 . Each vane 68 may have an angled vane blade portion 70 for redirecting flow (discussed below), and an attachment flange 72 for mounting the cross vane assembly 66 to the inside of the cooler housing 54 . The attachment flanges 72 may be secured to the cooler housing 54 by welding. Alternatively, the attachment flanges may be secured by adhesive, interference fit, fasteners (not shown), or other suitable means.
[0023] The operation of the exhaust gas cooler 50 , in view of FIGS. 1-6 , will now be discussed. When the vehicle engine 14 is running, the exhaust gasses 22 produced by the engine 14 flow through the exhaust pipe 28 , diesel oxidation converter 30 , first intermediate pipe 32 , diesel particulate filer 34 (where particulates are trapped), second intermediate pipe 36 , and muffler 38 . From the muffler 38 , the exhaust gasses 22 flow through the tailpipe 40 and the exhaust gas cooler 50 and out into the atmosphere.
[0024] As the exhaust gasses 22 flow out through the outlet 44 on the rearward edge 46 of the tailpipe 40 and into the cooler 50 , they create a vacuum around the rearward edge 46 . This vacuum causes ambient air 23 to be drawn in through the opening 64 (around the tailpipe 40 ) at the forward edge 56 of the cooler 50 . This ambient air 23 , then, moves through the cooler 50 with the exhaust gasses 22 and exits the cooler 50 at its open rearward edge 52 as the exhaust/air mixture 26 . The ambient air 23 absorbs some of the heat energy of the exhaust gasses 22 as they are mixed, thereby lowering the energy level of the exhaust gasses 22 and raising the energy level of the ambient air 23 . The overall temperature of the exhaust/ambient air mixture 26 exiting the exhaust gas cooler 50 , then, is lower than the exhaust gasses 22 as they exit the tailpipe 40 . The end result is a lower overall temperature of the mixture 26 exiting the vehicle 10 to the atmosphere, distributed through the larger diameter opening of the cooler 50 .
[0025] In addition, the exhaust gas cooler 50 may also contain the cross vane assembly 66 . The cross vane assembly 66 will create somewhat of a swirl flow pattern, which helps to better mix the exhaust gasses 22 with the lower temperature ambient air 23 as they flow through the exhaust gas cooler 50 . This may allow the ambient air 23 to more thoroughly absorb heat energy from the exhaust gasses 22 since they are better mixed, thereby more evenly lowering the temperature of the exhaust gasses 22 and raising the temperature of the ambient air 23 . The effective result is a lower temperature mixture 26 more evenly distributed through the larger diameter opening at the rearward edge 52 of the cooler 50 .
[0026] The exhaust gas cooler 50 is particularly advantageous for the vehicle 10 having the diesel engine 14 and the exhaust system 24 that employs the diesel particulate filter 34 . The regeneration process for the filter 34 can cause the temperature of the exhaust gas 22 to rise significantly over normal operating conditions. Accordingly, the exhaust gas cooler 50 , by mixing the very hot exhaust gasses 22 with the ambient air 23 , will help lower these very high temperatures before exiting the exhaust system 24 of the vehicle 10 . Although the exhaust gas cooler 50 may be most advantageous when employed with a vehicle having a diesel engine, the exhaust gas cooler can be employed with vehicles having different types of engines.
[0027] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.
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The invention concerns an exhaust gas cooler employed with a tailpipe of a vehicle exhaust system and a method of cooling exhaust gasses before being emitted from the exhaust system into the atmosphere. The exhaust gas cooler may include a cooler housing having a substantially cylindrical shape with an open forward edge, an open rearward edge, and an internal diameter that is larger than the external diameter of the tailpipe, and a cooler support attached to and supporting the cooler housing such that the rearward edge of the tailpipe is located within the cooler housing between the forward and rearward edges of the cooler housing.
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PRIORITY CLAIM
[0001] The present application claims priority to U.S. Provisional Application Ser. No. 61/367,984 entitled “Multi Packaging System for Medical Implants” filed on Jul. 27, 2010 to Urs Hulliger. The entire contents of this application are incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a multi packaging system for packaging of sterile implants comprising a carrier plate with several individual packings which are fixed to the carrier plate as separate units. Therefore, the present invention permits a user to organize the various implants with regard to their places of use and to order the implants with regard to their sizes and product specifications. According to the present invention, the implants may be arranged on a carrier plate, which can be deposited in a box in a manner such that the user can easily find a specific type and size of implant in a short amount of time. Furthermore, the implants are ordered on a short radius in a depositing system whereas otherwise the implants would be deposited in various ways.
BACKGROUND
[0003] The storage and accessibility of medical implants (e.g., in an operating room) can help to facilitate the sorting, storing, locating and handling of the implants. Currently, implants are individually deposited in a box positioned on a board in a drawer. To locate a desired implant, the user must read a label on each drawer. This system of depositing may be time-consuming and may require a large area of space.
[0004] A multi packaging system is known from the German Utility Patent No. DE 20 2005 016 818 U1. This multi packaging system has the disadvantage that each individual packing is fixed to a separate cardboard stripe by means of a blister and the entirety of individual packings is separately and loosely inserted in a folding pouch.
[0005] Another multi packaging system is known from the U.S. Pat. No. 5,249,672. This known multi packaging system has the disadvantage that the objects are not fixed on the (carrier) object but are retained by means of three straight plates. This system would be unsuitable for medical use since objects must be sterilized prior to surgical use. Furthermore, the objects are packaged in a folded cardboard, thus preventing the user from seeing how many objects are available therewithin. Furthermore, this system hinders access to the objects through the opening between the straight plates.
[0006] A further multi packaging system is known from the U.S. Pat. No. 5,386,912. This known multi packaging system has the disadvantage that the individual objects are only trapped on the carrier-object but not fixed thereto. In this alternative the complete system is inserted in a folded cardboard, thus having the same disadvantage discussed above with respect to U.S. Pat. No. 5,249,672.
[0007] A further multi packaging system is known from the U.S. Pat. No. 4,121,711. This known multi packaging system is also fixed on a folding card, thus also having the same disadvantages discussed above. Specifically, by virtue of the objects being fixed on a folded card, a user is unable to quickly or easily determine how many objects remain on the packaging system.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a multi packaging system for packaging of sterile implants comprising a carrier plate and N individual packings, wherein N≧2 and wherein said individual packings are attached to said carrier plate as units whereof each unit can be removed from said carrier plate without being opened.
[0009] According to an exemplary embodiment of the present invention, the carrier plate is quadrangular and has four edges, wherein the N individual packing are fixed separately adjacent to one of the edges of the carrier plate. One of the advantages of the multi packaging system according to the present invention is that due to the separate fixation of each individual packing to the carrier plate after removal of one packing the remaining packings are still fixed to the carrier plate and therefore the remaining packings do not drop out from a carrier device.
[0010] According to another exemplary embodiment of the present invention, the packings can be removed separately from each other and without being opened by means of a tear-off strip. This allows the remaining packings to remain fixed on the carrier plate although one single packing is removed via the tear-off strip.
[0011] According to another exemplary embodiment, the carrier plate is configured like an index card. This configuration allows easier handling and tracking for storage, identification and ordering purposes.
[0012] According to another exemplary embodiment said carrier plate comprises continuous numbering with one number located underneath each individual packing on the carrier plate. This configuration allows the user to easily determine how many packings remain on the carrier plate which facilitates the determination of when to order a new multi packaging system.
[0013] According to another exemplary embodiment the carrier plate has a legend strip on the top edge. This configuration allows the advantage that each carrier plate can be printed with the object and size or other description of its content. Furthermore, if there are several different carrier plates they can be sorted in series and the user can find the searched carrier plate at one glance.
[0014] According to another exemplary embodiment the carrier plate features P≧1 holes through the carrier plate on a free space on the carrier plate which is not covered by the packings. This configuration allows the advantage that the carrier plate can be inserted in a ring binder or something similar.
[0015] According to another exemplary embodiment a bar code is printed on the carrier plate, preferably under the second last or last individual packing. This configuration may allow an easy and efficient method of ordering a new carrier plate.
[0016] According to another exemplary embodiment the N packings are fixed to said carrier plate at their top edge by means a non-metallic strap and adjacent to one of the edges of said carrier plate in a longitudinal orientation, separate from each other and side by side. This configuration may allow the fixation of all packings on the carrier plate is assured.
[0017] According to another exemplary embodiment the N packings are fixed to the carrier plate at their top edges by means of an adhesive, such as glue, and adjacent to one of the edges of the carrier plate in a longitudinal orientation, separate from each other and side by side. This configuration may allow the packings to be fixed separate from each other or together via the adhesive.
[0018] According to another exemplary embodiment the N packings are fixed to the carrier plate at their top edges by means of a hot stamping method and adjacent to one of the edges of said carrier plate in a longitudinal orientation, separate from each other and side by side. This configuration allows the advantage that an easy method is provided for fixing plastic packings to a carrier plate which is not made of a metal.
[0019] According to another exemplary embodiment said multi packaging system comprises M≧2 carrier plates. This configuration may allow the multi packaging system to be configured as an extensive folder system when there is more than one carrier plate.
[0020] According to another exemplary embodiment the carrier plate can be attached via the hole to a mechanical paternoster conveying system. This configuration may allow multiple carrier plates to be inserted in a computer guided mechanical system which can control of the location of each carrier plate. This allows the user to search for a carrier plate and to have the searched carrier plate delivered to a specific location so that the user can easily access the carrier plate and remove a packing from the carrier plate for use.
[0021] According to another exemplary embodiment a paternoster conveying system recognizes a carrier plate by a bar code. This configuration may allow the user to enter the number represented by the bar code into the computer in order to search for and acquire a specific carrier plate.
[0022] According to another exemplary embodiment said carrier plate has a front side and a rear side and wherein said N individual packings are attached only to said front side and wherein said rear side is preferably used for receiving a bar code or other identification and administration means. This configuration may allow for easy ordering and/or a computerized searching database.
[0023] According to another exemplary embodiment said carrier plate has a front side and a rear side and wherein said N individual packings are attached to both of said sides. This configuration may allow a carrier plate to be loaded with twice the number of packings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Several exemplary embodiments of the present invention will be described in the following by way of example and with reference to the accompanying drawings in which:
[0025] FIG. 1 illustrates a top view of an exemplary embodiment of the multi packaging system according to the present invention;
[0026] FIG. 2 illustrates a top view on an exemplary embodiment of FIG. 1 of the multi packaging system according to the present invention showing printed numbers underneath each of the individual packings on the carrier plate; and
[0027] FIG. 3 illustrates a top view on an exemplary embodiment of FIG. 1 of the multi packaging system according to the present invention with a printed bar code.
DETAILED DESCRIPTION
[0028] The present invention relates to a packaging system for medical implants. The exemplary packaging system provides a plurality of individually packaged implants that are fixed to a carrier plate, the carrier plate being configured to permit a physician or other user to remove individual implants. The carrier plate is also provided with labels indicating a number of remaining implants on the carrier plate, thus providing the physician with a quick reading of the number of implants to facilitate performing of a particular procedure, as those skilled in the art will understand.
[0029] FIGS. 1-3 illustrate an exemplary embodiment including a multi packaging system 1 comprising N number of sterile individual packings 2 fixed to a carrier plate 9 . Each of the individual packings 2 may contain an implant such as, for example, a bone fixation element. The multi packaging system 1 may comprise more than one carrier plate 9 such that each carrier plate 9 holds packings 2 containing implants of a particular type and/or size. For example, a first carrier plate 9 may hold packings 2 containing bone fixation screws that are 40 mm in length while a second carrier plate 9 (not shown) may hold packings 2 containing bone fixation screws that are 42 mm in length. The carrier plate 9 may be quadrangular having four straight edges 10 , similar to an index card, for example. The carrier plate 9 may include a legend strip or tab 5 along one edge 10 so that the specific type and/or size of the implant may be indicated thereon. The carrier plate 9 may include at least one hole 6 through a free space of the carrier plate 9 , that is not covered by any of the packings 2 , for insertion in a ringed binder or other similar device. It will be understood by those of skill in the art that a quadrangular carrier plate 9 permits efficient organization of the packings 2 and ease of storage of the carrier plates 9 . It will be understood by those of skill in the art, however, that the carrier plate 9 may be any of a variety of shapes so long as the carrier plate permits individual packings 2 to be affixed thereto.
[0030] The individual packings 2 may be fixed to the carrier plate 9 independently of one another via a non-metallic strap 3 adjacent to an edge 10 of the carrier plate 9 . The individual packings 2 may be positioned side by side on the carrier plate 9 , in a longitudinal orientation such that the non-metallic strap 3 fixes a first end of each of the individual packings 2 to the carrier plate 9 . The non-metallic strap 3 may be torn off to permit the packings 2 to be individually removed from the carrier plate 9 and without having to open the individual packings 2 . Alternatively, the individual packings 2 may be fixed to the carrier plate 9 via any other known fixation process such as, for example, using an adhesive material (e.g. glue) or a hot stamping method. The packings 2 may include a perforated strip 4 along a portion thereof for opening the packings 2 after the packings 2 have been removed from the carrier plate 9 .
[0031] The carrier plate 9 may include a continuous numbering 7 printed thereon, underneath the individual packings 2 such that the numbering 7 indicates a number of packings 2 remaining on the carrier plate 9 as each of the packings 2 are removed therefrom. For example, a carrier plate 9 holding twelve packings 2 may be printed with continuous Arabic numerals “ 11 ” to “ 1 ” from left to right such that the numerals are revealed as each of the packings 2 are removed from the carrier plate 9 . As shown in FIG. 2 , for example, four packings 2 have been removed thus far, revealing numerals “11” to “8” and indicating that “8” packings remain. The remaining numbers “7” to “1” are printed underneath the remaining individual packings 2 on the carrier plate 9 and are revealed as each additional packing 2 is removed from the carrier plate 9 . The continuous numbering 7 shown in FIG. 2 has been printed to facilitate removal of the packings 2 from left to right. It will be understood by those of skill in the art, however, that the continuous numbering 7 may also be printed for removal of the packings 2 from right to left.
[0032] As shown in FIG. 3 , the carrier plate 9 may also include a barcode 8 printed thereon, the barcode 8 corresponding to the particular type and/or size of the implants held on the carrier plate 9 . Thus, when a limited number of packings 2 remain on the carrier plate 9 , the barcode 8 may simply be scanned to order additional implants of that particular type and/or size. The barcode 8 may be printed in a desired location on the carrier plate 9 such that visibility of the barcode 8 indicates that it is time to order additional implants. It will be understood by those of skill in the art that the barcode 8 may be used in a variety of different ways to track inventory.
[0033] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, composition of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention.
[0034] It will be appreciated by those skilled in the art that various modifications and alterations of the invention can be made without departing from the broad scope of the appended claims. Some of these have been discussed above and others will be apparent to those skilled in the art.
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A multi packaging system for packaging of sterile implants includes a carrier plate and a plurality of packings removably attached to the carrier plate. Each of the plurality of packings contains an implant and is individually removable from the carrier plate.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to methods of preparing 7-substituted camptothecin compounds and 7-substituted camptothecin analogs. Camptothecin (CPT) and CPT analogs have been reported to inhibit the enzyme topoisomerase I and have in vitro and in vivo anticancer activity. It has been shown that a large number of substituents can be placed at C7 of CPT without loss of activity (Redinbo et al., Science 279, 1504-1513, 1998).
[0003] 2. Background of the Invention
[0004] Camptothecin (CPT) is a naturally occurring cytotoxic alkaloid which is known to inhibit the enzyme topoisomerase I and is a potent anti-tumor agent. Camptothecin compounds have the general ring structure shown below.
[0005] Camptothecin was isolated from the wood and bark of Camptotheca acuminata by Wall et al. (Wall et al., 1966, J. Am. Chem. Soc., 88:3888).
[0006] Major synthetic efforts have been directed to derivatizing the B-ring at C7 to improve cytotoxic and in vivo activity.
[0007] The cytotoxic activity of camptothecin compounds is believed to arise from the ability of these compounds to inhibit both DNA and RNA synthesis and to cause reversible fragmentation of DNA in mammalian cells. Topoisomerase I relaxes both positively and negatively supercoiled DNA and has been implicated in various DNA transactions such as replication, transcription and recombination. The enzyme mechanism is believed to involve a transient breakage of one of the two DNA strands and the formation of a reversible covalent topoisomerase I enzyme-DNA complex. Camptothecin interferes with the DNA breakage-reunion reaction by reversibly trapping the enzyme-DNA intermediate termed the “cleavable complex.” The cleavable complex assay is a standard test for determining the potential and in vivo cytotoxic activity of camptothecin compounds. The high levels of topoisomerase I in several types of human cancer and the low levels in correspondingly normal tissue provide the basis for tumor treatment with biologically active camptothecin analogs.
[0008] U.S. Pat. No. 4,894,456 describes methods of synthesizing camptothecin compounds which act as inhibitors of topoisomerase I and are effective in the treatment of leukemia (L-1210). U.S. Pat. No. 5,225,404 discloses methods of treating colon tumors with camptothecin compounds.
[0009] Numerous camptothecin compounds and their use as inhibitors of topoisomerase I are reported by U.S. Pat. Nos. 5,053,512; 4,981,968; 5,049,668; 5,106,742; 5,180,722; 5,244,903; 5,227,380; 5,122,606; 5,122,526; and 5,340,817.
[0010] U.S. Pat. No. 4,943,579 discloses the esterification of the hydroxyl group at the 20-position of camptothecin to form several prodrugs. This patent further discloses that the prodrugs are water soluble and are converted into the parent camptothecin compounds by hydrolysis.
[0011] Wall et al. U.S. Pat. Nos. 5,646,159 and 5,916,892 disclose C 20 amino acid esters of CPT compounds.
[0012] Wall et al. U.S. Pat. No. 5,932,588 disclose CPT compounds bearing a C7 methylene leaving groups at C 7 such as —CH 2 L where L is Cl, Br, I, —OSO 2 CH 3 , —OSO 2 C 6 H 4 —CH 3 , etc.
[0013] Brangi et al., Cancer Research , 59, 5938-5946 Dec. 1, 1999, report an investigation of Camptothecin resistance in cancer cells and report the compound difluoro-10,11-methylenedioxy-20(S)-camptothecin and several C7-substituted compounds.
[0014] A need continues to exist, however, for a method of preparing 7-substituted camptothecin compounds. Refs: Du et al., Biorg. and Med. Chem . 10, 103-110 (2002); Dallavalle et al., J. Med. Chem . 44, 3264-3274 (2001).
[0015] The procedure of Sawada et al., Chem. Pharm. Bull . 39, 2574-2580 (1991) for preparing 7-alkyl compounds gives adequate yields for C 1-3 alkyl compounds; however, the yields for C 4 , C 5 , C 6 -alkyl rapidly become poor. We have discovered a novel way of preparing a large variety of alkyl and aryl C 7 -substituted compounds in excellent yields by the reaction of an orthoaminobenzonitrile or appropriately substituted orthoaminobenzonitrile with a large variety of organometallic reagent which will be described in detail in this application.
SUMMARY OF THE INVENTION
[0016] Accordingly, one object of the present invention is to provide a method of preparing 7-substituted camptothecin compounds in excellent yield and which cannot be prepared by Sawada et al. procedure (Sawada et al., Chem. Pharm. Bull . 39, 2574-2580 (1991)) which will be widely applicable to a large number of 7-substituents.
[0017] Another object of the present invention is to provide 7-substituted camptothecin compounds which cannot be made by the Sawada et al. procedure which include a variety of 7-substituents like sec-butyl, tert-butyl, cyclopentyl, p-fluorophenyl, p-tolyl, p-trifluoromethylphenyl, etc.
[0018] Another object of this invention is to prepare lipophilic camptothecin compounds with various substituents at the 7 position.
[0019] Another object of the present invention is to provide a method of treating leukemia or solid tumors in a mammal in need thereof by administration of 7-substituted camptothecin compounds.
[0020] Another object of the present invention is to provide a method of inhibiting the enzyme topoisomerase I and/or alkylating DNA of associated DNA-topoisomerase I by contacting a DNA-topoisomerase I complex with a 7-substituted camptothecin compound.
[0021] These and other objects of the present invention are made possible by a synthetic method for the preparation of 7-substituted camptothecin compounds of formula (I) or (II):
[0022] where
[0023] X is H; NH 2 ; F; Cl; Br; alkyl; O—C 1-6 alkyl; NH—C 1-6 alkyl; N(C 1-6 alkyl) 2 ; or C 1-8 alkyl;
[0024] or X is —Z—(CH 2 ) a —N—(C 1-6 alkyl) 2 wherein Z is selected from the group consisting of O, NH and S, and a is an integer of 2 or 3;
[0025] or X is —CH 2 NR 2 R 3 , where (a) R 2 and R 3 are, independently, hydrogen, C 1-6 alkyl, C 3-7 cycloalkyl, C 3-7 cycloalkyl-C 1-6 alkyl, C 2-6 alkenyl, hydroxy-C 1-6 alkyl, C 1-6 alkoxy-C 1-6 COR 4 where R 4 is hydrogen, C 1-6 alkyl, perhalo-C 1-6 alkyl, C 3-7 cycloalkyl, C 3-7 cycloalkyl-C 1-6 alkyl, C 2-6 alkenyl, hydroxy-C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkoxy-C 1-6 alkyl, or (b) R 2 and R 3 taken together with the nitrogen atom to which they are attached form a saturated 3-7 membered heterocyclic ring which may contain a O, S or NR 5 group, where R 5 is hydrogen, C 1-6 alkyl, alkyl, aryl, aryl substituted with one or more groups selected from the group consisting of C 1-6 alkyl, amino, C 1-6 alkylamino, alkyl, C 1-6 alkoxy, C 1-6 alkoxy-C 1-6 alkyl and alkyl, C 1-6 alkoxy, aryl, and aryl substituted with one or more C 1-6 alkyl, C 1-6 alkyl, or C 1-6 alkoxy-C 1-6 alkyl groups;
[0026] R is C 1-30 alkyl, substituted C 1-30 alkyl, C 1-30 alkenyl, substituted C 1-30 alkenyl, C 1-30 alkynyl, substituted, C 1-30 alkynyl, C 3-30 cycloalkyl, substituted C 3-30 cycloalkyl, C 6-18 aryl, substituted C 6-18 aryl, C 6-18 aryalkyl, (C 1-30 alkyl) 3 silyl, (C 1-30 alkyl) 3 silyl C 1-30 alkyl,
[0027] Y is independently H or F, and
[0028] n is an integer of 1 or 2,
[0029] and salts thereof
[0030] comprising:
[0031] i) reacting ortho amino cyano aromatic compound of formula (III) or (IV)
[0032] with an organometallic reagent R -M and
[0033] ii) condensing a resulting product with a 20(S)tricyclic ketone of formula (VII)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Unless indicated to the contrary, the term “alkyl” as used herein means a straight-chain or branched chain alkyl group with 1-30, preferably 1-18 carbon atoms, more preferably 1-8 carbon atoms, including methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, n-hexyl, n-heptyl, n-octyl, 2-ethylhexyl, n-nonyl, n-decyl, undecyl, dodecyl, myristyl, heptadecyl and octadecyl groups. Unless otherwise indicated, the term “alkyl” also includes C 3-30 cycloalkyl groups such as cyclopropyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl groups.
[0035] “Substituted” means substituted with one or more heteroatom(s) and/or halogens and/or alkyl groups of 1 to 4 carbon atoms and/or alkenyl and/or alkynyl groups of 2 to 4 carbon atoms and/or cycloalkyl groups of 3 to 7 carbon atoms and/or aryl groups of 6 to 12 carbon atoms and/or heteroaryl groups, and in which the alkyl, alkenyl, alkynyl, cycloalkyl, aryl or heteroaryl group may be further substituted with one or more heteroatoms. Where their valency permits, heteroatoms may be substituted either within the carbon chain or by attachment to it by single or double bonds. For example, , —CH 2 —CH 2 —O—CH 3 , CH 3 —CH 2 —CH 2 O—, —CH 2 —CH 2 —C(═O)—NH 2 , CH 3 —CH 2 —C(O)—NH— and CF 3 —CC— all fall within this definition.
[0036] Unless indicated to the contrary, the term “aryl” as used herein means a carbocyclic aromatic ring having 6-18 carbon atoms, preferably 6-10 carbon atoms in the aromatic ring structure. The aromatic rings may be substituted by one or more alkyl group, preferably alkyl groups having 1-10 carbon atoms. A particularly preferred aryl group is phenyl.
[0037] Unless indicated to the contrary, the term “aralkyl” as used herein means a straight-chain or branched chain alkyl group as defined above for the term “alkyl” bonded to an aryl group as defined above for the term “aryl”. Preferred aralkyl groups are benzyl, phenethyl, etc.
[0038] The present method may be practiced by condensation of an ortho amino cyano phenyl compound of formula III or IV
[0039] where Y is independently H or F and n is an integer of 1 or 2;
[0040] X is H, NH 2 , F, Cl, Br, O—C 1-6 alkyl, S—C 1-6 alkyl, NH—C 1-6 alkyl, N(C 1-6 alkyl) 2 , or C 1-8 alkyl,
[0041] or X is —Z—(CH 2 ) a —N—(C 1-6 alkyl) 2 wherein Z is selected from the group consisting of O, NH and S, and a is an integer of 2 or 3,
[0042] or X is —CH 2 NR 2 R 3 , where (a) R 2 and R 3 are, independently, hydrogen, C 1-6 alkyl, C 3-7 cycloalkyl, C 3-7 cycloalkyl-C 1-6 alkyl, C 2-6 alkenyl, C 1-6 alkoxy-C 1-6 COR 4 where R 4 is hydrogen, C 1-6 alkyl, C 3-7 cycloalkyl, C 3-7 cycloalkyl-C 1-6 alkyl, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkoxy-C 1-6 alkyl, or (b) R 2 and R 3 taken together with the nitrogen atom to which they are attached form a saturated 3-7 membered heterocyclic ring which may contain a O, S or NR 5 group, where R 5 is hydrogen, C 1-6 alkyl, aryl, aryl substituted with one or more groups selected from the group consisting of C 1-6 alkyl, amino, C 1-6 alkylamino, perhalo-C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkoxy-C 1-6 alkyl and is hydrogen, C 1-6 alkyl C 1-6 alkoxy, aryl, and aryl substituted with one or more C 1-6 alkyl, or C 1-6 alkoxy-C 1-6 alkyl groups;
[0043] with an organometallic compound R-M.
[0044] Compounds of formula I and II may be prepared by conventional methods known to those of ordinary skill in the art, without undue experimentation. For example, compounds of formula (I) and (II) may be prepared by oxidation of a monoprotected diamine, followed by removal of the amine protecting group.
[0045] Non limiting examples of suitable organometallic compounds are cyclohexylmagnesium halide, allyl magnesium halide, vinyl magnesium halide, ethyl magnesium halide, 4-fluorophenyl magnesium halide, isopropenyl magnesium halide, isopropyl magnesium halide, methyl magnesium halide, ethynyl magnesium halide, cyclopentyl magnesium halide, phenyl magnesium halide, benzyl magnesium halide, propyl magnesium halide, 1-propynyl magnesium halide, p-tolyl magnesium halide, o-tolyl magnesium halide, 1-trimethylsilymethyl magnesium halide, hexyl magnesium halide, 2-thiophenyl magnesium halide, 4-dimethylaminophenyl magnesium halide, 4-chloro 1-butenyl 2-magnesium halide, p-methoxylbenzyl magnesium halide, methoxymethyl magnesiumhalide, p-trifluoromethylphenyl magnesium halide, and p-chloro phenylmagnesium halide. These organometallic reagents may be prepared by conventional methods known to those of ordinary skill in the art without undue experimentation.
[0046] The reaction of the organometallic reagent compound with the compound of formula I or formula II, may be accelerated by the addition of a catalyst. Suitable catalysts include, but are not limited to, CuBr, CuCl, or CuI.
[0047] The reaction of the organometallic reagent compound with the compound of formula I or formula II, may be conducted in an organic solvent. The most common solvents used are ethers, preferably tetrahydrofuran, diethyl ether or the like.
[0048] The reaction may be conducted at from 0-70° C., preferably in refluxing tetrahydrofuran.
[0049] The product of condensation of organometallic reagent compound with the compound of formula III or formula IV, is an o-amino ketone of structure V or VI
[0050] The product o-amino ketone may be isolated and purified or reacted directly with the tricyclic ketone (VII) as described below. Condensation with a tricyclic ketone of formula VII yields the 7- substituted camptothecin.
[0051] Tricyclic ketone of formula VII may be prepared by conventional methods known to those of ordinary skill in the art, such as that described by Wall et al. U.S. Pat. No. 5,122,526, the relevant portions of which are hereby incorporated by reference.
[0052] The condensation with tricyclic ketone (VII) is typically conducted under acid catalyzed conditions. The dehydration is preferably performed to help drive the condensation reaction.
[0053] Condensation of tricylic ketone (VII) with the aminoketone V or VI may be in a suitable organic solvent such as toluene, benzene, xylene or the like.
[0054] The Friedlander reaction of the orthoaminoketone and the tricycloketone may be conducted preferably in refluxing toluene.
[0055] Camptothecin compounds have an asymmetric carbon atom at the 20-position making two enantiomeric forms, i.e., the (R) and the (S) configurations, possible. This invention includes both enantiomeric forms and any combinations or mixtures of these forms. The invention also includes other forms of the camptothecin compounds including solvates, hydrates, polymorphs, salts, etc. Particularly preferred compounds are camptothecin derivatives having the (S) configuration at the 20-position.
[0056] Throughout the present application many CPT compounds have been defined with a substituent X as shown in structure I or II where X is defined and many substituents are shown. With the exception of the simple substituents where R is C 1-5 alkyl (which can be prepared by the method of Sawada et al. ( Chem. Pharm. Bull . 39, 2574-2580 (1999))), the other compounds recited herein can not be made by conventional methods, but require, to the best of the inventors' knowledge, the use of the method of the present invention. Using the method of Sawada et al, the yield of alkyl became progressively lower essentially terminating where R is C 5 alkyl. All other R substituents shown herein can be made only by the present method involving Grignard reactions, especially analogs like 7-t-butyl- 10,11-methylenedioxy-CPT, 7-trimethylsilylmethyl-10,11-methylenedioxy-CPT, 7-naphthylmethyl-10,11-methylenedioxy-CPT, 7-p-fluorophenyl-10,11-methylenedioxy-CPT, 7-p-trifluoromethyl-10,11-methylenedioxy-CPT, and 7-p-tolyl-10,11-methylenedioxy-CPT. A number of compounds made by this method have shown unusual properties. For example, Table 1 gives the methylene chloride solubility of a number of compounds which are made by the methods described by this patent. For example, 7-butyl-10-aminocamptothecin made by this procedure is remarkably lipophilic. 10-Aminocamptothecin has a solubility of — 0.2 mg/ml. However, 7-n-butyl-10-aminocamptothecin has a solubility of 140 mg/mL in methylenechloride, unexpectedly making this compound the most lipophilic camptothecin known. It has been found by several groups that lipophilic substituents at the 7 position have excellent activity in the inhibition of topoisomerase I and in in vitro and in vivo cancer therapy.
TABLE 1 Sobulity in CH 2 Cl 2 Compound Solubility (mg/ml) 9-Methyl-CPT 0.1 mg/ml 10-Amino-CPT 0.2 mg/ml 10,11-ED-CPT 0.2 mg/ml Camptothecin 0.6 mg/ml 9-Amino-10,11-MD-CPT <0.02 mg/ml 9-Amino-CPT <0.03 mg/ml 10-OH-CPT <0.04 mg/ml 7-Butyl-10-OH-CPT <0.05 mg/ml 10,11-MD-CPT <0.008 mg/ml 7-Butyl-9-methyl-CPT 0.18 mg/ml 9-Nitro-10,11-MD-CPT 0.25 mg/ml 7-Benzyl-10,11-CPT 1.8 mg/ml 7-Benzyl-10,11-MD-CPT 1.8 mg/ml 7-Butyl-10-methoxy-CPT 2 mg/ml 7-p-Fluorophenyl-10,11-MD-CPT 2.55 mg/ml 10-Methoxy-CPT 3 mg/ml 7-p-Tolyl-10,11-MD-CPT 4.6 mg/ml 7-p-Chlorophenyl-10,11-MD-CPT 6.3 mg/ml 7-Butyl-10,11-ED-CPT 7 mg/ml 7-Butyl-10,11-MD-CPT 8.5 mg/ml 7-Butyl-CPT 20 mg/ml 7-(sec)Butyl-CPT 33 mg/ml 7-Butyl-10-Amino-CPT 145 mg/ml
[0057] References for the increase in cytotoxic potency: Dallavale et al. Novel Cytotoxic 7-Aminomethyl and 7-Aminomethyl Derivatives of Camptothecin, Biorg. & Med. Chem. Lett . 11, 291-294 (2001), Bom et al. Novel A, B, E-Ring Modified Camptothecins Displaying High Lipophilicity and Markedly Improved Blood Stability, J. Med. Chem . 42, 3018-3022 (1999), Bom et al., Novel Silotecan 7-Tertbutyldimethylsilyl-10-hydroxycamptothecin Displays High Lipophilicity, Improved Human Blood Stability, and Potent Anticancer Activity, J. Med. Chem . 43, 3970-3980 (2000).
[0058] We have utilized a standard method for ascertaining the lipophilicity of a number of camptothecin analogs. This involves the solubility in methylene chloride. This solvent is an excellent solvent for fat-soluble compounds. As can be noted with only one exception, compounds with the 7-butyl substituent are considerably more soluble than those without this constituent. Thus camptothecin is soluble only to the extent of 0.6 mg/ml whereas 7-butyl-camptothecin has a solubility of 20 mg/ml. 10-Amino-camptothecin is soluble only to the extent of 0.2 mg/ml. Very unexpectedly, 7-butyl-10-amino-camptothecin is very soluble at 145 mg/ml. It is also conceivable that camptothecin analogs with 7-pentyl or 7-hexyl substituents or 7-cyclopentyl or 7-cyclohexyl substituents will have increased solubility.
[0059] Another compound with special properties is 7-p-fluorophenyl-10,11-methylenedioxycamptothecin with an IC 50 of 0.692. In contrast, 10,11-methylenedioxy-CPT has an IC 50 of 1.24. The 7-p-fluorophenyl-10,11-methylenedioxycamptothecin is the most cytotoxic compound that has ever been made.
[0060] Within the scope of the present invention, the lactone ring of the camptothecin compounds shown above may be opened by alkali metal or alkaline earth metal bases (MOH) for example, sodium hydroxide or calcium hydroxide to form alkali metal or alkaline earth metal salts of the open ring salt form of the camptothecin compounds, illustrated for example only for the alkylenedioxy compound.
[0061] Open ring compounds generally have better solubility in water. The group M may also be any pharmaceutically acceptable cation, obtained either directly by ring opening or by cation exchange of a ring open salt. Suitable groups M include Li + , Na + , K + and Mg +2 .
[0062] The C 20 OH CPT compounds of the present invention may be prepared by conventional methods known to those of ordinary skill in the art, such as that described by Wall et al. U.S. Pat. No. 5,122,526, the relevant portions of which are hereby incorporated by reference.
[0063] Esterification with an amino acid at C 20 is possible by conventional methods known to those of ordinary skill in the art. Suitable esters formed at C 20 are those described in U.S. Pat. No. 6,268,375, the relevant portions of which are hereby incorporated by reference. Substitution at C 9 with groups such a nitro and amino is also possible in a manner analogous to that described in the literature.
[0064] The compounds of the invention having the group —CH 2 —L at C 9 are prepared from known 20(S)—CPT compounds bearing a halogen, for example, a bromine atom, at the C 9 position. The halogen atom can be readily converted into the corresponding cyano analog by reaction with CuCN, followed by hydrolysis to form the corresponding carboxy analog. The carboxy analog is reduced to the corresponding hydroxy methyl analog which can be reacted with Ph 3 P—CCl 4 to provide the corresponding chloromethyl analog. The chloromethyl analog can be readily converted to the bromomethyl and iodomethyl analogs using LiBr or LiI. The remaining compounds of the invention are prepared from these compounds by reaction with the corresponding acid chloride, sulfonyl chloride, etc. These reactions are well known to one having ordinary skill in this art.
[0065] Compounds in which L is Br or I are readily prepared from the compound in which L is Cl by simple halide exchange employing LiBr or LiI in dimethylformamide (DMF) solution (Larock, R. C., Comprehensive Organic Transformations, VCH Publishers, Inc., p. 337, N.Y. 1989).
[0066] C 20 esters may be prepared by esterifying the 20-position hydroxyl group of a camptothecin compound to form an ester containing a water-soluble moiety. Generally, the camptothecin compound is initially suspended in methylene chloride or other inert solvent, stirred and cooled. To the cooled mixture is added one equivalent of an acid having the formula HOOC—CH 2 —CH 2 —NR 8 R 9 , where R 8 and R 9 are independently, hydrogen, C 1-8 alkyl, C(O)—(CH 2 ) m —NR 10 R 11 , where m is an integer from 1 to 6, or —C(O)CHR 12 NR 13 R 14 , where R 12 is the side chain of one of the naturally occurring α-amino acids and R 10 , R 11 , R 13 and R 14 are each independently hydrogen or C 1-8 alkyl. Suitable side chains R 12 are the side chains of the amino acids glycine, α-alanine, β-alanine, valine, leucine, isoleucine, phenylalanine, tyrosine, tryptophan, leucine, arginine, histidine, aspartate, glutamate, asparagine, glutamine, cysteine and methionine. A particularly useful ester can be prepared from the peptide β-alanine-lysine which forms a very water-soluble dihydrochloride Salt. One equivalent of dicyclohexylcarbodiimide (DCC) and a catalytic amount of an amine base, preferably a secondary or tertiary amine, are also added to the mixture, which is then stirred to complete the reaction. Any precipitate which forms is removed by filtration and the product is isolated after removal of the solvent.
[0067] The free amine(s) may be converted to an acid addition salt by the addition of a pharmaceutically acceptable acid. Suitable acids include both inorganic and organic acids. Suitable addition salts include, but are not limited to hydrochloride, sulfate, phosphate, diphosphate, hydrobromide, nitrate, acetate, malate, maleate, fumarate, tartrate, succinate, citrate, lactate, methanesulfonate, p-toluenesulfonate, palmoate, salicylate and stearate salts. The salts may be purified by crystallization from a suitable solvent.
[0068] The camptothecin compounds are administered in a dose which is effective to inhibit the growth of tumors. As used herein, an effective amount of the camptothecin compounds is intended to mean an amount of the compound that will inhibit the growth of tumors, that is, reduce the site of growing tumors relative to a control in which the tumor is not treated with the camptothecin compound. These effective amounts are generally from about 1-60 mg/kg of body weight per week, preferably about 2-20 mg/kg per week.
[0069] The compounds of the present invention may be administered as a pharmaceutical composition containing the camptothecin compound and a pharmaceutically acceptable carrier or diluent. The active materials can also be mixed with other active materials which do not impair the desired action and/or supplement the desired action. The active materials according to the present invention can be administered by any route, for example, orally, parenterally, intravenously, intradermally, subcutaneously, or topically, in liquid or solid form.
[0070] For the purposes of parenteral therapeutic administration, the active ingredient may be incorporated into a solution or suspension. The solutions or suspensions may also include the following components: a sterile diluent such as water for injection, saline solution, fixed oils, polyethylene glycols, glycerine, propylene glycol or other synthetic solvents; antibacterial agents such as benzyl alcohol or methyl parabens; antioxidants such as ascorbic acid or sodium bisulfite; chelating agents such as ethylenediaminetetraacetic acid; buffers such as acetates, citrates or phosphates and agents for the adjustment of tonicity such as sodium chloride or dextrose. The parenteral preparation can be enclosed in ampoules, disposable syringes or multiple dose vials made of glass or plastic.
[0071] Another mode of administration of the compounds of this invention is oral. Oral compositions will generally include an inert diluent or an edible carrier. For the purpose of oral therapeutic administration, the aforesaid compounds may be incorporated with excipients and used in the form of tablets, gelatine capsules, troches, capsules, elixirs, suspensions, syrups, wafers, chewing gums and the like. Compositions may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents. Tablets containing the active ingredient in admixture with nontoxic pharmaceutically acceptable excipients which are suitable for manufacture of tablets are acceptable. These excipients may be, for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate granulating and disintegrating agents, such as maize starch, or alginic acid; binding agents, such as starch, gelatin or acacia; and lubricating agents, such as magnesium stearate, stearic acid or talc. Tablets may be uncoated or may be coated by known techniques to delay disintegration and adsorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate alone or with a wax may be employed. Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, such as peanut oil, liquid paraffin or olive oil.
[0072] The tablets, pills, capsules, troches and the like may contain the following ingredients: a binder such as microcrystalline cellulose, gum tragacanth or gelatin; an excipient such as starch or lactose, a disintegrating agent such as alginic acid, Primogel, corn starch and the like; a lubricant such as magnesium stearate or Sterotes; a glidant such as colloidal silicon dioxide; and a sweetening agent such as sucrose or saccharin or flavoring agent such as peppermint, methyl salicylate, or orange flavoring may be added. When the dosage unit form is a capsule, it may contain, in addition to material of the above type, a liquid carrier such as a fatty oil. Other dosage unit forms may contain other various materials which modify the physical form of the dosage unit, for example, as coatings. Thus tablets or pills may be coated with sugar, shellac, or other enteric coating agents. A syrup may contain, in addition to the active compounds, sucrose as a sweetening agent and certain preservatives, dyes and colorings and flavors. Materials used in preparing these various compositions should be pharmaceutically or veterinarially pure and non-toxic in the amounts used.
[0073] Aqueous suspensions of the invention contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients include a suspending agent, such as sodium carboxymethylcellulose, methylcellulose, hydroxypropylethyl cellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia, and dispersing or wetting agents such as a naturally occurring phosphatide (e.g., lecithin), a condensation product of an alkylene oxide with a fatty acid (e.g., polyoxyethylene stearate), a condensation product of ethylene oxide with a long chain aliphatic alcohol (e.g., heptadecaethylene oxycetanol), a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol (e.g., polyoxyethylene sorbitol mono-oleate), or a condensation product of ethylene oxide with a partial ester derived from fatty acid and a hexitol anhydride (e.g., polyoxyethylene sorbitan mono-oleate). The aqueous suspension may also contain one or more preservatives such as ethyl or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents and one or more sweetening agents, such as sucrose, aspartame, saccharin, or sucralose.
[0074] Oil suspensions may be formulated by suspending the active ingredient in a vegetable oil, such as arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oil suspensions may contain a thickening agent, such as beeswax, hard paraffin or cetyl alcohol. Sweetening agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an antioxidant such as ascorbic acid.
[0075] Dispersible powders and granules of the invention suitable for preparation of an aqueous suspension by the addition of water may be formulated from the active ingredients in admixture with a dispersing, suspending and/or wetting agent, and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those disclosed above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
[0076] The pharmaceutical composition of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil, such as olive oil or arachis oil, a mineral oil, such as liquid paraffin, or a mixture of these. Suitable emulsifying agents include naturally occurring gums, such as gum acacia and gum tragacanth, naturally occurring phosphatides, such as soybean lecithin, esters or partial esters derived from fatty acids and hexitol anhydrides, such as sorbitan mono-oleate, and condensation products of these partial esters with ethylene oxide, such as polyoxyethylene sorbitan mono-oleate. The emulsion may also contain sweetening and flavoring agents.
[0077] Syrups and elixirs may be formulated with sweetening agents, such as glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative, a flavoring or a coloring agent.
[0078] The pharmaceutical compositions of the invention may be in the form of a sterile injectable preparation, such as a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a nontoxic parenterally acceptable diluent or solvent, such as a solution of 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water and Ringer's solution, an isotonic sodium chloride. In addition, sterile fixed oils may conventionally be employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid may likewise be used in the preparation of injectables. Sterilization may be performed by conventional methods known to those of ordinary skill in the art such as by aseptic filtration, irradiation or terminal sterilization (e.g. autoclaving).
[0079] Aqueous formulations (i.e., oil-in-water emulsions, syrups, elixirs and injectable preparations) may be formulated to achieve the pH of optimum stability. The determination of the optimum pH may be performed by conventional methods known to those of ordinary skill in the art. Suitable buffers may also be used to maintain the pH of the formulation.
[0080] The compounds of this invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable nonirritating excipient which is solid at ordinary temperatures but liquid at the rectal temperatures and will therefore melt in the rectum to release the drug. Non-limiting examples of such materials are cocoa butter and polyethylene glycols.
[0081] They may also be administered by intranasal, intraocular, intravaginal, and intrarectal routes including suppositories, insufflation, powders and aerosol formulations.
[0082] The compounds of the present invention may also be administered in the form of liposome or microvesicle preparations. Liposomes are microvesicles which encapsulate a liquid within lipid or polymeric membranes. Liposomes and methods of preparing liposomes are known and are described, for example, in U.S. Pat. Nos. 4,452,747, 4,448,765, 4,837,028, 4,721,612, 4,594,241, 4,302,459 and 4,186,183. The disclosures of these U.S. patents are incorporated herein by reference. Suitable liposome preparations for use in the present invention are also described in WO-9318749-A1, J-02056431-A and EP-276783-A.
[0083] The camptothecin compounds may be used individually to inhibit the growth of tumors. Alternatively, combinations of two or more camptothecin compounds may be used or combinations of one or more camptothecin compounds with one or more known anti-tumor compounds. When a camptothecin compound is combined with a conventional anti-tumor compound, the camptothecin compound will generally be present in an amount ranging from about 1-99 wt. %, preferably, 5-95 wt. % of the combined amount of camptothecin and conventional anti-tumor compound. The pharmaceutical compositions noted above may contain these combinations of compounds together with an acceptable carrier or diluent.
[0084] The ester compounds of the invention may be administered to treat leukemia and solid tumors in mammals, including humans. The esters of the present invention are prodrugs which are hydrolyzed to camptothecin compounds demonstrating inhibitory activity on topoisomerase I. The camptothecin compounds formed by hydrolysis of the esters of the invention are also effective in treating leukemia and solid tumors in mammals. Numerous camptothecin compounds have been shown to be effective against leukemia using the standard L1210 leukemia assay (Wall et al. (1993), Journal of Medicinal Chemistry, 36:2689-2700). High activity of camptothecin and camptothecin analogs has also been shown in the P388 leukemia assay (Wall (1983), Medical and Pediatric Oncology, 11:480A-489A). The latter reference also provides a correlation between anti-leukemia activity as determined by the L1210 and the P388 leukemia assays with efficacy of camptothecin compounds against solid tumors. Compounds reported as active in the leukemia assays also have demonstrated activity in a number of solid tumors including a colon xenograft, a lung xenograft, a Walker sarcoma and a breast xenograft (Wall (1983), Table IV, page 484 A). Recent studies have confirmed the correlation between topoisomerase I inhibitory activity and anti-leukemia/anti-tumor activity of camptothecin compounds (Giovanella et al. (1989), Science, 246: 1046-1048). The compounds of the present invention are particularly effective in the treatment of colon, lung, breast and ovary solid tumors, brain glioma and leukemia. These compounds may also be used to treat malaria.
[0085] Different aminoketones used were made by following the general procedure of reacting the nitrile with an appropriate Grignard reagent and hydrolyzing the product.
EXAMPLE 1
2-Amino-4,5-methylenedioxy-phenylbenzylmethanone
[0086] To a stirred solution of 1.5 g (10.0 mmol) of 2-amino-4,5-methylenedioxy-benzonitrile in THF (40 mL) was added CuBr (50 mg, 0.34 mmol) and benzylmagnesium chloride (40 mL, 1.0 M solution in Et 2 O). The reaction mixture was refluxed for 12 h. After cooling to 25° C., H 2 O (5 mL) was added followed by 15% H 2 SO 4 (15 mL). After stirring for 14 h, ether (50 mL) was added. Organic layer was separated. Aqueous layer was extracted with ether (2×50 mL). The combined organic layer was dried and evaporated. Following chromatography (silica gel, CHCl 3 ), 1.2 g (52%) of the title compound was obtained. IR (CHCl 3 ) 1675 cm −1 MS m/z 255 (M + ).
EXAMPLE 2
7 -Benzyl-10,11-MD-20(S)-Camptothecin
[0087] A mixture of S-tricyclic ketone (1.0 g, 4.2 mmol), 2-amino-4,5-methylenedioxy-phenylbenzylmethanone (1.1 g, 4.3 mmol) acetic acid (1 mL), p-TsOH (50 mg) in toluene (100 mL) was refluxed for 15 h. After removing the solvent, the crude product was purified by column chromatography (silica gel, CHCl 3 ) to yield the product as a cream powder (1.33 g, 66%) 1 H-NMR (DMSO-d 6 ) δ 0.89 (t, 3H), 1.91 (m, 2H), 4.62 (s, 2H), 5.22 (s, 2H), 5.41 (s, 2H), 6.10 (s, 2H), 6.50 (s, IH), 6.90-7.10 (m, 5H), 7.21 (s, IH), 8.07 (s, IH), 8.22 (s, IH); MS: m/z 483 (M+1) + .
EXAMPLE 3
7-Trimethylsilylmethyl-10,11-MD-20(S)-Camptothecin
[0088] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of trimethylsilyl magnesium chloride as the Grignard reagent. 1 H-NMR (DMSO-d 6 +CDCl 3 ) δ 0.87 (t, 3H), 1.83 (m, 2H), 2.28 (s, 2H), 5.11 (s, 2H), 5.37 (s, 2H), 6.25 (s, 2H), 6.47 (s, 1H), 7.20 (s, 1H), 7.43 (s, 1H), 7.48 (s, 1H). MS m/z 478 (M + ).
EXAMPLE 4
7-t-Butyl-10,11-MD-20(S)-Camptothecin
[0089] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of t-butylmagnesium chloride as the Grignard reagent. 1 H-NMR (DMSO-d 6 ): δ 0.88 (t, 3H), 1.77 (s, 9H), 1.91 (m, 2H), 5.40 (s, 2H), 5.55 (s, 2H), 6.25 (s, 2H), 6.50 (s, 1H), 7.22 (s, 1H), 7.44 (s, 1H), 7.56 (s, 1H). MS m/z 448 (M + ).
EXAMPLE 5
7- Benzyl-20(S)-Camptothecin
[0090] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of benzylmagnesium chloride and orthoamino benzonitrile. 1 H-NMR (DMSO-d 6 ) δ 0.89 (t, 3H), 1.92 (m, 2H), 4.62 (s, 2H), 5.20 (s, 2H) 5.38 (s, 2H), 6.58 (s, 1H), 7.1-7.3 (m, 5H), 7.35 (s, 1H), 7.68 (t, 1H), 7.84 (t, 1H), 8.18 (d, 1H), 8.29 (d, 2H). MS m/z 439 (M+1) + .
EXAMPLE 6
7-Benzyl-10,11-DFMD-20(S)-Camptothecin
[0091] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of 2-amino-3,4-difluoromethylenedioxybenzonitrile and benzylmagnesium chloride. 1 H-NMR (DMSO-d 6 ): δ 0.85 (t, 3H), 1.82 (m, 2H), 4.60 (s, 2H), 5.29 (s, 2H), 5.39 (s, 2H), 6.51 (s, 1H), 6.88-7.12 (m, 5H), 8.08 (s, 1H), 8.26 (s, 1H). MS m/z 518 (M + ).
EXAMPLE 7
7-Benzyl-10-hydroxy-20(S)-Camptothecin
[0092] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of appropriately protected orthoaminobenzonitrile and benzylmagnesium chloride. 1 H-NMR (DMSO-d 6 ): δ 0.89 (t, 3H), 1.86 (m, 2H), 4.57 (s, 2H), 5.25 (s, 2H), 5.41 (s, 2H), 6.5 (s, 1H), 7.05-7.19 (m, 5H), 7.23 (s, 1H), 7.36 (d, 1H), 7.92 (d, 1H), 10.29 (s, 1H). MS m/z 454 (M + ).
EXAMPLE 8
7-p-Fluorophenyl-10,11-MD-20(S)-Camptothecin
[0093] The title compound was prepared following analogous procedures as described in Example 1 and 2 and involving the use of p-fluorophenyl magnesium bromide. 1 H-NMR (DMSO-d 6 ): δ 0.91 (t, 3H), 1.86 (m, 2H), 5.00 (2H), 5.43 (s, 2H), 6.30 (s, 2H), 6.55 (s, 1H), 6.99 (s, 1H), 7.29 (s, 1H), 7.52-7.75 (m, 5H. MS: m/z 486 (M + ).
EXAMPLE 9
7-p-Chlorophenyl-10,11-MD-20(S)-Camptothecin
[0094] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of p-chlorophenyl magnesium bromide. 1 H-NMR (DMSO-d 6 ): δ 0.93 (t, 3H), 1.89 (m, 2H), 5.08 (s, 2H), 5.46 (s, 2H), 6.33 (s, 2H), 6.55 (s, 1H), 7.05 (s, 1H), 7.34 (s, 1H), 7.67 (s, 1H), 7.71 (d, 2H), 7.79 (d, 2H). MS: m/z 502 (M + ).
EXAMPLE 10
7-p-Tolyl-10,11-MD-20(S)-Camptothecin
[0095] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of p-tolyl magnesium bromide. 1 H-NMR (DMSO-d 6 ): δ 0.85 (t, 3H), 1.82 (m, 2H), 2.45 (s, 3H), 4.94 (s, 2H), 5.39 (s, 2H), 6.24 (s, 2H), 6.49 (s, 1H), 6.97 (s, 1H), 7.24 (s, 1H), 7.44 (m, 4H), 7.83 (s, 1H). MS: m/z 482 (M + ).
EXAMPLE 11
7-Cyclohexyl-10,11-MD-20(S)-Camptothecin
[0096] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of cyclohexyl magnesium bromide. 1 H-NMR (DMSO-d 6 +CDCl 3 ) δ 0.86 (t, 3H), 1.2-1.95 (m, 12H), 2.42 (m, 1H), 5.20 (s, 2H), 5.36 (s, 2H), 6.25 (s, 2H), 6.48 (s, 1H), 7.15 (s, 1H), 7.42 (s, 1H), 7.66 (s, 1H). MS: m/z 474 (M + ).
EXAMPLE 12
7-n-Hexyl-10,11-MD-20(S)-Camptothecin
[0097] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of n-hexyl magnesium bromide. 1 H-NMR (DMSO-d 6 +CDCl 3 ): δ 0.84-1.89 (m, 15H), 2.63 (m, 2H), 5.19 (s, 2H), 5.34 (s, 2H), 6.26 (s, 2H) 6.49 (s, 1H), 7.16 (s, 1H), 7.39 (s, 1H), 7.68 (s, 1H). MS: m/z 476 (M + ).
EXAMPLE 13
7-p-Trifluoromethylphenyl-10,11-MD-20(S)-Camptothecin
[0098] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of p-trifluoromethylphenyl magnesium bromide. 1 H-NMR (DMSO-d 6 +CDCl 3 ): δ 0.89 (t, 3H) 1.87 (m, 2H), 5.08 (s, 2H), 5.41 (s, 2H), 6.29 (s, 2H), 6.57 (s, 1H), 7.01 (s, 1H), 7.30 (s, 1H), 7.48-8.06 (m, 5H). MS: m/z 536 (M + ).
EXAMPLE 14
7-n-Butyl-10-Amino-20(S)-Camptothecin
[0099] The title compound was prepared following analogous procedures as described in Examples 1 and 2 and involving the use of 2,5-diaminobenzonitrile and n-butyl magnesium bromide. 1 H-NMR (DMSO-d 6 ): δ 0.86 (t, 3H), 0.95 (t, 3H), 1.42-1.86 (m, 6H), 2.97 (m, 2H), 5.19 (s, 2H), 5.39 (s, 2H), 5.94 (s, 2H), 6.44 (s, 1H), 7.04 (s, 1H), 7.15 (s, 1H), 7.22 (d, 1H), 7.82 (d, 1H). MS: m/z 419 (M + ).
[0100] 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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Methods of forming camptothecin compounds which are effective anti-tumor compounds are disclosed. These compounds inhibit the enzyme topoisomerase I and may alkylate DNA of the associated topoisomerase I-DNA cleavable complex.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application contains subject matter which is related to the subject matter of the following co-pending applications, filed on the same day, which is assigned to the same assignee as this application, International Business Machines Corporation of Armonk, N.Y. Each of the below listed applications is hereby incorporated herein by reference in its entirety: Ser. Nos. 11/262,051 and 11/262,050.
TRADEMARKS
IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. S/390, Z900 and z990 and other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to packaging of computing systems and more particularly to packaging of large computing systems that include one or more central electronic complexes (CECs).
2. Description of Background
Increased packaging density continues to challenge the computer system developers. This is true of all computing system environments, whether they are comprised of a single small unit or a plurality of systems networked to one another. In large and complex system environments, however, these problem associated with increased density become even more of a concern. This is because in more complex environments, the size of the environment multiplies the number of issues to be resolved. In addition, in large environments resolution of all problems, even seemingly isolated ones, are codependent on other existing factors in the environment, especially when different components in the environment are packaged together in a single assembly or networked in close proximity. Consequently, the designers of such environments are faced with increasingly difficult challenges, especially where the design requires the environment to be housed in a predefined system footprint. Two of the more difficult challenges to resolve are the issues of heat dissipation and structural integrity of the environment.
The designers of computing environments have utilized unique approaches in order to maximize air-cooling capabilities within a predefined system footprint. This requirement results from the heat dissipated from packages residing in large computing systems and how it affects the computing system's internal areas adjacent to heat producing components that can affect both electrical and structural integrity of the system as a whole. In addition, many large computing environments incorporate one or more large central electronic complexes (CECs) to support logic entities, such as daughter cards, modules and the like, whereby mid-plane boards have historically been vertically mounted (in reference with the ground plane).
Unfortunately, in such systems, the designs that address structural rigidity issues of the environment do not always provide an acceptable solution to the challenges posed by heat dissipation. This is because in such designs, the mid-plane orientation within the CEC is particularly important in minimizing adverse dynamic loading effects. In doing so, however, the configuration orientation impedes efficient-air cooling approaches, such as the simple front to back cooling using an omega form air flow pattern.
Current prior art solutions are not able to address the many problems that challenges, such as that of heat dissipation and dynamic loading effects of such large computing environments in a single design. Therefore, it is desirous to have an assembly that addresses actuation, structural issues and dynamic loading issues of the current systems without affecting thermal management and other seemingly isolated issues that have a great impact on one another and the overall performance of any large computing system environment, especially those that include one or more CECs.
SUMMARY OF THE INVENTION
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method and incorporated assembly provided for mating electronic unto a computer rack comprising a main housing engageably securable to a slide assembly. The slide assembly is capable of being secured to a side of the computer rack and having sliding features such that the slide assembly and the main housing when engaged can be telescoped out or returned to a closed position. The main housing having a vertical wedge for securing said assembly to said rack more securely and a drive wedge for moving the vertical wedge such that it can telescope into and out of said rack with said slide mechanism via a lead screw.
In one embodiment of the present invention, the slide mechanisms further comprise a fixed housing and a sliding feature moveably engaged to this housing such that said sliding feature can move from a first position to a second position to provide telescoping feature for the mechanism.
In another embodiment a dwell feature is provided. To accomplish the dwell feature, the vertical wedge and/or the housing are formed such that they accommodate a connector system. A variety of different connector systems can be conceived but in a preferred embodiment, the connector system comprises of a pin and hole feature where the amount of movement of the dwell feature is dependent on the pin and hole relationship of the housing and the vertical wedge.
In an alternate embodiment, one or more stiffening member(s) can be connected to the assembly in areas surrounding the surface-mount interconnect, such as the mid-plane connector area of a large computing environment. In addition guidance mechanism can also be provided to provide a better connection.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an exploded view of the different components that make up the actuation assembly as per one embodiment of the present invention;
FIGS. 2 a and 2 b provide an illustration of the components of FIG. 1 once assembled and delineate the telescoping slide feature of the slide mechanism;
FIGS. 3 a and 3 b are detailed illustrations of the actuation mechanism as per one embodiment of the present invention;
FIG. 4 is a detailed illustration showing the wedge mechanism as per one embodiment of the present invention;
FIG. 5 is an illustration of the outrigger and slide features of the assembly as per one embodiment of the present invention; and
FIG. 6 provides an illustration of an alternate embodiment of the present invention having a stiffening member incorporated into its design.
DESCRIPTION OF THE INVENTION
FIGS. 1 through 6 provide an actuation assembly as per one embodiment of the present invention. Before discussing additional details pertaining to the present invention, it should be noted that the many advantages of the present invention will become more apparent by referring to co-pending applications Ser. No. 11/262051 and Ser. No. 11/262050. Co-pending application Ser. No. 11/262051 addresses provides for an quick and flexible assembly to which the present invention's actuation assembly can be mounted to further address dynamic loading and heat dissipation concerns, as well as others. In addition, co-pending application, Ser. No. 11/262050, for a cassette assembly that can be mounted inside the packaging assembly of Ser. No. 11/262051 and be further attached to the present invention's actuation assembly to provide additional advantages. It should be noted, however, the while the enumerated co-pending applications were recited to suggest a preferred embodiment for the use of present invention, the teachings of present invention is not limited to the environments and assemblies as suggested by the aforementioned co-pending applications and that the present invention can be implemented separately if desired.
Referring back to the embodiment provided by FIGS. 1 through 6 , the actuation assembly provided introduces an improved mechanism that provides for actuation of a high density connector within a desired direction. It should be noted that in many circumstances accommodating a high density connector associated with the electronic cards, specifically logic cards assemblies, lying within a direction that is perpendicular to the insertion direction provides a mechanical challenge to the designers of large systems as discussed. This is because, although blind-docking approaches can seemingly be implemented, but the overall physical size and weight and the nature of the interconnect density of large computing systems, eliminates the feasibility of adopting these approaches.
The name actuation assembly, should not imply an actuation mechanism only, as the assembly provided by the present invention also provides advantages in terms of structural integrity and support, especially when used in conjunction with and for mounting the cassette assembly on the packaging assembly of the previously enumerated inventions. In instances where a rack is used, the present invention provides added structural integrity and support to the entire rack assembly. However, in providing such support the present invention addresses the difficulties associated with service calls that are currently providing challenges to prior art designs.
Structural support and weight increase in large computing environments are inversely related in current prior art systems. While weight management efforts leads to potentially less rigid assemblies, more rigid assemblies often make service calls difficult and costly. One solution addressed by the present invention is to accommodate the needs of servicing field replacement unit (FRU) calls as made by such large computing environments. Servicing of the FRU's within each logic card assembly without the assistance of weight supporting tools will be a great advantage in large system environments.
Ease of serviceability and improved connectability is also enhanced by the present invention by providing a guidance mechanism and an improved mating arrangement. This is especially advantageous in environments where one or more central electronic complexes (CECs) are incorporated into a rack. This is because, in one embodiment of the present invention, the assembly is specially designed for vertical actuation of large logic card entities that are being mated to mid-plane boards of CECs mounted in horizontal positions (in reference to the ground plane). This will also allow for improved thermal management as it provides front to back cooling schemes.
It should also be noted that the figures as will be discussed, illustrate a preferred embodiment of the present invention where large computing environment(s) housing one or more central electronic component (CEC) in a rack are discussed. However, the discussion and figures are only provided for ease of understanding and other embodiments and arrangements can easily be supported by the teachings of the present invention. Thus, present invention should not be limited to those embodiments and figures as will be presently discussed.
Referring back to the figures, FIG. 1 provides for an exploded view of the different components of the present invention. FIG. 1 comprises of a main housing 100 , a drive wedge 120 , and a lead screw 140 . A wedge 130 (also referred to as a first wedge to differentiate it from the drive wedge 120 ) is also illustrated in FIG. 1 . In a preferred embodiment, the wedge 130 will be substantially vertically oriented and therefore the wedge 130 will hereinafter be referred to as vertical wedge 130 since the illustrated figures depict a preferred embodiment, although other wedge orientations can be possible.
FIG. 1 also illustrates a plurality of slide assemblies or mechanisms 110 , hereinafter referred to as slide mechanisms 110 . The slide mechanisms, in turn comprise of a sliding body 112 and sliding features 111 engageably slidable within the body 112 (as illustrated) to provide a telescoping feature. In a preferred embodiment, the slide assemblies 110 are symmetrical to one another. The telescoping nature of the slide 110 can be best understood by reference to FIG. 2 a and FIG. 2 b . In FIG. 2 a , a retracted slide view 220 is provided, while FIG. 2 b provides for an extended view 250 . In one embodiment of the present invention, the telescoping slides 110 also contain multiple détente positions, to provide controlled, pre-defined deployment positions during servicing of the environment.
It should also be noted that while a variety of materials and processing combinations can be used and employed to fabricated the components illustrated in FIG. 1 , in a preferred embodiment, cast and/or machined aluminum or structural polymer, including any required inserts, is used in fabrication of the main housing 100 and vertical and drive wedges 110 and 120 . Machined steel can be preferably used for the lead screw and roller ball bearing based custom slide mechanisms.
FIGS. 3 through 6 illustrate the assembly 200 once the different components as shown in FIG. 1 are engaged with one another. In one embodiment of the present invention, the assembly can be mounted to one or more daughter card(s). This is because when using high density, blind-docking connector applications, it is important that one connector element is allowed to float to find its mating half. Since the mother board(s) in large environments is usually fixed, the floating member is often the right angle daughter card. Mounting the assembly 200 to the daughter card also minimizes system level costs of the environment by employing a “pay as you add” burden philosophy. In this way, a fully populated configuration is not required, regardless of the number of daughter cards installed.
FIGS. 3 a and 3 b provides a more detailed view of the assembly after the different components as shown in FIG. 1 are engaged. As illustrated in FIGS. 3 a and 3 b , the main housing and the vertical wedge are complementarily engaged with the sliding mechanism being engaged on their adjacent sides. The lead screw 140 is also mounted on the vertical wedge 130 as shown.
The telescoping nature of the slide assembly 110 is further shown alongside the movement of vertical wedge, referenced by the arrows marked as 300 in FIG. 3 a . The movement of the drive wedge 120 is also illustrated, as referenced by arrows 350 in FIG. 3 b.
FIG. 4 , further enhances the illustration of FIGS. 3 a and 3 b by providing the details of the actuation dwell feature. As shown in the figures, the main housing 100 , in one embodiment of the invention, supports the drive wedge 120 and mates to pin retention features on the mid-plane enabling the controlled docking of the node as previously discussed. To address the aforementioned connector “float to dock” requirement, the main housing 100 of the actuator assembly 200 is pinned and not positively clamped to the mid-plane board, thereby allowing the node to shift lightly as the connector alignment features engage. The mid-plane pin engagement locations are illustrated in FIG. 4 at 410 .
To accomplish these tasks the vertical wedge and/or the housing are formed such that they accommodate a connector system 400 as shown in FIG. 4 . A variety of different connector systems can be conceived as appreciated by a person skilled in the art. In the embodiment that is illustrated, however, the connector system 400 comprises of a pin and hole feature 401 and 402 respectively. In the embodiment shown in the figures, the amount of movement of the dwell feature is dependent on the pin and hole relationship of the housing 100 and wedge 130 .
To understand the dwell feature of the assembly, FIGS. 3 a , 3 b and 4 will now be discussed in connection to one another. As was shown in FIGS. 3 a and 3 b , the drive wedge 120 is designed to move from one a first position to a second position, such as move front to back, via the lead screw 140 and works with the vertical wedge 130 to provide the actuation movement and travel. In a preferred embodiment, friction control for the wedges 120 and 130 , are implemented in the form of roller cam followers, bronze followers or pins (of round, square or some such cross-section) alternatively. A tool actuated lead screw, preferably, provides the force to move the mechanism and travels to a stop position (a down stop in the figures) housed either at the node/mid-plane interface or within the dwell feature defined in the vertical wedge 130 . In doing so, the mechanism ensures a controlled contact wipe of the connector system 400 is implemented. In one embodiment, the mechanism can be selectively tuned by introducing the dwell or flat spot in the wedge and thus eliminating the advancement of the travel in that direction (i.e. vertical direction in the figures). This is done while providing tactile feed back to indicate full connector engagement. In addition, upon reaching the down stop, in this embodiment, the mechanism has a positive torque without transmitting load into either the connector system or the mother or daughter boards.
FIG. 5 provides for an illustration of the assembly 200 into a rack or housing assembly 500 that houses one or more electronic components housed on logic cards, in an environment that includes at least one CEC. Telescoping feature of the slide mechanism 110 is also illustrated. One intent in providing the illustration of FIG. 5 is to provide better detail as with regards to structural support means incorporated between the logic card assembly and CEC assembly, to facilitate logic card installation and servicing. Specifically, to eliminate lift and support field tools used during logic card servicing and internal pluggable FRU replacement, the assembly 200 incorporates ball bearing (rigid, or some such configuration) slides enabling the deployment of the logic card assembly out of the CEC enclosure. As noted in the previous discussion and in accordance to FIG. 5 , the slide mechanisms 110 can incorporate détente features to provide multiple, controlled deployment positions during servicing as desired.
In addition, the slide mechanisms 110 provide additional support and control with the employment of logic card based features, especially when engaged with the outrigger u-channels 510 of CEC top and bottom plates when used with the assembly of the previously enumerated application Ser. No. 11/262,051.
In one embodiment of the present invention, the fixed portion of each slide 110 is attached to vertical wedge 130 and the sliding members 111 are attached to the node (not shown). Positional stops and détente features are incorporated into the custom outrigger 510 to control the deployment distance as well. The outrigger also provides additional telescopic movement and support to the slide mechanisms 110 when the node is fully deployed for FRU servicing (especially intra-logic FRU servicing). In one embodiment, the outriggers 510 can assist in cable management as well by facilitating temporary and/or permanent support for cables during shipping, normal system operation of the environment and/or logic card servicing.
FIG. 6 provides for an alternate embodiment of the present invention where additional supporting and stiffening features are connected to the assembly 200 . As illustrated in FIG. 6 , the stiffening and support structure 600 can be incorporated in areas surrounding the surface-mount interconnect, such as the mid-plane connector area 610 . The stiffening member 600 can be fastened such that in surrounds connector on the daughter card and provides attachment to the assembly 200 . In addition guidance mechanism 601 can also be provided to provide a better connection and mating of (daughter board) logic cards as illustrated.
The stiffening member 600 minimizes or entirely eliminates potentially damaging strains on the logic cards where the electronic components reside and the daughter board connector solder-attached interface.
Many materials and fabrication schemes are available for the stiffening member 600 as known by those skilled in the art. However, in a preferred embodiment, the stiffening member 600 is formed from a cast or machined metal or metallic molded polymer.
Now that the figures are discussed individually, the key features of the assembly 200 will be discussed in general with respect to all the figures. As provided the approach provided by the assembly 200 provides for an integrated outrigger mechanism enabling the removal of the mid-plane, where used, in the field without the removal of the nodes or pluggable FRUs within them ( FIGS. 5 and 6 ). The assembly also provides for a means to smoothly guide support and actuate large daughter card assemblies relying only on the specified characteristics (gatherability) of the interconnect system ( FIGS. 4 through 6 ). The mechanism incorporates a dwell and integrated positional (downstop) feature minimizing adverse mechanical effects to the interconnect system both during and after mating and even during transportation and shipping of any computing environment such as the ones provided in a rack system. In addition, the mechanisms provided in the assembly 200 provide for additional structural support, especially to the SMT connector, whereby minimizing dangerous mechanical strains on the connector during actuation. In addition, the assembly provides the means to replace worn or damaged slides or actuators without removing the mid-plane board.
In one embodiment, the assembly 200 also provides for a pinned approach that facilitates a floating actuation effect, whereby allowing the assembly 200 to be resident on a daughter card rather than its mating mid-plane board. This feature focuses any cost burden to the daughter card which in turn minimizes impact to non-fully populated system configuration in a computing environment.
While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
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An actuation assembly and method is provided for mating electronic unto a computer rack comprising a main housing engageably securable to a slide assembly. The slide assembly is capable of being secured to a side of the computer rack and having sliding features such that the slide assembly and the main housing when engaged can be telescoped out or returned to a closed position. The main housing having a vertical wedge for securing said assembly to said rack more securely and a drive wedge for moving the vertical wedge such that it can telescope into and out of said rack with said slide mechanism via a lead screw.
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This is a continuation of application Ser. No. 923,227, filed Oct. 27, 1986, now U.S. Pat. No. 4,775,015, issued Oct. 4, 1988.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sliding-weight operated tools, and more particularly to sliding-weight operated hole boring tools.
2. Background of the Invention
Sliding-weight operated tools have been around for a number of years U.S. Pat. No. 716,274, issued in 1902, discloses one such tool, which comprises a rod having dual collars, a sliding weight disposed on the rod between the collars, and tool bits disposed on the rod on opposite ends of the rod from the collars. The tool was designed to be used to form holes in masonry, and in operation, one of the tool bits (for example, a hollow cylinder) is placed against the masonry such that the tool extends perpendicularly from the masonry. The sliding weight is then repeatedly and forcefully slid into contact with the collar adjacent the tool bit. The momentum of the weight is transferred to the tool bit at each strike of the collar by the weight, thereby causing the tool bit to penetrate the masonry and form a hole therein.
U.S. Pat. No. 3,050,095 discloses another sliding-weight operated tool, which comprises a hexagonal rod having a tear-drop shaped tool bit on one end thereof, a first collar adjacent the other end, a second collar intermediate the first collar and the tool bit, and a sliding weight disposed on the rod between the two collars. The sliding-weight has two handles projecting outwardly therefrom, and the tool is described as being useful for boring holes in tree stumps. In operation, the sliding weight is slid upwardly and downwardly between the two collars and when it strikes the second collar, the impact is transmitted to the tool bit, which forms a hole in the tree stump.
U.S. Pat. No. 3,568,657 discloses a tool for breaking rocks, similar to the tool of U.S. Pat. No. 716,274, in which various means are provided to remove the sliding weight from the tool.
Yet another sliding-weight operated tool is described in U.S. Pat. No. 4,241,795. In that tool (a "manual jack hammer"), the sliding weight is a rod disposed within a shaft, and strikes a tool bit, a portion of which is elastically retained in the lower end of the shaft.
While it appears that these tools would function well in carrying out the jobs for which they were intended, they are inherently limited by their structure as to the length or depth of holes which they are capable of boring. Also, they would not function well in certain soil conditions.
SUMMARY OF THE INVENTION
The device of the present invention is a sliding-weight operated boring tool which is preferably variable in length to allow holes of various length or depth to be formed therewith. The device preferably has means to facilitate boring in tough soil conditions.
The sliding-weight operated boring tool has a tool drive means adjacent one end thereof, and a tool bit adjacent the other end. The tool drive means serves to provide a driving force to enable the tool bit to form a hole, and comprises a shaft and a sliding weight, the shaft having means to limit relative movement between the shaft and the sliding weight. The means to vary the length of the tool preferably comprises elongated stems with means to quickly and easily connect the stems intermediate the tool drive means and the tool bit.
A hole may be begun with a tool bit directly connected to the tool drive means. The sliding weight is reciprocated on the shaft, and each strike of the movement-limiting means by the sliding weight imparts momentum to the tool bit, lengthening the hole. Elongated stems are periodically added to the tool to enable the tool to bore a hole having the desired length or depth.
If the soil is particularly hard to bore through, it may be desirable to use a pressurized fluid, such as water, to aid in the boring of the hole. In such a case, means are provided to connect a source of fluid to the tool, and means are provided to allow the fluid to pass through the tool, and exit via one or more fluid ports in the tool bit.
The tool bit is preferably shaped such that it forms a hole having compacted walls as it penetrates the ground, and also compacts, against the walls of the hole as the tool bit is removed therefrom, dirt which may fall into the hole.
It is an object of the present invention to provide a variable length sliding-weight operated boring tool.
It is a further object of the present invention to provide a sliding-weight operated boring tool having means to quickly and easily vary the length thereof.
Another object of the present invention is to provide a sliding-weight operated boring tool having means to allow a fluid to pass therethrough.
Yet another object of the present invention is to provide a variable-length sliding-weight operated boring tool which has means to allow a fluid to pass therethrough.
It is also an object of the present invention to provide a sliding-weight operated boring tool having a tool bit comprising means to form a bore having compacted walls, and means to compact dirt against the wall of a bore when the tool is retrieved from a bore.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects and advantages of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 is a perspective view of component parts of the preferred embodiment of the device of the present invention.
FIG. 2 is a perspective view of the preferred embodiment of the device of the present invention being used to wet bore a horizontal hole.
FIG. 3 is a perspective view of the preferred embodiment of the present invention being used to dry bore a vertical hole.
FIG. 4 is a perspective view of the device of the preferred embodiment of the present invention assembled for dry boring.
FIG. 5 is a perspective view of the preferred embodiment of the present invention assembled for wet boring.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the device of the present invention is a sliding-weight operated hole boring tool 10, component parts of which are illustrated in FIG. 1. Tool 10 includes a tool drive means 40 comprising a hollow shaft 41 having collars 42, 43 disposed adjacent ends thereof, and a sliding weight 20 carried on shaft 41 between collars 42 and 43. Collars 42 and 43 serve to limit movement of sliding weight 20 relative to shaft 41. A first end 44 of shaft 41 has male threads thereon for receiving a female-threaded end 32 of an elongated bore stem 30, and a second end 45 of shaft 41 is provided with female threads for receiving either a male threaded plug 55 or an elbow hose coupling 50, depending on whether the soil conditions permit dry boring or require wet boring.
Sliding weight 20 comprises a sleeve 21, adapted to be easily gripped by one's hand, and two weight collars 22 disposed adjacent opposite ends thereof. Each bore stem 30 has, in addition to female-threaded end 32, a male-threaded end 31 for receiving either another bore stem 30, or a tool bit 60. Tool bit 60 comprises two generally frustoconical portions 61 and 62 on opposite ends of a cylindrical portion 63. A plurality of water ports 64 are provided in front frustoconical portion 61 of tool bit 60, to permit water to be ejected into the bore when wet boring is necessary. A heavy duty supply hose 70 has a male-threaded end 71 for attachment to elbow 50, and a quick-connect coupling 72 on the other end for connection to a suitable source of pressurized fluid, such as a water hose.
Threaded connectors are the preferred means for connecting tool bit 60, bore stems 30 and tool drive means 40, as they provide a relatively strong, fluid-tight connection and enable assembly and disassembly of tool 10 to be performed relatively quickly and easily.
Shaft 41, sleeve 21 and bore stems 30 are made of a suitably strong material, such as steel. Weight collars 22 and tool bit 60 are preferably made of steel.
When dry boring, plug 55 is screwed into female-threaded end 45 of shaft 41, a female-threaded end 32 of a bore stem 30 is screwed onto male-threaded end 44 of shaft 41, and tool bit 60 is screwed onto male-threaded end 31 of bore stem 30 (FIG. 4). If boring a vertical hole (FIG. 3), tool 10 is vertically positioned with front frustoconical portion 61 on the ground at the spot where the hole is to be bored. Sliding weight 20 is slid up and down on shaft 41 and, with each downward slide, forcefully contacts collar 42. Momentum is transferred from sliding weight 20 to tool bit 60 via bore stem 30. As tool bit 60 is pounded into the ground, front frustoconical portion 61 forces soil to the sides of the bore, forming a bore with compacted walls. When the bore is so deep that end 44 of shaft 41 is adjacent the surface of the ground, tool drive means 40 is disconnected from bore stem 30, a second bore stem is connected to the first bore stem, and tool drive means 40 is connected to the second bore stem. Tool bit 60 is again pounded into the ground by means of sliding weight 20, and more bore stems are added as needed to achieve a bore having the desired depth. Tool bit 60 is designed to penetrate such things as brick and broken concrete, so one must take care to locate any existing utilities, as tool bit 60 may also cut through metal pipes and cables. Once the desired depth has been reached, tool 10 is pulled from the bore, either in one piece or in sections. Any dirt that may fall or have fallen into the bore is compacted against the wall of the bore, by back frustoconical portion 62 of tool bit 60 during retrieval of tool 10. Should any resistance to the removal of tool 10 be encountered, sliding weight 20 may be used to strike collar 43 to facilitate the removal of tool 10.
When dry boring a horizontal hole, the procedure is essentially the same. Tool 10 is aligned coaxially with the longitudinal axis of the desired bore, and sliding weight 20 is slid back and forth on shaft 41, transferring momentum to tool bit 60 when sliding weight 20 forcefully contacts collar 42 on each forward slide.
When wet boring, plug 55 is replaced with elbow hose coupling 50 and heavy duty hose 70 (FIG. 5). A garden hose 80 (shown in FIG. 2) is connected to heavy duty hose 70, providing a source of pressurized water for tool 10. The water flows through shaft 41, bore stems 30, and exits tool 10 via fluid ports 64 in tool bit 60. With the water flowing through tool 10, sliding weight 20 is slid back and forth or up and down (depending on whether a horizontal or vertical hole is being bored) until end 44 of shaft 41 is adjacent an end of the hole. A faucet supplying water to garden hose 80 is shut off and/or garden hose 80 is disconnected from heavy duty hose 70 (preferably, quick-connect coupling 72 is of a type that no water flows out of garden hose 80 when it is disconnected from heavy duty hose 70), and another bore stem 30 is added to tool 10. Garden hose 80 (if it had been disconnected) is then connected again to tool 10, and boring of the hole resumes. When the hole is completed (FIG. 2), garden hose 80 is again disconnected from tool 10, and tool 10 is pulled out of the hole, in one piece if space permits, or is disassembled as it is removed.
It should be noted that the sliding weight could comprise a rod which would fit in a shaft, with a handle at an end of the rod. Also, a more massive sliding weight than would be practical for use in horizontal boring could be used when boring a vertical hole, in which case the sliding weight could comprise handles to facilitate lifting of the sliding weight. These and other modifications could be made to the preferred embodiment shown and described herein, without departing from the spirit or scope of the present invention. I therefore pray that my rights to the present invention be limited only by the following claims.
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A sliding-weight operated hole boring tool can be used to make holes of various length or depth in varied soil conditions. A uniquely-shaped tool bit helps to form a smooth, clean hole. In preferred embodiments, detachable elongated stems are used to vary the length of the tool, and water is used to aid boring in hard soil.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 456,121 filed Jan. 10, 1983, now U.S. Pat. No. 4,503,236 issued Mar. 5, 1985, which in turn is a continuation-in-part of application Ser. No. 369,448 filed Apr. 19, 1982, now abandoned.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,288,596 discloses certain substituted furo[3,2-b]indoles which are reported to have anti-inflammatory and analgesic effects.
SUMMARY OF THE INVENTION
The invention sought to be patented in its generic chemical compound aspect is a compound having the structural formula I R 3 is ##STR1## wherein R is H, alkyl of from one to six carbon atoms, alkoxy of from one to six carbon atoms, halogen or nitro; R 1 is alkyl of from one to six carbon atoms, phenyl or benzyl; R 2 is alkyl of from one to six carbon atoms; R 3 is ##STR2## and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a first specific chemical compound aspect is the compound having the name 3,7-dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)4H-furo[3,2-b]indole-2-carboxamide, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a second specific chemical compound aspect is the compound having the name 3-ethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a third specific chemical compound aspect is the compound having the name 3-methoxy-4-phenyl-2-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a fourth specific chemical compound aspect is the compound having the name 3-ethoxy-4-phenyl-2-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in an fifth specific chemical compound aspect is the compound having the name 3-methoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a sixth specific chemical compound aspect is the compound having the name 3-methoxy-4-methyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in an seventh specific chemical compound aspect is the compound having the name 3-ethoxy-7-methoxy-4-phenyl -N-(1H-tetrazol-5yl)-4H-furo[3,2-b]indole-2-carboxamide, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a eighth specific chemical compound aspect is the compound having the name 3-methoxy-4-methyl-2-(1H-tetrazol-yl)-4H-furo[3,2-b]indole, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in a ninth specific chemical compound aspect is the compound having the name 3,7-dimethoxy-4-phenyl-2-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole, and the pharmaceutically acceptable salts thereof.
The invention sought to be patented in its generic chemical process aspect is a process for preparing a compound having structural formula I which comprises the steps of:
(a) alkylating a compound having the structural formula IV ##STR3## to produce a compound having the structural formula V ##STR4## wherein R, R 1 , and R 2 are as defined above and R 4 may be any convenient alkyl group,
(b) hydrolyzing the ester function of Compound V to produce the corresponding carboxylic acid if desired;
(c) converting the carboxylic acid or ester to the corresponding 1H-tetrazol-5-yl compound or N-(1H-tetrazol-5-yl)carboxamide if desired; and
(d) optionally converting the compound having structural formula I to a pharmaceutically acceptable salt.
The invention sought to be patented in its generic pharmaceutical composition aspect is a composition consisting essentially of a compound having structural formula I in combination with a pharmaceutically acceptable carrier.
The invention sought to be patented in one pharmaceutical method aspect is a method for treating allergies in a mammal in need of such treatment which comprises administering an effective amount of the above defined pharmaceutical composition to said mammal.
The invention ought to be patented in a second pharmaceutical method aspect is a method for treating postmyocardial infarct tissue damage in a mammal in need of such treatment which comprises administering a neutrophil-inhibiting effective amount of a compound as defined above to said mammal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compounds of the invention having structural formula I wherein R 3 is COOH are readily prepared by the following reaction sequence. ##STR5##
The starting materials having structural formula II are readily prepared by known procedures [see Berichte, 55, 1597 (1922) which describes Compound II wherein R=H]. Compound II is converted to Compound III by treatment with an ester of a haloacetic acid such as methyl bromoacetate in the presence of anhydrous potassium carbonate in a convenient solvent such as acetone. The two R 4 groups in structural formula III represent any convenient alkyl groups such as methyl or ethyl and they may be the same or different.
Compound III may next be treated with a strong base such as potassium-t-butoxide in a convenient solvent such as tetrahydrofuran to produce the compound having structural formula IV.
The hydroxyl group of Compound IV may next be alkylated in a conventional manner to produce Compound V. A convenient alkylating procedure utilizes a dialkylsulfate such as dimethylsulfate in the presence of a base such as potassium carbonate in a convenient solvent such as acetone.
The ester function of Compound V may then by hydrolyzed for example in an alcoholic basic medium such as methanolic sodium hydroxide to produce the compounds of formula I wherein R 3 is COOH.
The compounds of the invention wherein R 3 is ##STR6## may be prepared from the corresponding acids or esters by methods familiar to those skilled in the art. For example, the properly substituted carboxylic acid may be converted to the corresponding acid halide such as the chloride by treatment with thionyl chloride or oxalyl chloride and converted to the acid amide by treatment with ammonia. The amide is dehydrated by treatment with, for example, p-toluenesulfonyl chloride and pyridine in dimethylformamide thereby producing the corresponding nitrile, which when treated with sodium azide and aluminum chloride, for example, will yield the corresponding tetrazole. The above-described amides may also be prepared directly from the corresponding esters by treatment with, for example, lithium amide in liquid ammonia by methods familiar to those skilled in the art.
Other methods and reagents for converting carboxylic acids or esters into the corresponding tetrazoles will be familiar to those skilled in the art.
The compounds of the invention wherein R 3 is ##STR7## may be prepared from the corresponding acid halide, such as the above-described acid chloride, by treatment with 5-aminotetrazole. Alternatively, the properly substituted carboxylic acid may be directly coupled with 5-aminotetrazole; by use of such agents as N-ethoxycarbonyl-2-ethoxy-1,2-dihydroquinolone (EEDQ), dicyclohexylcarbodiimide (DCC) or 1,1'-carbonyldiimidazole and the like.
The compounds of the invention having structural formula I wherein R 3 is ##STR8## are acidic in nature and form pharmaceutically acceptable salts with both organic and inorganic bases such as alkyl amines, especially tertiary alkyl amines such as triethylamine, hydroxylated alkyl amines such as tris(hydroxymethyl)aminomethane, cycloaliphatic amines such as piperidine, alkylene diamines such as 1,2-ethanediamine, and basic amino acids such as L-(+) arginine, the alkali metal and alkaline earth hydroxides, and the alkali metal carbonates and bicarbonates, such as lithium, sodium, potassium, and calcium hydroxide, and the carbonates and bicarbonates of lithium, sodium, and potassium. The salts are prepared by reacting the tetrazole or the carboxamidotetrazole with the desired base in the conventional manner. The tetrazoles and the carboxamidotetrazoles differ from their respective salts somewhat in certain physical properties such as solubility in polar solvents, but the salts are otherwise equivalent to their respective acids for purposes of the invention.
The compounds of the invention display antiallergic properties when tested by the following procedure [modification of Shultz-Dale procedure, Agents and Actions, 8, 171 (1978)]: Guinea pigs, after one week environmental stabilization, are immunized IP with 1 mg crude ovalbumin (OA) in 1 ml saline with 50% complete Freund's Adjuvant (CFA). Twenty-one days later animals are killed by a blow to the head. Trachea and lungs are removed and placed in Tyrode's solution, pH 7.4, aerated with 5% CO 2 in O 2 .
Trachea: Connective and vascular tissue are removed and a wooden stick is inserted in the lumen. One end of the trachea is fixed with a pin. The stick is held against a surgical blade and rotated in a helical manner. Spirals formed are cut into two lengths, each containing two or more bands of transverse strips of tracheal muscle. The tissue is attached to transducers and maintained at 5 g tension. Sensitivity of the preamplifier is 2.0 mv/cm and of the amplifier, 0.02 mv/cm, with calibration of 20 mg force displacement per mm. After 45 minutes equilibration, the tissue is challenged with antigen.
Lung: The heart and lung are removed as a unit and the lung is perfused with buffer by the spontaneously beating heart for several minutes. Distal strips of lung from the diaphragmatic lobe approximately 0.3 cm wide and 3 cm long are removed and attached to transducers. Preload is 0.3 g of tension with sensitivity at 0.02 mv/cm on the amplifier and 0.5 mv/cm on the preamp and calibration of 1 mm=5 mg force displacement.
Test Design for Evaluation of Drugs: All tissues are challenged repetitively with the same concentration of antigen. After each concentration, the tissue is washed and allowed to stabilize. The original baseline tension is reestablished before the next challenge. Control contractions in lung must develop a minimum of 10 mg and in trachea, a minimum of 40 mg tension above baseline. When the contractions are reproducible, drug is introduced. Drug effects of baseline are monitored. Ten minutes later, after readjustment to baseline tension as indicated by consecutive reading one minute apart, tissue is again challenged with antigen. The concentration is monitored for at least 15 minutes and the tissue is washed free of antigen and drug. If the drug did not exhibit the Schultz-Dale reaction, the experiment is complete. Tissues are not used again. If inhibition takes place, a final antigen challenge is repeated to establish that the tissue is reactive to antigen.
Utilizing the above test procedure, the following results were obtained for representative compounds of the invention.
TABLE 1______________________________________ ##STR9## % InhibitionR R.sub.1 R.sub.2 R.sub.3 3 × 10.sup.-5 M______________________________________H CH.sub.3 CH.sub.3 ##STR10## 38H C.sub.6 H.sub.5 CH.sub.3 " 100CH.sub.3 O C.sub.6 H.sub.5 CH.sub.3 " 100CH.sub.3 O C.sub.6 H.sub.5 C.sub.2 H.sub.5 " 100H C.sub.6 H.sub.5 C.sub.2 H.sub.5 " 100H CH.sub.3 CH.sub.3 ##STR11## 26CH.sub.3 O C.sub.6 H.sub.5 CH.sub.3 " 100H C.sub.6 H.sub.5 C.sub.2 H.sub.5 " 100______________________________________
The compounds of the present invention have been found to also display the property of inhibiting the action of polymorphonuclear leukocytes (neutrophils).
Lautsch, Texas Rep. Biol. Med., 39, 371 (1979) has demonstrated that in cases of myocardial infarction, there is an accumulation of polymorphonuclear leukocytes in the damaged myocardial tissue. Romson et al, Circulation, 67, 1016 (1983) state that stimulated neutrophils release highly active and cytotoxic activated oxygen species such as the superoxide anion, hydroxyl radical, hydrogen peroxide, and singlet oxygen. These activated oxygen radicals degrade extracellular macromolecules, attack membrane phospholipids, and thus promote cell injury. In addition, activated neutorophils release lysosomal enzymes capable of proteolytic disruption and liquefaction of viable as well as irreversibly damaged tissue. Finally, stimulated neutrophils trigger membrane phospholipids to release arachidonic acid, which is converted by specific lipoxygenases to potent chemotactic hydroxy-eicosatetraenoic acids (HETEs). These chemoattractant substances promote the further recruitment of neutrophils onto the acute inflammatory response at the site of the tissue injury.
The compounds of the present invention inhibit the action of activated neutrophils and are thus useful in the amelioration and treatment of postmyocardial infarct tissue damage. The neutrophil inhibitory properties of the compounds of this invention were tested by means of an assay which determined the percent inhibition of the release of myeloperoxidase, lysozyme, beta-glucuronidase, superoxide anion, and hydrogen peroxide by neutrophils. The details of the procotol of this assay appear in Wright, et al, Infection and Immunity, 32, 731 (1981). The results of the tests appear in Table 2.
TABLE 2__________________________________________________________________________ ##STR12##Dose Myelo- Percent of Control Superoxide Hydrogen(μm/liter) peroxidase BGlucuronidase Lysosome Anion Peroxide__________________________________________________________________________1.0 96.8 ± 18.5 91.2 ± 15.7 96.0 ± 1.3 96.0 ± 5.8 77.7 ± 2.53.3 75.4 ± 29.8 67.1 ± 0.1 98.7 ± 6.8 98.7 ± 4.0 59.5 ± 2.810.0 40.4 ± 19.8 53.2 ± 9.8 56.4 ± 1.3 56.4 ± 0.7 34.3 ± 1.533.0 30.2 ± 17.4 43.0 ± 27.0 39.8 ± 4.1 39.8 ± 0.6 11.8 ± 4.3100.0 43.7 ± 30.9 38.2 ± 19.3 13.6 ± 13.6 13.6 ± 4.1 20.1 ± 6.2IC.sub.50 Value 18.0 21.5 17.4 19.8 5.3__________________________________________________________________________
The compounds of the invention can exist in unsolvated as well as solvated forms, including hydrated forms. In general, the solvated forms, with pharmaceutically acceptable solvents such as water, ethanol, and the like are equivalent to the unsolvated forms for purposes of the invention.
The alkyl groups and alkoxy groups contemplated by the invention comprise both straight and branched carbon chains of from one to about six carbon atoms. Representative of such groups are methyl, ethyl, isopropyl, pentyl, 3-methylpentyl, methoxy, ethoxy, i-propoxy, and the like.
Some of the compounds of the invention may comprise an asymmetric carbon atom. The pure D isomer, pure L isomer, as well as mixtures thereof are contemplated by the invention. Asymmetric carbon atoms may be present in a substituent such as an alkyl group. All such isomers as well as mixtures thereof are intended to be included in the invention.
The compounds of the invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of formula I, or a corresponding pharmaceutically acceptable salt of a compound of formula I, or a mixture of such compounds and/or salts.
For preparing pharmaceutical compositions from the compounds described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersable granules, capsules, cachets, and suppositories. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, or tablet disintegrating agents; it can also be an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active compound. In the tablet the active compound is mixed with carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain from 5 or 10 to about 70 percent of the active ingredient. Suitable solid carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methyl cellulose, sodium carboxymethyl cellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component (with or without other carriers) is surrounded by carrier, which is thus in association with it. Similarly, cachets are included. Tablets, powders, cachets and capsules can be used as solid dosage forms suitable for oral administration.
Liquid form preparations include solutions, suspensions, and emulsions. As an example may be mentioned water or water-propylene glycol solutions for parenteral injection. Liquid preparations can also be formulated in solution in aqueous polyethylene glycol solution. Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing, and thickening agents as desired. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, i.e., natural or synthetic gums, resins, methyl cellulose, sodium carboxymethyl cellulose, and other well-known suspending agents.
Preferably, the pharmaceutical preparation is in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, for example, packeted tablets, capsules and powders in vials or ampoules. The unit dosage form can also be a capsule, cachet, or tablet itself or it can be the appropriate number of any of these packaged forms.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from 1 mg to 100 mg according to the particular application and the potency of the active ingredient.
In therapeutic use as antiallergic agents, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 0.1 mg to about 100 mg per kilogram daily. A daily dose range of about 0.5 mg to about 25 mg per kilogram is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For conven:ence, the total daily dosage may be divided and administered in portions during the day if desired.
The following nonlimiting examples illustrate the inventor's preferred methods for preparing the compounds of the invention.
EXAMPLE 1
5-Methoxy-3-(2-methoxy-2-oxoethoxy)-1-phenyl-1H-indole-2-carboxylic acid methyl ester
A mixture of 59.5 g (0.20 mole) of 3-hydroxy-5-methoxy-1-phenyl-1H-indole-2-carboxylic acid methyl ester, 32.0 g (0.23 mole) of potassium carbonate (anhydrous), and 19 ml (34.7 g, 0.23 mole) of methyl bromoacetate in 800 ml acetone was stirred at reflux for 24 hours. The mixture was cooled, and the insoluble material was filtered and washed several times with fresh acetone. The combined filtrates were evaporated to yield the crude diester product as an oil which slowly crystallized. A sample recrystallized several times from methanol was analytically pure, mp 97°-100° C.
EXAMPLE 2
3-Hydroxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
A suspension of 30 g (0.27 mole) of potassium tert-butoxide in 400 ml of tetrahydrofuran was stirred and cooled in ice while a solution of 67.0 g (0.18 mole) of 5-methoxy-3-(2-methoxy-2-oxoethoxy)-1-phenyl-1H-indole-2-carboxylic acid methyl ester was added over 45 minutes. The rate of addition was adjusted to maintain the temperature of the reaction mixture at <15° C. The mixture was allows to slowly warm to room temperature and was stirred for 16 hours. The mixture was again cooled in ice, treated with 25 ml of glacial acetic acid, and added to 2.75 kg ice/water. After stirring for several hours, the solid was filtered, stirred in 1.0 l fresh water, and refiltered. Recrystallization from N,N-dimethylformamide/water yielded the furoindole product as a yellow solid of mp 141°-144° C. (49.8 g, 74% yield). An additional recrystallization from 2-methoxyethanol/water yielded a sample of analytical purity, mp 141°-143° C.
EXAMPLE 3
3,7-Dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
A mixture of 30 g (0.089 mole) of 3-hydroxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester, 13.4 g (0.098 mole) of anhydrous potassium carbonate, and 9.0 ml (12.0 g, 0.095 mole) of dimethyl sulfate in 525 ml acetone was stirred at reflux for 42 hours. The mixture was cooled and the insoluble material was washed several times with fresh acetone. The combined filtrates were evaporated, and the residue was recrystallized from methanol/water to yield to methoxy ester product (25.0 g, 80% yield), mp 89°-92° C. Several additional recrystallizations yielded an analytically pure sample, mp 93°-95° C.
EXAMPLE 4
3,7-Dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid
A suspension of 11.5 g (0.033 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester in 200 ml of 50% aqueous ethanol was treated with 25 ml of 10% aqueous sodium hydroxide solution. After stirring at reflux for 90 minutes, the reaction mixture was cooled and distributed between 750 ml of water and 250 ml of dichloromethane. The insoluble material (primarily the sodium salt of the product) was removed by filtration. The filtrate layers were separated, and the organic layer was discarded. The aqueous layer was washed several times with fresh dichloromethane, cooled in ice, and acidified with 4N hydrochloric acid. The precipitate crude product was filtered and washed with water. The original insoluble sodium salt was stirred for several hours in 400 ml of cold 1N hydrochloric acid, and the product acid was filtered, washed with water, and combined with the material obtained from acidification of the original aqueous layer. The crude yield of the furoindole acid was 9.4 g (85%) yield). A sample recrystallized from acetone/water was analytically pure, mp 148° C. (dec).
EXAMPLE 5
3,7-Dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide
A mixture of 7.5 g (0.022 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid and 7.5 g (0.046 mole) of 1,1'-carbonyldiimidazole in 50 ml of N,N-dimethylformamide was stirred and heated on the steam bath for 30 minutes. The mixture was cooled, 2.6 g (0.026 mole) of 5-aminotetrazole monohydrate was added, and heating was continued for an additional 30 minutes. The cooled reaction mixture was added to 350 g ice/water and acidified with 4N hydrochloric acid. The precipitated product was filtered, washed with water, and recrystallized from N,N-dimethylformamide/water (charcoal) to yield 6.0 g (61% yield) of the tetrazole amide product as a complex containing 0.5 mole of N,N-dimethylformamide. An additional recrystallization as above yielded an analytically pure sample of mp 231° C. (dec).
EXAMPLE 6
3-Ethoxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
Prepared by the procedure described in Example 3, except that diethyl sulfate was substituted for dimethyl sulfate. There was obtained 5.0 g (36% yield) of the ethoxy ester product from 12.9 g (0.038 mole) of 3-hydroxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester. Several recrystallizations from aqueous methanol yielded the product as white needles in analytical purity, mp 119°-120.5° C.
EXAMPLE 7
3-(2-Methoxy-2-oxoethoxy)-1-phenyl-1H-indole-2-carboxylic acid methyl ester
Prepared by the procedure described in Example 1 from 120 g (0.45 mole) of 3-hydroxy-1-phenyl-1H-indole-2-carboxylic acid methyl ester. Recrystallization of the crude product from ethyl acetate/hexane yielded 102 g (67% yield) of the diester, mp 76°-80° C. An additional recrystallization yielded an analytically pure sample, mp 76°-77° C.
EXAMPLE 8
3-Hydroxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
Prepared by the procedure described in Example 2 from 29.0 g (0.085 mole) of 3-(2-methoxy-2-oxoethoxy)-1-phenyl-1H-indole-2-carboxylic acid methyl ester. Recrystallization of the crude product from ethanol yielded 15.9 g (60% yield) of the enol ester in analytical purity, mp 152°-154° C.
EXAMPLE 9
3-Methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
Prepared by the procedure described in Example 3 from 16.0 g (0.052 mole) of 3-hydroxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester. Recrystallization of the crude product from aqueous ethanol yielded 13.5 g (81% yield) of the methoxy ester in analytical purity, mp 131°-133° C.
EXAMPLE 10
3-Ethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester
A mixture of 24.3 g (0.079 mole) of 3-hydroxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester and 10.7 g (0.095 mole) of potassium tertbutoxide in 240 ml of dimethyl sulfoxide was stirred and treated over 45 minutes with 64.4 g (54.7 ml, 0.42 mole) of diethyl sulfate. After stirring for 24 hours, the mixture was added to 1.5 kg of ice/water. The clear liquid was decanted from the resulting gummy product. Recrystallization of the residual gum from aqueous ethanol yielded 18.8 g (71% yield) of analytically pure ethoxy ester, mp 82°-84° C.
EXAMPLE 11
3-Methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid
A suspension of 13.5 g (0.042 mole) of 3-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester in 75 ml of methanol was treated with 70.6 ml of 1.0 N aqueous sodium hydroxide. The mixture was stirred at reflux for 17 hours, then added to 1.4 l of water. The insoluble material was filtered, added to 1.0 l of water, and acidified with acetic acid while cooling in an ice bath. The crude acid product was recovered by filtration. The original filtrate from the reaction mixture and 1.4 l of water was also cooled in ice and acidified with acetic acid. The crude product obtained was filtered and combined with the earlier crop. The combined crude products were stirred in 400 ml of water, filtered, and recrystallized from methanol. There was obtained 5.8 g (45% yield) of analytically pure acid, mp 154°-155° C.
EXAMPLE 12
3-Methoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide
Prepared by the procedure described in Example 5 from 6.1 g (0.020 mole) of 3-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid. Recrystallization of the crude product from N,N-dimethylformamide/water yielded 4.4 g (59% yield) of analytically pure tetrazole amide, mp 270° C. (dec).
EXAMPLE 13
3-Methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid
Prepared by the procedure described in Example 4 from 35.8 g (0.13 mole) of 3-methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid ethyl ester. The crude acid product obtained was 23 g (72% yield). A sample recrystallized from N,N-dimethylformamide/water was analytically pure, mp 141° C. (dec).
EXAMPLE 14
3-Methoxy-4-methyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide
A mixture of 1.9 g (0.0078 mole) of 3-methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid and 1.4 g (0.0086 mole) of 1,1'-carbonyldiimidazole in 20 ml of N,N-dimethylformamide was stirred and heated on the steam bath for 20 minutes. The mixture was cooled, 0.85 g (0.0083 mole) of 5-aminotetrazole monohydrate was added, and heating was continued for an additional 20 minutes. Upon cooling, the tetrazole amide product precipitated, and the solid was filtered and washed with water. Recrystallization from N,N-dimethylformamide/water yielded 1.1 g (38% yield) of the product, mp 235° C. (dec). An additional recrystallization as above yielded an analytically pure sample (same mp) as a complex containing 1.0 mole of N,N-dimethylformamide.
EXAMPLE 15
3-Methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid ethyl ester
Prepared by the procedure described in Example 3 from 47 g (0.18 mole) of 3-hydroxy-4-methyl-4H-furo-[3,2-b]indole-2-carboxylic acid ethyl ester. Recrystallization of the crude product from aqueous ethanol yielded 42.2 g (85% yield) of the methoxy ester product, mp 90°-92° C. An additional recrystallization as above yielded an analytically pure sample, mp 93°-95° C.
EXAMPLE 16
3-Hydroxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid ethyl ester
A suspension of 10.8 g (0.096 mole) of potassium tert-butoxide in 200 ml of benzene was treated over 15 minutes with a solution of 22.4 g (0.074 mole) of 3-(2-ethoxy-2-oxoethoxy)-1-methyl-1H-indole-2-carboxylic acid ethyl ester in 100 ml of benzene. The mixture was then stirred at reflux under a nitrogen atmosphere for 18 hours. The solvent was removed under vacuum, and the residue was cooled in ice and treated with 300 ml of ice water and 200 ml of chloroform. After acidification with acetic acid, the layers were separated, and the aqueous layer was washed with additional chloroform. The combined organic layers were washed with water, 5% aqueous sodium bicarbonate (twice), and again with water. After drying over anhydrous sodium sulfate, the organic layer was evaporated, and the residue was recrystallized from aqueous methanol. There was obtained 8.2 g (43% yield) of the enol ester product, mp 116°-119° C. Several additional recrystallizations as above yielded an analytically pure sample, mp 121°-123° C.
EXAMPLE 17
3-(2-Ethoxy-2-oxoethoxy)-1-methyl-1H-indole-2-carboxylic acid ethyl ester
Prepared by the procedure described in Example 1 from 3-hydroxy-1-methyl-1H-indole-2-carboxylic acid ethyl ester and ethyl bromoacetate. The crude oil product obtained after evaporation was used for further synthesis without additional purification.
EXAMPLE 18
3-Ethoxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid
Prepared by the procedure described in Example 4 from 4.9 g (0.013 mole) of 3-ethoxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester. The crude acid product obtained was 4.0 g (85%) yield). A sample recrystallized from 2-methoxyethanol was analytically pure, mp 166°-167° C.
EXAMPLE 19
3-Ethoxy-7-methoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide
Prepared by the procedure described in Example 5 from 3.0 g (0.085 mole) of 3-ethoxy-7-methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid. Recrystallization of the crude product from N,N-dimethylformamide/water yielded 2.3 g (64% yield) of the tetrazole amide in analytical purity as a complex containing 1.0 mole of N,N-dimethylformamide, mp 243°-247° C.
EXAMPLE 20
3-Methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxamide
A flask fitted with a Dewar condenser containing dry ice/acetone was cooled in a dry ice/acetone bath and charged with 350 ml of anhydrous ammonia. A few crystals of hydrated ferric nitrate catalyst were added, and the cooling bath was removed. Lithium amide was then generated by the addition, over one hour, of 1.78 g (0.26 mole) of freshly cut lithium metal ribbon. After the addition of 65 ml of cold tetrahydrofuran, a solution of 16.5 g (0.060 mole) of 3-methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxylic acid ethyl ester in 75 ml of tetrahydrofuran was added over 30 minutes. The Dewar condenser was removed, and the mixture was stirred for 16 hours as the excess ammonia evaporated. The total reaction mixture was added to 600 g of ice/water, and the crude amide product was filtered and washed with water. Recrystallization from aqueous ethanol yielded 11.7 g (79% yield) of final product, mp 174°-177° C. An additional recrystallization as above yielded an analytically pure sample, mp 179°-182° C.
EXAMPLE 21
3-Methoxy-4-methyl-4H-furo[3,2-b]indole-2-carbonitrile
A mixture of 11.7 g (0.048 mole) of 3-methoxy-4-methyl-4H-furo[3,2-b]indole-2-carboxamide, 11.7 ml (11.5 g, 0.15 mole) of pyridine, and 14.0 g (0.073 mole) of p-toluenesulfonyl chloride in 70 ml of N,N-dimethylformamide was heated on the steam bath under a nitrogen atmosphere for four hours. The mixture was cooled and added to 500 g ice/water, and the crude nitrile product was filtered and washed with water. Recrystallization from ethanol yielded 9.5 g (88% yield) of the analytically pure nitrile, mp 144°-146° C.
EXAMPLE 22
3-Methoxy-4-methyl-2-(1H-tetrazol-5-yl)-4H-furo-[3,2-b)indole
A mixture of 11.3 g (0.050 mole) of 3-methoxy-4-metyl-4H-furo[3,2-b]indole-2-carboxamide, 10.0 g (0.15 mole) of sodium azide, and 8.5 g (0.16 mole) of ammonium chloride in 225 ml of N,N-dimethylformamide was heated on the steam bath under a nitrogen atmosphere for 90 hours. The mixture was cooled, added to 1500 g ice/water, and maintained at 0°-5° C. while being acidified with 6N hydrochloric acid (hydrazoic acid is evolved). The crude tetrazole product was filtered and washed with water. Recrystallization from 2-methoxyethanol/water yielded 7.5 g (56% yield) of the product. Several additional recrystallizations from acetone/water yielded an analytically pure sample containing 0.25 mole of water of hydration, mp 173° C. (dec).
EXAMPLE 23
3,7-Dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxamide
Prepared by the procedure described in Example 20 from 19.5 g (0.056 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester. Recrystallization of the crude product from aqueous ethanol yielded 13.4 g (72% yield) of amide, mp 210°-212° C. An additional recrystallization as above yielded an analytically pure sample, mp 210°-211° C.
EXAMPLE 24
3,7-Dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carbonitrile
Prepared by the procedure described in Example 21 from 12.5 g (0.037 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxamide. Recrystallization of the crude product from ethanol yielded 8.6 g (73% yield) of nitrile, mp 137°-139° C. An additional recrystallization as above yielded an analytically pure sample of identical mp.
EXAMPLE 25
3,7-Dimethoxy-4-phenyl-2-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole
Prepared by the procedure described in Example 22 from 7.2 g (0.023 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carbonitrile, except that the heating time was reduced to 19 hours. The crude tetrazole product after washing with water was recrystallized from 2-methoxyethanol/water and then from acetone/water to yield 3.3 g (40% yield) of product, mp 189°-191° C. An additional recrystallization from acetone/water yielded an analytically pure sample containing 0.5 mole of water of hydration, mp 191°-192° C.
EXAMPLE 26
1,2-Dihydro-6-methoxy-1-phenyl-4H-3,1-benzoxazine-4-one
A mixture of 15.0 g (0.062 mole) of 5-methoxy-2-(phenylamino)benzoic acid and 75 ml of 37% aqueous formaldehyde solution in 75 ml of ethanol was heated on the steam bath for 75 minutes. The mixture was cooled and added to 400 g ice/water. The crude oxazine product was filtered, stirred in 75 ml of 5% aqueous sodium bicarbonate, and refiltered to yield 13.0 g (83% yield) of the product, mp 99.5°-101° C. A sample recrystallized from hexane was analytically pure, mp 100°-102° C.
EXAMPLE 27
2-[(Cyanomethyl)phenylamino]-5-methoxy-benzoic acid
To a solution of 268 g (4.1 mole) of potassium cyanide in 1.6 l of water was added 1021 g (4.0 mole) of 1,2-dihydro-6-methoxy-1-phenyl-4H-3,1-benzoxazine-4-one at a rate such that the reaction mixture temperature was 35°-40° C. The resulting solution was stirred and maintained at 35°-40° C. for two hours, and then added dropwise to a solution of 8.0 l of ice water and 800 ml of acetic acid. The resulting suspended solid was filtered and washed with water to yield 1084 g (96% yield) of the crude nitrile, mp 122°-130° C. This material was used for further synthesis without additional purification.
EXAMPLE 28
2-[(Carboxymethyl)phenylamino]-5-methoxy-benzoic acid
To a solution of 3.4 l of 25% aqueous sodium hydroxide being stirred at reflux was added 1936 g (6.86 mole) of 2-[(cyanomethyl)phenylamino]-5-methoxy-benzoic acid in portions over one hour. After the addition of 1.0 l of water, the resulting solution was stirred at reflux for an additional hour. The solution was cooled, added to 18 kg ice/water, and treated with acetic acid until pH 7. The mixture as filtered, and the filtrate was cooled in ice and made strongly acidic with concentrated hydrochloric acid. The resulting solid was filtered and washed with water to yield 1612 g (78% yield) of the crude diacid product, mp 158°-161° C. This material was converted to the diester without additional purification.
EXAMPLE 29
5-Methoxy-2-[(2-methoxy-2-oxoethyl)phenylamino]benzoic acid methyl ester
A mixture of 113 g (0.40 mole) of 2-[(carboxymethyl)phenylamino]-5-methoxy-benzoic acid in 800 ml of N,N-dimethylformamide was treated with 128 g (0.80 mole) of 25% aqueous sodium hydroxide. After stirring at ambient temperature for 30 minutes, there was added 156 g (1.10 mole) of iodomethane. The mixture was stirred without external heating for three hours, then warmed to 50°-55° C. for 30 minutes. The reaction mixture was added to 1 kg ice/water and the product was extracted by washing several times with dichloromethane. The combined organic layers were back-washed with saturated sodium bicarbonate solution, then water, and dried over anhydrous sodium sulfate. Evaporation of the organic layer left the crude diester as an oil, 106 g (80% yield), which was used for additional synthesis. A sample of the oil crystallized from methanol yielded the final product as a solid in analytical purity, mp 85°-87° C.
EXAMPLE 30
3-Hydroxy-5-methoxy-1-phenyl-1H-indole-2-carboxylic acid methyl ester
A mixture of 1.7 kg (5.2 mole) of 5-methoxy-2-[(2-methoxy-2-oxoethyl)phenylamino]benzoic acid methyl ester, and 303 g (5.6 mole) of sodium methoxide in 10.0 l of anhydrous methanol was stirred at reflux for 90 minutes. The mixture was cooled to 20° C., filtered, and treated with 336 g (320 ml, 5.6 mole) of glacial acetic acid. The mixture was cooled in ice, and the precipitated crude product was filtered and washed with cold methanol followed by hexane. There was obtained 1267 g (82% yield) of the indole product of analytical purity, mp 114°-116° C.
EXAMPLE 31
3-Methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxamide
Prepared by the procedure described in Example 20 from 23.3 g (0.073 mole) of 3-methoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carboxylic acid methyl ester. Recrystallization of the crude product from absolute ethanol yielded 13.7 g (61% yield) of analytically pure amide containing 0.20 mole of water of hydration, mp 207°-208° C.
EXAMPLE 32
3-Methoxy-4-phenyl-4H-furo[3,2-b]indole-2-carbonitrile
Prepared by the procedure described in Example 21 from 13.4 g (0.044 mole) of 3-methoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carboxamide. Recrystallization of the crude product from ethanol/N,N-dimethylformamide yielded 10.3 g (82% yield) of analytically pure nitrile, mp 182°-184° C.
EXAMPLE 33
3-Methoxy-4-phenyl-2-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]-indole
Prepared by the procedure described in Example 25 from 8.9 g (0.031 mole) of 3-methoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carbonitrile. The crude product was recrystallized from dichloromethane/methanol/hexane to yield 3.0 g (29% yield) of analytically pure tetrazole, mp 212° C. (dec).
EXAMPLE 34
3-Ethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid
A suspension of 12.0 g (0.036 mole) of 3-ethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid methyl ester in 100 ml of methanol was treated with 60 ml of 1.0 N aqueous sodium hydroxide. After stirring at reflux for 20 hours, the cooled reaction mixture was added to 1.2 kg ice/water, and the mixture was acidified with acetic acid. The crude product was filtered, stirred in 600 ml water, and refiltered. Recrystallization from ethanol yielded 5.1 g of analytically pure acid containing 0.35 mole of water of hydration, mp 146°-147° C. An additional 1.8 g of product was obtained from the recrystallization filtrate, for a total yield of 6.9 g (59% yield).
EXAMPLE 35
3-Ethoxy-4-phenyl-N(1H-tetrazol-5-yl)-4H-furo[3,2-b]-indole-2-carboxamide
Prepared by the procedure described in Example 5 from 4.7 g (0.015 mole) of 3-ethoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carboxylic acid. Recrystallization of the crude product from N,N-dimethylformamide yielded 3.4 g (50% yield) of the tetrazole amide in analytical purity as a complex containing 1.0 mole of N,N-dimethylformamide, mp 244°-247° C.
EXAMPLE 36
3-Ethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxamide
Prepared by the procedure described in Example 20 from 8.5 g (0.025 mole) of 3-ethoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carboxylic acid methyl ester. The crude amide product, after being washed with water and dried, was 7.5 g (92% yield). This material was converted to the nitrile without additional purification. A portion of the crude amide recrystallized from ethanol yielded an analytically pure sample, mp 187°-188° C.
EXAMPLE 37
3-Ethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carbonitrile
Prepared by the procedure described in Example 21 from 6.5 g (0.020 mole) of 3-ethoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carboxamide. The crude product (5.5 g, 90% yield), after being washed with water and dried, was converted to the corresponding tetrazole without additional purification. A portion of the crude nitrile recrystallized from methanol yielded an analytically pure sample, mp 121°-122° C.
EXAMPLE 38
3-Ethoxy-4-phenyl-2(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole
Prepared by the procedure described in Example 22 from 5.3 g (0.018 mole) of 3-ethoxy-4-phenyl-4H-furo-[3,2-b]indole-2-carbonitrile. The crude product was chromatographed over silica gel to remove unreacted nitrile. A sample recrystallized from ethanol was analytically pure, mp 189°-192° C.
EXAMPLE 39
3,7-Dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid, tris(hydroxymethyl)aminomethane salt
A suspension of 0.67 (0.0020 mole) of 3,7-dimethoxy-4-phenyl-4H-furo[3,2-b]indole-2-carboxylic acid in 100 ml of warm methanol was treated with a warm solution of 0.25 g (0.0021 mole) of tris(hydroxymethyl)aminomethane in 30 ml of methanol. The mixture was digested on the steam bath until nearly one phase, then was filtered hot. The cooled filtrate was evaporated, and the residue was recrystallized from methanol/ether to yield 0.50 g (53% yield) of the hygroscopic "TRIS" salt, mp 151°-153° C.
EXAMPLE 40
3,7-Dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole-2-carboxamide, sodium salt
A suspension of 11.0 g (0.027 mole) of 3,7-dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole-2-carboxamide in 300 ml of warm methanol was treated with a warm solution of 28.0 ml (0.028 mole) of 1.0 N aqueous sodium hydroxide. The mixture was digested on the steam bath and then filtered hot. Cooling yielded a precipitate, which was filtered and washed several times with cold acetone. There was obtained 5.2 g (45% yield) of the carboxamido tetrazole sodium salt, mp 268° C. (dec).
EXAMPLE 41
3,7-Dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole-2-carboxamide, L-(+)-arginine salt
Prepared by the procedure described in Example 40 from 11.0 g (0.027 mole) of 3,7-dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide in 500 ml of methanol and a solution of 5.1 g (0.029 mole) of L-(+)-arginine in 15 ml of warm water. There was obtained 6.8 g (42% yield) of the hygroscopic arginine salt, mp 170° C. (dec).
EXAMPLE 42
3-Ethoxy-7-methoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide, L-(+)-arginine salt
Prepared by the procedure described in Example 39 from 3.0 g (0.0072 mole) of 3-ethoxy-7-methoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide in 350 ml of methanol and a solution of 1.4 g (0.0080 mole) of L-(+)-arginine in 3.0 ml of water. Recrystallization of a sample of the residue from methanol/acetone yielded the hygroscopic arginine salt, mp 155° C. (dec).
EXAMPLE 43
3,7-Dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole-2-carboxamide, piperidine salt
Prepared by the procedure described in Example 39 from 2.54 g (0.0063 mole) of 3,7-dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide in 200 ml of methanol and 3.0 ml (2.58 g; 0.030 mole) of added piperidine. Recrystallization of the residue from methanol/acetone yielded 1.75 g (55% yield) of the hygroscopic piperidine salt, mp 161°-164° C.
EXAMPLE 44
3,7-Dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo-[3,2-b]indole-2-carboxamide, hemi-1,2-ethanediamine salt
Prepared by the procedure described in Example 39 from 3.0 g (0.0074 mole) of 3,7-dimethoxy-4-phenyl-N-(1H-tetrazol-5-yl)-4H-furo[3,2-b]indole-2-carboxamide in 200 ml of methanol and 0.6 ml (0.54 g; 0.0090 mole) of added 1,2-ethanediamine. Recrystallization of the residue from methanol/ether yielded 1.8 g (56% yield) of the hygroscopic hemi-1,2-ethanediamine salt, mp 150° C. (dec).
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Novel tetrazolyl- and carboxamidotetrazolyl-substituted 4H-furo[3,2-b] indoles are useful for treating allergies or for treating or ameliorating postmyocardial infarct tissue damage. Also disclosed are methods for preparing said indoles, pharmaceutical compositions containing said indoles and methods for using said pharmaceutical compositions.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to commonly assigned, co-pending U.S. patent applications Ser. No. ______ (D. 89670) entitled SELF-ALIGNED PRINT HEAD AND ITS FABRICATION to Richard W. Sexton et al., Ser. No. ______ (D. 89619) entitled INTEGRATED CHARGE AND ORIFICE PLATES FOR CONTINUOUS INK JET PRINTERS to Shan Guan et al. and Ser. No. ______ (D. 89584) entitled ELECTROFORMED INTEGRAL CHARGE PLATE AND ORIFICE PLATE FOR CONTINUOUS INK JET PRINTERS to Shan Guan et al. filed concurrently herewith.
FIELD OF THE INVENTION
[0002] The present invention relates to continuous ink jet printers, and more specifically to the fabrication of an electroformed charge plate and its integration with a silicon orifice plate for such.
BACKGROUND OF THE INVENTION
[0003] Continuous-type ink jet printing systems create printed matter by selective charging, deflecting, and catching drops produced by one or more rows of continuously flowing ink jets. The jets themselves are produced by forcing ink under pressure through an array of orifices in an orifice plate. The jets are stimulated to break up into a stream of uniformly sized and regularly spaced droplets.
[0004] The approach for printing with these droplet streams is to use a charge plate to selectively charge certain drops and to then deflect the charged drops from their normal trajectories. The charge plate has a series of charging electrodes located equidistantly along one or more straight lines. Electrical leads are connected to each such charge electrode, and the electrical leads in turn are activated selectively by an appropriate data processing system.
[0005] Conventional and well-known processes for making the orifice plate and charge plate separately consist of photolithography and nickel electroforming. Orifice plate fabrication methods are disclosed in U.S. Pat. No. 4,374,707; No. 4,678,680; and No. 4,184,925. Orifice plate fabrication generally involves the deposition of nonconductive thin disks onto a conductive metal substrate using photolithographic processes. Nickel is this electroformed onto the conductive metal mandrel and partial covers the nonconductive thin metal disks to form orifices. After this electroforming process, the metal substrate is selectively etched away leaving the orifice plate electroform as a single component. Charge plate electroforming is described in U.S. Pat. No. 4,560,991 and No. 5,512,117. These charge plates are made by depositing nonconductive traces on a metal substrate followed by deposition of nickel in a similar fashion to orifice plate fabrication, except that parallel lines of metal are formed instead of orifices. Nickel, which is a ferromagnetic material, is unsuitable for use with magnetic inks. Nor can low pH ink (pH of approximately 6 or less) be used with nickel, which is etched by low pH ink. As a result, nickel materials are very suited to alkaline based fluids. U.S. Pat. No. 4,347,522 discloses the use electroforming or electroplating techniques to make a metal charge plate.
[0006] An ink jet printhead having an orifice plate and a charge plate requires precise alignment of these components to function properly. For high resolution ink jet printheads this alignment process is a difficult labor intensive operation that also requires significant tooling to achieve. It is desirable to develop a printhead that would simplify the alignment of the charging electrodes and the orifices from which ink is jetted.
[0007] Accordingly, it is an object of the present invention to provide a fabrication process of the orifice plate and charge plate that permits the use of both low pH and magnetic inks. It is another object of the present invention to provide such an orifice plate and charge plate as one, self-aligned component with high yield and robust connection.
SUMMARY OF THE INVENTION
[0008] According to a feature of the present invention, a charge plate is fabricated for a continuous ink jet printer print head by applying an etch-stop to one of the opposed sides of an electrically non-conductive substrate. An array of charging channels is etched into the substrate through the etch-stop adjacent to the predetermined orifice positions. The charging channels are passivated by depositing a dielectric insulator into the charging channels; and electrical leads are formed by coating the passivated charging channels with metal.
[0009] According to another feature of the present invention, a second etch-stop layer is applied to the other of the opposed sides of the substrate; and an array of orifices is formed through the orifice plate substrate at the predetermined orifice positions. The orifices extend between the opposed sides.
[0010] In a preferred embodiment of the present invention, the opposed sides of the orifice plate substrate are initially coated with a silicon nitride layer and the orifices are formed by etching into the orifice plate substrate through openings in the silicon nitride layer on said one of the first and second opposed sides. An ink channel is formed on the second of the opposed sides of the substrate by coating the second opposed sides of the substrate with a silicon nitride layer and etching into the orifice plate substrate through an opening in the silicon nitride layer on the second side of the orifice plate substrate.
[0011] The ink channel may be formed by deep reactive ion etching. The step of applying an etch-stop to the opposed sides of the substrate may be effected by sputtering. The charge electrodes may be placed alternatively on the two sides of the nozzle array.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a cross-sectional view of a silicon substrate, silicon nitride layer, and patterned photo resist layer usable in the present invention;
[0013] FIG. 2 is a perspective view of the orifice plate at this point in the fabrication process;
[0014] FIGS. 3-9 are cross-sectional views of the initial steps in a process for fabricating an integrated orifice plate and charge plate according to the present invention;
[0015] FIG. 10 is a perspective view of the orifice plate at the completion of FIG. 9 in the fabrication process;
[0016] FIGS. 11 and 12 are cross-sectional views of steps in a process for fabricating an integrated orifice plate and charge plate according to the present invention;
[0017] FIG. 13 is a perspective view of the orifice plate at the completion of FIG. 12 in the fabrication process;
[0018] FIGS. 14 and 15 are cross-sectional views of steps in a process for fabricating an integrated orifice plate and charge plate according to the present invention;
[0019] FIG. 16 is a perspective view of the orifice plate at the completion of FIG. 15 in the fabrication process;
[0020] FIG. 17 is a cross-sectional view of a step in a process for fabricating an integrated orifice plate and charge plate according to the present invention; and
[0021] FIG. 18 is a perspective view of the completed integral charge plate and orifice plate according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] It will be understood that the integral orifice array plate and charge plate of the present invention is intended to cooperate with otherwise conventional components of ink jet printers that function to produce desired streams of uniformly sized and spaced drops in a highly synchronous condition. Other continuous ink jet printer components, e.g. drop ejection devices, deflection electrodes, drop catcher, media feed system, and data input and machine control electronics (not shown) cooperate to effect continuous ink jet printing. Such devices may be constructed to provide synchronous drop streams in a long array printer, and comprise in general a resonator/manifold body to which the orifice plate is attached, a plurality of piezoelectric transducer strips, and transducer energizing circuitry.
[0023] FIG. 1 shows a silicon substrate 10 coated on both sides with thin layers 12 and 14 of silicon nitride. The layers may, for example, be 1000-2000 Å of silicon nitride or 5000 Å-10000 Å of low stress silicon nitride. In the preferred embodiment, the silicon substrate is dipped into buffered hydrofluoric acid, which chemically cleans the substrate, prior to application of the silicon nitride layers by a method such as low-pressure chemical vapor deposition. The silicon nitride will serve as an insulation layer, as explained below. A photoresist 16 has is then applied, such as by spin coating, to one side of the composite 10 , 12 , and 14 . The photoresist has been imagewise exposed to UV radiation through a mask (not shown) and developed to leave a pattern for forming charging channels 18 as explained below. Photoresist is removed from the areas which are to become the charging electrodes and leads. Positive tone photoresist is preferred. Of course in a true cross-sectional view, the layers at the rear of the charging channel would be seen as straight lines across the top of the channel, but they have been omitted from this and subsequent figures so that the channel can be more easily seen.
[0024] Looking ahead to FIG. 2 , there is a plurality of charging channels 18 (one per nozzle) and the channels are preferably staggered along the length of silicon substrate 10 . Of course, there are many more charging channels than shown in FIG. 2 , which is simplified for diagramming purposes. Charging channels 18 are etched into silicon substrate 10 in those regions not covered by the photoresist by means such as deep reactive ion etching. A preferred channel has a depth to width ratio of 5:1. The side wall and the bottom of the charging channels 18 are passivated using PECVD (plasma enhanced chemical vapor deposition) of silicon nitride (Si 3 N 4 ) or, preferably, silicon oxide. This is illustrated by a passivation layer 20 in FIG. 3 . A preferred silicon nitride or silicon oxide thickness is 0.5 to 0.8 um. This passivation layer also covers the photoresist 16 as well.
[0025] In FIG. 4 , passivation layer 20 , both in the charging channels and on top of the photoresist has been metallized with a metal layer 22 of gold, copper or nickel on top of an adhesion layer of chromium or titanium. A preferred metallization technique is sputtering, which has good coating step coverage. A preferred metal film thickness is 0.2 μm to 0.4 μm. When the assemblage is immersed in a solvent solution such as, for example, acetone, those portions of the metal layer 22 and the oxide passivation layer 20 that have been deposited onto the photoresist will lift off the wafer as the photoresist dissolves. The metal layer 22 applied to the bottom and side walls of the charging channels remains in place, forming the drop charging electrodes and leads. Next, an O 2 plasma is used to clean the wafer surface, producing the intermediate illustrated in FIG. 5 .
[0026] The charging channel 18 is filled with sacrificial material 24 , as shown in FIG. 6 . The sacrificial material may be SU-8 or AZ 100nXT, both well known to persons skilled in the art. The material is lightly baked and planarized using chemical mechanical polishing to produce the intermediate shown in FIG. 7 .
[0027] A layer 26 of a positive photoresist is spun onto the wafer. Another photolithography step patterns the photoresist 26 , as illustrated in FIG. 8 , so as to define an array of predetermined spaced-apart orifice positions;
[0028] Referring to FIG. 9 , a nozzle opening hole 28 is etched into the silicon substrate 10 using deep reactive ion etching. Deep reactive ion etching is a special form of reactive ion etching that provides a deep etched profile with relatively straight sidewalls. The etching depth, illustrated in FIG. 9 , is controlled by the duration of the etch process. FIG. 10 illustrates the process at this juncture of the fabrication procedure.
[0029] The photoresist layer 26 is repatterned to expose additional portions of the silicon nitride layer 12 . The newly exposed silicon nitride layer is removed as illustrated in FIG. 11 . Referring to FIG. 12 , nozzle opening hole 28 and a trench 30 are simultaneously deep reactive ion etched. Again, the etching depth is controlled by the duration of the etch process. FIG. 13 illustrates the process at this point of the fabrication procedure.
[0030] Having completed the fabrication steps on the first side of the substrate, a photoresist layer 32 has been applied to the silicon nitride layer 12 on the second opposed side of the substrate, and is patterned to correspond to an ink channel, as shown in FIG. 14 . The silicon nitride layer 12 is away according to the photoresist pattern. In FIG. 15 , an ink channel 34 has been etched into silicon substrate 10 such as by means of deep reactive ion etching. The silicon nitride layer 12 acts as an etch-stop for the deep reactive ion etching. The deep reactive ion etching is stopped after the ink channel is etched sufficiently deep to open up the nozzle opening holes 28 .
[0031] FIG. 16 illustrates the process at this juncture of the fabrication procedure. Photoresist 32 is striped using, say, acetone and the wafer surface is O 2 plasma cleaned. FIGS. 17 and 18 illustrate the completed electroformed metallic charge plate with orifice plate. For simplicity the figures have shown a very limited number of orifices and their corresponding charging electrodes, it must be understood that typically the structure can have in excess of 10 orifices per millimeter and can have array lengths in excess of 100 millimeters. It also must be understood that a plurality of completed electroformed metallic charge plate with orifice plate units can be fabricated on and diced from a single silicon wafer.
[0032] The silicon nitride 14 covered face of this structure can then be attached to a drop generator body. When pressurized with ink, ink is jetted from the nozzle opening holes 28 , passing from the ink channel 34 side to the trench 30 side. When the ink is appropriately stimulated to produce stable drop formation, the ink streams, the drop breakoff point should be located in front of the sacrificial material 24 filled charging electrodes.
[0033] By means of appropriately designed photomasks and mask aligners, the desired placement of the orifices relative to the charging electrodes can be readily achieved. Since multiple completed electroformed metallic charge plate with orifice plate units are fabricated concurrently without the need to individually align the charge plate and the orifices considerable savings in fabrication cost are possible.
[0034] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
[0000]
10 . silicon substrate
12 . silicon nitride layer
14 . silicon nitride layer
16 . photoresist
18 . charging channels
20 . passivation layer
22 . metal layer
24 . sacrificial material
26 . photoresist
28 . nozzle opening hole
30 . trench
32 . photoresist layer
34 . ink channel
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A charge plate is fabricated for a continuous ink jet printer print head by applying an etch-stop to one of the opposed sides of an electrically non-conductive substrate. An array of charging channels are etched into the substrate through the etch-stop layer adjacent to predetermined orifice positions. The charging channels are passivated by depositing a dielectric insulator into the charging channels; and electrical leads are formed by coating the passivated charging channels with metal. A second etch-stop layer is applied to the other of the opposed sides of the substrate, and an array of orifices is formed through the orifice plate substrate at the predetermined orifice positions. The orifices extend between the opposed sides.
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FIELD OF THE INVENTION
The present invention relates to a care and monitoring device and, especially, to a hopping wireless medical care and monitoring device suitable for use at home or in a hospital and its method of operation.
BACKGROUND OF THE INVENTION
Improved medical care is resulting in an aging population. Recent developments in communication and wireless technology resulting in remote medical care systems are an important field for markets, industries and research centers. Many related medical care products have been studied and developed.
Most wireless medical care monitoring uses one-way communication, which is passive communication equipment that connects to a wireless station, that transmits signals continuously and that must have a base station for operation. Consequently, wireless signal transmission is very inconvenient.
Therefore, the need for a system and method to provide more efficient signal transmission for a patient's medical monitoring devices still exists.
SUMMARY OF THE INVENTION
The present invention relates to a wireless medical care system using hopping communication and allowing multiple users to access their medical information without any limitation of distance.
According to the present invention, a wireless hopping node medical care monitoring system that is ANT multiple hopping nodes comprises at least one hopping node, at least one physical status measuring apparatus, a server, a network and at least one end-user apparatus. The at least one hopping node forms at least one channel to transmit a wireless signal. ANT is an open access multicast wireless sensor network technology protocol. The at least one physical status measuring apparatus is used to detect a patient's physical status. The server is connected to the at least one hopping node and the network topology for receiving signals, or transmitting a measuring data or an alarm in the wireless signal form through the multiple hopping node network system. The at least one user-end apparatus is connected to the physical status measuring apparatus for reading a physical status data and transmitting the physical status data in wireless form from the at least one hopping node to the server. Each user-end apparatus also receives a wireless signal from another hopping node to output an alarm according to the instruction of the wireless signal.
In a preferred embodiment, each user-end apparatus comprises:
a central processing unit,
an ANT wireless network unit electrically connected to the central processing unit for transmitting signals between the at least one hopping node in a bi-direction pathway,
a physical input signal unit electrically connected to the central processing unit,
an alarm output signal unit electrically connected to the central processing unit,
a monitoring unit electrically connected to the central processing unit, an input interface, and
a real-time timer unit electrically connected to the central processing unit, wherein:
the central processing unit reads the physical measuring data from the physical input signal unit for outputting a wireless signal through the ANT wireless network unit and then transmitting the wireless signal to the server;
the alarm output signal unit receives the wireless signal from the central processing unit;
the monitoring unit shows the wireless signal from the central processing unit.
In a preferred embodiment, each hopping node further comprises:
a hopping micro processing unit, and
a hopping wireless transmitting unit electrically connected to the hopping micro processing unit, wherein the hopping wireless transmitting unit carries out a wireless signal transmission under the ANT network system.
In a preferred embodiment, each hopping node follows a channel argument and the network topology for transmitting a wireless signal, and the channel argument comprises a hopping number, radio frequency, channel number, channel identification, channel period and channel type.
In a preferred embodiment, the network topology for each hopping node is a master line network topology or a slave line network topology, and the channel comprises:
a receiving channel,
a transmitting channel,
a user channel for transmitting a wireless signal to the user-end apparatus, and
a reserved channel for when a failure hopping node occurs.
In a preferred embodiment, the hopping nodes for building the served channel prevents another hopping node from building a new reserved channel by a broadcast signal.
A method for transmitting a wireless medical care system comprises:
setting a multiple hopping node system under an ANT network system comprising:
a server, multiple hopping nodes, and a user-end apparatus,
forming a communicating channel following a network topology for building the channel automatically, and
transmitting a wireless signal between the user-end apparatus and the server by the channel, with the wireless signal including a physical measuring data or an alarm.
In a preferred embodiment, forming the communication channel further comprises automatically forming a reserved channel when a failure hopping node is occurs.
In a preferred embodiment, the physical measuring data is read from the user-end apparatus and is transmitted in the wireless signal at the wireless signal transmitting.
In a preferred embodiment, the server transmits the physical measuring data or an alarm to the user-end apparatus.
As the skilled artisan will appreciate, any such method may be modified according to the needs of experiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a preferred embodiment of a wireless hopping node medical care monitoring device in accordance with the present invention.
FIG. 2 is a functional block diagram of a preferred embodiment of an end-user apparatus in accordance with the present invention.
FIGS. 3 a to 3 c are functional block diagrams of repair conditions in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a wireless hopping node medical care monitoring device and a method of operating the device. The following descriptions of preferred embodiments of this invention are presented for purposes of illustration and description only and are not intended to be exhaustive or to be limiting to the precise form disclosed.
With reference to FIG. 1 , a preferred embodiment of a wireless hopping node medical care monitoring device is an ANT multiple node hopping network and comprises at least one end-user apparatus ( 10 ), at least one physical status measuring apparatus ( 20 ), at least one hopping node ( 30 ) and a server ( 40 ). In the multiple nodes hopping network, one of the hopping nodes ( 30 ) is used as a relay and the at least one user-end apparatus ( 10 ) and the server ( 40 ) may be the source or the destination when transmitting a package from a source to a destination.
The multiple node hopping network can be used in any building and will not be limited by range of wireless waves. For example, the multiple nodes hopping network may be used in large hospitals for medical care, sanatoriums or homes. Different types of hopping nodes ( 30 ) may be used depending on the need required. The signal may be transmitted farther and continuously.
With further reference to FIG. 2 , each end-user apparatus ( 10 ) in accordance with the present invention may comprise a central processing unit ( 11 ), an ANT wireless transmission unit ( 12 ), a physical input signal unit ( 13 ), an alarm output signal unit ( 14 ), a monitoring unit ( 15 ), an input interface ( 16 ) and a real-time timer unit ( 17 ). The central processing unit ( 11 ) connects bidirectionally to each hopping node ( 30 ) by the ANT wireless transmit unit ( 12 ) connects to the central processing unit ( 11 ) to allow a bidirectional signal transmission. When the ANT wireless transmit unit ( 12 ) receives an input wireless signal from one of the hopping nodes ( 30 ), the central processing unit ( 11 ) will output an alarm signal to control the alarm output signal unit ( 14 ), the monitoring unit ( 15 ) or the real-time timer unit ( 17 ). For example, the input signal may be a drug-taking alarm signal, a physical measuring alarm signal, a real-time signal or a barrier alarm signal. The central processing unit ( 11 ) controls the alarm output signal unit ( 14 ), a monitoring unit ( 15 ) or the real-time timer unit ( 17 ) according to the different input signals. The results are shown on a monitoring unit ( 15 ), or the alarm output signal unit ( 14 ) may show results from the central processing unit ( 11 ).
The ANT wireless transmit unit ( 12 ) may receive a signal from the central processing unit ( 11 ) and transmits a signal to one of the hopping nodes ( 30 ), so that the signal could be transmitted by any hopping node ( 30 ) to the server ( 40 ).
The physical input signal unit ( 13 ) may be an electrical signal connecting interface selected from a group but not limited to a USB, RS232 or any kind of wireless transmission interface comprising Bluetooth or infrared ray technology. The physical input signal unit ( 13 ) is electrically connected to and reads data from one of the physical status measuring apparatuses ( 20 ) and then transmits data to the central processing unit ( 11 ). The central processing unit ( 11 ) then transmits the data read from the physical status measuring apparatus ( 20 ) by the multiple hopping network system.
The alarm output signal unit ( 14 ) may be any electrical component with alarm functions including flashing or buzzing. The monitoring unit ( 15 ) may be a monitor or a LED monitor controlled by the central processing unit ( 11 ). The input interface ( 16 ) may be a human-computer interface installed in the end-user apparatus ( 10 ). The real-time timer unit ( 17 ) may be an electrical component with timer functions.
Each physical status measuring apparatus ( 20 ) may be an electrical detecting device for physical status measuring, such as an electrical hemadynamometer, an oximeter or a blood sugar machine. The physical status measuring apparatus ( 20 ) is electrically connected to the physical input signal unit ( 13 ) and transmits data to the central processing unit ( 11 ) to be stored.
Each hopping node ( 30 ) meets the requirements of the ANT network, and all the hopping nodes ( 30 ) communicate with the end-user apparatus ( 10 ) and each other through the ANT network. The hopping nodes ( 30 ) comprise a hopping microprocessing unit and a wireless hopping transmitting unit electrically connected to the hopping microprocessing unit. The hopping microprocessing unit controls the transmission and reception of wireless signals from the wireless hopping transmitting unit to form a pathway from the end-user apparatus ( 10 ).
All hopping nodes ( 30 ) are set by the ANT network. Each hopping node ( 30 ) may communicate with one of the other hopping nodes ( 30 ) or one of the end-user apparatuses ( 10 ) respectively through a specific channel. The communication between two points may build on Master and Slave conditions. To enable communicating between the hopping nodes ( 30 ) in the ANT network, the method for arranging the specific channels between the hopping nodes ( 30 ) comprises setting a channel argument including Network, radio frequency, hopping number, channel number, channel identification, channel type, channel period, data types and data format. Before operating the wireless communication between two hopping nodes ( 30 ), the channel argument should be set up. However, a Master hopping node ( 30 ) may use different arguments and devices under one channel for the communication.
When the hopping node ( 30 ) transmits a signal, it also receives signals from other hopping nodes ( 30 ) connected to the end-user apparatus ( 10 ) or the server ( 40 ). In a preferred embodiment of the present invention, each hopping node ( 30 ) is connected to three specific channels and one reserved channel, which functioned function as a receiving channel (Rx Channel, Slave), a transmitting channel (Tx Channel, Master), a patient channel and a reserved channel, respectively. The receiving channel (Rx Channel, Slave) receives a signal from a previous hopping node ( 30 ). The transmitting channel (Tx Channel, Master) communicates with a next hopping node ( 30 ). The patient channel communicates with the end-user apparatus ( 10 ). The reserved channel connects automatically to the network when failure conditions occur. When a hopping node ( 30 ) is subjected to failure conditions, the previous hopping node ( 30 ) will connect to the reserved channel to build a transmitting channel, and the next hopping node ( 30 ) also connects to the reserved channel to build a receiving channel.
The server ( 40 ) connects to the hopping nodes ( 30 ) and transmits a signal when a drug-taking alarm or a physical alarm signal is output from an end-user apparatus ( 10 ), and a first hopping node (A) will receive a signal from the server ( 40 ), and the hopping node (A) transmits a signal to check whether the end-user apparatus (A) is included in a network the same as hopping node (A). If the end-user apparatus (A) is not included in the network, the hopping node (A) will transmit the signal to a second hopping node (B). Similarly, the second hopping node (B) would check whether the end-user apparatus (A) is included in a network the same as the second hopping node (B). If the end-user apparatus (A) is included in the same network as the second hopping node (B), the second hopping node (B) will transmit a signal back to the server ( 40 ) and the signal will pass all the hopping nodes ( 30 ) in this channel for feedback. Further, if an end-user apparatus ( 10 ) could not be found in any of the hopping nodes ( 30 ) in the network, the signal will be transmitted to the end hopping node ( 30 ). The end hopping node ( 30 ) will feedback a signal to show that the end-user apparatus ( 10 ) is not included in this wireless network.
Each hopping node ( 30 ) may receive signals from a server ( 40 ) or an end-user apparatus ( 10 ) and subsequently may transmit signals following a reserved network topology method. For example, the network topology method and each hopping node ( 30 ) will follow a line network topology for data transmission. For instance, a signal will be passed according to the order of the ID number of each hopping node ( 30 ), such as A to B to C to D. For example, hopping node C will automatically connect to hopping node B and hopping node D and will build communication channels between hopping node B and hopping node D to avoid interference between communication channels. In accordance with the present invention, a specific argument and multi-function model are set for each communication channel for avoiding each other.
Further, power for the hopping node ( 30 ) is supplied from a battery. When the battery is discharged (lower than a threshold), each hopping node ( 30 ) will transmit an alarm signal to the server ( 40 ) to remind personnel to change the battery.
A method for setting an argument between the receiving channel (Slave) and the transmitting channel (Master) is as follow. For example, the device may comprise five hopping nodes and the Hopping Node IDs are:
(1) hopping node 31 : Hopping Node ID=0x31
(2) hopping node 32 : Hopping Node ID=0x32
(3) hopping node 33 : Hopping Node ID=0x33
(4) hopping node 34 : Hopping Node ID=0x34
(5) hopping node 35 : Hopping Node ID=0x35
According to the Hopping Node ID, a channel number will be set depending on channel identification. The order between the channel identification and channel number follows. A channel between the server ( 40 ) and hopping node 31 : Channel number=0, channel identification=0x30. A channel between hopping node 31 and hopping node 32 : Channel number=1, channel identification=0x31. A channel between hopping node 32 and hopping node 33 : Channel number=0, channel identification=0x32. A channel between hopping node 33 and hopping node 34 : Channel number=1, channel identification=0x33. A channel between hopping node 34 and hopping node 35 : Channel number=0, channel identification=0x34.
An example of the principle of setting communication follows. When the channel identification is an odd number, the channel number for communicating with a previous hopping node is set as 0, and channel identification=(Hopping Node ID-1); and the channel number for communicating with a following hopping node is set as 0, and channel identification=Hopping Node ID.
When the channel identification is an even number, the channel number for communicating with a previous hopping node is set as 1, and channel identification=(Hopping Node ID-1); and the channel number for communicating with a following hopping node is set as 1, and channel identification=Hopping Node ID.
When a failure of one hopping node ( 30 ) is detected, the failed hopping node ( 30 ) will transmit a failure signal that comprises a signal for transmitting to a following hopping node to the server ( 40 ) for overcoming the failure condition.
Furthermore, a channel between each hopping node in accordance with the present invention has an automatic repair function. With further reference to FIGS. 3A to 3C , an example is used to illustrate the failure condition and the automatic repair condition.
When a failure condition occurs at a first hopping node ( 34 ), the network system formed by multiple hopping nodes is in a breakdown condition. A receiving channel of a second hopping node ( 35 ) next to the failed first hopping node ( 34 ) could not read any signal. However, after a short period of time (eg. 30 seconds), the second hopping node ( 35 ) will connect automatically to a first reserved channel to become a receiving channel (Slave). Until the connection is made, all signal reception will pass the reserved channel. The channel identification (=68) of the first reserved channel becomes a 2-fold change of the failed hopping node (channel RIM identification=34), and a previous hopping node ( 33 ) of the failed hopping node ( 34 ) transmits a waiting signal and also connects to a second reserved channel to become the transmitting channel (Master). At this time, all data is passed through the first reserved channel and the second reserved channel, and the channel identification of the second reserved channel also becomes a 2-fold change (=68), so that a new transmitting pathway is created and so that the failed hopping node ( 34 ) could be ignored for the data transmission. A user or a master user will know the failure condition by the different channel identification or transmitting pathway, and repair the failed hopping nodes. Therefore, when a failure condition occurring in any single hopping node will not breakdown data transmission or the transmitting pathway.
After repairing the pathway with a failed hopping node ( 34 ), a previous hopping node of the failed hopping node will transmit a broadcast signal to close the receiving channel (Slave).
When a second failed hopping node ( 35 ) occurs, the previous hopping node ( 33 ) will follow the model as previously described and transmit a signal to the repaired hopping node ( 34 ). The transmitting pathway will be changed as the repaired hopping node ( 34 ) transmits to a following hopping node ( 36 ).
To conclude, the wireless hopping node medical care and monitoring device in accordance with the present invention comprises a server ( 40 ), at least one end-user apparatus ( 10 ) and at least one hopping node ( 30 ) for wireless transmission of data.
The method for data transmission comprises the steps of (1) building a multiple hopping nodes network, (2) automatically forming communicating channels, and (3) transmitting a wireless signal. Step 1 of building a multiple hopping nodes network comprises building a network under an ANT network. The ANT network comprises a server ( 40 ), multiple hopping nodes ( 30 ) and at least one end-user apparatus ( 10 ). Step 2 of automatically forming communicating channels comprises forming channels between adjacent hopping nodes ( 30 ) to form a network topology. Step 3 of transmitting a wireless signal comprises transmitting a wireless signal between the end-user apparatuses ( 10 ), the server ( 40 ) and the hopping nodes ( 30 ). The wireless signal comprises physical measuring data and a medical alarm signal.
In step 2, when one of the hopping nodes ( 30 ) fails, adjacent hopping nodes, i.e. the previous one and the next one, will create a reserved channel after a short waiting period.
In step 3, first physical measuring data is read from a physical status measuring apparatus ( 20 ) of the end-user apparatus ( 10 ), and the data will transform to a wireless signal transmitted between the multiple hopping nodes, and the network to the server ( 40 ). Then, the server ( 40 ) passes second physical measuring data or the medical alarm signal to the end-user apparatus ( 10 ) to allow a person to read the second physical measuring data or the alarm signal.
The device in accordance with the present invention is not to be limited in scope by the specific embodiments described in the detailed description. Various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims.
All patents, applications, publications, test methods, literature, and other materials cited herein are hereby incorporated by reference.
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A hopping wireless medical caring and monitoring system, which is an ANT multiple nodes hopping network, includes at least one hopping node, at least one physical status measuring apparatus, a server and at least one user-end apparatus. The server communicates with the at least one user-end apparatus via the ANT network. The user-end apparatus reads a medical measurement result from the physical status measuring apparatus and transmits the results to the server via the ANT network. The wireless remote health and medical caring and monitoring system is suitable for home-care or a hospital.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application relates and claims priority to provisional patent application 61/077,007, filed Jun. 30, 2008, which is herein incorporated by references for all purposes.
TECHNICAL FIELD
[0002] This disclosure relates generally to roofing products, and more particularly to the use of a fastening system and method for a thermoplastic olefin (TPO) roofing membrane.
BACKGROUND
[0003] A single ply building membrane is a membrane typically applied in the field using a one layer membrane material (either homogeneous or composite), rather than multiple layers built-up. These membranes have been widely used on low slope roofing and other applications. The membrane can comprise one or more layers, have a top and bottom surface, and may include a reinforcing scrim or stabilizing material. The scrim is typically of a woven, nonwoven, or knitted fabric composed of continuous strands of material used for reinforcing or strengthening membranes. Such single ply membranes typically comprise base (bottom) and cap (top) polyolefin-based sheets (layers) with a fiber reinforcement scrim (middle) sandwiched between the other two layers. The scrim is generally the strongest layer in the composite. Other materials from which the membranes may be formed include, but are not limited to, polyvinyl chloride (PVC), chlorosulfonated polyethylene (CSPE or CSM), chlorinated polyethylene (CPE), and ethylene propylene diene terpolymer (EPDM).
[0004] A typical method of preparing membranes having scrims comprises unwinding a support sheet, scrim, or stabilizing material, and coating the support material by extrusion of a molten compounded polymers, including one or more fillers, UV and thermal stabilizers, and various pigments and fire retardant agents. Then the process provides for cooling and solidifying the membrane, and winding the membrane into a roll. A novel scrim for use with such single-ply roofing membranes is disclosed in co-pending patent application U.S. 2006/0292945, which is commonly assigned with the present disclosure and incorporated herein by reference in its entirety.
[0005] Single ply heat welded membranes are the fastest growing segment of the low slope roofing materials market. The two main membranes are produced from either thermoplastic olefin (TPO) or polyvinyl chloride (PVC) polymer. In both cases, the membranes consist of two layers of the polymer with a reinforcement scrim laminated in-between, as mentioned above. Such membranes are supplied as wide sheets, typically about 4 to 10 feet wide, in rolls up to 200 feet length. A particular advantage of these membranes is that they can be overlapped and then heat welded together. This results in a monolithic membrane with significantly reduced risk of leakage.
[0006] Roofing systems get tested in a wide variety of ways. In one particular test, the intent is to measure how well a system would stay intact when exposed to high wind loads. Typically, high wind loads result in upward forces that can result in part or all of the roofing system lifting off. To test for this so called “wind uplift” resistance, a deck is built to replicate a roof construction. Typically, these are 10 ft×20 ft or larger assemblies that include a welded seam where the end of one piece of the roofing membrane is connected to the beginning of another membrane sheet. The decks are sealed underneath in such a way that the underside of the roofing system can be pressurized. The pressure is then raised in increments until failure of the roofing system, namely, when the roofing system begins to lift off of the structure. The pressure prior to failure is then the rating of that particular roofing system.
[0007] Single ply membranes in low slope applications are typically installed above a layer of insulation such as polyisocyanurate (polyiso) slab stock foam. Polyiso foam is produced with a facer on either side, typically a cellulosic felt or paper.
[0008] Closely spaced mechanical fasteners used for mechanical attachment of the overlap section of the two membranes to the underlying roofing structure in the conventional method of installation. Such mechanical fasteners typically consist of metal plates and screws that penetrate down through the insulation (polyiso boards) and into the supporting steel or other type of deck material.
[0009] However, such conventional roofing assemblies provide for fastening only along the weld seam via fasteners driven down into the steel deck for the mechanical attachment of just the overlap portion of the membranes. Unfortunately, this means that for wide sheets there can be up to a 10 feet span between attachment points in one direction. System designs attempt to compensate for such a large span between attachment points by increasing the density of fasteners in the other direction, sometimes by moving them as close as 6 inch on center. However, this has a cost impact and has limited benefit.
[0010] An alternative method of securing single ply roofs has been commercialized by O.M.G. Inc located in Massachusetts. O.M.G. sells round metal plates that have been coated with a thermoplastic polymer (or PVC) that acts as a hot melt adhesive. These are currently being sold under the name RhinoBond®. Such plates are distributed evenly using around 6 per 4×8 foot polyiso foam board, and are attached to the roof structure using conventional roofing screws. Such screws hold the plates in place and penetrate through the insulation boards and down into the steel deck, thereby better anchoring the roofing system. Once the membrane is in place over the foam boards having the coated round plates, an induction heater is used to heat each plate in turn, melting the adhesive coating and gluing the plates to the membrane along the locations where the plates have been located. However, even with this approach, installation time is even longer since each coated plate must first be mechanically attached through the insulation board and into the underlying roof structure.
[0011] Accordingly, there is a need for an improved technique for securing single ply roofing membranes to the roofs of structures that does not suffer from the deficiencies found in conventional approaches. For example, simpler installation steps resulting in faster installation times would be especially desirable. The principles disclosed herein provide such a technique.
SUMMARY
[0012] This invention relates to an improved fastening technique for heat-weldable single ply roofing membranes comprised of thermoplastic polymer material. In one embodiment, the technique involves strips of rigid material such as metal coated on exterior surfaces with thermoplastic polymer material, incorporated into the upper surface of polyisocyanurate insulating foam boards. In an alternative embodiment, such rigid strips are simply laid out across the entire roof surface. In either approach, once the membrane is laid out over the coated strips, which are laid out over the insulation boards or directly on the roofing deck if boards are not used, the coated strips are heated, for example, with an induction heater, such that the thermoplastic polymer coating on the strips becomes fused on the exterior side to either the insulation boards or the roofing deck and on the interior surface to the thermoplastic polymer-based membrane. In yet another embodiment of the disclosed technique, the coated strips may be incorporated into the surface of an underlayment, such as GAF-Elk's Versashield®, which functions as an underlying layer for the single ply membrane. In this embodiment, the underlayment having the incorporated coated strips is installed over the roofing deck using mechanical attachments, and then a heating device is used after the membrane is laid over the underlayment to fuse the thermoplastic polymer material on the interior surface of the rigid strips to the membrane. In all embodiments, the overlap portion between adjoining membrane sheets may also be heat welded and/or secured with a mechanical fastener, as found in conventional approaches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a top down view of the installation of a conventional polyiso single ply system;
[0014] FIG. 2 illustrates a partial side cross-sectional view of the installation of a conventional polyiso single ply system;
[0015] FIG. 3 illustrates a top down view of the installation of a polyiso single ply system in accordance with the present disclosure; and
[0016] FIG. 4 illustrates a partial side cross-sectional view of the installation of a polyiso single ply system in accordance with the present disclosure.
[0017] FIG. 5 illustrates a partial side cross-sectional view of the installation of a polyiso single ply system in accordance with the present disclosure.
[0018] FIG. 6 illustrates a partial side cross-sectional view of the installation of a polyiso single ply system in accordance with the present disclosure.
[0019] FIG. 7 illustrates a partial side cross-sectional view of the installation of a polyiso single ply system in accordance with the present disclosure.
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates a top down view of the conventional installation of a single ply membrane. The membrane sheets are laid down with a section of overlap 103 . Closely spaced mechanical fasteners 105 are used for mechanical attachment of the bottom layer at the overlap section 103 of the two single ply membranes 102 to the roof structure. Such mechanical fasteners 105 typically consist of metal plates and screws that penetrate down through the insulating boards 101 . The overlapping section 103 is then heated creating a heat weld 104 .
[0021] FIG. 2 illustrates the partial cross-sectional view of the installation of a single ply membrane 102 shown in FIG. 1 . The insulating board 101 is shown layered on top of the steel or other type of deck material 201 . Two sheets of single ply membrane 102 are shown on top of the insulating board 101 aligned so that there is a section of overlap 103 between them. The mechanical fastener 105 is shown penetrating through the bottom one of the single ply membranes 102 and through the insulating board 101 into the decking material 201 . The overlapping section 103 is then heat welded as mentioned above. The mechanical fastener 105 and the heat weld 104 are located within the overlap region 103 of the two single ply membranes 102 .
[0022] FIG. 3 illustrates a plan view of one embodiment of a roof installation technique in accordance with the disclosed principles. This figure also shows the single ply membrane 102 with a section of overlap 103 layered on top of the insulating board 101 . The overlap 103 is heated to form a heat weld 104 that holds the two sheets of single ply membrane 102 together.
[0023] The technique in accordance with the present disclosure avoids the use of individual plate fasteners 105 used in the conventional process described above. Instead, in one embodiment, rigid strips 301 having heat-weldable thermoplastic polymer material on exterior and interior surfaces are used to provide for a more continuous adhesion of the membrane 102 down onto the insulating boards 101 . As used herein, the term “rigid” when referencing the strips 301 means that the strips are resistant to bending or flexing and are sufficiently stiff to maintain their linear shape. However, it does not mean that the strips are not flexible at all, such as with a metal tape measure that is extremely rigid from side-to-side, but somewhat flexible up and down. Moreover, the rigid strips 301 may be formed in lengths from about 3 ft to about 10 ft, and may be about one-half inch to several inches wide and from 1/16 inch to ¼ inch thick. Of course, other sizes may also be employed for the rigid strips 301 .
[0024] The insulating boards 101 are first laid across the roofing deck and secured to the roofing deck. Securing of the insulating boards 101 may be done using mechanical fasteners driven through the boards 101 and down into the roofing deck. Alternatively, an adhesive, such as a urethane adhesive, may be used to adhere the insulating boards 101 onto the roofing deck. Once the insulating boards 101 are secured to the roofing deck, the rigid strips 301 are periodically dispersed on the exterior surface of the insulating boards 101 . Exemplary spacing between each rigid strip 301 may be 36 inches, however, other amounts of spacing may also be selected. The single ply membrane 102 is then laid on top of the rigid strips 301 , and the overlap sections 103 between separate membrane sheets 102 may be heat-welded together. For example, a heated mandrel may be moved along the overlap section 103 between the overlapping membranes pieces 102 . As the mandrel moves along the overlap section 103 , the mating surfaces of the overlapping membrane pieces 102 are heated and then pressed together to complete the heat weld seal between the two. Of course, other techniques for heat-welding or otherwise bonding the overlap section 103 may also be employed.
[0025] After the membrane has been laid out across the roofing deck, the membrane 102 is heated directly above the locations of the strips 301 . Once heated, the thermoplastic material on the exterior or upper surface of the rigid strips 301 fuses directly with the single ply membrane 102 . In this embodiment, the heating also causes the thermoplastic polymer material on the interior or lower surface of the rigid strips 301 to adhere the strips 301 to the polyiso insulating boards 101 , or directly to the roofing deck 201 if no insulating boards 101 are employed. One advantageous technique that may be employed to perform the heating of the thermoplastic material on the rigid strips 301 in the above-described manner is via induction heating. For example, a heated roller may be rolled across the membrane 102 directly over the rigid strips 301 , where the heat from this roller device is transferred through the membrane 102 to the thermoplastic polymer on the rigid strips 301 sufficient to melt the thermoplastic material and adhere the components together as described above. Other techniques to heat the thermoplastic polymer material on the rigid strips 301 sufficiently to adhere to the membrane 102 and to the insulating boards 101 (if employed) may also be employed. For example, hot air may be directed at the areas of the membrane 102 where the rigid strips 301 are located to cause the desired adhesion. Also, a heated iron or similar flat device may be slid across the membrane 102 in the appropriate locations to cause the desired melting and adhering of the components. Of course, other heating techniques may also be employed, however, some heating techniques may not be sufficient as they may melt the membrane 102 before transferring enough heat down to the rigid strips 301 to melt their coating. Accordingly, heating by heat induction is the preferred embodiment.
[0026] An advantage of this novel technique is that adhesion of the membrane 102 to the insulating board 101 or other surface can be improved since any number of rigid strips 301 may be employed at any location across the membrane 102 . As a result, wind uplift performance (related to the system's ability to withstand severe weather conditions) is improved. In addition, wider sheets of single ply membrane 102 can be installed without compromising roofing performance since the mechanical attachment of the membrane sheets 102 is not only at the overlap between adjoining sheets 102 , as is the case in the conventional installation method described in FIGS. 1 and 2 , but also along the length of each rigid strip 301 . An additional advantage is that installation of the roofing system would be easier than conventional approaches where the insulating boards 101 are adhered to the roofing deck since the installer does not need to handle washers or mechanically fasten coated plates down to the roofing structure. Accordingly, faster installation times and less installation materials results in overall costs being lowered.
[0027] FIG. 4 illustrates a partial side cross-sectional view of the installation technique described in this disclosure. Again, the figure illustrates the use of the insulating boards 101 layered on top of the roof decking 201 . As discussed above, the insulating boards 101 may be mechanically fastened to the roofing deck 201 or they may be adhered. Rigid strips 301 with thermoplastic polymer material on both exterior and interior (i.e., upper and lower, when mounted) surfaces are located between the polyiso foam insulation board 101 or roofing deck 201 and the single ply membrane sheets 102 . The membrane sheets 102 can be heated to form a heat weld 104 at the location of their overlap 103 , as described above. Also as described above, the thermoplastic material on the exterior and interior surfaces of the rigid strip 301 can also be heated using induction heating, or other appropriate heating technique, to fuse the rigid strip 301 directly to the single ply membrane 102 and either the roofing deck 201 or the polyiso foam boards 101 , depending on what the strips 301 are directly contacting in each particular installation.
[0028] FIG. 5 illustrates an embodiment of the disclosed principles in which insulation foam boards 101 are manufactured with rigid strips 301 , for example, made of metal or other rigid material, incorporated into the exterior surface of the insulating boards 102 . These rigid strips 301 are coated on their exterior surface with a thermoplastic polymer material, such as TPO, and are built into the facer on the top/exterior surface of the foam boards 101 . Once the insulation boards 102 having these strips 301 are installed on the roof structure, the membrane 102 is laid over the boards 101 . A heating device is then used to fuse the coating of thermoplastic polymer material 501 on the strips 301 to the membrane 102 as described above. Since the strips 301 are built into the boards 101 , and the boards 101 have been secured to the roof structure 201 (e.g., mechanically or adhesively), the membrane 102 is secured to the roof structure 201 where the strips 301 have been laid out. In addition, the strips 301 may have holes at periodic positions along their lengths to provide for mechanical attachments that penetrate down to the roofing deck 201 . Moreover, mechanical fasteners used to secure the rigid strips 301 may simultaneously be the means by which the insulating boards 101 are secured to the roofing deck 201 .
[0029] FIG. 6 illustrates another embodiment of the disclosed principles in which the rigid strips 301 may be incorporated into the surface of an underlayment 601 , such as GAF-Elk's Versashield®. Such an underlayment 601 functions as an underlying sealing layer for single ply membranes. In this embodiment, the underlayment 601 having the incorporated rigid strips 301 is installed on the insulation boards 101 using conventional techniques. The membrane 102 is then laid over the underlayment 601 , and a heating device is used to fuse the coating 501 on the strips 501 to both the membrane 102 and the underlayment 601 . Again, such strips 301 could have holes arranged longitudinally for mechanical attachment down into the roofing deck 201 . Also, insulation boards 101 may or may not be used with this approach. Since the strips 301 are integrated into the underlayment 601 , and the underlayment 601 has been secured to the roof structure 201 or to insulation boards 101 secured to the roof structure 201 , the membrane 102 is now secured to the roof structure 201 where the strips 301 have been laid out by the selected heating and fusing process.
[0030] FIG. 7 illustrates another embodiment in which polyiso foam insulation boards 101 are manufactured with a foil facer 702 . The foil facer 702 would be coated with lines of hot melt adhesive 701 . Again the insulation boards 101 are installed on the roof structure 201 , and the membrane sheets 102 laid over them. A heat device is then used to melt and adhere the adhesive strips 701 to the foil 702 (or other sturdy material) of the insulation boards 101 . Also, the heating of the thermoplastic material 501 on the exterior surface of the rigid strips 301 bonds the strips 301 to the membrane 102 , as in previous embodiments. Since the insulating boards 101 have been secured to the roof structure 201 , and the rigid strips 301 adhered to the boards 101 with the hot-melt adhesive 701 and bonded to the membrane 102 , the membrane 102 is now secured to the roof structure 201 where the rigid strips 301 have been located.
[0031] Yet another approach is the laying out of continuous strips of precoated metal 301 across the entire roof surface. These coated strips 301 would be laid over the insulation boards 101 that have been secured to the roof structure 201 . The coated strips 301 may have holes at periodic positions along their length to provide for standard mechanical attachments that would simply hold the rigid strips 301 from moving around while the membrane 102 is laid on top of the strips 301 . The membrane 102 is then laid over the rigid strips 301 , and a heating device is used to fuse the thermoplastic polymer material on the strips 301 to both the membrane 102 and the underlying roof structure 201 or insulation boards 101 . Thus, the coating is what structurally bonds the strip 301 to the roofing deck 201 , and the strip 301 to the membrane 102 , rather that a large number of roofing screws used to structurally secure the strips to the deck. Not only does this cut the installation time significantly, but it also allows securing the membrane 102 to the roofing deck 201 without making a large number of holes through the deck.
[0032] While various embodiments in accordance with the disclosed principles have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.
[0033] Additionally, the section headings herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings herein.
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This invention relates to an improved fastening technique for single ply roofing membranes comprised of thermoplastic polymer material. In one embodiment, a method of installing a roof on a structure may comprise providing a single-ply roofing membrane comprising thermoplastic polymer material, and periodically securing rigid strips over a roofing deck. In such embodiment, the rigid strips have thermoplastic polymer material on corresponding exterior surfaces thereof. The method may further include laying the roofing membrane over the roofing deck, where the rigid strips are located between the roofing deck and the roofing membrane. Then the method may include heating the roofing membrane and the rigid strips simultaneously, perhaps using a heat induction technique, such that thermoplastic polymer material on the exterior surfaces of the rigid strips fuses directly with the thermoplastic polymer material of the roofing membrane.
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BACKGROUND OF THE INVENTION
This is a Continuation-in-Part application of U.S. patent application Ser. No. 07/815,776, filed Jan. 2, 1992 now abandoned.
This invention related generally to refrigeration systems and, more particularly, to the control of refrigerant flow in a centrifugal compressor.
In large chiller systems, a centrifugal compressor is commonly driven by an electric motor that generates a significant amount of heat. It is therefore the usual practice to cool the motor by introducing liquid refrigerant into the motor casing, with the resultant refrigerant gas then being returned to the system by way of a return line passing to the evaporator or cooler. Because of the need to maintain a relatively low pressure within the motor casing in order to maximize the cooling effect, while at the same time providing a pressure high enough to thereby prevent the migration of oil into the motor casing from the adjacent transmission, it is common practice to place a back-pressure valve in the refrigerant return line, its function being to maintain a predetermined pressure drop across the return line and to thereby maintain a predetermined level within the motor casing.
One form of such a valve that has been used is a spring biased flapper valve which tends to open against the bias as the pressure differential increased. While the approach has been satisfactory for lower pressure refrigerants such as R-11, it has been found to be unsatisfactory in higher pressure systems such as one with R-22 refrigerant. That is, with R-22, it has been found that such a flapper valve does not provide the required responsiveness to maintain the desired pressure drop across the valve.
Other types of commercial pressure regulators are available to perform the function in high pressure systems. However, they tend to be large, expensive and complicated.
Existing back-pressure valves are designed to maintain a given pressure drop across the valve when the refrigerant is flowing from the motor casing, with the valve being in the most open position when the flow volume is the greatest and being in a closed or near closed position when the volume flow is at a minimum. Accordingly, in a reverse flow condition, that is with the refrigerant flowing from the cooler back into the motor casing, the back-pressure valve will be in a generally closed down position. This can be a problem under shut-down conditions.
During normal operation, the motor casing is maintained at a pressure level above that of the adjacent transmission. However, when the compressor is shut down, the refrigerant tends to flow in the reverse direction so as to equalize the pressure in the system. The transmission therefore undergoes a rapid increase in pressure, but the motor, which is effectively isolated from the rest of the system by the closed back-pressure valve, remains at a relatively low pressure. As a result, the differential pressure forces the oil from the transmission into the motor casing, with the oil then being subsequently pumped to the evaporator when normal operation resumes. This represents a loss of oil from the system, will result in efficiency losses, and may result in damage to the system components.
It is therefore an object of the present invention to provide an improved back-pressure valve for a centrifugal compressor.
Another object of the present invention is the provision in a high pressure centrifugal compressor for a back-pressure valve which is simple, effective, and economical in use.
Yet another object of the present invention is the provision in a centrifugal compressor for preventing loss of oil during shut-down conditions.
Another object of the present invention is to provide a minimum flow area at zero pressure differential, and a maximum flow area at high positive pressure and at all negative pressures.
Still another object of the present invention is the provision for a back-pressure valve which allows the pressure in the motor casing to rise during shut-down conditions.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with aspect of the invention, a piston is reciprocally mounted within a cylindrical body and is biased toward a closed position against an inlet opening closest to the motor casing. As the pressure in the motor casing increases, the piston tends to move against the bias away from the inlet opening to thereby increase the flow of refrigerant and to thereby decrease the pressure differential. In this way, the valve tends to maintain a constant pressure differential across the inlet opening.
In accordance with another aspect of the invention, the piston is tapered in form, with the end further from the motor casing being of a larger diameter than the other end thereof. In the relatively closed position, the larger diameter end is near or within the inlet opening and the other end thereof projects through the inlet opening, toward the motor casing. In the relatively open position, the entire piston moves into the cylindrical body to thereby increase the flow of refrigerant along the tapered surface of the piston.
By another aspect of the invention, the piston is mounted on a shaft that is reciprocally mounted, in a cantilevered manner, from a discharge and of the cylindrical body. A compression spring surrounds the rod and is held in compression by a retainer element rigidly secured to the shaft. The piston has a cavity formed in its larger diameter end for receiving the retainer element therein, in axially abutting relationship.
By yet another aspect of the invention, the shaft is extended through and beyond the inlet opening such that it extends well beyond the system small diameter end. Thus, during coast down and shut-down conditions, when the pressure in the cooler is substantially greater than that in the motor casing, the piston is moved along the shaft to a point outside of the inlet opening to thereby allow the relatively unrestricted flow of refrigerant into the motor casing to thereby equalize the pressure in the system. A retainer ring is secured near the end of the shaft to limit the movement of the piston on the shaft.
By yet another aspect of the invention, the valve is mounted or positioned such that the shaft is oriented vertically with the piston resting on the retainer. Thus, after coast down and shut-down conditions, when the pressure in the cooler is equal to that in the motor, the piston falls back into a position of minimum flow area.
By a slight variation of the invention, the valve can be positioned in a vertical or a horizontal fashion and yet be allowed to come to a position of minimum flow area when the differential pressure between the motor and the cooler is zero. This is accomplished by adding a spring between the piston and the top of the shaft. The spring is designed such that the free length is equal to the distance between the top of the shaft and the piston in the minimum area position. Thus, after coast down and shut-down conditions, the spring of low stiffness will push back the piston to the position of minimum flow area. Further, this additional spring will be of low stiffness such that the valve will open even with a small negative pressure differential. A positive pressure differential will move the piston against the spring between the piston and the valve body.
In the drawings is hereinafter described, a preferred embodiment is depicted; however, various modifications and other constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross sectional view of a centrifugal compressor having the back-pressure valve of the present invention incorporated therein;
FIG. 2 is an enlarged partial view thereof;
FIG. 3 is a longitudinal sectional view of the back-pressure valve of the present invention;
FIG. 4 is a top end view thereof;
FIG. 5 is a longitudinal sectional view thereof, showing the refrigerant flow during normal operating conditions;
FIG. 6 is a longitudinal sectional view thereof, showing the flow of refrigerant during shut-down conditions;
FIG. 7 is a longitudinal sectional view of a modified embodiment of the invention with the valve in a horizontal position, showing the refrigerant flow during normal operating conditions;
FIG. 8 is a longitudinal sectional view of a modified embodiment of the invention with the valve in a horizontal position, showing the refrigerant flow during shut-down conditions;
FIG. 9 is a graphic illustration of the various pressures during shut-down conditions of a compressor having a back-pressure valve with no reverse flow feature; and
FIG. 10 is a graphic illustration of the various pressures during shut-down conditions of a compressor having a back-pressure valve with a reverse flow feature.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the invention is shown generally at 10 as embodied in a centrifugal compressor system 11 having an electric motor 12 at its one end and a centrifugal compressor 13 at its other end, with the two being interconnected by a transmission 14.
The motor 12 includes an outer casing 16 with a stator coil 17 disposed around its inner circumference. The rotor 18 is then rotatably disposed within the stator winding 17 by way of a rotor shaft 19 which is overhung from, and supported by, the transmission 14. The transmission 14 includes a transmission case 21 having a radially extending annular flange 22 which is secured between the motor casing 16 and the compressor casing 23 by a plurality of bolts 24, with the transmission case 21 and the compressor casing partially defining a transmission chamber 30.
Rotatably mounted within the transmission case 21, by way of a pair of axially spaced bearings 26 and 27 is a transmission shaft 28 which is preferably integrally formed as an extension of the motor shaft 19. The collar 29, which is an integral part of the shaft or attached by shrink fitting, is provided to transmit the thrust forces from the shaft 28 to the thrust bearing portion of the bearing 26. The end of shaft 28 extends beyond the transmission case 21 where a drive gear 31 is attached thereto by way of a retaining plate 32 and a bolt 33. The drive gear 31 engages a driven gear 34 which in turn drives a high speed shaft 36 for directly driving the compressor impeller 37. The high speed shaft 36 is supported by journal bearings 39 and 40.
In order to reduce windage losses in the transmission 14 and to prevent oil losses from the transmission chamber 30, the transmission chamber 30 is vented to the lowest pressure in the system (i.e., compressor suction pressure) by way of passage 55, tube 65, and compressor suction pipe 75.
In order to cool the motor 12, liquid refrigerant is introduced from the condenser (not shown) into one end 41 of the motor 12 by way of an injection port 42. Liquid refrigerant, which is represented by the numeral 43, enters the motor chamber 45 and boils to cool the motor 12, with the refrigerant gas then returning to the cooler by way of a motor cooling return line 44. A back-pressure valve 46 is included in the line 44 in order to maintain a predetermined pressure differential (i.e., about 5-6 psi) between the motor chamber 45 and the cooler, which typically operates at about 80 psia. Compressor suction pipe 75, at the point where transmission vent tube 65 is connected, is typically at a pressure 1-2 psi less than the cooler. This establishes a transmission pressure of about 78-79 psia. Thus, during normal operation, the pressure in the motor chamber is maintained at 85-86 psia, which is about 6-8 psia or 7.6-10.3% above that in the transmission chamber 30.
Also, fluidly communicating with the motor chamber 45 is an opening 47 in the annular flange 22 of the transmission case 21. A line 48 is attached at its one end to the opening 47 by way of a standard coupling member 49. At the other end of the line 48 is a coupling member 51 which fluidly connects the line 48 to a passage 52 formed in flange member 53 as shown in FIG. 1 and as can be better seen in FIG. 2. The bearing 40 functions as both a journal bearing to maintain the radial position of the shaft 36 and as a thrust bearing to maintain the axial position thereof. An oil feed passage 54 is provided as a conduit for oil flowing radially inwardly to the bearing surfaces, and an oil slinger 50 is provided to sling the oil radially outward from the shaft 36. An annular cavity 56 then functions to receive the oil which is slung off from the bearing 40 and to facilitate the drainage of oil through a passage 57 and back to the sump 58.
In order to provide a counteraction to the aerodynamic thrust that is developed by the impeller 37, a "balance piston" is provided by way of a low pressure cavity 59 behind the impeller wheel 37. A passage 61 is provided in the impeller 37 in order to maintain the pressure in the cavity 59 at the same low pressure as the compressor suction indicated generally by the numeral 60. This pressure (downstream of the guide vanes 70) typically varies from around 77 psia at full load, down to 40 psia at 10% load. Since the pressure in the transmission casing is higher (i.e., equal to the compressor suction pressure upstream of the inlet guide vanes 70, or about 78-79 psia) than that in the cavity 59, and especially at part load operation, a labyrinth seal 62 with its associated teeth 63 is provided between the bearing 40 and the impeller 37 to seal that area against the flow of oil from the transmission into the balance piston 59.
The labyrinth seal 62 is pressurized with the refrigerant vapor in the motor chamber 45, which vapor passes through the line 48, the passage 52, and a passage 66 in the labyrinth seal 62. Thus, the labyrinth seal 62 is pressurized at the motor casing pressure of 85-86 psia, which is 6-8 psi above the transmission pressure during normal operation.
Considering now what occurs when the compressor is shut down, the purpose and function of the present invention will be more clearly understood. When the motor 12 is turned off, the impeller 37 stops but, as a precautionary measure, the oil pump continues to run for another 30 seconds or so. Since the discharge pressure at this time is approximately 200 psi, and the compressor suction pressure is around 77 psi, the refrigerant immediately beings to flow in the reverse direction and continues that flow until the pressure within the system is equalized at around 115-120 psi. Because of the vent tube 65, the transmission chamber 30 rises to that pressure level very quickly. However, unless the back-pressure valve 46 allows for the relatively free flow of refrigerant into the motor casing 16, that casing remains relatively isolated from the system at a pressure level of about 85 psi. Because of this significant pressure differential, oil is then forced to flow from the transmission chamber 30 through the bearings 27 and 26, and through a low speed shaft labyrinth 25 just down-stream of the collar 29 to enter the motor casing 16. The oil also tends to flow from the high speed labyrinth seal 62 through the passage 66, the passage 52, and the line 48 to enter the motor casing in this manner. As a result, a significant supply of oil is removed from the system and then enters the cooler by way of the conduit 44 when the compressor is again turned on. The present invention, therefore, has for one of its purposes, that of preventing the flow of oil into the motor casing 16.
Referring to FIGS. 3 and 4, the back-pressure valve 46 of the present invention is shown in its installed position within the motor cooling return line 44 by way of a pair of flanges 76 and 77 which are secured by way of brazing or the like. It is installed such that its axis is oriented vertically so that gravity can act on the piston element thereof as will be described hereinafter. The valve 46 comprises a valve body 78, a shaft 79, a tapered plug or piston 81, a compression spring 82, and a retainer 83. There are also three retaining rings 84, 86, and 87 which are attached to the shaft 79 in a manner to be described more fully hereinafter.
The valve body 78 is cylindrical in form and has an inlet end 88 and a discharge end 89, with the inlet 88 having an inlet opening 91 and the discharge end 89 having a plurality of discharge opening 92. During normal operation, the refrigerant flows into the inlet opening 91, through the valve body 78 and out the discharge openings 92.
Secured within a cylindrical sleeve 93 and projecting axially into the valve body 78 from the discharge end 89 is the shaft 79, which is free to reciprocate within the sleeve 93 but is limited in one direction by the retaining ring 87, which is snapped into a groove in the shaft 79 and engages the discharge end 89.
The compression spring 82 is disposed over the sleeve 93 and is maintained in a compressed state by the retainer 83, which is slideably disposed on the shaft 79 but secured on its one end by the retaining ring 86 which fits into a groove on the shaft 79. As will be seen, the retainer 83 is cylindrical in form and fits into a cylindrical cavity 94 at one end of the tapered plug 81.
The tapered plug 81 has a larger diameter at its one end 96 closer to the discharge end 89, and a smaller diameter at its other end 97. The outer diameter of the plug one end 96 is slightly smaller than the diameter of the inlet opening such that the plug 81, which is slideably mounted on the shaft 79, is free to move out of the inlet opening 91 and come to rest against the retaining ring 84 to thereby allow refrigerant flow to occur in the opposite direction during shut-down conditions as will be described hereinafter. Similarly, during normal operation with relatively small pressure differentials, the clearance between the plug 97 and the sides of the inlet opening 91 allows for a small amount of refrigerant to flow through the inlet opening 91 and out the discharge openings 92. But when the pressure differential increases, the plug 97 engages the retaining ring 86 and moves the entire shaft 79 against the bias of the compression spring 93 to thereby increase the space between the plug 97 and the edge surrounding the inlet opening 91.
Referring now to FIG. 5, the back-pressure valve is shown in an operational condition wherein the pressure within the motor casing has increased to a point where the tapered plug 81 is moved against the retaining ring 86 to overcome the bias of the spring 93 and to thereby move the shaft 79 to the point where the retaining ring 87 is moved away from the discharge end 89 as shown. In this position, the clearance between the tapered plug 81 and the structure surrounding the inlet opening 91 is increased to thereby allow an increased flow of refrigerant. This increased flow will in turn reduce the pressure differential to the predetermined level of 5-6 psi. In this way, the valve 46 functions to maintain that pressure differential during normal operation.
When the unit is shut down as described hereinabove, the flow of refrigerant is reversed within the system, the pressure in the cooler will rise to around 115 psi, while the pressure in the motor casing 16 will remain at around 85 psi. Because of this significant pressure differential, the tapered plug 81 will be quickly moved to the position as shown in FIG. 6, which will then allow the relatively unrestricted flow of refrigerant through the inlet opening 91 and into the motor casing 16. The pressure in the motor casing 16 will therefore rise to about the same level of 115 psi, which is the same pressure as exists in the transmission chamber 30. Thus, the problem of oil being forced into the motor casing 16 is thereby avoided.
As mentioned hereinabove the valve 46 is installed with its shaft being oriented in a vertical position with the retaining ring at the top. Thus, after shut down has occurred and pressures are equalized by the movement of the plug 81 upwardly and the flow of refrigerant to the motor housing as shown in FIG. 6, then the force of gravity acts as a bias to move the plug 81 back to the minimum flow position in preparation for the next start up.
The modification of the valve as shown in FIGS. 7 and 8, will allow the valve to be mounted in any orientation between vertical and horizontal layouts since the valve is no longer dependent on gravity to provide the bias following pressure equalization upon shut down. A spring 98 is added between the piston 81 and the retaining ring 84 to provide this function. The spring 98 is of low stiffness such that it will not require a substantial negative pressure differential to move the tapered plug 81 towards the retaining ring 84. Also the free length of the spring is selected such that it is equal to the length between the retaining ring 84 and the retaining ring 86. This will ensure that the tapered ring 81 is not pushed beyond the position of minimum area when there is no pressure differential between the motor and the cooler.
The operation of the valve is identical to that for the valve of FIGS. 5 and 6 as described above except that the plug 81 is biased by the spring 98 from moving against the retainer ring 84 as shown in FIG. 8. However, when the reverse flow condition is present upon shut down, the inlet opening 91 will still be sufficient to allow the relatively unrestricted flow of refrigerant into the motor casing 16. The spring will then act to move the plug 81 back to the minimum flow position following pressure equalization.
Referring now to FIGS. 9 and 10, the respective pressures in the cooler, the transmission and the motor are plotted as a function of time, with the chart being plotted at a speed of 12,000 mm per hour. In the test presented by the graph of FIG. 9, the system had a back-pressure valve with a relatively short shaft 79 such that the retainer ring 84 was in abutting relationship with the plug other end 97 to restrict any substantial flow of refrigerant in the reverse direction. As will be seen in FIG. 9, the pressure in the cooler (curve A) quickly rises to a level of about 115 psi, and that in the transmission (curve B) follows very closely thereto, whereas the pressure in the motor casing, as indicated by the curve C, tends to rise at a much more gradual rate such that a substantial differential exists. This pressure differential will cause the loss of oil as described hereinabove.
With the back-pressure valve 46 designed as described hereinabove, i.e. with the tapered plug having the freedom to move outside of the inlet opening 91 to permit a reverse flow of refrigerant as shown in FIGS. 6 and 8, the resulting pressures will occur as shown in the test data of FIG. 10. Here, the increase in pressure within the motor casing very closely approximates the increase in pressure of both the cooler and the transmission. As a result, the pressure differential between the motor casing and the transmission is minimal, and the loss of oil from the system is also minimized.
Once the pressure in the motor is equal to that in the cooler, gravity or spring force, depending on the construction of the valve, will force the piston to a minimum area position. If the piston is not so returned to the minimum area position, then at subsequent machine start, the cooler and motor pressure will be equal, resulting in oil loss from the transmission into the motor housing.
Although the present invention has been shown and described with respect to preferred and modified embodiments, it will be understood by those skilled in the art that various changes in the form and detail thereof may be made without departing from the true spirit and scope of the claimed invention.
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A shaft-mounted piston is reciprocally disposed on the axis of a valve inlet opening such that increased pressure from within the motor casing of a centrifugal compressor causes the piston to move in the direction of the refrigerant flow, against a biasing means, to increase the flow of refrigerant through the opening, and to thereby regulate the pressure drop across said valve to a predetermined level. The shaft has an extended portion projecting through the piston toward the motor casing such that when the compressor is shut down and the pressure is thus greater in the valve than in the motor casing, the piston can move out of the inlet opening to the extended portion of the shaft to thereby allow the unrestricted flow of refrigerant into the motor casing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. Nos. 61/183,013 and 61/183,003 filed Jun. 1, 2009.
FIELD OF THE INVENTION
[0002] This invention relates to formulations of conductive inks and pastes that include gettering species for improved performance in electronic devices.
BACKGROUND OF THE INVENTION
[0003] Water, oxygen, and unwanted organic residues can be detrimental to semiconductor device operation or useful lifetime. This is specifically true in organic semiconductor-based devices such as organic light emitting devices or photoresponsive devices where water or oxygen can lead to electrode degradation or degradation of the active light emitting, absorbing, or charge transporting materials that are necessary for proper functioning of the device. In general, an electronic device includes the placement of conductive electrodes or isolated features along with dielectric or semiconducting materials. In the cases of typical organic light emitting devices or photoresponsive devices, active semiconducting and/or emissive, absorptive or charge transport materials are sandwiched between conductive electrodes that provide charge carrier injection or charge carrier extraction into or out of the active regions within the device. The electron injecting electrode is referred to as the cathode. In some organic light emitting devices, such as the doped organic light emitting device structures produced in U.S. Pat. No. 6,605,483, the device stack is formed with an underlying, semi-transparent, hole-injecting anode electrode arranged on a substrate, that might have water or oxygen barrier properties, followed by a layer of active material, and with a cathode electrode placed on top of and in direct contact with the active material. In some instances, this device is then encapsulated by deposition of thin barrier films on top of the cathode, or by sealing the device through the use of a barrier film and/or adhesive that is fixed to the cathode side of the device, thereby encapsulating the device and restricting the ingress of O 2 or H 2 O through the anode-side barrier substrate film and the topside encapsulation films. This process can also trap O 2 , CO 2 , H 2 , H 2 O, or other unwanted species that are present from the starting materials or introduced during the fabrication process into the interior of the device, where they could interact with the electrodes or active materials in the device.
[0004] Typical conductive paste components, in addition to the conductive materials themselves which might be metal flakes, particles, nanoparticles, nanotubes, organic conductors, or polymeric conductors, can be sources of residual water or impurities. For example, a conductive paste formulation might also include polymer or organic binder materials, such as polyesters, polyurethanes, conducting polymers, polythiophenes, polyanilines, or epoxies, that can contain residual water or other impurities, or it might attract, absorb, or produce residual unwanted impurities once printed onto the device. Other materials that could be sources of unwanted impurities in the ink include surfactants and additives, including ionic, nonionic, and amphiphilic agents, and impurities on particle surfaces or dispersed in the nonmetallic component of the ink or paste.
SUMMARY OF THE INVENTION
[0005] The present invention uses an included getter to remove or reduce the concentration of the unwanted impurities that are present in a conductive paste or ink formulation, or that are introduced into the paste or printed feature during the deposition process or prior to encapsulation of a device. The unwanted impurities can also be formed during device operation or be introduced into the device through ingress of materials from the environment. In one form of the invention, the gettering species are temporarily inactive, of reduced activity, or latent acting at the time of deposition. Gettering materials, such as those that remove, sequester, or convert H 2 O, CO 2 , H 2 , O 2 or other unwanted species, can be included directly into the conductive ink or paste formulation such that these unwanted species are removed from the electrode formed by these inks or pastes, or these unwanted species are removed or are lowered in concentration in adjacent parts of the device or encapsulation package. These reductions may happen during or immediately after the fabrication or sealing of the device, or they may occur after some activation delay. In terms of duration, they may be used to remove initial residual unwanted gasses or impurities in the device or they may be used to remove unwanted species that appear in or near the device later in its product cycle, such as by ingress through the encapsulation materials or by outgassing, or by reactions that occur within the device or encapsulation materials themselves. Of particular interest are H 2 O, O 2 , CO 2 , H 2 , or residual solvent getter materials that primarily perform their function after the formation of a conductive feature using the ink, such that the materials remove the unwanted species at a time when those species are no longer intentionally present. For example, the getter material is present during the fabrication of the cathode for an organic light-emitting device or a photovoltaic or photoconductive device from printing or coating, but is able to perform its action after the initial fabrication step. In the present invention, getter that originates in the conductive paste that is not permanently saturated or consumed by exposure to H 2 O, O 2 or solvents in the process environment, such as while processing in air from solvent-borne solutions.
IN THE DRAWING
[0006] FIG. 1 illustrates voltage (V) and brightness (cd/m 2 ) as a function of time for performance comparison between a standard silver cathode device and a silver-silane cathode device, tested at 2 mA/cm 2 current density in a nitrogen glove box.
DETAILED DESCRIPTION OF THE INVENTION
[0007] In the present invention, a gettering species is directly included in a conductive paste or ink formulation used as an electrode in an electronic device. The terms “paste” and “ink” are used interchangeably in this description to describe flowable solutions. The getter becomes active, is desaturable, or has sufficient capacity such that it acts after an air or process environment exposure step. This concept is generally applicable to electronic devices where conductive pastes or inks are used to form an electrode, and are particularly applicable to organic light-emitting diodes (OLEDs) and photovoltaic devices. The use of techniques to ensure that the getter material is at least temporarily inactive, of reduced activity, or latent acting at the time of deposition provides improved gettering function after the electronic device is encapsulated and activated. Thus, getter materials that may be activated after the paste is deposited and the electronic device encapsulated are particularly useful. Control of the activation of the getter materials may be achieved by using a number of techniques, for example, thermally, optically, electrically, through protection by a matrix that controls diffusion of the unwanted species to the getter material, or with a solvent that protects the getter until the solvent is removed in a later processing step such as heating or vacuum treatment (where the heating or vacuum treatment is in an environment free of unwanted species such as water, oxygen, and hydrogen). Some getters may also be reformed in a later step, such as silicon gel or some zeolites, such that water or other absorbed species in the getter can be driven off thermally or with vacuum or other means such that the getter is reactivated at a later stage.
[0008] In one embodiment, a silane-based getter additive that is thermally activated to react with water was shown to improve device performance. Another embodiment of the present invention is the inclusion of material in an electrode paste that converts H 2 O, O 2 , CO 2 , H 2 , or other impurities into a benign species which does not react adversely with device components. Another embodiment includes gettering materials that act latently or upon activation in a later processing step to convert an unwanted impurity, such as water, to a more volatile species, for example a lower alcohol via the hydrolysis reaction of a tetraethylorthosilicate additive at an elevated temperature, which is then more easily or more rapidly removed in a drying step than the original form of the unwanted species. This enables the faster removal of, for example, H 2 O which can require high temperatures, long dwell time or low vacuum levels for effective removal from active device materials. H 2 O and related impurities can be rate limiting steps for processes based on water-borne, hydrophilic or hygroscopic device materials such as conducting polymers (PEDOT:PSSA), electrolyte materials (such as ethylene oxides), dielectrics (such as polyvinylphenol, polymethylmethacrylate, sol gels, SiOx, silicon nitride). Therefore, increasing the ease of removal of these species improves processing throughput, lowers equipment cost and/or reaches desirable low impurity levels that are not be practically achievable due to the time/temperature limitations of other device materials. For example, the use of polyester plastic substrates limits safe process temperatures to below 200 C and more typically below 170 C for polyesterterapthalate.
[0009] A cathode paste in accordance with the present invention would preferably include at least one air-stable high work-function metal, at least one polymer binder, at least one alkoxysilane organic/inorganic moisture getter, at least one organic solvent, and at least one surfactant. Examples of suitable high work function materials for a cathode include silver, gold, aluminum, carbon (black, particles, nanotubes, fullerenes, graphite, graphene), tungsten, copper, chromium, nickel, and molybdenum. Examples of polymer binder materials in addition to those described earlier, include thermosets and thermoplastics, cellulose-derivative polymers, polyester copolymers, vinyls, methacrylates, silicones, and siloxanes. In some cases, fluorinated and partially fluorinated polymers may be desired for reduced affinity and permeability for water and less reactivity. Suitable organic solvents can be matched with process requirements and chosen from a wide variety of solvents. Examples of such solvents are carbitol acetates, ethyl acetates, butyl carbitol, butyl carbitol acetate, terpenes, higher alcohols, dibasic esters, and lactones. Many surfactants are also suitable, including ionic and nonionic surfactants, amphiphilic materials, fatty acids, oleic acides, alkylated carboxylic acids, ethoxypropyloxy copolymers, silicones and siloxane copolymers. If desired, matrix materials can be used for the purposes discussed earlier. Examples of suitable matrix materials are those used as binder materials.
[0010] Examples of the present invention are inks where the alkoxysilanes in the total cathode paste ratio can be from 0.01% to 10% by weight to provide the needed effect but avoiding impairment of cathode function. Generally it is also useful for plastic substrate-based devices to use a getter material that can be hydrolyzed in the temperature range from room temperature to 200 C. This concept includes use of other compounds such as those based on alkoxyl-substituted aluminum (III), antimony (III), barium (II), titanium (IV), or zirconium (IV). Thermally-, light- or time-activated organometallics are also useful as electrode getter additives.
[0011] Other embodiments include solvent or otherwise stabilized metal oxide particles (such as Ca, Ba, Sr, Mg or Si oxides or similar), highly porous oxides, nanosize particulate adsorbers, or zeolite particles such as aluminosilicates and their derivatives. For H 2 gettering, metal oxides such as PdO or PtO are useful. It is advantageous if these particles are of relatively small size (<100 microns in the x, y, z dimensions, more preferably <10 microns) such that they do not interfere with device operation or lead to larger cathode nonuniformities that can cause device operational non-uniformity or lead to electrical shorting of devices. The particles are preferably from 0.1% to 25% by weight of the total cathode paste. At too high a concentration the gettering materials can interfere with the electrical properties of the electrode.
[0012] Highly desiccating pastes can be formed with some of the above materials which use matrix and solvent effects to initially restrict their interaction with moisture during processing. Examples of matrix effects include the use of low solubility or permeability matrices to limit impurity ingress. Solvent effects can include the use of solvent vapor pressures in the vicinity of the liquid feature to block impurity ingress. This can allow for reasonable air processing windows for printable or dispensable pastes and wet or semi-wet printed films formed from them.
[0013] Furthermore, an attractive mode for encapsulating a device involves the use of gettering materials to remove H 2 O, CO 2 , H 2 , O 2 or other unwanted species trapped in the device from the starting materials or during fabrication, and that are sealed inside the device encapsulation package during its initial construction. The getter material performing these functions may be within the cathode or electrode features.
[0014] The electrode could also be composed of a vertically nonuniform (in the direction parallel to the printed surface or electrode interface normal) or multilayered structure, such that the composition of the getter varies within the electrode. This can serve to isolate gettering materials that might damage the electrode interface region if in immediate contact, but may be beneficial if placed very close to these interface to perform its gettering function. It may also be that the getter may interfere with interfacial injection or charge transport in certain layers of a cathode or electrode. In that case, a multilayer cathode with a low getter concentration at the interface or in a critical transport region of the electrode optimizes the electrical functions while the more heavily gettered layer provides the beneficial gettering action. The getter may also be included in ink or paste-derived interconnect lines which may be printed as part of the electrode or cathode itself, as one of the printed layers in a multilayer cathode, or as separated printed electrode interconnect features. Getter in these features serves to absorb impurities introduced into the device package in the ink or paste itself, and can also serve to absorb or block impurities ingressing into the device package from the outside environment through or near the electrode interconnect line. This is significant as electrode interconnect lines passing from the active device area within the package to the outside of the sealed part of the package can cause local channels in the encapsulation adhesives and barrier materials or the lines themselves can have a higher impurity transmission rate. Therefore it can be advantageous to include gettering materials in those lines also.
[0015] As noted above, the electrode structure of a device need not be uniform. For example, the electrode may be formed by more than one layer of ink or paste, where the getters used and their concentrations are different. The concentrations may vary uniformly between the interface with the active part of the device toward the opposite side or the electrode, but need not vary uniformly. In some cases, it may be desirable for the electrode paste in conduct with the active portion of the device to have no getter or a low concentration of getter, in order to avoid contamination of the active portion of the device.
[0016] The electrode paste of the present invention can include getters that react with or otherwise convert an unwanted residual component of the paste, or other unwanted species, into a more benign material. In some cases, such unwanted residual components or other unwanted species may be converted into another compound that is more volatile, has higher diffusivity, or is otherwise easier to remove or transport.
[0017] The use of a getter that during or after the processing removes the unwanted species can produce higher performance devices, and also allows for reduced environmental control of the process environment, thereby providing a simpler, and faster, manufacturing process, lower cost devices, and allows use of less expensive processing equipment.
Example 1
Tetraethylorthosilicate-Blended Silver Conductive Paste for Use as a Cathode for an Organic Light Emissive Device
[0018] a. Preparation of tetraethyl orthosilicate (silate) blended silver (Ag) paste
Into 99 g of a commercial silver paste consisting primarily of Ag flakes and particles, polymer binders, surfactants, and volatile solvents, was added 1 g tetraethyl orthosilicate (silane) to form 1% silane content in the paste. The paste was then mixed overnight at room temperature prior to printing.
[0020] b. Control: Fully Screen-Printed White Light-Emitting Devices with Standard Ag Cathodes
A doped light-emitting polymer (LEP) ink (based on LEP provided by Sumation, a joint venture of Sumitomo Chemical and Cambridge Display Technology) was screen-printed onto a pre-patterned indium tin oxide (ITO)-coated polyethylene terephthalate (PET) substrate with an active area of 1 cm 2 . After removing the solvents by heating the substrate under vacuum, a top electrode Ag standard silver paste was printed onto the LEP layer and dried to form the cathode and interconnect layer and complete the device fabrication. The device was then transferred into a nitrogen glove box and tested under a constant current density at 2 mA/cm 2 . Both luminance (Cd/m 2 ) and voltage (V) were recorded as function of time ( FIG. 1 ). Maximum luminance (Lmax) was 326 Cd/m 2 , maximum luminance efficiency (L.E.) was 16.3 Cd/A, and maximum power efficiency (P.E.) was 3.41 m/W. We have converted the lifetime at Lmax to lifetimes at 100 Cd/m 2 using an extrapolation t 1/2 ×(Lmax/100) y , where t 1/2 is the time to half maximum luminance Lmax, and y is an exponent generally varying from 1.2 to 2.1. For these fully screen-printed devices based on this type of LEP, this factor y has been found to be approximately 1.8. Thus, this device had a luminance lifetime (100 Cd/m 2 ) of 2180 h when 1.8 y factor is used.
[0022] c. Fully Screen-Printed White Light-Emitting Devices with Silane-Blended Ag Cathodes
A device was fabricated in a similar as described above for the control, by using the Ag-silane paste described above instead of Ag-standard paste. Its Lmax was 355 Cd/m 2 , L.E. was 17.7 Cd/A, and P.E. was 3.61 m/W. This device had a luminance lifetime, at 100 Cd/m 2 , of 3250 h extrapolated using a luminance vs. lifetime acceleration exponent of 1.8 ( FIG. 1 ). This improvement in luminance lifetime follows similar improvements in devices dried using an external getter in close proximity to the cathode. This indicates that the Ag silane device had a better lifetime performance due to removal of moisture present in Ag paste by hydrolysis of the silane additive upon heating, while its silanol product did not have a compensating adverse impact on the device. This reduction in moisture in the cathode region can improve function and reduce degradation of the cathode. It can also create a diffusion gradient for water which then drives water out of the active region of the device (LEP containing areas in this example). Water-induced photooxidation of active layer components and dopant deactivation by moisture are both device performance degradation mechanisms which can be reduced in impact by the reduction of the moisture content in the active region. Note that photooxidation is also a performance degradation mechanism in photovoltaic, sensor, and switching devices. As indicated in the reaction in Scheme 1, one of the alkoxyl groups on the silane undergoes hydrolyzation with water, generating ethanol, which is more easily removed than water due to its higher vapor pressure or lower binding to the paste components during the LEP annealing process. Such hydrolysis reactions can continue between additional water and the silanol with remaining alkoxyl groups. Since ethanol can be removed effectively by thermal annealing, the hydrolysis reaction of silane becomes irreversible and water can be chemically removed, resulting in better device lifetime.
[0000]
[0024] Although the present invention has been particularly described with reference to embodiments thereof, it will be readily apparent to those of ordinary skill in the art that various changes, modifications and substitutes are intended within the form and details thereof, without departing from the spirit and scope of the invention. Accordingly, it will be appreciated that in numerous instances some features of the invention will be employed without a corresponding use of other features. Further, those skilled in the art will understand that variations can be made in the number and arrangement of components illustrated.
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A conductive electrode paste or ink formulation including a getter removes or reduces the concentration of the unwanted impurities in an electronic device. These reductions may happen during or immediately after the fabrication or sealing of the device, or they may occur after some activation time or event. Water, oxygen, carbon dioxide, hydrogen, and residual solvents are gettered.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a U.S. National Phase Patent Application based on International Application Serial No. PCT/EP2010/062413 filed Aug. 25, 2010, the disclosure of which is hereby explicitly incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a locking cover made of a molded plastic material for a vessel having a neck.
2. Description of the Related Art
FR-2893922 discloses such a locking cover in which the cap is welded onto the ring. To access the contents of the vessel, the user breaks the connection between the cap and the ring, with the result that the cap is separated irreversibly from the cover, thus securizing the use of the vessel provided with said cover.
SUMMARY OF THE INVENTION
The present invention concerns a locking cover made of a molded plastic material for a vessel having a neck, intended for fixing a stopper in the neck of the vessel, comprising a cage with locking tongues or catches, which is configured to surround the stopper and the neck and lock them in position relative to each other in a given axial direction, a ring that is fastened around the cage and is configured with a central aperture that preserves access from outside the cover to the inside of the vessel by way of the stopper, and a cap configured to close said aperture.
This cap, cover or lid is generally fastened to the ring in such a way that it can be detached therefrom, but in an irreversible manner, without the ability to be put back in place in its initial state of closing the aperture.
The invention applies more particularly to a locking cover for a necked vessel used particularly in the medical field.
The object of the invention is to offer such a locking cover in which the cap is mounted on the cover in another manner that also permits irreversible separation of the cap from the cover.
To this end, the invention is directed to a locking cover made of a molded plastic material for a vessel having a neck, intended to fix a stopper in the neck of the vessel, comprising a cage with locking catches which is configured to surround the stopper and the neck and lock them in position relative to each other in a given axial direction, a ring that is fastened around the cage and is configured with a central aperture preserving access from outside the cover to the inside of the vessel by way of the stopper, and a cap configured to close said aperture, characterized in that the cap has a flat head large enough to cover said aperture and attachment tabs that project substantially perpendicularly to the head, said tabs being spaced apart along the annular periphery of the aperture of the ring and being gripped as in a vice between the ring and the cage.
The idea underlying the invention is, therefore, to fasten the cap to the cover by means of a clamping system of attachment tabs for fastening the cap in the cover, which system applies a clamping stress to both faces of each tab and/or a bending stress to the tabs in a direction oblique (for example, perpendicular) to the axial direction, thus rendering irreversible the detachment of the cap from the cover and also preventing any new cap from being placed on the cover.
The invention extends to a method for fastening a cap with attachment tabs on a locking cover as defined above, consisting in:
providing a cap with attachment tabs projecting perpendicularly to the flat head of the cap, placing the cap on the ring, the tabs of the cap extending axially into the aperture of the ring, inserting the cage into the ring so that the tabs of the cap are gripped, as in a vice, between the ring and the cage.
In one form thereof, the present invention provides a locking cover made of a molded plastic material for a vessel having a neck, intended to fix a stopper in the neck of the vessel, including a cage with locking tabs that is configured to surround the stopper and the neck and to lock them in position relative to each other in a given axial direction, a ring that is fastened around the cage and is configured with a central aperture that preserves access from outside the cover to the inside of the vessel by way of the stopper, and a cap configured to close the aperture, characterized in that the cap has a flat head large enough to cover the aperture and attachment tabs that project substantially perpendicularly relative to the head, the attachment tabs being spaced apart along the annular periphery of the aperture of the ring and being gripped as in a vice between the ring and the cage.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 schematically represents in axial section a locking cover according to the invention mounted on a stopper inserted in a vessel having a neck;
FIG. 2 is a schematic perspective view of the cage of the locking cover according to the invention;
FIG. 3 is a schematic perspective view of the ring of the locking cover according to the invention;
FIG. 4 is another schematic perspective view of the ring from FIG. 3 ;
FIG. 5 is a schematic perspective view of the cap of the locking cover according to the invention;
FIG. 6 is another schematic perspective view of the cap from FIG. 5 ; and
FIG. 7 schematically represents in axial section the locking cover according to the invention closed by a cap and mounted on a stopper.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the exemplifications set out herein illustrate embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
DETAILED DESCRIPTION
FIG. 1 depicts a locking cover 1 for a vessel 2 having a neck 3 according to the invention, intended to fix a stopper 4 in the neck 3 of the vessel 2 , the cover 1 being shown here merely placed on the neck 3 without being locked.
The neck 3 , which here has a circular opening, has at its end an outer peripheral lip 5 to which the locking cover 1 fixes itself when the cover 1 is locked on the neck 3 of the vessel 2 . The stopper 4 here has a conventional, generally cylindrical, “T” shape, with a head 4 A and a foot 4 B, the head being slightly larger in diameter than the foot 4 B, such that when the foot 4 B of the stopper 4 is inserted in the neck 3 , the head 4 A abuts against the lip 5 of the neck 3 .
As can be seen in FIG. 1 , the locking cover 1 comprises a cage 6 adapted to surround the stopper 4 and the neck 3 in the locked configuration of the cover 1 on the vessel 2 , and a ring 7 adapted to nest over the cage 6 , surrounding it. The cage 6 serves to fix the stopper 4 in the neck 3 by means of flexible tongues 8 , 9 disposed on the periphery of the cage 6 . In the mounted configuration of the cover 1 , the ring 7 laterally overlaps the cage 6 completely, thereby preventing any access to the cage 6 and the tongues 8 , 9 from outside the ring 7 .
In addition, according to the invention, the cover 1 is provided with a removable safety cap 23 that is clamped between the ring 7 and the cage 6 .
As can be seen in FIG. 2 , the cage 6 comprises two circlets 10 , 11 connected to each other by a plurality of substantially identical arms 12 extending in an axial direction A and forming between them first and second openings 13 , 14 corresponding to the mesh openings of the cage 6 .
Depicted here are a first, lower circlet 10 that is to be inserted first into the neck 3 of the vessel 2 , and a second, upper circlet 11 , which is preferably smaller in diameter than the first circlet 10 and is intended to rest on an upper portion 4 C of the head 4 A of the stopper 4 when the cover 1 is mounted on the stopper 4 . Circlet 11 defines, at the center of the cage 6 , an aperture 11 A—here circular—that is coaxial with the neck 3 of the vessel 2 when the cover 1 is placed on the neck 3 , to permit access to the stopper 4 and the vessel 2 .
It will be understood that circlet 11 and the arms 12 are sufficiently rigid so that they do not collapse as the cage 6 is inserted in the ring 7 .
Shown here are six arms 12 evenly distributed over the periphery of the circlets 10 , 11 , but their number can vary without departing from the framework of the invention.
As visible in FIG. 2 , first flexible tongues 8 adapted to fix themselves to the neck 3 of the vessel 2 and second flexible tongues 9 adapted to fix themselves to the stopper 4 —here, three of each—are disposed, preferably in alternation, on the periphery of circlet 10 between two consecutive arms 12 .
The first and second tongues 8 , 9 are disposed slantingly in, respectively, the first and the second openings 13 , 14 formed by the mesh openings of the cage 6 , and are supported by circlet 10 and extend toward the inside of the cage 6 and in the direction of second circlet 11 . In this way, when the cage 6 is inserted onto the neck 3 or the stopper 4 , the first and second tongues 8 , 9 can, in a first stage, deflect elastically into the first and the second openings 13 , 14 , respectively, assuming a position substantially parallel to the arms 12 , and then, in a second stage, resume their slanted position to lock the cage 6 respectively on the neck 3 or on the stopper 4 .
As visible in FIG. 2 , the first tongues 8 are offset in axial direction A with respect to the second tongues 9 . More precisely, the second tongues 9 are raised in the direction of the second circlet 11 , such that the distance between the end of a second tongue 9 and circlet 11 substantially corresponds to the height of the head 4 A of the stopper 4 , so as to lock the head 4 A of the stopper 4 between second tongues 9 and circlet 11 . Likewise, the distance between the end of a first tongue 8 and circlet 11 is adapted to lock the first tongues 8 against the lip 5 of the neck 3 of the vessel 2 when the cap 1 is locked on the neck 3 .
As represented in FIG. 2 , disposed on one and the other side of each first tongue 8 are regions 10 A of first circlet 10 that are relatively thin compared to the thickness of the mesh openings, thus forming cut-downs on each side of the tongue 8 and making these regions into breakaway regions that yield if an attempt is made to remove the cage 6 from the vessel 2 . It will be understood that regions 10 A represent the smallest wall section of the cage 6 . Thus, as the cover 1 is locked onto the neck 3 by the application of an axial or other force to the cage 6 , the first tongues 8 are retained by the lip 5 , thereby producing a torsion torque in regions 10 A. One or more of these regions 10 A can then break under the effect of the torsion and indicate that the vessel 2 has been opened. It will be noted that tongues 8 here are shaped in such a way that their height allows them to pass under the lip 5 of the neck 3 of the vessel 2 , and a pull exerted on the cage 6 causes them to rotate under the lip 5 , thus further increasing the torsion effect in regions 10 A.
It will be noted that first tongues 8 and the corresponding openings 13 here are wider than second tongues 9 and the corresponding openings 14 , thus making it possible for the cage 6 to be fixed more firmly to the neck 3 than to the stopper 4 .
As can be seen in FIG. 2 , each arm 12 of the cage 6 is further provided with an outer positive catch 15 that slants outward toward the first circlet 10 and is intended to fix the ring 7 on the cage 6 , the inclination of the catch 15 serving to facilitate the insertion of the cage 6 in the ring 7 .
It can also be seen in FIG. 2 that each arm 12 of the cage 6 is reinforced, at the level of its upper portion adjoining second circlet 11 , by an inner bulge 12 A intended to clamp the stopper 4 in place in the mounted position of the cover 1 .
In addition, formed on circlet 10 of the cage 6 , opposite every second tongue 9 , are respective notches 16 (here, three in number) intended to assist in orienting the cage 6 with respect to an automatic assembly machine during the assembly of the cage 6 and the ring 7 to form the cover 1 .
As can further be seen in FIG. 2 , the top edge of aperture 11 A of the cage forms a chamfered (beveled) annular shoulder 30 . This chamfered shoulder can be bordered outwardly by an annular channel or groove (not shown) to improve the seating of the attachment tabs of the cap 23 . The shoulder 30 thus has a tapered (or flared) outer surface forming one face of a vice in which the attachment tabs of the cap 23 will be gripped, as will be described below with reference to FIGS. 1 and 7 .
FIG. 3 represents the ring 7 in the form of a sleeve having a continuous, substantially cylindrical surface, which in the mounted configuration of the cover 1 surrounds the cage 6 to prevent access to the tongues 8 , 9 .
The ring 7 has an open bottom end 7 A that is to be inserted first onto the cage 6 and a top end 7 B that is partially closed, so as to leave an aperture 17 at the center of the ring 7 . Thus, when the ring 7 is nested on the cage 6 , the top end 7 B of the ring 7 partially overlaps the cage 6 , the respective apertures 17 , 11 A of the ring 7 and the cage 6 being coaxial. When the cap 1 is mounted on the neck 3 , apertures 17 , 11 A thus are coaxial with the neck 3 , to permit access to the stopper 4 and the vessel 2 .
Aperture 17 of the ring 7 has a bottom edge, which also forms an annular shoulder 18 that forms the second face of the vice in which the attachment tabs of the cap 23 are gripped. In the example, the two annular shoulders 18 and 30 here are circular and coaxial with each other in the mounted position of the cover. It can be provided that the cage 6 and the ring 7 are adjusted in relation to each other so that the attachment tabs 25 are clamped between the faces or jaws of the vice. It can also be provided that instead of or in addition to the clamping, the vice is configured to bend an end portion of the attachment tabs 25 in a direction oblique to axial direction A (for example perpendicular, that is, forming a 90° angle with axial direction A).
In addition, ring 7 is provided on its inner wall with notches 19 designed to cooperate with the catches 15 of the cage 6 to form an interlock device that locks the ring 7 on the cage 6 . The notches 19 are preferably blind, that is, they do not pass all the way through the wall of the ring 7 , to make for a compact cover 1 and to keep impurities from getting inside the cover 1 .
The ring 7 is further provided on its inner wall with internal guides 20 , 21 intended to interpose themselves between the arms 12 of the cage 6 to guide the positioning of the cage 6 relative to the ring 7 as the cage 6 is inserted in the ring 7 . It will be understood that the internal guides 20 , 21 preferably have dimensions respectively adapted to openings 13 , 14 , with a height in the axial direction A that is less than the height of openings 13 , 14 , to enable the tongues 8 , 9 to deflect into the openings 13 , 14 when the cover 1 is inserted on the neck 3 . Represented here for each guide 20 , 21 is a pair of respective bosses that position themselves laterally in a mesh opening of the cage 6 respectively against adjacent arms 12 of the cage 6 when the ring 7 and the cage 6 are nested one inside the other. These bosses here have a beveled shape on the side abutting an arm 12 , to further facilitate the guiding of the cage 6 into the ring 7 .
As represented in FIG. 4 , the top end 7 B of the ring 7 is provided with a shoulder 22 , circular in this case, which borders aperture 17 and is truncated to form two substantially parallel sides 22 A, thus providing a means of orienting the ring 7 relative to the automatic assembly machine. Shoulder 22 serves to create a space between the cap 23 and the ring 7 in direction A, once the cover 1 is assembled.
FIG. 5 shows a cap 23 or cover serving as a detachable lid for closing the central aperture 17 of the ring. This cap has tabs 25 which in the non-working position project perpendicularly to the flat head 23 A of the cap. The cap 23 , with the flat head 23 A and the tabs 25 , is here formed of a single molded piece. The flat head 23 A can have the shape of a disk or another, more complex shape, for example with sectors 24 . The tabs 25 are distributed circularly, and, in mounted position in the ring 7 , they are distributed along the periphery of the aperture 17 of the ring 7 . As is visible in FIG. 5 , the tabs 25 are straight in the non-working position, and thus present a cylindrical configuration. FIG. 5 shows a cap 23 with eight tabs 25 , which can have a free end 25 B that is beveled and/or provided with a locking bead 25 C. The locking bead 25 C preferably has larger dimensions than the space between the annular shoulder 18 of the ring 7 and the chamfered annular shoulder 30 of cage 6 , to further improve the protection of the cover 1 .
FIG. 6 shows the upper face 23 B of the cap 23 , which can be provided with gripping elements 26 , here in the form of reinforcing studs, to make the cap 23 easier to take hold of when it is to be removed from the cover 1 . The gripping elements could also be in the form of raised beads, for example circular-arc-shaped beads, or any element in relief facilitating the grasping of the cap 23 .
It will be understood that the overall cylindrical shape of the cage 6 and the ring 7 enables the cover 1 to adapt to all types of vessels 2 having a lipped circular neck 3 and does not require orienting either the cover 1 or the stopper 4 on the neck 3 . Similarly, owing to the circular shape of the cap 23 , there is no preferred angular orientation of the cap 23 on the ring 7 .
The cage 6 , the ring 7 and the cap 23 of the cover 1 are preferably made by molding a plastic material, adapted to withstand a lyophilization process if need be. In particular, the plastic material of the cage 6 is hard, so that the torsion described earlier above causes the breakaway regions 10 A to break rather than just elastically deform.
The respective shapes of the cage 6 , the ring 7 and the cap 23 are relatively simple, thus permitting the use of double-cavity molds with a single core and axial stripping, and, consequently, easy and inexpensive production. In addition, the simplified shapes of these elements advantageously make it possible to reduce the amount of material necessary for the production of the cover 1 .
The assembly operations for the ring, the cage and the lid of the cover 1 will now be described in more detail with reference to FIGS. 1 , 5 and 7 .
A cap 23 is first provided with straight attachment tabs 25 that extend axially in relation to the flat head 23 A of the cap, as can be seen in FIG. 5 .
This cap 23 is then placed on the ring 7 , the sufficiently large head 23 A of the cap covering the aperture 17 of the ring 7 , as shown in FIG. 7 , and the tabs 25 of the cap 23 passing through the aperture 17 of the ring 7 , extending axially in direction A.
The cage 6 is then inserted into the ring 7 in direction A as far as it will go, the openings 13 , 14 of the cage 6 being lined up with the respective bosses 20 , 21 of the ring 7 , as shown in FIG. 7 .
During the insertion of the cage 6 into the ring 7 , the annular shoulder 18 of the ring 7 and the chamfered annular shoulder 30 of the cage 6 are made to approach each other, which has the effect that each tab 25 of the cap 23 is held as in a vice between the two facing surfaces of the ring 7 and the cage 6 respectively, as can be seen in FIG. 1 .
When the cage 6 reaches abutment inside the ring 7 , the attachment tabs 25 of the cap 23 are deformed by bending, here in the middle portions of the tabs, and assume a configuration in which the tabs 25 splay out 90° from the axial direction A toward the outside of the cover 1 , thus effecting the clamping of the cap 23 between the ring 7 and the cage 6 . If need be, the beads at the free ends 25 B of the attachment tabs 25 can be inserted in the groove of the cage 6 .
It should be noted that the vice-like gripping of the attachment tabs 25 between the ring 7 and the cage 6 makes it possible to exceed the limit of elasticity of the attachment tabs 25 , with the result that if the cap 23 is separated from the cover 1 , the attachment tabs 25 of the cap 23 remain in a bent configuration. Thus, once the cap 23 has been separated from the cover 1 , it can no longer be put back between the ring 7 and the cage 6 of the cover 1 . It will be appreciated that this effect can be accentuated by the presence of beads at the free ends 25 B of the attachment tabs 25 .
When the cage 6 reaches abutment inside the ring 7 , the catches 15 of the cage 6 seat themselves in the notches 19 of the ring 7 , such that the cage 6 is locked in position in the ring 7 and the cap 23 remains clamped between the cage 6 and the ring 7 .
The head 4 A of the stopper 4 can then be inserted in the cage 6 until the upper portion 4 C of the stopper 4 comes into contact with the upper circlet 11 of the cage 6 . As the stopper 4 is inserted, the second tongues 9 deform elastically to let the stopper past and then go back to their initial shape once the stopper 4 is in place, positively engaging behind the head 4 A of the stopper 4 , so as to lock the stopper 4 in the position indicated in FIG. 4 . The stopper 4 is then fixed over its periphery in the cage 6 by the bulges 12 A, in the position indicated in FIG. 7 .
The assembly formed by the locking cover 1 and the stopper 4 can then be mounted on a vessel 2 by inserting the foot 4 B of the stopper 4 into the neck 3 of the vessel 2 simply by applying axial pressure to the cap 23 in direction A, thereby forcing the first tongues 8 to deform elastically in order to get past the lip 5 of the neck 3 , and then to resume their initial shape so as to positively engage behind the neck 3 and lock the cover 1 on the neck 3 . At the same time, the second tongues 9 partially deflect against the neck 3 of the vessel 2 .
The result is a closure for the vessel 2 that is leaktight due to the stopper 4 and tamper-proof by virtue of the locking cover 1 , since the cage 6 serves to lock the stopper 4 in the neck 3 and the ring 7 prevents any access to the cage 6 , and in particular to the tongues 8 , 9 . It will be appreciated that the cage 6 therefore serves as a link that fastens together the vessel 2 , the stopper 4 and the second ring 7 provided with the cap 23 , and that the second ring 7 serves as a safeguard.
For some medical applications, it may be necessary to lyophilize the contents of the vessel 2 . In that case, after contents for lyophilization have been introduced into the sterile vessel 2 , the foot 4 B of the stopper 4 locked in the cover 1 is placed in the neck 3 without pushing it all the way in and without engaging the first tongues 8 on the neck 3 , in the position shown in FIG. 1 . An opening in the foot 4 B of the stopper 4 (not shown) then makes it possible to proceed with the desired lyophilization. Once the lyophilization has been performed, the stopper 4 with the cover 1 can be pushed the rest of the way into the neck 3 , as indicated above, to hermetically seal the vessel 2 .
When it is desired to access the contents of the vessel 2 , the cap 23 is separated from the cover, for example by pulling on a sector 24 of the cap. After that, the upper portion 4 C of the stopper 4 need only be pierced with a needle to penetrate into the vessel 2 . The contents of the vessel 2 can then be used and, if need be, rehydrated.
Any attempt to remove the locking cover 1 from the vessel 2 will result in damage to the breakaway regions 10 A of the cage 6 , so single use of the vessel 2 is assured.
It will also be noted that since the stopper 4 is inserted in the cover 1 after the assembly of the cage 6 , the ring 7 and the cap 23 to form the cover 1 , the cover 1 and the stopper 4 can advantageously be stored separately before use.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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The invention relates to a locking cover ( 1 ), made of a molded plastic material, for a vessel having a neck, intended for locking a plug ( 4 ) in the neck ( 3 ) of the vessel ( 2 ), including a wire-cap ( 6 ) which surrounds the plug and the neck, a ring ( 7 ) which is attached around the wire-cap ( 6 ) and shaped so as to have a central opening ( 17 ) providing access from the outside of the cover ( 1 ) to the inside of the vessel via the plug, and a cap ( 23 ) attached to the ring and shaped so as to close said opening ( 17 ). The cap ( 23 ) comprises attachment tabs ( 25 ) which are spaced apart from each other along the annular periphery of the opening ( 17 ) of the ring ( 7 ) and which are clamped between the ring ( 7 ) and the wire-cap ( 6 ).
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This application is a continuation of application Ser. No. 07/981,657, filed Nov. 25, 1992 now abandoned.
FIELD OF THE INVENTION
This invention is in the area of computers and more specifically relates to bus controller architecture.
BACKGROUND OF THE INVENTION
The design of bus controllers has evolved over the years as performance requirements and customer needs have driven computer architectures to become more sophisticated and efficient. Specifically, the desire for higher performance has necessitated that a bus controller be able to operate with both a local bus and a system bus simultaneously and autonomously. Additionally, a bus controller that is not limited with regard to speed is needed; in this way both the local bus or the system bus may interact with the bus controller as fast as circuitry on the boards permit without suffering from speed limitations incurred by the bus controller. Lastly, a need has been felt for a bus controller that may operate as a master during a transaction or as a slave during a transaction simultaneously with both the local bus and the system bus, thus providing for more system flexibility.
The design of bus architectures typically include a number of compromises to optimize performance parameters that may be inversely related to one another. Certain bus architecture standards are designed as open standards to provide a general framework, yet provide flexibility so that performance criteria may be enhanced for specific system applications. Futurebus+ is one such open standard. The Futurebus+ standard is an IEEE specification #896.1-1991 and is described in an article entitled "Futurebus+ Coming of Age" (Theus, John, "Futurebus+ Coming of Age", Microprocessor Report, May 27, 1992, pp. 17-22).
It is an object of this invention to provide a dual bus controller architecture that enables simultaneous, autonomous interaction with both the local bus and the system bus and is compatible with the Futurebus+ bus architecture standard (IEEE spec #896.1-1991). It is another object of this invention to provide a dual bus controller architecture that allows both the local bus and the system bus to interact with the bus controller operating as a master or a slave without any imposed speed limitations. Other objects and advantages of the invention will become apparent to those of ordinary skill in the art having reference to the following specification together with the drawings herein.
SUMMARY OF THE INVENTION
A dual bus controller includes a system bus control module connected to a local bus control module. An optional filter is also connected to the system bus control module. A plurality of programmable status registers for the local bus is connected to the local bus control module and a time dependent reset circuit is connected to both the system bus control module and the local bus control module. The dual bus controller allows simultaneous, autonomous activity with both the local bus and the system bus via the local bus and system bus control modules. The unique interaction between the local bus and system bus control modules also allow both the local bus and system bus to interact with the dual bus controller operating as a slave without any imposed speed limitations by actively resolving bus collisions and "live-lock" conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block level diagram illustrating a backplane based computer system 10.
FIG. 2 is a block level diagram illustrating the preferred embodiment of the invention, a dual bus controller 22a.
FIG. 3 is a block diagram illustrating in greater detail a local bus control module 12 and a system bus control module 14 within dual bus controller 22a of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block level diagram illustrating a backplane based computer system 10. Computer system 10 includes a system bus 11 connected to a plurality of computer boards 13a-n. Each computer board 13a-n includes a local bus 24a-n, a bus controller 22a-n, and possibly a memory 26, a microprocessor 28, an input/output (I/O) device 30 or other type devices depending upon each board's 13a-n application requirements. Each board 13a-n communicates with one another via system bus 11.
FIG. 2 is a block level diagram illustrating the preferred embodiment of the invention, a dual bus controller 22a. Within bus controller 22a a system bus control module 14 is connected to a filter 18, a reset circuit 20, a system bus 11, a local bus control module 12, and a plurality of control status registers 16. Local bus control module 12 is also connected to control status registers 16, reset circuit 20, and a local bus 24a. Filter 18 is also connected to reset circuit 20 and to system bus 11.
System bus control module 14 monitors signals on system bus 11 (which in this particular embodiment is a Futurebus+ system bus) and maintains the appropriate handshake protocols necessary for proper operation with Futurebus+ 11. System bus control module 14 will be described in greater detail later. Local bus control module 12 monitors signals on local bus 24a and maintains the appropriate handshake protocols necessary for proper operation with local bus 24a. Additionally, local bus control module 12 also decodes and encodes commands from local bus 24a to Futurebus+ 11 and from Futurebus+ 11 to local bus 24a. This allows Futurebus+ 11 and local bus 24a to be completely independent of one another with respect to speed and handshake protocols. Therefore, local bus control module 12 acts as a command translator between Futurebus+ 11 and local bus 24a. Local bus control module 12 also provides synchronization circuitry which allows signals to cross the timing boundaries between different time domains. This allows either or both Futurebus+ 11 and local bus 24a to be asynchronous. (Futurebus+ 11 is an asynchronous bus).
Filter 18 is an optional filter that allows incoming signals from Futurebus+ 11 to be glitch filtered. This is sometimes desired when each computer card 13a-n in a backplane based computer environment is configured in a "wired-OR" configuration which is well known by those skilled in the art of system design. It is often desired to glitch filter incoming signals since they may suffer from the "wired-OR" glitch phenomena which is also well known by those skilled in the art. Other times, due to speed requirements or specific transaction types, filtering of incoming signals is not desirable; therefore the filter is optional and use will depend upon the specific operation being performed.
Reset block 20 is a time dependent reset circuit that conforms to the Futurebus+ spec noted earlier. Therefore, depending upon the duration of a reset signal being asserted, different types of reset operations take place. Different types of reset include: start, power-up, system initialization, and local bus initialization.
Control status registers 16 include a plurality of programmable status and configuration registers. Therefore, via software, control status registers 16 may be programmed to indicate the capability of the components within system 10. These capabilities may include: address size, data size, memory capacity, interrupt registers, timers, data speed capabilities, glitch filter settings, bus status, and enables.
FIG. 3 is a block level diagram illustrating in greater detail local bus control module 12 and system bus control module 14 of FIG. 2. It was stated earlier that local bus control module 12 monitors signals on local bus 24a and decoded command signals between local bus 24a and Futurebus+ 11. FIG. 3 illustrates the two separate functions of local bus control module 12, a local bus control 34, and a local bus decoder/encoder 36. Local bus control 34 may include a state machine and synchronizer. Local bus decoder/encoder 36 is composed of standard decoding circuitry well known by those skilled in the art. System bus control module 14 is composed of system bus control 38 which may include a state machine.
Dual bus controller 22a resides on computer board 13a and communicates with devices on board 13a via local bus 24a and with components on other boards via system bus 11. Bus controller 22a may advantageously become a bus slave of both local bus 24a and Futurebus+ 11 simultaneously with the ability to resolve both bus collisions and "live-lock" problems which are well known be those skilled in the art. Additionally, bus controller 22a may operate with both local bus 24a and Futurebus+ 11 simultaneously and autonomously, thereby improving system 10 performance. Thus, for example, bus controller 22a may simultaneously be sending data to a component on local board 13a via local bus 24a and performing an appropriate handshake with Futurebus+ 11. This improves system performance.
The following is an example illustrating the ability of bus controller 22a to operated as a slave simultaneously with both local bus 24a and Futurebus+ 11. Board A 13a wants to transfer data to board B 13b. Simultaneously, board B 13b wants to transfer data to board A 13a. Both boards make requests for Futurebus+ 11, yet only one board will receive a grant which will depend upon the priorities of each request. In this instance, board A 13a has a higher priority and receives a grant for Futurebus+ 11. Microprocessor 28a on board A 13a presently is the master of local bus 24a and controller 22a is the slave of local bus 24a. This same series of events occurs on board B with a microprocessor 28b (not shown) being the master on local bus 24b and the controller 22b the slave. The data then transfers from memory 26a to FIFO 40a via local bus 24a; FIFO 40a acts as a temporary data storage on board A 13a. Typically, on board A 13a processor 28a or memory 26a is master moving data into FIFO 40a via local bus 24a. Then controller 22a becomes the master on Futurebus+. While controller 22a is a master on Futurebus+, controller B 22b is a slave on Futurebus+. This typically would be a problem since bus controller 22b on board B 13b is now a slave of both local bus 24b and Futurebus+ 11 simultaneously, however bus controller 22b has the ability to recognize this potential problem through the monitoring of signals on local bus 24b and Futurebus+ 11. When this case occurs, bus controller 22b sends a signal to the microprocessor on board B 13b telling it to "back-off" on its attempt to send data to board A 13a. This frees local bus 24b to complete the transaction of sending data from board A 13a to board B 13b. Data is transferred to a memory 32b or an I/O device 30b on board B 13b via Futurebus+ 11, bus controller 22b, and local bus 24b. After completion of this transaction, board B may then complete its desired transaction of sending data from board B 13b to board A 13a. Similarly, when both local bus 24b and Futurebus+ 11 are bus masters bus controller 22b utilizes the "back-off" feature to avoid the bus collision that may occur.
It should also be noted that the "back-off" feature may work with either Futurebus+ 11 or a local bus 24a-n. However, bus controllers 22a-n are configured specifically to operate the "back-off" signal in the majority of cases with local buses 24a-n. This is to avoid the "live-lock" phenomena which is well known by those skilled in the art. If the "back-off" signal were used with Futurebus+ 11 it is possible that two boards, for example board 13a and board 13b, may alternately back each other off Futurebus+ 11 when attempting a transaction. Therefore, although Futurebus+ 11 is active (back-off signals are traveling along Futurebus+ 11) neither transaction is being executed and system 10 becomes "locked up". Bus controllers 22a-n traverse this problem by implementing the "back-off" signal on local buses 24a-n, therefore transactions always travel along Futurebus+ 11 without any impediments and the risk of system 10 lock-up is eliminated.
Dual bus controller 22a also may operate with both local bus 24a and Futurebus+ 11 simultaneously and autonomously. This feature is due primarily to the independent operation of local bus control module 12 and system bus control module 14. Below is an example illustrating how these modules interact to provide the decoupling feature and thereby the improved performance.
Bus controller 22a on board 13a monitors signals on both Futurebus+ 11 via system bus control module 14 and local bus 24a via local bus control module 12. Microprocessor 28a on board A 13a wants to transfer data to memory 32b on board B 13b. Local bus decoder 36 within local bus system module 12 in bus controller 22a decodes the address and determines that the address resides in memory 32b on board B 13b and translates a request to system bus control 38 within system bus control module 14. System bus control module 14, in response, makes a request for mastership of Futurebus+ 11. As system bus control module 14 is making a request for Futurebus+ 11 it also sends a signal to local bus control module 12 indicating that bus controller 22a is in the "request phase" of the transaction. After that event, this triggers the transfer of data from memory 26a to FIFO 40a on board A. After data has been sent to FIFO 40 a local bus control module 12 sends a signal to system bus control module 14 via local bus control 34 indicating that data is in FIFO 40a and ready for transfer to memory 32b on board B 13b which begins the "data phase" of the transfer. System bus control module 14 relays a signal back to local bus control module 12 indicating the that Futurebus+ 11 is in the "data phase" of the transaction. Local bus control module 12, in response to the "data phase" signal, effectively disconnects from system bus control module 14 and is therefore independent of the remainder of the data transfer to memory 32b on board B 13b. The data in FIFO 40a is transferred along Futurebus+ 11 to its destination in memory 32b on board B 13b during the Futurebus+ "data phase". While the transfer of data from FIFO 40a to memory 32b is occurring, new activity may occur on board A 13a along local bus 24a via local bus control module 12. In one instance, data from memory 26a could again be retrieved and stored in FIFO 40a for future transfer independent of the speed of the Futurebus+ transaction. The ability to operate along local bus 24a and Futurebus+ 11 simultaneously and autonomously greatly improves system performance in that certain operations may occur in a pipeline or parallel fashion as opposed to a serial fashion.
Table 1, listed below, is a Verilog program listing. Verilog is a behavioral program which translates macro-level system inputs into a gate level schematic and is well known by those skilled in the art of digital circuit design. The following Verilog program listing is a detailed representation of dual bus controller 24a-n and describes the gate-level construction of dual bus controller 24a-n. ##SPC1##
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A dual bus controller includes a system bus control module connected to a local bus control module. An optional filter is also connected to the system bus control module. A plurality of programmable status registers for the local bus is connected to the local bus control module and a time dependent reset circuit is connected to both the system bus control module and the local bus control module. The dual bus controller allows simultaneous, autonomous activity with both the local bus and the system bus via the local bus and system bus control modules. The unique interaction between the local bus and system bus control modules also allow both the local bus and system bus to interact with the dual bus controller operating as a slave without any imposed speed limitations by actively resolving bus collisions and "live-lock" conditions.
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[0001] The present invention relates to a mosquito bed net assembly. More specifically, the invention relates to a mosquito bed net assembly in which the bed net is a box net.
BACKGROUND OF THE INVENTION
[0002] Insecticide treated bed nets (ITNs) are one of the most effective tools available for the prevention of malaria. Not only have ITNs proved successful in protecting those who sleep directly underneath them, but widespread use of ITNs has been shown to reduce infection rates in the wider community, including those sleeping without nets.
[0003] The current generation of bed nets, termed long-lasting insecticidal nets (LLINs), remain central to malaria control and elimination in Africa where indoor transmission of malaria is of major significance. However, resistance to pyrethroids, currently the only class of insecticides approved for use on LLINs, is emerging at an alarming rate in Anopheles gambiae sensu stricto, the main indoor-biting vector of malaria in Africa, and the species most effectively targeted by LLINs. Accordingly, this resistance to currently-employed bed net insecticides represents a considerable threat for future malaria control. If, therefore, LLINs are to remain central to malaria prevention, new designs or approaches are urgently needed.
[0004] The present invention was devised with the foregoing in mind.
SUMMARY OF THE INVENTION
[0005] According to a first aspect of the present invention there is provided a mosquito bed net assembly comprising a mosquito bed net and a barrier member disposed above an upper portion of the bed net, wherein the bed net comprises a first insecticide and the barrier member comprises a second insecticide. The inventor has surprisingly found that for human-baited bed nets (i.e. those bed nets having a prone human beneath) the upper portion of the net, particularly the area directly above a prone human, is the area most visited by mosquitoes intent on feeding. At least one rationale for such a concentration of mosquito activity is the combined effect of bodily stimuli, such as heat and odour, emanating from the human below, which are channelled by the walls of the bed net to a focal point on its upper surface. For LLINs treated with approved pyrethroids, feeding mosquitoes have been demonstrated to adopt oscillating flight paths in the region above the bed net, whether or not they eventually make contact with the treated surface. Other studies have shown that those mosquitoes that do make contact with the upper treated surface of the bed net often go on to make further contacts therewith in a bouncing or hopping manner. The barrier member forming part of the present bed net assembly markedly increases the likelihood of such oscillating and bouncing mosquitoes coming into more frequent contact with an insecticide-treated surface. Additionally, the barrier member forming part of the present invention is located above, and therefore outside, the treated bed net meaning that it is unlikely, if not impossible, for it to come into contact with a human sleeping thereunder. As a consequence, insecticidal alternatives to pyrethroids may be applied to the barrier member, thereby increasing the likelihood of killing mosquitoes that have developed some resistance to pyrethroids. Suitably, the bed net is impregnated with the first insecticide and the barrier member is impregnated with the second insecticide.
[0006] In an embodiment, the first and second insecticides are the same. In view of the observed mosquito flying characteristics, the bed net assembly of the present invention is configured so as to increase the frequency of mosquito-bed net collisions, thereby increasing the likelihood of delivering a fatal dose of a single insecticide. The single insecticide may be any insecticide currently, or eventually, approved by the World Health Organisation Pesticide Evaluation Scheme (WHOPES) for use with LLINs.
[0007] Suitably, the first and second insecticides are different.
[0008] In an embodiment, the first insecticide comprises at least one pyrethroid insecticide. At present, pyrethroids are the only class of insecticides approved by the World Health Organisation Pesticide Evaluation Scheme (WHOPES) for use with LLINs.
[0009] In another embodiment, the second insecticide comprises at least one non-pyrethroid insecticide. The barrier member forming part of the present invention is located above the bed net, such that it is sufficiently distant from a human sleeping thereunder. As a consequence, the barrier member may be impregnated with other, preferably more effective non-pyrethroid insecticides, whose use on standard LLINs would otherwise be barred under the regulations imposed by WHOPES. Optionally, the second insecticide may comprise at least one pyrethroid insecticide in combination with at least one non-pyrethroid insecticide.
[0010] Suitably, the upper portion is defined by an upper surface of the net bed.
[0011] In an embodiment, the barrier member is formed from netted, meshed or webbed fabric. For the sake of cost and ease of manufacturing, the barrier member may be made from the same material as the bed net itself. Alternatively, the barrier member may be made from a more, or less, porous material, which may be partially or wholly stiffened depending on the specific form of the barrier member, and the availability of any overhead suspending means. In an embodiment, the bed net assembly is made from polyester.
[0012] In another embodiment, at least a portion of the barrier member is attached to the upper surface of the bed net. The barrier member forming part of the present invention may therefore be integrally formed with the bed net. Suitably, the barrier member is attached to the upper surface by stitching, gluing or any other known attachment means.
[0013] In a further embodiment, at least a portion of the barrier member is suspendable from above the upper surface of the bed net. Depending on the location in which the bed net assembly is to be used, the barrier member, or at least part of it, may be configured so as to be suspendable from above, such as from a ceiling or other overhead object, such that the barrier member is not itself in contact, or in intimate contact, with the bed net. Alternatively, the barrier member may be formed integrally with the bed net, whilst at the same time being configured so as to be suspendable, or partially suspendable, from above.
[0014] Suitably, the barrier member extends substantially perpendicularly to the upper surface of the bed net. The barrier member forming part of the present invention may be configured so as to project upwardly from the plane defined by the bed net's upper surface. Such a configuration is particularly effective at intercepting such oscillating and low-flying mosquitoes, and delivering to them a fatal dose of an insecticide.
[0015] In an embodiment, the barrier member comprises a first upstanding planar sheet. The barrier member may be a simple rectangular sheet whose bottom edge is associated with the upper surface of the bed net.
[0016] In another embodiment, the first planar sheet extends longitudinally along at least a portion of the length of the bed net. The barrier member may extend along the length of the bed net. Suitably, the longitudinally-extending barrier member is disposed at a substantially medium point along the width of the upper surface of the bed net. More suitably, the first planar sheet extends along the entire length of the bed net.
[0017] In another embodiment, the first planar sheet extends laterally along at least a portion of the width of the bed net. The barrier member may extend along the width of the bed net. Suitably, the laterally-extending barrier member is disposed at a substantially medium point along the length of the upper surface of the bed net. More suitably, the first planar sheet extends along the entire width of the bed net. Optionally, the laterally-extending barrier member is disposed approximately one third along the length of the upper surface of the bed net, such that it lies substantially over the chest area of a sleeping human.
[0018] In a further embodiment, the barrier member further comprises a second upstanding planar sheet, wherein the second planar sheet intersects and is perpendicular to the first planar sheet. The barrier member may therefore be formed from intersecting lateral and longitudinal planar sheets, thereby presenting further surfaces for contact with hostseeking mosquitoes.
[0019] In a further embodiment, the barrier member is conical, frustoconical or cylindrical. Suitably, the barrier member is centrally located on the upper surface of the bed net. Optionally, the barrier member is disposed approximately one third along the length of the upper surface of the bed net, such that it lies substantially over the chest area of a sleeping human. The base of the conical, frustoconical or cylindrical barrier member may define an opening in the upper surface of the bed net, thereby increasing the surface area of the upper surface at the point where bodily stimuli are believed to be most concentrated. Alternatively, where the upper surface of the bed net is unbroken, the conical, frustoconical or cylindrical barrier member may comprise one or more mosquito opening, thereby increasing the likelihood of mosquitoes becoming trapped within the barrier member where they can receive a lethal dose of insecticide. Optionally, the one or more openings define an opening to an internal passage provided within the barrier member. Optionally the internal passage is tapered towards the upper surface. Optionally, only an inner surface of the barrier member comprises the non-pyrethroid insecticide.
[0020] In another embodiment, the barrier member is disposed substantially co-planar to the upper surface of the bed net. Such a configuration is particularly effective at intercepting oscillating and low-flying mosquitoes, and delivering to them a fatal dose of an insecticide.
[0021] Suitably, the barrier member extends across substantially the same area as the upper surface of the bed net. Accordingly, the barrier member may be of substantially identical dimensions to the upper surface of the bed net, such that it may be viewed as a second upper surface. More suitably, the barrier member may be spaced above the upper surface of the bed net by supporting means disposed at its corners.
[0022] More suitably, the barrier member further comprises a mosquito opening, permitting mosquito access to the space beneath the barrier member. Incoming mosquitoes pass through the barrier member's opening and contact the upper surface of the bed net. Those which go on to exhibit low-flying characteristics become sandwiched between the bed net's upper surface and the co-planar barrier member, thereby restricting the mosquitoes' freedom of movement and hence increasing the likelihood of receiving a fatal dose of insecticide. The opening may be centrally-located on the upper surface, or in another region where bodily stimuli are believed to be at their most concentrated.
[0023] In an embodiment, the co-planar barrier member is disposed above the upper surface at a distance of between 0.5 and 10 cm. The narrow gap between the bed net's upper surface and the barrier member increases the likelihood of delivering a fatal dose of insecticide. Suitably, the edges of the barrier member do not form a closed structure with the respective side walls of the bed net. Accordingly, the upper surface of the bed net is accessible to a user to enable dead mosquitoes to be easily removed by sweeping, blowing or vacuuming.
[0024] In another embodiment, the co-planar barrier member has a top surface and a bottom surface. Suitably, both the top and bottom surfaces are impregnated with the second insecticide. More suitably, only the bottom surface is so impregnated. Such a configuration reduces the risk of human contact with the insecticide.
[0025] In yet another embodiment, the barrier member further comprises stiffening means. Stiffening means may be used in order that the barrier member retains its structure and orientation in use. The stiffening means may be disposed around the edges of the barrier member, as a frame. Alternatively, the stiffening means may be located at regular, or irregular, intervals along the length or width of the barrier member. Suitable stiffening means include ribs, rigid strips, wire frames, wire mesh or support posts.
[0026] In a further embodiment, the first insecticide comprises at least one insecticide selected from the group consisting of allethrin, bifenthrin, cyfluthrin, cypermethrin, cyphenothrin, deltamethrin, esfenvalerate, etofenprox, fenpropathrin, fenvalerate, flucythrinate, flumethrin, imiprothrin, lambda-cyhalothrin, methofluthrin, permethrin, prallethrin, resmethrin, silafluofen, sumithrin, tau-fluvalinate, tefluthrin, tetramethrin, tralomethrin, transfluthrin and pyriproxyfen. At present, pyrethroids are the only class of insecticides approved by the World Health Organisation Pesticide Evaluation Scheme (WHOPES) for use with LLINs, although other, non-pyrethroid insecticides are currently being tested for their suitability.
[0027] In another embodiment, the second insecticide comprises at least one insecticide selected from the group consisting of organophosphates, carbamates, pyrroles, hormone mimics and biological insecticides. In use, the barrier member comprising the second insecticide is sufficiently distant from the user such that more potent, non-pyrethroid insecticides can be used. Suitably, the second insecticide comprises at least one insecticide selected from the group consisting of pirimiphos methyl, propoxur, bendiocarb, indoxycarb, chlorphenapyr, pyriproxyfen, methoprene, Bacillus thuringiensis israelensis and entomopathogenic fungi.
[0028] In still another embodiment, the first insecticide further comprises a synergist. When the bed net assembly of the present invention is to be used in those areas where mosquitoes have developed, or are developing, resistance to pyrethroid-type insecticides, a synergist may be used in combination with the first insecticide in order to restore its efficacy. Suitably, the synergist is piperonyl butoxide.
[0029] In a further embodiment, the bed net is a box net. Box nets are among the most common types of mosquito bed net is use and generally take the form of a rectangular box. The flat, upper surface of the box net provides an ideal site on which to locate the barrier member forming part of the present invention.
[0030] According to a second aspect of the present invention, there is provided a kit comprising:
a. a mosquito bed net, and b. a barrier member disposed above an upper portion of the bed net, wherein the bed net comprises a first insecticide and the barrier member comprises a second insecticide.
[0033] According to a third aspect of the present invention, there is provided a barrier member as herein defined, the barrier member being configured to be associated with an upper portion of a mosquito bed net.
[0034] It will be appreciated that the barrier member may be identical in form any of the barrier members forming part of any of the mosquito bed net assemblies described herein. It will also be appreciated that the barrier member may comprise any insecticide discussed hereinbefore in respect of the barrier members forming part of the mosquito bed net assemblies.
[0035] In one embodiment, the barrier member is configured to be attached to an upper portion of a mosquito bed net.
DETAILED DESCRIPTION OF THE INVENTION
[0036] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying figures, in which:
[0037] FIG. 1 is a view from the front, one side, and above of one embodiment of the present invention.
[0038] FIG. 2 is a view from the front, one side, and above of another embodiment of the present invention.
[0039] FIG. 3 is a view from the front, one side, and above of another embodiment of the present invention.
[0040] FIG. 4 is a view from the front, one side, and above of another embodiment of the present invention.
[0041] FIG. 5 is a view from the front, one side, and above of another embodiment of the present invention.
[0042] FIG. 6 is a view from the front, one side, and above of another embodiment of the present invention.
[0043] FIG. 7 is a view from the front, one side, and above of another embodiment of the present invention.
[0044] FIG. 8 is a view from the front, one side, and above of another embodiment of the present invention.
[0045] FIG. 9 shows an example of the frequency of mosquito-net contacts at various points on both insecticide-treated bed nets and untreated bed nets.
[0046] FIG. 10 shows an example of the flight path of multiple mosquitoes over a human-baited bed net.
[0047] FIG. 11 shows an example of the flight path of a single mosquito over a human-baited bed net.
[0048] A mosquito bed net assembly 10 a - h includes a mosquito bed “box net” 12 impregnated with a pyrethroid insecticide and having a top surface 14 , and a barrier member 16 a - h impregnated with a non-pyrethroid insecticide and disposed above top surface 14 .
[0049] Referring to FIG. 1 , barrier member 16 a is formed from a rectangular planar sheet of netted material, attached to top surface 14 via its lower edge 18 and extending upwardly in a direction perpendicular to top surface 14 . Barrier member 16 a is located at a middle point along the length of top surface 14 , and extends across its entire width. Barrier member 16 a is attachable at uppermost corners 20 a,b to a ceiling or other overhead object.
[0050] Referring to FIG. 2 , barrier member 16 b is formed from a rectangular planar sheet of netted material, attached to top surface 14 via its lower edge 22 and extending upwardly in a direction perpendicular to top surface 14 . Barrier member 16 b is located at a middle point along the width of top surface 14 , and extends across its entire length. Barrier member 16 b is attachable at uppermost corners 24 a,b to a ceiling or an overhead object.
[0051] Referring to FIG. 3 , barrier member 16 c is formed from first and second rectangular planar sheets 26 , 28 of netted material, attached to top surface 14 via their lower edge 32 and extending upwardly in a direction perpendicular to top surface 14 . First planar sheet 26 is located at a middle point along the width of top surface 14 , and extends across its entire length. Second planar sheet 28 is located at a middle point along the length of top surface 14 , and extends across its entire width, such that first and second planar sheets 26 , 28 are arranged perpendicular to one another and intersect one another at a middle point 34 along their lengths. Barrier member 16 c is attachable at uppermost corners 30 a - d to a ceiling or other overhead object.
[0052] Referring to FIG. 4 , cylindrical barrier member 16 d is formed from stiffened netted material and includes a cylindrical outer wall 38 , extending upwardly from upper surface 14 , and a top wall 40 lying in the same plane as upper surface 14 . Barrier member 16 d is centrally located on upper surface 14 and is attached thereto via its lower edge 42 . Barrier member 16 d is open at its bottom face, defining an opening 44 in the upper surface 14 .
[0053] Referring to FIG. 5 , cylindrical barrier member 16 e is formed from stiffened netted material having a cylindrical outer wall 46 extending upwardly from upper surface 14 , a top wall 48 lying in the same plane as upper surface 14 , and a bottom wall defined by upper surface 14 . Barrier member 16 e is centrally located on upper surface 14 and is attached thereto via its lower edge 50 . Only the innermost surfaces of outer wall 46 and top wall 48 are impregnated with the non-pyrethroid insecticide. A plurality of openings 52 are disposed at regular intervals around cylindrical outer wall 46 . Top wall 48 also includes a centrally-disposed opening 54 . Openings 52 , 54 act as entrance points for mosquitoes.
[0054] Referring to FIG. 6 , frustoconical barrier member 16 f is formed from stiffened netted material having a conical outer wall 56 extending generally upwardly from upper surface 14 , a bottom wall defined by upper surface 14 , and an upper edge 58 defining an opening 60 Barrier member 16 f is centrally located on upper surface 14 and is attached thereto by its lower edge 62 . Only the innermost surface of outer wall 56 is impregnated with the non-pyrethroid insecticide. Opening 60 acts as an entrance point for mosquitoes.
[0055] Referring to FIG. 7 , cylindrical barrier member 16 g is formed from stiffened netted material having a cylindrical outer wall 64 extending upwardly from upper surface 14 , a top wall 66 lying in the same plane as upper surface 14 , and a bottom wall defined by upper surface 14 . Barrier member 16 g is centrally located on upper surface 14 and is attached thereto by its lower edge 68 . Only the innermost surfaces of outer wall 64 and top wall 66 are impregnated with the non-pyrethroid insecticide. Top wall 66 includes a centrally disposed opening 70 , acting as an entrance point for mosquitoes.
[0056] Referring to FIG. 8 , barrier member 16 h is formed from a rectangular planar sheet of netted material arranged to lie above, and in an identical plane to, upper surface 14 , and spaced apart therefrom at a distance of approximately 2-3 cm. Barrier member 16 h is of identical dimensions to upper surface 14 , and is held apart therefrom by vertical support posts 72 a - d extending between the respective four corners of barrier member 16 h and upper surface 14 . Barrier member 16 h also includes a centrally disposed circular opening 74 , approximately 30-40 cm in diameter, acting as an entrance point for mosquitoes The distance between upper surface 14 and barrier member 16 h is maintained in the region of opening 74 by a plurality of vertical support posts 76 extending between the edge of opening 74 and upper surface 14 . Only the underside surface of barrier member 16 h is impregnated with the non-pyrethroid insecticide.
[0057] In use, and referring to FIG. 9 , mosquito bed net assembly 10 a - h addresses the findings that for human-baited bed nets, the upper portion of the net, particularly the area directly above a prone human, is the area most visited by mosquitoes intent on feeding.
[0058] Referring to FIG. 10 , an experiment conducted in total darkness using IR lighting and IR-sensitive cameras demonstrates the flight path of 25 female Anopheles gambiae mosquitoes over a standard, human-baited bed bet. FIG. 9 clearly shows a density of mosquito activity on the upper surface of the bed net, particularly in a central portion, with little to no activity occurring at the side walls. FIG. 9 further demonstrates mosquitoes' tendency to adopt oscillating flight paths within this densely populated region. By virtue of barrier member 16 , which comprises a non-pyrethroid, and therefore comparatively more potent, insecticide, mosquito bed net assembly 10 a - h , in particular bed net assembly 10 a - g , provides improved protection against those mosquitoes having a tendency to adopt such oscillating flight paths over the upper surface of the bed net. Barrier member 16 is therefore ideally located to maximize contacts with such mosquitoes and deliver to them a lethal dose of insecticide.
[0059] Referring to FIG. 11 , other experiments conducted in total darkness using IR lighting and IR-sensitive cameras demonstrate the tendency of Anopheles gambiae mosquitoes to exhibit low-flying trajectories over the upper surface of a standard, human-baited bed net, often making frequent contact with the upper surface. By virtue of barrier member 16 , which comprises a non-pyrethroid, and therefore comparatively more potent, insecticide, mosquito bed net assembly 10 a - h , in particular bed net assembly 10 h , provides improved protection against those mosquitoes having a tendency to adopt these so-called “bouncing” flight trajectories over the upper surface of the bed net. Barrier member 16 a - h , in particular barrier member 16 h , is therefore ideally located to maximize contacts with such bouncing mosquitoes and deliver to them a lethal dose of insecticide.
[0060] The improved mosquito-killing efficacy of bed net assembly 10 a - h does not compromise the health of a user, since when using mosquito bed net assembly 10 a - h , a user is protected from non-pyrethroid-containing barrier member 16 a - h by upper surface 14 of box net 12 . Accordingly, bed net assembly 10 a - h adheres to the stringent requirements imposed by WHOPES, yet offers markedly improved mosquito killing potential.
[0061] After using bed net assembly 10 a - h , a user simply removes dead mosquitoes from upper surface 14 by known means, including brushing, blowing or vacuuming.
[0062] While specific embodiments of the invention have been described herein for the purpose of reference and illustration, various modifications will be apparent to a person skilled in the art without departing from the scope of the invention as defined by the appended claims. For example, barrier member 16 a - h , which has been described as being formed from netted material, may equally be formed from other meshed or webbed fabrics. Whilst barrier member 16 a - g has been described as being attached to upper surface 14 via its lower edge, it is equally envisagable that barrier member 16 a - g be suspended entirely from a ceiling or other overhead object, without therefore making intimate contact with upper surface 14 . Similarly, barrier member 16 a,b , which has been described as having portions attachable to a ceiling or other overhead object, may equally comprise one or more rigid support member so as to render it free-standing. Moreover, the positions of barrier member 16 a - g on upper surface 14 , or its general shape, may vary depending on the flight trajectory tendencies of the surrounding mosquitoes. For example, barrier member 16 may be located in the region approximately one third along the length of upper surface 14 , such that it is provided substantially above the chest of a user.
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Mosquito bed net assembly 10 a - h includes a mosquito bed net ( 12 ) impregnated with a first insecticide and a barrier member 16 a - h located above an upper surface ( 14 ) of the bed net ( 12 ) and being impregnated with a second insecticide. In use, bed net assembly 16 a - h increases the likelihood of delivering a lethal dosage of insecticide to mosquitoes flying in frequently-visited areas of a bed net, without increased attendant health risk to a user.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 637,771, filed Aug. 3, 1984, now abandoned.
BACKGROUND OF THE INVENTION
Field Of The Invention
This invention relates to steam irons, and more particularly, to the steam generating and ironing surface heating means of a steam iron of the compact, portable, snap-together type.
Portable irons are in use, where the separate handle locks on to the base during use, and where the handle wraps around the base to provide a flat, compact assembly for storage.
To provide a more compact iron body, a thin heating element, such as a semiconductor having a positive resistance temperature coefficient or a positive temperature coefficient thermistor, has been used. While these heating elements in theory can generate heat in the ironing temperature range, such as between 200° C. and 240° C., they have not worked satisfactorily in practice. These heating elements have only been able to provide heat to the bottom plate or ironing surface in the temperature range of between 140° C. and 170° C. This poor performance has been due to the dissipation of the heat to other adjacent surfaces and to poor heating element contact with the bottom plate resulting in uneven and insufficient heating of this ironing surface.
The above-mentioned problem was not solved by merely increasing the heat generating capacity of the heating element. Increasing this heat generating capacity has sometimes caused the iron to become overly hot, with the danger of possibly burning other parts of the iron.
SUMMARY OF THE INVENTION
The housing of the iron was redesigned to contain water. This redesign have the original purpose of redistributing the generated heat via the water, to bring the bottom plate of the iron up to the ironing temperature of approximately 200° C. However, this redesign also generated steam, which as is commonly known is a desirable commodity for eliminating wrinkles, i.e., it assists the ironing process.
The invention features a steam generating iron having a compact heating source. In order to maximize steam generation, a serpentine-like fluid passage is provided within the hollow housing of the iron adjacent the heating element. This serpintine-like passage provides for a greater volume water heating area that efficiently absorbs heat from the heating element and quickly conveys the heat to the water for generating steam. The bottom ironing surface has a steam vent for the generated steam. A source of water is carried by the housing and is in fluid communication with the passage.
A heating element is disposed within the housing and is operatively adjacent the serpentine-like passage for heating water in the housing for generating steam. The serpentine-like passage provides an extended heating surface whereby the heating element can efficiently generate enough steam to heat the sole plate to provide a sufficient ironing temperature.
It is an object of the present invention to provide an improved portable iron.
Yet another object of the invention is to adequately heat the ironing surface or sole plate of the iron.
A further object of the invention is to generate steam for ironing.
It is another object of the invention to provide a portable steam iron having a compact heating element and an extended water heating area.
A further object of the invention is to use a flat, thin heating element for the iron.
The foregoing and other objects and features of the invention will be apparent from the following description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a steam iron according to this invention;
FIG. 2 is a plan view of the iron;
FIG. 3 is a side view of the iron;
FIG. 4 is a bottom view of the iron;
FIG. 5 is a transverse-sectional view taken along the line 5--5 of FIG. 2 with the handle removed and the body of the iron stored in the handle;
FIG. 6 is a fragmentary cross-sectional view taken along line 6--6 of FIG. 2;
FIG. 7 is a side cross-sectional view of the bottom of the iron;
FIG. 8 is an exloded perspective view of a heat generating element and fluid passage which is used in the iron;
FIG. 9 is a schematic diagram showing circuitry in the iron; and
FIG. 10 schematically shows the circuit in an alternate embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the steam iron of this invention has a body 1 and a separable and attachable handle 2. The main iron body 1 is hollow forming a hollow housing as hereinafter described. Main body 1 comprises the sole plate 3, the base peripheral cover 4, and the top cover 5. Referring to FIGS. 7 and 8, the main body 1 houses a heat generating means 30 which is mounted on the sole plate 3. Steam vent openings 39 and 27 are provided in the sole plate 3 at the front tip 60 and in the below described steam passage 22, respectively. the base peripheral cover 4 extends around the sole plate 3 and the top cover 5, which is thermally non-conductive and therefore a heat insulator, resides above the peripheral cover 4. The peripheral cover 4 and the top cover 5 can be unitary elements or two parts fastened together by suitable means well known in the art.
As shown in FIGS. 7 and 8, there is a steam generating unit 20 which includes a serpentine steam passage 22 mounted on the upper side of the sole plate 3 at the front end thereof. The steam generating unit 20 is a separate member mounted on sole plate 3. The bottom wall 20a of unit 20 is formed with steam vent openings coinciding with the steam vent openings 39 in sole plate 3. It has a cover 36 closing the top of passage 22 and is integrated with a heater housing 21. The passage 22 is defined by upstanding partitions 29 to make it an elongate pathway. Together, the steam generatng unit 20 and the heater housing 21 comprise a heating assembly 61.
The sole plate 3 of the iron has steam vent openings 39 which concide with the internal openings 27 through the bottom wall 20a of the unit 20. In addition, the entrance side of the steam passage 22, which is at the rear of the unit 20 between the partitions 29 and which receives dripping water, is positioned along the front side of the below described heat generating means 30, whereby that entrance side of the passageway 22 can be easily heated. The surface area of the passageway 22, to which water is exposed for heating it, is made larger by providing a large number of small protrusions 28 on the bottom wall 20a of the unit 20.
As shown in FIG. 6, there is a cover 36 over the open top of the steam passage 22, which cover has a water supply opening 40. The cover 36 prevents leakage of the steam.
The heat generating means 30 is enclosed within a heater housing 21 which is integrated with the unit 20. The lower surface of the heater housing 21 contacts the upper side of the sole plate 3 of the iron, whereby the latter is heated by that contact. Specifically, the heat generating means 30 for the steam generating unit 20 is disposed in the heater housing 21 in a chamber 23 formed therein and which is being downwardly open, adjacent the rear of the steam generating unit 20. The heat generating means 30 in the chamber 23 includes an heater plate 33 that is, for example, either in the form of a plate of a semiconductor material having a positive temperature coefficient (PTC) of resistance or in the form of a positive temperature coefficient (PTC) thermistor. A pair of electrode plates 32a and 32b respectively contact the opposite top and bottom surfaces of the heater plate 33. Respective heat conductive plates 31 and 35 contact the outer sides of the electrode plates 32a and 32b. The plate 33 and elelectrode plates 32a and 32b are disposed in a supporting electrically insulating frame 34, which includes notches 34a and 34b for the projecting terminals on the plates 32a and 32b.
The thickness of the heat generating means 30 including the thermally conductive and electrical insulating plates 31 and 34 is the same as the depth of the chamber 23. This is accomplished by positioning the plates 31, 33, and 35, the electrodes 32a and 32b, and the insulating frame 34 as close together as possible.
There is a peripheral gap between the peripheral portion of heat generating means 30 and its chamber 23 into which a heat resistant electrically-insulative-fixing agent 25, such as silicon rubber, is injected. The insulating frame 34 and the electrically-insulative-fixing agent 25 prevent short-circuiting between electrode plates 32a and 32b.
The heat generating means 30 is attached to the sole plate 3, as shown in FIG. 7, by inserting the tapered studs 3a and 3b of the sole plate 3 into the openings 24a and 24b in respective flanges 24d and 24e projecting from the ends of the heater housing 21. the studs 3a and 3b are fixed in position by screws 38a and 38b.
Water is supplied in drip fashion to the serpentine steam passage 22 from a detachable cylindrical water container or supply 14 which is nested in a depression 11 defined in the top of the cover 5. A feed orifice 15 from the water container 14 meters the water supply. Orifice 15 fits into the opening 16 which is provided on the upper surface of the cover 5. In the opening 16, there is a grommet or sealing collar 41, as shown in FIG. 5. The orifice 15 is made to drip water at a fixed rate into the steam passage 22 through the collar 41. The water enters the steam passage through the supply opening 40. The water is converted to steam at high thermal efficiency because the passage 22 has a long meandering route.
FIG. 9 shows heat generating means 30, represented schematically by its heater plate 33, and a thermo-switch 6 connected in series. The thermo-switch 6, has a housing 58 which supports the ends of a pair of bendable terminal plates 53 and 54 in proximity. These plates make contact via their respective opposed contacts 53a and 54a. The contact 53a of the housing also supports a bendable bimetallic strip 56. At the tip of the bimetallic strip 56, there is an insulating protrusion 57 which passes through a hole 45 in plate 54 to engage plate 53. The contact 53a of the bendable terminal plate 53 is moved out of electrical contact with the contact 54a of terminal plate 54 by the bimetallic strip 56 when the heat generating means 30 heats the strip 56 to a sealed operating temperature.
At the end of the terminal element plate 54 is an insulating tip 52 of an adjustment screw 51 which is screw threadably advanced through the housing 58. Screw 51 is connected to the temperature adjustment knob 6a shown in FIGS. 1-3. The adjustment knob 6a is turned to a select temperature setting (as shown in FIG. 1), which causes screw 51 to force the tip 52 to bend the plate 54 to a predetermined extent, which selects the temperature at which the bimetallic strip 56 will cause the contacts 53a, 54a to move out of electric contact. The temperature adjusting knob 6a also serves the role of an ON and OFF switch for the electric source. At the OFF setting, the insulating tip 52 is advanced the furthest into the housing, and the terminal contacts 53a and 54a are separated. This opens the circuit containing electric source 42. The deflection of the cooled bimetal piece 56 will still not bend the terminal plate 53 enough to restore the circuit to a closed position when knob 6a is turned to OFF.
The temperature adjustment knob 6a has four rotary setting positions for selecting OFF and ON, low temperature, medium temperature, and high temperature. The rotation of the screw threaded shaft of the knob moves the insulating tip 52. When the bimetal piece 56 bends at high temperature, both contact elements 53a and 54a are made to separate in advancing degrees according to the temperature setting. When the temperature adjustment knob 6a has been rotated to the highest temperature position, both terminal contacts 53a and 54a are not separated by the bimetal piece 56 until that piece has been severely bent by the temperature of the iron.
In the alternative embodiment shown in FIG. 10, a plurality of heater plates 33a, 33b, and 33c, respectively, which generate different amounts of heat are selectively used for adjusting the heat generation, instead of using the aforementioned thermo-switch 6. These three plates are connected in parallel with the electric source 42. The side terminal elements 50c, 50b, and 50a, which correspond to the respective heater plates 33c, 33b and 33a, connect to the electric source 42 through contact means 6b. When the temperature adjusting knob 6a (not shown in FIG. 10) is rotated to the low temperature position, this moves the contact 6b so that electric contact is made with the heater plate 33c which generates a low volume of heat. When the knob is rotated to the medium temperature position, electric contact is also made by contact 6b with heater plate 33b to generate a medium volume of heat. When the knob is rotated to the high temperature position, electric contact is additionally made by contact 6b with the heater plate 33a to generate a high volume of heat. The arrangement can be adapted to enable various ones of the heater plates 33a, b, c, to be electrified.
The handle 2 also serves as a case for the main ironing body 1. It has an open side 2a for the insertion of the main ironing body 1. The open area 2b is filled by the inserted iron body 1. To assemble the iron, the bottom 2c of the handle 2 is engaged with the groove 10, which is provided on the upper surface of the top cover 5. The engagement of this handle 2 to the top cover 5 occurs through the front notch 19 at the tip of the handle 2 engaging at the tip 10b of the lip of the groove 10, and through the U-shaped ridges 18 engaging the engagement lips 10a on both sides of the rear edges of groove 10.
The rear edge of the groove 10 is open. As the handle 2 is moved either inward or outward from the main iron body 1, its bottom part 2c contacts the bottom of the groove 10. Thus, the engagement or disengagement between the handle 2 and the main ironing body 1 is accomplished.
In addition, abutment 12 limits the rearward travel of the installed handle 2. Abutment 12 is biased by a spring (not shown) to protrude above the groove 10 and, at the time when it is desired to detach handle 2 from body 1, abutment 12 is pushed down against its spring by the operator's finger to ease handle removal.
At the time when the iron is not in use and the handle is separate from the iron, the front tip of the iron body 1 is inserted into the handle 2. Surface 8 on the side of the iron body is a guide for this insertion, and ridge 18 on handle 2 contains groove 18c as a stop for the engagement of the handle 2 with the main ironing body 1.
Handle 2 serves the additional purpose of locking the knob 6a in an "OFF" position when the iron is not in use. The temperature adjusting knob 6a has a part of its peripheral surface undercut as at 7. The portion above the undercut overhangs body 5 when knob 6a is set at the rotary position of "OFF". The ridge portions 18a of handle 2 fits in the undercut 7 of knob 6a when the main body 1 has been inserted. While the main body 1 is in the handle 2, the ridge portion 18a makes it impossible to rotate the knob 6a, and particularly to rotate that knob to the "ON" position. When the iron body 1 is to receive the handle 2, it becomes impossible to insert the handle unless the adjusting knob 6a is in the "OFF" position. This is a power safety feature.
A reel for cord 13 is defined by the undercut portion 9 at the back of the body of the iron.
The heat generating means 30 used in this invention is less complex than the conventional Nichrome heating wire, and it enables design of a steam iron of thin construction. Furthermore, there is little danger of the development of conventionally experienced trouble, such as wire multilation.
Since, the heat generating means 30 is accommodated in a chamber 23, heat from both the lower and the upper heater plate surfaces is utilized to heat the sole plate 3. This is accomplished by the heater 21 that helps heat water to steam in adjacent passage 22.
In an actual test, the bottom of one of the irons according to the invention was heated to a temperature in the range of between 200 and 210 degrees Centigrade. The consumed power ranged between 70 and 150 watts (70 watts at the time when steam was not used, and 150 watts at the time when steam was used) at 120 volts.
The aforementioned heater housing 21 has the serpentine steam passage 22 adjacent to it. As a result, the area of contact with the bottom surface 3 of the iron increases, so that it becomes possible to effectively consume the heat generated by the heat generating means 30. By generating steam, the iron not only utilizes almost all the available heat being generated, but also provides a better iron surface.
Although the present invention has been described in connection with preferred embodiments thereof, many variations and modifications will now become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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An electric steam iron housing has a sole plate with a generally flat upper surface having affixed thereto a one-piece heating assembly having a front portion and a rear portion. The front portion contains a serpentine steam generating passage with an inlet communicating with a water supply container on the housing and steam outlet leading to steam vent openings extending through the sole plate. The rear portion includes top and sidewalls defining a downwardly open chamber in which is disposed a multilayer PTC electric heating element assembly in surface-to-surface contact with the upper surface of the sole plate for heating the sole plate and the steam generating passage. An adjustable thermostat responsive to the temperature of the sole plate is connected in series with the heating element. The handle of the iron is detachable and designed to serve as a storage case for the iron and the iron can be placed in the case only when the thermostat adjustment knob is in the "Off" position.
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BACKGROUND OF THE INVENTION
This invention relates to building construction generally, and more particularly to a method and device for reinforcing metal roofs against wind lift.
As wind blows over a roof, the roof panels are subject to static air pressure from below, and a reduced or negative pressure above, according to Bernoulli's principle. Additionally, wind tends to "climb" the windward wall of a building, so that the leading edge of the roof on the windward side may actually have a positive angle of attack with respect to the wind, which increases the lifting force, particularly at the very edge and leading corners of the roof. The forces developed by high winds can be very large, and, depending on the height, orientation, roof slope, and other factors, these forces may be sufficient to cause seams and panel fasteners to fail. Once this happens, an entire portion of a roof can tear away, with potential disastrous results for the occupants or contents of the building. If the roof clips release, allowing the roof panels to break free completely, there is an additional hazard to people and objects downwind of the building. Therefore, we are concerned with strengthening roof panel seams and attachments, to prevent such failures.
We have determined that metal standing seam roofs fail, in many cases, during the uplift mode, due to concentrated loads developed at the location of clips which attach the roof panels to substructure. Such loads cause local distortion and buckling of some panels long before the panel itself fails in bending or other roof components fail. Our approach to solving this problem is to reinforce the panel-to-panel seams, and the points of load transfer to the structure, and thus prevent seam distortion, panel buckling, and seam failure. To do so, we have developed a seam clamp that maintains seam and corrugation geometry during uplift loading.
SUMMARY OF THE INVENTION
An object of the invention is to strengthen a standing seam between metal roof panels, to provide improved resistance to wind damage, without significantly increasing costs.
Another object of the invention is to strengthen a metal roof, without requiring an increase in gauge of the roof, or any modification of its seam structure.
A further object of the invention is to provide for simple manufacture and installation of roof strengthening components.
One other object is to avoid detracting from the appearance of a metal panel roof while reinforcing it.
These and other objects are attained by a seamed metal roof formed from an array of panels having lateral edges interconnected by rolled seams, and a plurality of seam clamps placed at high-stress points on the roof. Each clamp comprises a first elongate part having a mating surface, a longitudinal recess having dimensions like those of the seam, a second elongate part having a mating surface opposing the recess and the mating surface of the first part, and a fastener for drawing said parts together, to confine the seam in the recess.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a side elevation of a building having a metal panel roof, showing wind flow over the roof;
FIG. 2 is an isometric view of a portion of the building roof, taken from above the building;
FIG. 3 is a detailed view of a portion of FIG. 2, at an enlarged scale;
FIG. 4 is a detailed view of another portion of FIG. 2, also at an enlarged scale;
FIG. 5 is a cross-sectional view of a portion of the roof, taken in the direction of arrows 5--5 in FIG. 2; and
FIG. 6 is an exploded isometric view of the seam reinforcing clamp shown in FIGS. 2, 3 and 5.
FIG. 1 shows a typical standard metal building in a windy situation, wind flow being indicated at various points by arrows. It can be seen that the roof panels P are subject to lifting forces F resulting both from airfoil effects, and by dynamic pressure forces developed at the roof edge where there is a positive angle of attack α.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 2-5 illustrates a roof formed from an array of separate roof panels P, interconnected along their lateral edges by standing seams S, which are formed in situ by automatic machinery. The longitudinal ends of the panels simply overlap, and are usually sealed, depending on the environment and purpose of the roof.
As best seen in FIG. 5, the lateral edges 12, 14 of each panel are bent along lines 16, 18, and 20, so that when joined, they form a corrugation 22 giving the roof resistance against bending along the direction of the seams. Note also the series of transverse embossments 24 (FIG. 2), which provide bending resistance in the transverse direction. A flange 26 is formed along each lateral edge of each panel, and two apposed flanges of neighboring panels are rolled together to form a rolled seam S. Tabs or straps 32 extending from attachment clips 30, previously installed at intervals on or in a purlins, bar joists or like substructure 28, are rolled into the seam, thus securing the panels to the sub-structure. One may refer to U.S. Pat. No. 4,543,760, which is incorporated herein by reference, for details of the attachment clip.
The foregoing structure is conventional, and has been relied on for years. Under very high wind loading, even rolled seams may fail. Failure tends to occur where concentrated loads are applied, that is, at the points where the attachment clips meet the seams, and particularly in areas of highest wind loading, near the leading edges and corners of the roof. We have determined that the strength of the roof can be dramatically increased by reinforcing the seams by externally clamping them at these potential failure points. The clamp shown in detail in FIGS. 5 and 6 provides the necessary reinforcement, without requiring any alteration of conventional roof construction.
Referring to FIG. 6, a seam reinforcing clamp 40 embodying the invention comprises two metal parts 42 and 44, which can easily be produced by extrusion. For convenience, we refer to the part 42 as "female" and the part 44 as "male". The geometry of the clamp is determined by that of the seam (including the clip strap rolled into it), which has a height H and a rolled width W. The female part 42 of the clamp has a foot 46 approximately 3/4 inch wide (extending slightly beyond the top surface of the corrugation, to prevent deformation of the corrugation) at the bottom of a vertically extending body 48. An enlarged head 50 has a longitudinal V-groove 52 running along its inner face 54 approximately midway between the top surface 56 of the head and a recess 58 defining the bottom of the head. The height and width of the recess are chosen so just as to accept the rolled seam in either direction. By closely confining the seam at stress points, we have found that seam failure is better prevented.
The inner face 54 of the head 50 forms a mating plane with the opposite part, and it will be observed that the foot 46 is offset from this plane by a distance at most equal to twice the gauge of the panel metal, plus the thickness of a clip strap 30, so the flanges are kept in face-to-face abutment, preventing any tendency to open the seam. Note that the bottom inner edges of each of the parts 42 and 44 is radiused to preserve minimum bend radius of the panel material, and to keep from cutting into the panel surface.
The male part 44 has, like the female part, a foot 60 at the bottom of a leg 62; unlike the body 48, however, the leg 62 is of uniform thickness, except for a longitudinally extending V-rib 64 at the same level as the V-groove 52. Each of the parts has a bolt hole 66, 68 near its lengthwise mid-point; the centerline of the hole approximately passes through the apex of the V-shaped groove and rib. A bolt 70 is passed through the holes, and secured with a nut 72 and lockwasher 74. If desired, more than one bolt, or a different type of fastener could be used to hold the male and female parts together; this would be considered within the skill of the artisan. Regardless, when the parts are thus assembled, the rib and groove fit together, and the bottom surfaces of the feet are coplanar, standing on the top of the corrugation.
As mentioned, the clamp should be installed on roof seams at their most highly stressed points, that is, over attachment clips near the roof edges and corners. In preliminary testing of the invention, an approximate doubling of blow-off loads has been observed with 24-gauge metal roofing.
Since the invention is subject to modifications and variations, it is intended that the foregoing description and the accompanying drawings shall be interpreted as illustrative of only one form of the invention, whose scope is to be measured by the following claims.
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A seamed metal roof is formed from an array of panels having lateral edges interconnected by rolled seams, and a plurality of clamps, each comprising a first elongate part having a mating surface, a longitudinal recess having dimensions like those of the seam, a second elongate part having a mating surface opposing the recess and the mating surface of the first part, and a fastener for drawing said parts together, to confine the seam in the recess.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a safety system for eliminating any risk of liquids being carried to the torch nose-piece or to the vent hole, during burning or dispersion of the gases associated with the production or with the treatment of hydrocarbons on land and off-shore.
The present invention relates to a safety system for eliminating any risk of liquids being carried to the torch nose-piece during burning of the gases associated with the production of hydrocarbons, more especially off-shore.
Generally, it is known that liquids carried along in the nose-piece of a torch, particularly resulting from choking up of the gas/oil or gas/condensate separators, constitutes a serious danger in hydrocarbon treatment and production installations and in particular in fixed or floating off-shore production installations.
In fact, on leaving the nose-piece of the torch, the oil or the condensates carried along by the gas are set on fire and fall flaming back down on to the installation or in the immediate vicinity thereof, thus endangering the whole installation and the lives of the whole of the staff.
This danger is all the more important, in off-shore installations, since the staff risk being imprisoned on the platform or the floating burning support and since further the oil or the condensate floating on the sea may form a sheet of fire prohibiting any possibility of evacuation.
To try to eliminate this risk, one of the best arrangements used up to present is formed by placing, between the liquid hydrocarbon driving source and the nose-piece of the torch, three capacities, namely a separator, a safety purifying installation and a torch foot tank, mounted in series in the gas flow chain, these capacities being respectively equipped with three high level detection devices which cause, should the liquid level exceed a predetermined height, closure of the hydrocarbon feed of the installation.
Furthermore, in such an installation, the torch foot tank has, or may have, a liquid retention capacity, such that it allows sufficient time for the hydrocarbon feed valves of the installation to be closed manually.
However, it is clear that in any case, principally in the case where the torch is vertical or subvertical on the production support, the safety of the staff and of the whole of the platform will depend:
on the operation of the automatic detection and mechanical actuation automatic devices which are always subject in time and depending on the operating conditions to break-downs, and
as a last resort, on the time in which the liquid is retained in the torch foot tank, which is dimensioned with respect to the anticipated duration of human intervention, which is always problematic and the hazardous character of which does not conform to good safety logic.
Furthermore, it should also be noted that the torch foot tank, which is generally placed in a low part of the installation, because of its dimensions risks causing considerable, even inacceptable inconvenience.
SUMMARY OF THE INVENTION
The invention has then as its aim to do away with all these disadvantages.
It thus proposes a safety system comprising, in the gas flow chain between the liquid drive source and the nose piece of the torch, at least one chamber defining an excess volume or capacity such as for example a torch foot tank provided with an overflow column discharging below the level of the sea, at a given distance from its tapping point in said capacity.
Thus, a particularly simple and reliable safety system is obtained possibly completing or even replacing the usual safety systems, and which has the advantage of using no detection device and no mechanical means subject to break-downs.
Thus, in the case of a slow or sudden derangement of the system, the excess liquid will be discharged into the sea with a very low fire risk probability since:
it would require a considerable hot point in the zone where the liquid will reach the surface of the sea to cause ignition thereof,
because of the depth at which it is discharged, and because of the sea currents which exist in most sites, the liquid will only rise to the surface at a certain distance from the installations.
Furthermore, the overflow column, in some applications, will be equipped with a device for discharging inside the column different products whose main purposes will be, but not limitatively so, to delay or prevent the liquid hydrocarbons from rising to the surface, reducing, delaying or inhibiting the pollution caused by the hydrocarbons.
Moreover, in some applications, the torch will be equipped with manual or automatic ignition and extinction means allowing the flame to be initiated or blown out in different operating configurations or for safety reasons or similar.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described hereafter, by way of non limiting examples, with reference to the accompanying drawings in which:
FIG. 1 is a schematical representation of a first production installation equipped with a safety device according to a first embodiment of the invention;
FIG. 2 is a schematical representation of a second installation requiring less space and equipped with anti-pollution means;
FIG. 3 is a schematical representation of a third installation in which the barrel of the torch serves as torch foot tank.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the installation comprises first of all a liquid hydrocarbon drive source formed by an intake separator 1 receiving the crude oil or the gas through an intake pipe 2. This separator is equipped conventionally with a normal oil or condensate take-off circuit 3 and a gas outlet connected to a gas flow chain 4 as far as the nose-piece 5 of the torch.
This gas flow chain 4 comprises, between separator 1 and the nose-piece of torch 5, a torch foot tank 6 equipped, in a conventional way, with a droplet take-off circuit 7 comprising a pump 8 or not.
Separator 1 and torch foot tank 6 are both equipped with a high liquid level detection circuit 30, 32 (liquid level detectors) for closing, should the liquid level become abnormally high, the gas or crude oil feed of the installation.
According to the invention, this installation comprises an overflow column 10 tapped (tapping 11) on the torch foot tank 6 at a position corresponding to a maximum predetermined level emerging below the level 12 of the sea at a distance L R below the tapping 11 on said tank 6.
This overflow column 10 is equipped with a discharge conduit opening or device 14' and means 13' for removing liquid hydrocarbons overflowing in the overflow column so as to reinsert them into the normal treatment circuits. These take-off means will be formed, for example, by different types of pumps or liquid or gas ejectors (gas lift). They may be positioned during construction of the installation or later and they may be removable or not.
Thus, under normal operating conditions, the two level detection systems will inform the operators of a malfunction and will turn off the crude oil intake if the malfunction has not been corrected.
Should a sudden derangement and non operation of the two level detection circuits occur, the liquids will be discharged into the sea through the overflow column 10, the torch continuing to be fed with gas, until the defect has been corrected or unitl the crude oil intake has been closed manually or automatically.
Thus a circuit is obtained of very high safety. However, because of the dimensions of the torch foot tank 6, it presents a considerable disadvantage (which may be eliminated by means of the arrangements which will be described more especially with reference to FIGS. 2 and 3).
It should be stated that, to obtain acceptable operation, the overflow column 10 must satisfy given dimensioning criteria complying with at least two main conditions, namely:
to prevent the liquids rising in the torch barrel 13, should choking occur;
to prevent gas leaving through the lower end 14 of the overflow column 10 during normal service.
These conditions may be expressed as follows:
(A) To avoid choking up of the torch foot tank 6 or the rise of liquids in barrel 13, the flow of liquids into the sea should be ensured, which implies that the following equation (1) is at least satisfied, without taking into consideration the different pressure drops in the ducts:
P.sub.1 +(L.sub.1 ×d.sub.o)9.81≧P.sub.atm +(L.sub.R -L.sub.1)(d.sub.w -d.sub.o)9.81 (1)
in which:
L 1 is the height of the tapping 11 with respect to the highest level of the sea (expressed in m);
L R is the length of the overflow column 10 (expressed in m);
P 1 is the pressure inside the torch foot tank 6 (expressed in P a );
P atm is the atmospheric pressure (in P a );
d o is the voluminal mass of the liquid (in Kg/m 3 at T 1 °;
d w is the voluminal mass of the sea water (kg/m 3 at T 2 °).
The most unfavorable conditions being reached when P 1 =P atm (the case of stopping after choking up and total filling with liquid of the overflow column 10 over the length L R ), the relationship (1) may be simplified to:
L.sub.1 ×d.sub.o ≧(L.sub.R -L.sub.1)(d.sub.w -d.sub.o) (2)
Applications
(1) For d w =1020
d o =700 (imperfectly degasified oil)
L R =50 m
the minimum height L 1 is 15.7 m (example 1)
(2) Under the same conditions as above but with a better degasified oil of d o =800, the height L 1 becomes 10.8 m (example 2).
(3) Under the same conditions as in example 1 but with a shorter overflow column 10, L R =40 m, the minimum height L 1 is 12.5 m (example 3).
(4) Under the same conditions as in example 3 but with an oil density d o =800, the minimum height L 1 becomes=8.62 m (example 4).
(B) To prevent gas leaving through the lower end of the overflow column 10, the following relationship should be confirmed:
9.81(L.sub.R -L.sub.2)d.sub.w +P.sub.atm ≧P.sub.1 (3)
In which L 2 is the height of the tapping with respect to the lowest level of the sea (expressed in m).
Applications
(1) with d x =1020
L R =50 m
L 2 =30 m
P atm =1.013×10 5 P a
the pressure P 1 should be less than 3.013×10 5 P a .
(2) with d x =1020
L R =40 m
L 2 =30 m
P atm =1.013×10 5 P a
the pressure P 1 should be less than 2.013×10 5 P a .
It follows, from an examination of the preceding relationships 1 and 3, that the safety system prposed will not be applicable in all cases, and in particular in water depths which are too shallow.
If, for a given set-up, the relationships 1 and 3 are confirmed with reasonable safety coefficients, and if the dimensioning of the ducts is correct to take into account the different pressure drops, the risk of the torch being choked up is very unlikely.
However, the risk of liquid being carried to the nose-piece of torch 5 remains, except if the torch foot tank 6 is designed and sized as a gas-liquid (two phase) separator in one possible embodiment, operating at a very low level. This leads to the use of a tank 6 whose dimensions and weight risk being prohibitive.
Moreover, since the oil/gas separation takes place without real control, in the torch foot tank 6 where the internals are practically excluded, the risk of carrying along droplets of liquid remains high.
An examination of relationships 1 and 3 shows that the increase in dimensions L 1 and L R leads to an improvement in safety.
Pollution
Should choking up occur, whether the installation comprises this safety system or not, the amount of liquids discharged into the sea will be substantially the same.
Nevertheless, for choking up of limited duration, the volume of liquid "trapped" in the overflow column may be raised in the installations and discharged. However, the danger of inopportune ignition of liquid hydrocarbons is considerably less than when directly discharged in the sea.
In FIG. 1, the liquids are discharged into the sea "like a spring", that is to say that it will need a considerable hot point in the zone where the liquid hydrocarbons will reach the surface of the sea to cause ignition thereof. However, taking into consideratioon the sea currents which may exist on a good number of sites, the liquid hydrocarbons will only come to the surface at a remote distance from the installations.
By way of example, for an overflow column 10 discharging at 50 m below the mean level of the water and with oil of voluminal mass 850, this oil will only come to the surface at about 60 m from the vertical of column 10 for a current of 0.25 knot.
Effect of the waves
The level of the water inside the overflow column 10 will follow with a delay and damping the level of the water on the outside. However, this point should be confirmed so as to avoid air intakes into the torch barrel 13, especially in the case of short overflow columns 10 and small gas flows. As a general rule, the longer the overflow column 10, the less will be the effect of the waves.
To take into account the points mentioned above, an arrangement (FIG. 2) is developed as follows:
The torch foot tank 6, generally placed at a low point of the installation, during normal service is used to remove accumulated liquid (circuits 7,8). Its dimensions and its weight become acceptable again. It is completed by a liquid/gas separator 15 placed at the lower part of the torch barrel 13, this latter only being useful should choking up occur.
This separator 15 may be housed in the tower 16 supporting the torch. It operates at a very low level and at low pressure.
From a certain depth, the overflow column 10 may possibly be expanded to form an additional retention volume 17, thus avoiding any pollution for a limited period of time. The liquid hydrocarbons thus trapped may be subsequently reinserted into the installations by means 13.
The lower part of column 10 may be fitted with lateral strainers so as to better disperse the liquid hydrocarbons into the sea.
Finally, for some applications, the embodiment shown in FIG. 3 presents a simplified solution.
The vertical torch barrel 20 is formed by a tube of variable section or not, being possibly for some applications self-resistant to external forces, and having a diameter such that the rise speed of the gas is sufficiently low for the gas/liquid separation to take place. The speeding up of the gas may be provided if necessary at the torch nose-piece 5 by passing through a reduced tubular section 21 or by any other means.
The lower end 22 of the torch barrel serves as torch foot tank under normal operating conditions, and is equipped with an overflow column 10 such as those previously described as well as a droplet take-up circuit 7, 8 and 13'.
An additional simplification will consist for some applications in constructing the overflow column-torch barrel assembly as a continuous tubing with possibly variable section, the droplet take-up circuit being then installed at a suitable height on the continuous tubing.
Furthermore, in all the installation configurations of this safety system, this latter may use, for its construction, already existing tube parts, made from steel or other materials such as concrete, and able to fulfil other functions such as supporting the installations. The support thereof may also be provided by means of frames or supports required or not for fulfilling other functions.
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A safety system for eliminating the risk of liquids, rather than gases, being carried to a torch nose-piece or to a vent hole, during burning or dispersion of the gases associated with the production or treatment of hydrocarbons, particularly on off-shore installations. The gas flow line is connected to a storage volume or capacity, such as a torch foot tank. An overflow column is also connected to the gas flow line, and discharges below a liquid level, such as for example the sea, at a distance from the connection to the overflow column.
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FIELD OF THE INVENTION
[0001] As liquid fuel enters a vehicle gasoline tank during fueling, fuel vapors are displaced out of the tank and into the atmosphere. This invention relates to a coupling which includes a cap assembly (female coupling half) which sealingly engages a standard vehicle gasoline tank and a nozzle assembly (male coupling half) which is attached to or is integral with the spout of a hand-held fuel dispensing nozzle. The cap assembly may be adapted to any existing vehicle gasoline tank or it may be installed without an adapter as an integral part of a vehicle gasoline tank.
[0002] The nozzle assembly on the spout of the dispensing nozzle couples with the cap assembly of the vehicle gas tank during fueling and provides for fuel vapor recovery directly from the vehicle gasoline tank to the vacuum recovery system. A predetermined pressure differential between the vehicle gasoline tank and the atmosphere is maintained by a vent valve and a vent sleeve in the cap assembly.
BACKGROUND OF THE INVENTION
[0003] It is highly desirable to recover fuel vapor during refueling of a vehicle gasoline tank. Damage to the environment caused by vapor escape to the environment is well documented in U.S. Pat. No. 5,327,943 to Strock et al. issued Jul. 12, 1994. Hydrocarbon vapor release to the atmosphere when exposed to sunlight can react with air contaminants to create ozone.
[0004] Fuel costs continue to soar and the present crude oil price exceeds $30.00 per barrel thus making vapor recovery economical. U.S. Pat. No. 4,429,725 to Walker et al. cites a 97.6% recovery of the vapor which would have been emitted (without vapor recovery) but for the use of the '725 invention.
[0005] U.S. Pat. Nos. 5,385,178 and 5,295,521 to Bedi disclose a flat planar surface disposed on a filler cap with the cap being threaded into an existing gasoline tank receptacle. Bedi '178 and '521 further disclose two commercially available coupling halves mounted into or on the flat planar surface. The couplings halves mate with commercially available reciprocal coupling halves. One coupling feeds and is connected to a fuel vapor return line and the other coupling feeds and is connected to fuel a supply line. The vapor return line is separate from and independent of the fuel dispensing nozzle.
[0006] There are two known vapor recovery systems: balanced pressure systems and vacuum assist systems. Balanced pressure systems use an elastomeric boot or other positive sealing device to engage and seal the fill opening of the tank during refueling. “The interior of the boot is connected to a vapor return conduit to the underground storage tank so that hydrocarbon vapors emitted during fueling naturally flow to the storage tank to maintain the pressure balance between the vehicle tank and the storage tank. The vacuum assist differs from the balanced pressure system because it does not require a tight sealing boot or some other positive sealing arrangement with the fill opening or filler pipe of the vehicle tank. Instead, the vapor return conduits are connected through a vapor pump or other vacuum inducing assist device to collect and transport the vapors emitted during fueling to the storage tanks.” See, the '943 patent to Strock et al. at column 1, lines 51 - 69 .
[0007] Given the high cost of fuel and given the environmental damage caused by fuel vapor in the atmosphere, it is highly desirable to increase the efficiency of the vapor recovery process. An increase in the efficiency of the vapor recovery process will produce a better environment with attendant financial savings. The coupling of the instant invention combines the features of positive sealing and vacuum assist. The nozzle assembly seals against the cap assembly. Passageways in the cap and nozzle assemblies permit fluid and gaseous communication between the vehicle tank and the service station storage tank.
[0008] The invention will be better understood when reference is made to the Summary of the Invention, Brief Description of the Drawings, Description of the Invention and Claims which follow below.
SUMMARY OF THE INVENTION
[0009] A coupling for a fuel storage tank such as a vehicle gasoline tank is disclosed and claimed. The coupling includes a cap assembly (female coupling half) and a nozzle assembly (male coupling half). The cap assembly is sealingly attached to the vehicle gasoline tank and the nozzle assembly is affixed to the spout of a dispensing nozzle. Once attached to an existing gasoline tank the female coupling half (cap assembly) is normally not removed except if maintenance is to be performed. Additionally, the female coupling half (cap assembly) may be removed from the vehicle gasoline tank if the vehicle is being fueled at a nonconforming service station (i.e., one which does not employ the nozzle assembly of the instant invention. The cap assembly includes a body and the body includes a plurality of apertures in communication with the vehicle gasoline tank. A passageway interconnects the plurality of apertures with a plurality of ports. A substantially flush faced valve covers and closes the ports when the cap assembly is not coupled to the nozzle assembly. The valve uncovers and opens the ports when the coupling halves, namely, the cap assembly and the nozzle assembly are coupled together.
[0010] The nozzle assembly includes an annular passageway formed by an outer sheath which is concentric with an inner fluid conduit. The nozzle assembly includes a plug mounted and secured partially in the annulus having radial ports therein. A flush faced valve is formed by the plug having ports and a sliding sleeve. The spout of a dispensing nozzle is generally the portion of the nozzle which is distal (remote) from the hand-held portion of the nozzle. Apertures in the outer sheath enable communication between the vehicle fuel tank and the passageway of the nozzle assembly when the coupling halves are coupled together. The passageway of the cap assembly communicates with the vehicle gas tank via apertures. Ports of the cap assembly communicate with the passageway of the cap assembly and with the nozzle assembly via the apertures in the outer sheath of the nozzle assembly when the coupling halves are coupled together.
[0011] When the male coupling half (nozzle assembly) and the female coupling half (cap assembly) are uncoupled little or no spillage occurs due to the flush face configuration of the valve in the female half and the flush face configuration of the plug in the male half.
[0012] Vapor from a vehicle gasoline tank is displaced during fueling of the vehicle as the volume for the vapor is reduced by incoming fuel. Use of the term “fueling” herein includes the term “refueling.” When vapor is displaced it is directly communicated to a vacuum assisted recovery system. Seals insure that the vapor remains in the passageway of the coupling halves and does not migrate to the atmosphere. Seals also insure that the liquid gasoline is delivered to the vehicle gasoline tank without fluid or vapor migration to the atmosphere.
[0013] When the halves are coupled together vapor recovery is effected utilizing mechanical seals and passageways under the influence of a vacuum. When the halves are uncoupled the cap assembly functions to relieve excess pressure within the vehicle gasoline tank. As liquid gasoline is consumed a vacuum is created within the tank and the cap assembly also functions to add air from the atmosphere into the tank.
[0014] It is an object of the present invention to provide a coupling for a vehicle gasoline tank and gasoline dispensing nozzle which maximizes vapor recover from the vehicle gasoline tank.
[0015] It is a further object of the present invention to provide a cap assembly which sealingly interconnects with a vehicle gasoline tank.
[0016] It is a further object of the present invention to provide a cap assembly which includes an adapter enabling interconnection with existing vehicle gasoline tanks.
[0017] It is a further object of the present invention to provide a cap assembly which includes a vent valve for relieving pressure when a curtain pressure differential between the interior of a vehicle gasoline tank and the atmosphere is exceeded.
[0018] It is a further object of the present invention to provide a cap assembly which includes a vent sleeve for admitting air to the interior of a vehicle gasoline tank when a curtain pressure differential between the atmosphere and the interior of the gasoline tank is exceeded.
[0019] It is a further object of the present invention to provide a cap assembly which is small enough to fit within the gasoline cap access door and the vehicle gasoline tank.
[0020] It is a further object of the present invention to provide a nozzle assembly affixed to the spout of a dispensing nozzle.
[0021] It is a further object of the present invention to provide a low or no spill fuel coupling.
[0022] It is a further object of the present invention to provide a cap assembly for the removal of gasoline or other fuel vapor directly from a fuel storage tank through apertures in the cap assembly which interconnect with an annular passageway which, in turn, interconnects with ports.
[0023] It is a further object of the present invention to provide a cap assembly which includes a main valve for covering and uncovering ports which interconnect with an annular passageway.
[0024] It is a further object of the present invention to provide a cap assembly, or female coupling half, which sealingly couples together with a nozzle assembly, or male coupling half.
[0025] It is a further object of the present invention to provide a cap assembly which sealingly couples with a nozzle assembly and which further includes a sealed passageway interconnecting the vehicle gasoline tank and a vacuum source interconnected with a passageway in the nozzle assembly.
[0026] It is a further object of the present invention to provide a female coupling half and a male coupling half adapted to interconnect with a vehicle gasoline tank.
[0027] It is a further object of the present invention to provide a nozzle assembly which includes a plug having ports for the delivery of liquid when coupled with the cap assembly. The plug is partially press fit into an annular space defined by the inner fluid conduit and the outer sheath of the nozzle assembly.
[0028] It is a further object of the present invention to provide a nozzle assembly which has an inner fluid conduit, an outer sheath having a plurality of apertures therein, a plug partially press fit within and tack welded to the fluid conduit and outer sheath, a sliding sleeve affixed to a sleeve guide, and a body.
[0029] The invention will be better understood when reference is made to the Brief Description of the Drawings, Description of the Invention and Claims which follow hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a front elevational view of the cap assembly (female coupling half).
[0031] [0031]FIG. 2 is a front elevational view of another embodiment of the cap assembly illustrating a locking protrusion.
[0032] [0032]FIG. 2A is a top view of the cap assembly of FIG. 2.
[0033] [0033]FIG. 3 is a front elevational view of the nozzle assembly (male coupling half).
[0034] [0034]FIG. 4 is a front elevational view of the cap assembly coupled together with the nozzle assembly.
[0035] [0035]FIG. 5 is a cross-sectional view of the cap assembly (female coupling half) of FIG. 1.
[0036] [0036]FIG. 5A is an enlarged portion of FIG. 5 illustrating the valves.
[0037] [0037]FIG. 6 is a cross-sectional view of the nozzle assembly of FIG. 3.
[0038] [0038]FIG. 6A is a cross-sectional view of the nozzle assembly shown with a sensing conduit in the annulus formed by the outer sheath and the inner fluid conduit.
[0039] [0039]FIG. 6B is an enlarged portion of FIG. 6A.
[0040] [0040]FIG. 7 is a cross-sectional view of the cap assembly coupled together with the nozzle assembly.
[0041] [0041]FIG. 7A is an enlarged portion of the cap assembly illustrated in FIG. 7.
[0042] [0042]FIG. 8 is a cross-sectional view of another embodiment of the invention for use with an original equipment vehicle gasoline tank.
[0043] [0043]FIG. 9 is a front elevational view of a typical gasoline tank fuel connection with the vehicle's gas cap removed.
[0044] [0044]FIG. 10 is a schematic diagram illustrating the method of utilizing the coupling with an existing gasoline tank.
[0045] A better understanding of the drawings will be had when reference is made to the Description of the Invention and Claims which follow hereinbelow.
DESCRIPTION OF THE INVENTION
[0046] [0046]FIG. 7 is a cross-section of the cap assembly 100 coupled together with the nozzle assembly 300 . The cap assembly 100 is sometimes referred to herein as the female coupling half and the nozzle assembly 300 is sometimes referred to herein as the male coupling half. The nozzle assembly or male coupling half 300 is affixed to the spout portion 704 of a fuel dispensing nozzle (not shown). Fuel dispensing nozzles are well known and one such fuel dispensing nozzle is illustrated in U.S. Pat. No. 4,429,725 to Walker et al. issued Feb. 7, 1984. The nozzle assembly includes an outer sheath 604 and an inner fluid conduit 603 as viewed in FIG. 7. The outer sheath 604 is concentric with the inner fluid conduit 603 and includes apertures 606 therein. Apertures 606 are viewed in FIG. 7 as well as in FIG. 6. Generally, apertures 606 are circumferentially spaced in the outer sheath in two rows. Annulus 605 is formed between the inner conduit 603 sometimes referred to as the fluid conduit 603 and the outer sheath 604 . See, FIG. 6.
[0047] Still referring to FIG. 6, plug 601 is generally cylindrically shaped and includes a diametrically reduced section 602 which is press fit into annulus 605 . The press fit is indicated by reference numeral 614 as indicated in FIG. 6. Additionally, plug 601 is tack welded 615 to the outer sheath 604 . Plug 601 includes flush face 305 which engages the substantially flush face of main valve 508 during coupling. When the coupling halves are uncoupled, valve 508 closes and prevents vapor and/or fluid from escaping. Similarly, when the coupling halves are uncoupled, sliding sleeve 301 closes and seals ports 612 and prevents fluid spillage from the nozzle assembly. Very low spillage occurs upon disconnection of the coupling halves because the flush face 305 of the plug 601 abuts the substantially flush face of valve 508 and little or no fluid can reside between the faces when the coupling is connected.
[0048] Seal 609 is part of the male coupling half 300 also referred to as the nozzle assembly 300 . See, FIGS. 6 and 7. Seal 609 resides in an interior circumferential groove or recess in body 303 . Body 303 is secured to the outer sheath 604 by a set screw 604 and a ferrule 611 . When the nozzle assembly 300 is coupled to the cap assembly 100 , seal 609 functions as a locking seal and it interlocks with circumferential groove 526 as best viewed in FIGS. 5 and 5A. During the process of coupling some slight misalignment is allowed between the male coupling half 300 and the female coupling half 100 .
[0049] [0049]FIG. 3 is a front elevational view of the nozzle assembly 300 . The nozzle assembly includes a sliding sleeve 301 which is affixed by a threaded interconnection to a guide 302 . Body 303 is secured to the outer sheath 604 by set screw 304 and the ferrule 611 .
[0050] Referring again to FIG. 7, reference numeral 607 indicates the gasoline (or other fuel) flow path and reference numeral 701 is a flow arrow indicating the path of fuel flow during fueling. During fueling the liquid fuel flows through the fluid conduit 603 leftwardly when viewing FIG. 7 and proceeds through flow ports 612 in plug 601 .
[0051] [0051]FIG. 7A is an enlarged portion of the cap assembly 100 illustrated in FIG. 7. Referring to FIG. 7A, liquid fuel flows through apertures 612 as indicated by a flow arrow 701 into and through chamber 703 , past main valve 508 of the cap assembly and through ports 509 of the main valve 508 and into adapter 104 .
[0052] Adapter 104 is viewed in FIGS. 1 and 5. Referring to FIGS. 5 and 7A, adapter 104 is an offset flow conduit and cap 102 which is threaded to body 101 may rotate relative to the adapter 104 . Adapter 104 is retained within body 101 of the cap assembly by retaining ring 501 and spring 504 . Teflon seals 502 and 503 seal the adapter 104 so that fluid may not escape from the interior of the cap assembly 100 .
[0053] Cap assembly 100 includes a single continuous thread 103 located on the cap 102 of the assembly 100 . Grips 105 on cap 102 enable the cap assembly 100 to be threadably interconnected by hand with an existing vehicle fuel tank. The cap assembly 100 may be threaded to an existing vehicle gasoline tank by simply removing the original gas cap on the tank and replacing it with the cap assembly 100 of the present invention. Cap assembly 100 is small enough to fit inside of vehicle fuel doors when the door is closed and the cap assembly is fully threaded into the receptacle of the gas tank.
[0054] Adapter 104 is inserted into and through the flapper valve 905 as indicated in FIG. 9. FIG. 9 is not to scale relative to any of the other drawing figures. Adapter 104 is offset from the central axis of the cap assembly. The cap assembly is generally cylindrically shaped and it may be gripped by grips 105 and the cap assembly screwed into an existing gasoline tank threaded connection as illustrated in FIG. 9. Reference numeral 900 illustrates the typical gasoline tank connection (nozzle receptacle) on a vehicle with the gas cap removed. Front face 901 of the receptacle engages seal 525 of the cap assembly preventing vapor from escaping to the atmosphere. The initial thread (or beginning thread) is indicated by reference numeral 902 on the receptacle. Reference numeral 903 indicates the continuous thread as it extends helically inwardly toward the gas tank. Reference numeral 904 indicates guides whereby the adapter 104 is guided into the flapper valve 905 . On some automobiles, guides 904 are used to direct the spout 704 of the dispensing nozzle into flapper valve 905 of the fuel tank. Reference numeral 906 is the housing of the typical gasoline tank cap on the vehicle.
[0055] Once adapter 104 is inserted into and through flapper valve 905 the helical threads 103 of the cap assembly engage the reciprocal helical threads 902 / 903 as illustrated in FIG. 9 until seal 525 on cap 102 engages the face 901 of the gas tank receptacle.
[0056] Apertures 106 in the threaded portion of the cap assembly 100 (female coupling half) are illustrated in FIGS. 1, 4, 5 , 7 , and 7 A. Apertures 106 exist in the single continuous helical thread 103 . Thread 103 mates with thread 902 / 903 but the mating of the threads does not create a seal and gasoline vapors (or other fuel vapors) from the gasoline tank enter apertures 106 as indicated on FIG. 7 and 7 A. The vapor migrates along and between the thread 103 of the cap assembly which is screwed into the mating helical thread 903 of the gas tank receptacle 900 (nozzle receptacle). Seal 525 is an elastomeric seal which abuts the front face 901 of the gasoline tank receptacle 900 preventing escape of fuel vapor to the environment. Flow arrow 702 indicates the path of the gasoline vapors. Annulus 520 is formed between generally cylindrical cap 102 and generally cylindrical body 101 of the cap assembly 100 . Passageway designs other than an annulus may be used in the cap assembly and the nozzle assembly without departing from the spirit and scope of the invention. For instance, a bore of a plurality of bores may be used as set forth in FIG. 8.
[0057] Referring to FIG. 5A, a plurality of circumferentially spaced ports 521 are located in body 101 of the female coupling half 100 . Main valve 508 is generally cylindrically shaped and includes circumferentially spaced flow ports 509 therein. Spring 507 acts between valve guide 505 and valve 508 to urge valve 508 into the closed position as illustrated in FIG. 5. Valve 508 is illustrated in the open position in FIG. 7. Valve guide 505 is also generally cylindrically shaped and has four circumferential supports spaced at 90° from each other. Spring 504 is operable between adapter 104 and valve guide 105 . Spring 504 urges the valve guide 505 to its rightward most position as viewed in FIG. 5.
[0058] Threads 522 indicate the interconnection between the cap 102 and the body 101 . The adapter 104 is retained within the body 101 of the cap assembly 101 by retaining ring 501 as illustrated in FIG. 5. FIG. 5A is an enlarged portion of FIG. 5 and illustrates vent valve 512 and vent sleeve 510 . Vent valve 512 permits the release of pressure within the fuel storage tank when pressure exceeds a predetermined value. Washer 506 retains vent valve 512 and the vent sleeve 510 in position. When vapor pressure in the tank exceeds a predetermined differential between the tank and the atmosphere, pressure applied to internal face 523 of vent valve 512 urges valve 512 rightwardly against spring 513 . Spring 513 is operable between vent valve 512 and main valve 508 . When sufficient pressure is applied to face 523 , spring 513 compresses and vapor is released around seal 514 . Seal 514 is an ordinary Viton O-ring seal. Viton is a registered trademark of Dupont Dow Elastomers L.L.C. Corporation of Wilmington, Del.
[0059] When fuel is used from the gas tank to fuel the automobile engine, a vacuum is created within the tank which must be relieved. To accomplish the vacuum relief, vent sleeve 510 includes an external face 524 which experiences atmospheric pressure. When the atmospheric pressure exceeds a predetermined level, spring 511 is compressed. Spring 511 is operable between valve washer 506 and vent sleeve 510 . When vent sleeve 510 is moved sufficiently leftwardly, air flows around Viton O-ring seal 515 and into the gas tank.
[0060] Seals 518 and 519 are also elastomeric Viton O-ring seals and they seal circumferentially spaced ports 521 which reside in cap assembly 100 . Reference numeral 517 is also an elastomeric Viton O-ring seal which seals between cap 102 of the female coupling half and the sliding sleeve 301 of the male coupling half upon coupling. See, FIG. 7.
[0061] Referring again to FIG. 7, reference numeral 702 indicates the flow path of the fuel vapor which is recovered from the fuel tank during fueling. Reference numeral 702 illustrates the path of vapor through ports 521 and apertures 606 and into the annulus 605 . Seal 613 , a Viton O-ring seal is an additional seal between the outer sheath 604 and the environment. Seals 518 and 519 are the primary seals which seal ports 521 and apertures 606 and seals 613 and 517 are backup seals. Seal 608 , a Viton O-ring seal is an additional backup seal between the sliding sleeve 301 and the outer sheath 604 . Spring 610 is operable between sliding sleeve 301 and body 303 . In FIG. 7, spring 610 is shown compressed as sliding sleeve 301 has been moved rightwardly compressing it.
[0062] [0062]FIG. 4 is a front elevational view of cap assembly 100 coupled together with the nozzle assembly 300 . Reference numeral 400 illustrates the cap assembly and nozzle assembly coupled together. FIG. 2 is a front elevational view of another embodiment of the cap assembly 200 illustrating a locking protrusion 201 , a key type lock. Adapter 204 is indicated in FIG. 2.
[0063] [0063]FIG. 6 is a cross-sectional of the nozzle assembly 300 illustrated in FIG. 3. FIG. 6 illustrates the nozzle assembly in the closed position with spring 610 urging sliding sleeve 301 leftwardly. FIG. 7 illustrates the open position of the nozzle or put another way, the open position of sliding sleeve 301 with respect to port 612 of the nozzle. Sleeve 301 of the nozzle assembly functions as a valve with respect to ports 612 .
[0064] [0064]FIG. 8 is a cross-sectional view of another embodiment of the invention for use with an original equipment vehicle gasoline tank. Reference numeral 800 indicates the original equipment female half 800 which can be welded to a gasoline tank. Reference numeral 801 illustrates a plurality of passageways from the tank. When female half 800 is coupled together with the nozzle assembly 300 of FIG. 7, the flow arrow indicating a path of vapor flow as indicated by reference numeral 702 will be the same.
[0065] [0065]FIG. 6A is a cross-sectional view of the nozzle assembly shown with the sensing conduit 616 in the annulus formed by the outer sheath 604 and the inner fluid conduit 603 . The sensing conduit 616 may be used for detecting fluid in the vapor return line. When the gas tank is full it is possible for fluid to come into apertures 106 . However, an appreciable amount of fluid is not expected in apertures 106 . FIG. 6B is an enlarged view of a portion of FIG. 6A illustrating the apertures 606 in better detail.
[0066] The O-rings used in the invention are elastomeric O-rings made of Viton. The cap 102 and body 101 of the cap assembly 100 are preferably made from aluminum. Preferably the adapter seals 502 , 503 are made of Teflon and preferably the adapter 104 is aluminum. Retaining ring 501 which retains the adapter 104 is preferably made from stainless steel. Vent valve 512 in the cap assembly 100 is preferably made of stainless steel and the vent sleeve 5120 in the cap assembly is preferably made of aluminum. The main valve 508 in the cap assembly 100 is preferably made of aluminum and the valve guide 505 is preferably made of stainless steel. In regard to the nozzle assembly 300 the sliding sleeve 301 is preferably made of stainless steel as is the sliding sleeve guide 302 . Similarly, the body of the nozzle assembly is preferably made of stainless steel.
[0067] [0067]FIG. 10 is a schematic diagram 1000 illustrating the method of utilizing the coupling with an existing gasoline tank. First, the existing gas cap is removed from the existing nozzle receptacle 900 as indicated by reference numeral 1001 . The adapter 104 of the cap assembly is then inserted into and through the flapper valve 905 of the gasoline tank. See, reference numeral 1002 and FIG. 9.
[0068] The cap assembly 100 is threaded into the nozzle receptacle by rotating 1003 the cap assembly with respect to the adapter thus attaching 1004 cap assembly 100 to the gasoline tank. The nozzle assembly and the cap assembly are coupled 1005 and locked 1006 together. Vapors are extracted 1007 from the gasoline tank into and through the cap and nozzle assemblies. The process of utilizing the nozzle and cap assemblies together is the same when used on a new gasoline tank except steps 1001 , 1002 , and 1003 are not needed and the cap assembly is welded to the gasoline tank 1004 . If the cap assembly must be removed for maintenance or for use at a non-conforming service station (i.e., one that does utilize the male coupling half of the instant invention), the cap assembly is simply unscrewed from the nozzle receptacle.
[0069] The instant invention has been described herein with sufficient particularity in regard to the preferred embodiments. Those skilled in the art will recognize that many changes and modifications may be made to the invention as disclosed without departing from the spirit and scope of the appended claims.
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A coupling device for fueling automobile gasoline tanks is disclosed and claimed. The coupling has two parts: a cap assembly (female half) and a nozzle assembly (male half). Little or no spillage occurs due to opposing flush faces of the female main valve and the plug of the male. The cap assembly is affixed to an existing gasoline tank (fuel storage tank) or alternatively can be supplied as original equipment on a new automobile. Fuel vapor is extracted from the automobile fuel tank with high efficiency and returned to the pumping station for storage and/or reprocessing. Vapors and/or liquid fuel are extracted through the portion of the gasoline tank cap assembly which resides within the tank. Apertures in the cap assembly communicate with an annular passageway which removes the vapors to ports which mate with peripheral apertures in a concentric nozzle having an outer sheath and an inner fluid conduit. The gasoline tank cap assembly includes a vent valve for relieving pressure within the tank when necessary. A vent sleeve is also provided for supplying air to the gasoline tank when necessary. A method of recovering fuel vapor from a fuel storage tank is also disclosed and claimed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of pending U.S. patent application Ser. No. 13/656,344, filed Oct. 19, 2012, titled “Methods and Devices for Treating Hypertension,” which application claims priority to U.S. Provisional Patent Application No. 61/549,007, filed Oct. 19, 2011, titled “Hypertension and Heart Rate Reduction,” and U.S. Provisional Patent Application No. 61/648,060, filed May 16, 2012, titled “Methods and Devices for Treating Hypertension,” and U.S. Provisional Patent Application No. 61/681,469, filed Aug. 9, 2012, titled “Methods and Devices for Treating Hypertension Using an Electroactive Transducer,” and U.S. Provisional Patent Application No. 61/681,513, filed Aug. 9, 2012, titled “Support Assemblies For The Treatment of Hypertension,” the entireties of which are hereby incorporated by reference.
BACKGROUND
This invention relates generally to methods and devices for the treatment of hypertension. More specifically, methods and devices which treat hypertension using devices disposed extra corporally.
Hypertension, or high blood pressure, affects millions of people every day and is a serious health hazard. Hypertension is associated with an elevated risk for heart attack, heart failure, arterial aneurysms, kidney failure and stroke. There are many factors that may affect blood pressure, such as: salt intake, obesity, occupation, alcohol intake, smoking, pregnancy, stimulant intake, sleep apnea, genetic susceptibility, decreased kidney perfusion, arterial hardening and medication(s). Many times people are unaware that they suffer from hypertension until it is discovered during a medical check-up with their health care practitioner (HCP), or worse, it is discovered when they are hospitalized for a hypertension related condition such as a heart attack or stroke.
Blood pressure is controlled by a complex system within the body, one component of this system is known as the arterial baroreflex (ABR). The baroreflex is the fastest autonomic reflex responding to changes in blood pressure. The baroreceptor nerve endings are embedded in vessels throughout the circulatory system and encode both mean pressure and rate of change of pressure as a frequency. Centers in the brainstem process spikes in the frequency information, integrating it with other information and providing a signal to the sinoatrial (SA) pacemaking node of the heart via efferent fibers in the vagus nerve. When blood pressure becomes too high, the resulting vagal nerve signal triggers the release of acetylcholine at the SA node of the heart, slowing the heart rate and thus lowering the blood pressure.
Baroreceptors are located in the transverse aortic arch and the carotid sinuses of the left and right internal carotid arteries. The baroreceptors found within the aortic arch monitor the pressure of blood delivered to the systemic circuit, and the baroreceptors within the carotid arteries monitor the pressure of the blood being delivered to the brain.
As described above, the arterial baroreceptors are stretch receptors that are stimulated by distortion of the arterial wall when pressure changes. The baroreceptors can identify the changes in the average blood pressure or the rate of change in pressure with each arterial pulse. Action potentials triggered in the baroreceptor endings are then conducted to the brainstem where central terminations (synapses) transmit this information to neurons within the solitary nucleus. Reflex responses from such baroreceptor activity can trigger increases or decreases in the heart rate. Arterial baroreceptor (ABR) sensory endings are simple, sprayed nerve endings that lie in the tunica adventitia of the artery. An increase in the mean arterial pressure increases depolarization of these sensory endings, which results in action potentials. These action potentials are conducted to the solitary nucleus in the central nervous system by axons and have a reflex effect on the cardiovascular system through autonomic neurons.
At normal resting blood pressures, baroreceptors discharge at approximately 1 out of every 3 heart beats. If blood pressure falls, the arteries retract in diameter and the baroreceptor firing rate decreases with the drop in blood pressure the brain send a signal to the heart to increase blood pressure by increasing heart rate. Signals from the carotid baroreceptors are sent via the glossopharyngeal nerve (cranial nerve IX). Signals from the aortic baroreceptors travel through the vagus nerve (cranial nerve X). Arterial baroreceptors inform reflexes about arterial blood pressure.
The arterial baroreflex system is a dynamic system that is capable of adapting to ever changing situations. The ABR is the reason why we do not pass out when moving from a seated to standing position. In this instance the ABR senses a change in blood pressure and accommodates the change by sending the appropriate signal to regulate blood pressure. The ABR system also performs an essential function to regulate blood pressure during exercise, wherein during exercise your heart rate increases as well as your blood pressure, however, at a certain point during exercise the ABR will intervene, allowing the heart rate to further increase but not allowing the blood pressure to further increase.
As stated above, hypertension currently affects a large and growing population. Currently treatments for hypertension range from prescribed lifestyle changes and the use of pharmaceutical products. Within the past couple of years, new surgical therapies are emerging. These surgical therapies either lead to the implantation of a device for stimulating a patient's carotid baroreceptor or to the disconnection of the nerves of the renal arteries.
If prescribed lifestyle changes do not address a patient's hypertension, their HCP will typically prescribe drug therapy to treat their hypertension. There are multiple classes of pharmaceutical products that can be utilized to treat hypertension. These include vasodilators to reduce the blood pressure and ease the workload of the heart, diuretics to reduce fluid overload, inhibitors and blocking agents of the body's neurohormonal responses, and other medicaments. Many times, a HCP will prescribe one or more of these products to a patient to be taken in combination in order to lower their blood pressure. However, the use of pharmaceutical products is not without their risks. Many of these products carry severe warnings of potential side effects. Additionally, each patient may respond differently to the products, therefore multiple office visits may be required before the right dosage and type of pharmaceutical products are selected, which leads to greater health care costs. Further still there are a number of patients who either do not respond to medication, refuse to take medication, or over time the medication no longer provides a therapeutic effect. Recently, new clinical trial data has drawn correlations between the use of diuretic pharmaceutical products to treat high blood pressure and the formation of diabetes within the patient.
For patients who do not respond to drug therapy, there are medical devices and treatments that can be utilized to treat high blood pressure. Some of these devices involve invasive surgical procedures including the implantation of a permanent medical device within a patient's artery to impart a force at a specific location within the artery which then may cause a lowering of blood pressure. However, these devices are relatively new or are still under development and have not been proven over a long period of time. Also, since the device is a permanent implant, there is always the possibility of complications during the implantation process or infections related to the implantation.
As described above, another type of invasive medical device is an electrical signal generating implant, where electrodes are placed adjacent to the carotid artery. With this process, the surgeon must be careful not to sever any of the nerves while implanting the device. If the nerves are severed, then the device will not function properly and may lead to long term health complications for the patient. However, even more troubling is that the patient has now permanently lost a baroreceptor for controlling blood pressure naturally, which may lead to complications later, which are currently unknown. Additionally, the implant device requires regular battery replacement, which to do so requires another invasive surgical procedure.
Another type of invasive medical device and procedure being developed is the use of ablation catheter to denervate the carotid body, specifically the chemoreceptors of the carotid body. Similar to the device and procedure described above, this device permanently causes a disconnection between the chemoreceptors and the nervous system/brain. The long term effects are unknown, additionally, other nerves maybe destroyed or disconnected during the procedure which may lead to other side effects.
Another type of invasive medical procedure to treat hypertension being developed is to use an ablation catheter placed within the renal artery, where a series of energy pulses are performed to ablate (sever) the nerves surrounding the artery, thereby effectively disconnecting the nerves of the kidney from the body. This procedure results in a permanent and non-reversible change to the patient's nervous system, this procedure is being referred to as renal nerve ablation or renal denervation. The long term effects of such a permanent treatment are unknown at this time as this approach is relatively new on the market. Recently published data has shown that not all patients respond to this surgical procedure, that is after the procedure, some of the patients show little to no changes in their blood pressure. This may be concerning as now these patients have had their renal arteries permanently disconnected from their kidneys, which may lead to long term effects which are unknown at this time. Additionally, the costs associated with an invasive medical procedure are not insignificant, only to prove that the procedure had no effect, thus, instead of potentially lowering the cost of treatment for these patients, the cost of treating their hypertension was significantly added to.
Additionally, the recently published data also shows that patients who respond to renal denervation may still remain hypertensive. Thus, the renal denervation procedure may not be a “cure,” instead it may be seen as an adjunctive therapy, as such these patients may remain on drug therapies or are recommended to remain on drug therapy after having undergone renal denervation.
Yet another invasive surgical approach to address hypertension is a combination of a device and a pharmaceutical product, wherein a catheter with a needle disposed near its distal end are placed within the renal artery. Once in position, a liquid pharmaceutical product is injected into the wall of the artery, whereby the pharmaceutical product is designed to chemically ablate the renal nerves. Here again, this treatment procedure is considered to be a permanent solution, whereby the nerves are permanently severed. Long term efficacy of the severing of the renal nerves is unknown. Additionally, long term effects of the procedure are also unknown.
Human skin acts as the protective barrier between our internal body systems and the outside world. Our skin in combination with our bodies nerves provides for the ability to perceive touch sensations and gives our brains a wealth of information about the environment around us, such as temperature, pain, and pressure. Without such a nervous system, we wouldn't be able to feel our feet hitting the floor when we walked, we wouldn't sense when something sharp cut us, and we wouldn't feel the warmth of the sun on our skin.
Human skin is composed of several layers. The very top layer is the epidermis and is the layer of skin you can see. In Latin, the prefix “epi-” means “upon” or “over,” thus the epidermis is the layer upon which the dermis is disposed (the dermis is the second layer of skin). The epidermis, made of dead skin cells, is waterproof and serves as a protective wrap for the underlying skin layers and the rest of the body. It contains melanin, which protects against the sun's harmful rays and also gives skin its color. When you are in the sun, the melanin builds up to increase its protective properties, which also causes the skin to darken. The epidermis also contains very sensitive cells called touch receptors that give the brain a variety of information about the environment the body is in.
The second layer of skin is the dermis. The dermis contains hair follicles, sweat glands, sebaceous (oil) glands, blood vessels, nerve endings, and a variety of touch receptors. The dermis' primary function is to sustain and support the epidermis by diffusing nutrients to it and replacing the skin cells that are shed off the upper layer of the epidermis. New cells are formed at the junction between the dermis and epidermis, and they slowly push their way towards the surface of the skin so that they can replace the dead skin cells that are shed. Oil and sweat glands eliminate waste produced at the dermis level of the skin by opening their pores at the surface of the epidermis and releasing the waste.
The bottom skin layer is the subcutaneous tissue which is composed of fat and connective tissue. The layer of fat acts as an insulator and helps regulate body temperature. It also acts as a cushion to protect underlying tissue from damage when you bump into things. The connective tissue keeps the skin attached to the muscles and tendons underneath.
Our sense of touch is controlled by a huge network of nerve endings and touch receptors disposed within the skin which is known as the somatosensory system. This system is responsible for all the sensations we feel: cold, hot, smooth, rough, pressure, tickle, itch, pain, vibrations, and more. Within the somatosensory system, there are four main types of receptors; mechanoreceptors, thermoreceptors, nociceptors, and proprioceptors.
It is important to understand how specialized receptors adapt to a change in stimulus (anything that touches the skin and causes sensations such as hot, cold, pressure, tickle, etc.). A touch receptor is considered rapidly adapting if it responds to a change in stimulus very quickly. This means that it can sense right away when the skin is touching an object and when it stops touching that object. However, rapidly adapting receptors can't sense the continuation and duration of a stimulus touching the skin (how long the skin is touching an object). These receptors best sense vibrations occurring on or within the skin. A touch receptor is considered slowly adapting if it does not respond to a change in stimulus very quickly. These receptors are very good at sensing the continuous pressure of an object touching or indenting the skin but are not very good at sensing when the stimulus started or ended.
Mechanoreceptors are receptors which perceive sensations such as pressure, vibrations, and texture. There are four known types of mechanoreceptors whose only function is to perceive indentions and vibrations of the skin: Merkel's disks, Meissner's corpuscles, Ruffini's corpuscles, and Pacinian corpuscles.
The most sensitive mechanoreceptors, Merkel's disks and Meissner's corpuscles, are found in the very top layers of the dermis and epidermis and are generally found in non-hairy skin such as the palms, lips, tongue, soles of feet, fingertips, eyelids, and the face. Merkel's disks are slowly adapting receptors and Meissner's corpuscles are rapidly adapting receptors so your skin can perceive both when you are touching something and how long the object is touching the skin.
Located deeper in the dermis and along joints, tendons, and muscles are Ruffini's corpuscles and Pacinian corpuscles. These mechanoreceptors can feel sensations such as vibrations traveling down bones and tendons, rotational movement of limbs, and the stretching of skin.
Another type of receptors are thermoreceptors, as their name suggests, these receptors perceive sensations related to the temperature of objects the skin feels. They are found in the dermis layer of the skin. There are two basic categories of thermoreceptors: hot and cold receptors.
Cold receptors start to perceive cold sensations when the surface of the skin drops below 95° F. They are most stimulated when the surface of the skin is at 77° F. and are no longer stimulated when the surface of the skin drops below 41° F. This is why your feet or hands start to go numb when they are submerged in icy water for a long period of time.
Hot receptors start to perceive hot sensations when the surface of the skin rises above 86° F. and are most stimulated at 113° F. But beyond 113° F., pain receptors take over to avoid damage being done to the skin and underlying tissues.
Thermoreceptors are found all over the body, but cold receptors are found in greater density than heat receptors. The highest concentration of thermoreceptors can be found in the face and ears.
Another type of receptor are pain receptors, commonly known as nociceptors, “Noci-” in Latin means “injurious” or “hurt.” These receptors detect pain or stimuli that can or does cause damage to the skin and other tissues of the body. There are over three million pain receptors throughout the body, found in skin, muscles, bones, blood vessels, and some organs. They can detect pain that is caused by mechanical stimuli (cut or scrape), thermal stimuli (burn), or chemical stimuli (poison from an insect sting).
These receptors cause a feeling of sharp pain to encourage you to quickly move away from a harmful stimulus such as a broken piece of glass or a hot stove stop. They also have receptors that cause a dull pain in an area that has been injured to encourage you not to use or touch that limb or body part until the damaged area has healed. While it is never fun to activate these receptors that cause pain, these receptors play an important part in keeping the body safe from serious injury or damage by sending these early warning signals to the brain.
Another receptor type are proprioceptors, the word “proprius” means “one's own” and is used in the name of these receptors because they sense the position of the different parts of the body in relation to each other and the surrounding environment. Proprioceptors are found in tendons, muscles, and joint capsules. This location in the body allows these special cells to detect changes in muscle length and muscle tension. Without proprioceptors, we would not be able to do fundamental things such as feeding or clothing ourselves.
While many receptors have specific functions to help us perceive different touch sensations, almost never is just one type active at any one time. When drinking from a freshly opened can of soda, your hand can perceive many different sensations just by holding it. Thermoreceptors are sensing that the can is much colder than the surrounding air, while the mechanoreceptors in your fingers are feeling the smoothness of the can and the small fluttering sensations inside the can caused by the carbon dioxide bubbles rising to the surface of the soda. Mechanoreceptors located deeper in your hand can sense that your hand is stretching around the can, that pressure is being exerted to hold the can, and that your hand is grasping the can. Proprioceptors are also sensing the hand stretching as well as how the hand and fingers are holding the can in relation to each other and the rest of the body.
None of the sensations described above and felt by the somatosensory system would make any difference if these sensations could not reach the brain. The nervous system of the body takes up this important task. Neurons, which are specialized nerve cells that are the smallest unit of the nervous system, receive and transmit messages with other neurons so that messages can be sent to and from the brain. This allows the brain to communicate with the body. When your hand touches an object, the mechanoreceptors in the skin are activated, and they start a chain of events by signaling to the nearest neuron that they touched something. This neuron then transmits this message to the next neuron which gets passed on to the next neuron and on it goes until the message is sent to the brain. Now the brain can process what your hand touched and send messages back to your hand via this same pathway to let the hand know if the brain wants more information about the object it is touching or if the hand should stop touching it.
Vibration experiments have been conducted to test the effects of vibration, the results of such an experiment were published in 1961 in the Journal of Physiol. (1961), 159 pp. 391-409, entitled “Response of Pacinian Corpuscles to Sinousoidal Vibration, by M. Sato. In this experiment it was proven that vibrations can excite the nervous system similar to utilization of electrical stimulation.
Other experiments have shown that the 1st Node of Ranvier gaps can be excited by either mechanical transduction or acoustic stimulation. The 1st Node of Ranvier gaps are gaps formed between myelin sheaths between different cells.
In a 1967 publication entitled “The Relative Sensitivity to Vibration of Muscle Receptors of the Cat,” M. C. Brown, I. Engberger and P. B. C. Matthews, Journal Physiol. (1967), 192 PP 773-800, the authors tested vibrations and concluded that vibratory effects persist as long as the vibration continues. Additionally, the authors cited another publication, 1966 Matthews, “Reflex excitation of the soleus muscle of the decerebrate cat caused by vibration applied to tendon” where vibration, was applied to a non-contracting muscle, provides a way of selectively activating nearly all of the nerve fibers from the primary endings to discharge repetitively. In contrast to electrical stimulation, vibration provides for a more selective activation.
Electrical stimulation will stimulate those nerves which are located in the close proximity to the electrical source, however, electrical stimulation will seek the lowest resistance pathway and is typically localized to the area of application. In contrast, vibrational stimulation carries the benefit of exciting afferent fibers at a distance from the location of the application of the vibration.
In 2000 a publication by Alfrey entitled “Characterizing the Afferent Limb of the Baroreflex” Rice University, Houston Tex., April 2000, UMI Microform 99-69-223. The author concluded that the baroreflex is the fastest autonomic reflex responding to changes in blood pressure. Baroreceptor nerve endings embedded in vessels throughout the circulatory system encode both mean pressure and rate of change of pressure as a frequency-modulated train of action potentials (spikes). Centers in the brainstem process the spike train information, integrating it with information from higher centers and providing a signal to the sinoatrial (SA) pacemaking node of the heart via efferent fibers in the vagus nerve. When blood pressure becomes too high, the resulting vagal signal triggers the release of acetylcholine at the SA node of the heart slowing heart rate and thus lowering blood pressure.
In another paper, published in 2004 by Syntichaki et al., entitled “Genetic Models of Mechanotransduction: The Nematode Caenorhabditis elegans ” Physol Rev. 84: 1097-1153, 2004 10.1152/physrev.0043.2003, it was found that all vertebrates respond to similar mechanosensory stimuli, therefore it's likely that two humans would have similar response to the same wavelengths or frequencies.
Lastly, while there are number of different therapies available on the market and new therapies emerging, there are patient populations that cannot be treated through the use of the existing drugs or devices.
One such population is patients who develop high blood pressure during pregnancy. Health care practitioners are generally hesitant to prescribed pharmaceutical products in these situations as there may be unknown side effects to the mother and unborn child. Furthermore, many hypertensive pharmaceutical products have not been properly tested for use during pregnancy; therefore, there is much hesitancy on behalf of the prescribing physician to use such drug products due to potential untested side-effects as well as potential litigation arising from a side-effect. Pregnancy induced hypertension, gestational hypertension or preeclampsia may not be a permanent condition and may be resolve after delivery. Therefore, the use of permanent therapies, such as renal denervation, may not be warranted in this situation. Additionally, surgical procedures are not generally recommended during pregnancy.
There is yet another hypertensive population emerging in today's world is the hypertensive adolescent. Over the past 30 years, the number of adolescent hypertensives has risen to a rate of over 3.7% diagnosed hypertensive and 3.4% diagnosed pre-hypertensive. Only 1 in 4 adolescents are currently diagnosed. Many of the currently available pharmaceutical products have not been tested on an adolescent population, therefore, as described above, many physicians are hesitant to prescribe drug therapies due to unknown side effects or long term effects they may have. Furthermore, the adolescent population poses yet another difficulty in that they are still developing and undergoing puberty and bone growth. Therefore, there is a need for a non-invasive, non-pharmaceutical solution to address this growing patient population.
Thus, it would be desirable to provide improved methods, devices and systems for artificial and selective activation of a patient's baroreflex or nervous system in order to achieve a variety of therapeutic objectives, including the control of hypertension, renal function, heart failure, and the treatment of other cardiovascular disorders. It would be particularly desirable if such methods and systems were non-invasive, reversible, safe and/or external to the patient.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention there is provided a device for treatment of hypertension, comprising, a housing, the housing have a proximal end and a distal end; and a driver assembly within the housing, the driver assembly electrically coupled to an energy source, the energy source disposed within the housing.
In accordance with the present invention there is provided a device for imparting energy to a patient, comprising, a housing, the housing having a proximal end, a distal end and defining a volume therebetween; a driver assembly is disposed within the volume of the housing; an energy source coupled to the driver assembly; and an electronics module coupled to the driver assembly and the energy source, wherein the electronics module controls the driver assembly.
In accordance with the present invention there is provided a device for treating hypertension, the device comprising, a housing, the housing having a proximal surface and a distal surface, wherein the housing further includes a mounting system, the mounting system including a first member and a second member, the first member associated with the housing and the second member configured to be received by tissue; and a driver assembly within the housing.
In accordance with the present invention this is provided a device for imparting energy to a patient, the device comprising: a housing, the housing having a first surface and a second surface, the surfaces defining a volume therebetween, wherein the housing further includes a mounting system, the mounting system including a first member and a second member, the first member associated with the housing and the second member configured to be received by tissue; a driver assembly disposed within the volume of the housing; an energy source coupled to the driver assembly; and an electronics module coupled to the driver assembly and the energy source.
In accordance with the present invention there is provided a method of providing therapy, the method comprising: applying a therapy applying device to a collar bone of a patient; and activating a driver assembly within the therapy applying device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary embodiment of the therapy system in accordance with the present invention;
FIG. 2 is an isometric view of a therapy providing device in accordance with the present invention;
FIGS. 3A-3D are exemplary illustrations of housings of the therapy providing device in accordance with the present invention;
FIG. 4A is a top view of a housing of the therapy providing device in accordance with the present invention;
FIG. 4B is a cross-sectional view of the housing of FIG. 4A taken about line B-B;
FIG. 4C is a cross-sectional view of another housing in accordance with the present invention;
FIG. 5 is an exploded view of a therapy providing device in accordance with the present invention;
FIG. 6 is an isometric view of a circuit board in accordance with the present invention;
FIG. 7 is a plan view of a haptic speaker in accordance with the present invention;
FIG. 8 is an isometric view of an electroactive polymer transducer in accordance with the present invention;
FIG. 9 illustrates a cross-sectional view of the electroactive polymer transducer of FIG. 8 in communication with a driver;
FIG. 10 is a plan view of an alternative embodiment of an electroactive polymer transducer in accordance with the present invention;
FIG. 11 is an isometric view of a charging/base station in accordance with the present invention;
FIG. 12 is a side view of the therapy providing device of the present invention in combination with a CPAP mask assembly;
FIG. 13A is a bottom view illustrating a therapy device including an adhesive mounting system;
FIG. 13B illustrates the therapy device of FIG. 13A as disposed on a user;
FIGS. 14A and 14B illustrate an alternative mounting arrangement for the therapy device of the present invention;
FIG. 14C is a cross-sectional view of the mounting system of FIGS. 14A and 14B ;
FIGS. 15A and 15B illustrate another mounting arrangement for the therapy device of the present invention;
FIGS. 16A and 16B illustrate a magnetic mounting system in accordance with the present invention;
FIGS. 17 and 18 illustrate embodiments of support structures for use with the present invention;
FIGS. 19A-19C illustrate another housing in accordance with the present invention, the housing configured to be received about a user's shoulders;
FIGS. 20A and 20B illustrate alternative clothing mounting arrangements for the therapy device of the present invention;
FIG. 21A illustrates an exemplary embodiment of a computing device in accordance with the present invention;
FIG. 21B illustrates and exemplary screen view of a program displayed on the exemplary computing device of FIG. 21A in accordance with the present invention;
FIG. 22 illustrates a flow diagram for a software program in accordance with the present invention;
FIG. 23A illustrates a therapeutic frequency curve for the therapy provided by an exemplary embodiment of the present invention;
FIG. 23B illustrates a timed therapy sequence in accordance with an embodiment of the present invention;
FIG. 24A illustrates a patient's blood pressure reading over a twenty-four hour period, showing a hypertensive patient; and
FIG. 24B illustrates the blood pressure of the patient of FIG. 24A after receiving therapy in accordance with the device and methods of the present invention.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
In accordance with the present invention there is provided devices and methods for the treatment of hypertension. The device of the present invention is configured to be detachably attached to a user, wherein the device is aligned with a bone of the user's body. Once affixed to the patient, the device can be activated either manually or remotely, wirelessly or wired, through the use of a software program running on a computing device or a software program within the device. The activation may be timed to coincide with a patient's sleep pattern, such that therapy is provided by the device to the patient in the evening and again in the morning prior to the patient waking up. It is believed that providing therapy during a sleep cycle is beneficial.
In accordance with embodiments of the present invention the device is detachably attached to a patient's tissue and is intended to engage a portion of the patient's skeletal frame, particularly the clavicle. It shall be understood that although the present invention is described in reference to the collar bone or clavicle, it shall be understood that this should not be limiting in any manner. As described above, in a preferred embodiment the methods and devices of the present invention utilize the clavicle. However, the methods and devices of the present invention may be utilized with other dermal bones such as the skull, jawbone, knee cap (patella) or non-dermal bones such as the wrist bone, ribs, scapula. Methods and devices of the present invention can also be used above any portion of the body containing somatory sensors such as proprioceptors, nociceptors, mechanoreceptors or thermoreceptors. Dermal bones are unique in that dermal bone does not form from cartilage first and then calcify. Dermal bone is formed within the dermis and it grows by accretion only; that is, the outer portion of the bone is deposited by osteocytes. Dermal bones have been utilized to transmit sound for other devices such as in hearing aids.
Referring now to FIG. 1 , there is shown the therapy system 100 in accordance with the present invention. As shown in FIG. 1 , the therapy system 100 in accordance with the present invention may include a pair of therapy providing devices 200 and optionally a computing device 300 . The therapy providing system 100 may further include a charging/storage system as will be described in detail below with reference to FIG. 11 . Additionally, the therapy providing device 200 may further include an integrated or separate attachment system to detachably attach the system 100 to a user's skin as will be described in greater detail below.
As shown in FIG. 1 , the computing device 300 in one aspect is configured to communicate with the therapy providing device 200 through a wireless communication protocol such as through the use of, WIFI, BLUETOOTH, ZIGBEE, RFID, NFC, ANT+, cellular, infrared or other known wireless communication protocols. Alternatively, the computing device 300 and the therapy providing devices 200 may be communicatively coupled together using a physical connection such as an electrical wire, a plurality of electrical wires, electrical cable, fiber optic or using other known physical connections capable of transmitting signals between the devices. As shown in FIG. 1 , it is contemplated that the methods of use in accordance with the present invention would utilize two therapy providing devices 200 as shown. If two therapy providing devices 200 are utilized, they are intended to be disposed on a user about the left and right clavicle. In accordance with the present invention a single therapy providing device 200 may be utilized for treatment according to the present invention, or multiple therapy providing devices 200 may be utilized for therapy. The two therapy providing devices 200 can be communicatively coupled together utilizing a physical connection or a wireless connection such as those described above.
Referring now to FIG. 2 , there is shown an isometric view of a therapy providing device 200 . As shown in FIG. 2 , the therapy providing device 200 includes a housing 210 . The housing 210 defined by a proximal end 212 and a distal end 211 , and first surface 214 and a second surface 215 (not shown), the proximal end, distal end and first and second surfaces and defining a volume therebetween, wherein the volume includes additional structures and components as will be described below. As shown in FIG. 2 , the first surface 214 includes a power button 260 , a LED indicator light 262 , and at least one pair of charging pins 265 . The multiple charging pins 265 may be including on the therapy providing device 200 , whereas the multiple pins 265 are disposed symmetrically about an axis (not shown) passing through the power button 260 . Placement of the charging pins 265 about an axis extending through the power button 260 allows for the therapy providing device 200 to be placed within a charger without care as to orientation as each side of the therapy providing device 200 includes charging pins 265 , such that the therapy providing device 200 will engage the changing pins in the charging station in either orientation. Additional details with regard to a charging station/base will be described in greater detail below with reference to FIG. 11 . Additionally, the housing 201 may further include magnets 230 or a metallic material disposed within recesses formed in the first and second ends 211 , 212 of the housing 210 . Alternatively, the magnets 230 may be integrally formed with the housing 210 during a manufacturing process such as injection molding.
The housing 210 may be formed of multiple pieces which may then be assembled using known assembly methods such as glue, ultrasonic welding, heat welding, rotational welding, snap-fit construction, use of fasteners such as screws or pins, or the like. In accordance with the invention, the housing 210 may be formed of two pieces or multiple pieces, wherein one section of the housing 210 includes all sides except the second surface 215 , thereby forming a shell into which the components can be disposed, then the second surface 215 could be attached to the other portion of the housing 210 to form the therapy providing device 200 . The housing 210 may be constructed of biocompatible materials such as polymers, plastics, fabrics or metals. The housing 210 may be formed using manufacturing processes such as machining, injection molding, 3-d printing, vacuum forming, deep drawing or the like. In accordance with the invention, the materials utilized in construction of the housing 210 of the therapy providing device 200 shall be chosen such that the materials have good biocompatibility as it is intended that the therapy providing device 200 will be placed in skin contact during use, where in certain usages the skin contact may be for prolonged time.
Further still, it is contemplated that the therapy providing device 200 may be wrapped with a biocompatible membrane. An example of a suitable membrane is available from 3M and sold under the tradename of TEGADERM.
Referring now to FIGS. 3A-3D there are shown exemplary embodiment of the second surface 215 in accordance with the present invention. As shown in FIG. 3A , the second surface 215 may be formed as a planar surface. Referring now to FIG. 3B , in this figure, the second surface 215 is formed of multiple pieces, wherein one component 216 is configured to be received by the other portion of the housing and the second component 217 is configured to be received by a user's tissue, this portion 217 may be formed of a more pliable or conformable material than the first component 215 , wherein the more pliable material 217 may conform or shape to the user's anatomy more readily. In accordance with the invention, the second component 217 may be formed of a compliant material such as and open or closed cell foam material, such that when the therapy providing device 200 is disposed upon a user for therapy, the compliant foam surface conforms to the user's anatomy. Additionally, the materials selected may be chosen such that they are anti-microbial/bacterial.
Referring now to FIGS. 3C and 3D there is shown another exemplary embodiment wherein the second surface 218 is shown having a first thickness, wherein the material of which the first surface 218 is formed is selected such that the material may be shaped or contoured to be received by a patient's skin, particularly in an area adjacent the patient's clavicle. The shaped surface may be in the form of a concave shape. Further still, the material 218 of FIGS. 3C and 3D may be selected such that the material defines a deformable structure, such that when the housing is placed over the patient's clavicle the housing conforms to the patient's anatomy as shown in FIG. 3D . In yet another embodiment, a portion of the housing may be custom formed to each individual user through the application of heat, whereby the housing or a portion of the housing is heated and then pressed onto the patient, the heated portion of the housing conforming to the patient's anatomy, or heated and molded by through an application of force. In another aspect, the second component 217 may be embodied in the form of a flexible membrane in which an expandable foam material may be injected into. In use, the therapy providing device would be placed on the user in a chosen location, the expandable foam material could then be injected into the flexible membrane while the therapy providing device is held against the user. As the foam expands and cures, the second component 217 would take the shape of the user's anatomy, thereby providing a customized fit. Lastly, it is further contemplated that the housing includes an enlarged or thickened surface that can be ground or machined away to conform to the patient's anatomy. Further still, a mold may be taken of the patient's anatomy, whereby a housing can then be manufactured from the mold taken from the user's anatomy, thereby customizing the fit of the therapy providing device to each user.
Referring now to FIGS. 4A-C there are shown additional housing designs in accordance with the present invention. As shown in FIG. 4A the alternative housing is formed in a generally circular fashion, wherein the housing contains additional components as will be described in greater detail below. Also as shown in FIG. 4A , the housing 270 may further include a wire or cable connection extending from the housing 270 as described above. Referring now to FIG. 4B , there is shown a cross-sectional view of the housing 270 of the therapy providing device 200 ″ of FIG. 4A taken about line B-B of FIG. 4A . As shown in the cross-sectional view, the alternative housing 270 is formed having a generally convex shape. Referring now to FIG. 4C there is shown a cross-sectional view of yet another alternative embodiment of a housing 272 , in this embodiment the housing 272 has a generally convex shape as previously described, however, in this embodiment the housing 272 includes concave portions 271 . In use, the housing 272 is placed on a user, adjacent to the user's clavicle, wherein a force can be applied to the housing 272 adjacent to each concave portion 271 forcing air out of the concave portions 271 , thereby causing a vacuum to be formed thereby suctioning the housing 272 to the user's tissue. It is contemplated that the housings 270 and 272 shown in FIGS. 4A-4C may be constructed of a biocompatible flexible material, such that the housing conforms to the user's anatomy when placed thereupon. Examples of suitable materials of which the housings 270 , 272 may be formed from are: silicone, urethanes, rubber, silicone, latex and the like.
Referring now to FIG. 5 , there is shown an exploded view of a therapy providing device 200 in accordance with the present invention. As described above and shown in FIG. 2-4 , the therapy providing device includes a housing 210 , wherein the housing includes provisions for a power switch 260 as well as provisions for LED indicators 262 and charging pins 265 as described above. The power switch 260 maybe a separate component disposed within the housing 210 or it may be embodied as a reduced thickness portion (not shown) of the housing 210 which can be formed to project slightly above the first surface 214 of the housing 210 , whereby in use, a user can apply a light force to the raised portion to active a switch disposed beneath the raised portion. Forming a raised portion integral to the first surface of the housing 210 to be utilized as a switch simplifies construction, eliminates additional components, this construction also eliminates the need to form a hole within the first surface of the housing which may require sealing against liquids. Further, the provisions for the LED 262 and the charging pins 265 may be in the form of openings formed within the housing to receive such items. Alternatively, the LED 262 provision may be embodied in the form of an opaque or clear section within the housing 210 during manufacture to allow light to project therethrough from a LED 503 mounted on a circuit board 500 disposed below the housing 210 . Additionally, it is contemplated that the charging pins 265 may also be integrally formed during the manufacture of the housing 210 . For example, if the housing 210 is manufactured using an injection molding process, the charging pins 265 could be disposed within the injection mold as an insert, whereby the charging pins 265 would be captured in the housing 210 during the molding process. Alternatively, the housing 210 can include openings for charging pins 265 to project through. Further still, the housing 210 may include openings having tapered wall portions, forming pockets within the first surface 214 , thereby providing access to charging pads/pins 504 disposed on a circuit board 500 disposed below the first surface 214 of the housing 210 . The housing 210 may further include an indentation 229 formed therein or a plurality of indentations 229 , allowing a user to grasp the housing 210 .
As shown in FIG. 5 , the therapy device 200 further includes a first circuit board 500 and a second circuit board 550 . The first circuit board 500 is disposed adjacent to the first surface 214 of the housing 210 , wherein the first circuit board 500 includes a power switch component 502 , at least one indicator LED 503 configured to indicate the power status of the therapy providing device 200 . The first circuit board 500 further includes charging pins/pads 504 , wherein the charging pins/pads may be configured to project through the housing 210 as described above, or alternatively, the housing 210 may include openings formed therein to access the charging pins/pads 504 . The power switch 502 may be embodied as a physical switch, such as a slide switch, or may be embodied as a touch sensitive or capacitive sensitive switch, or may be embodied as a pressure sensitive switch. The first circuit board 500 further includes a connector (not shown) which is configured to electrically connect the first and second circuit boards. The connector may be embodied as solder holes in which wires can be disposed into or may be embodied in the form of a plug or header assemble, wherein the plug/header are configured to accept a cable, wire, ribbon cable or a flexible pcb to facilitate electrical communication between the boards. The first and second circuit boards may be constructed of known materials and methods, whereby the boards may be hard rigid board assemblies or may be constructed using flexible board manufacturing technologies. Although, it is described above that the present invention utilizes two circuit boards, this should not be considered limiting in any manner, it is contemplated that the electronic components of the present invention may be embodied on a single circuit board or on multiple circuit boards.
As shown in FIG. 5 , disposed below the first circuit board 500 is an energy source 240 . The energy source 240 may be in the form of a battery pack. The battery pack may be a rechargeable pack or a single use pack which may be embodied as gel batteries or absorbed glass mat batteries. Suitable examples of batteries that may comprise the pack are lithium ion (Li-ion), lead-acid, nickel-cadmium (NiCd), nickel-zinc (NiZn), zinc-oxide, nickel metal hydride (NiMH), Lithium ferrous-oxide (LiFo) or other known battery technologies. It is further contemplated that instead of utilizing a battery for an energy source a capacitor and related circuitry could be utilized.
In the event that the energy source 240 is embodied as a battery pack, the battery pack may be embodied in the form of a fabricated pack, where individual cells are soldered together, or alternatively, the battery pack could be arranged to utilize conventional battery sizes such as AAA, AA, CR2032, LR44, 9-volt, A23 and the like.
It is further contemplated that the battery pack may be further divided into a primary battery pack and a backup battery pack. In use, the primary battery would be initially utilized, if the pack malfunctions or loses its charge or its charge is used, the backup battery pack would then be enabled to continue the therapy.
If the battery pack as described above is chosen to be a rechargeable, there is a need to provide a charging circuit within the circuit boards 500 or 550 . The charging circuit may utilize either a physical connection to enable charging or may use a non-contact or inductive charging arrangement. If a physical connection is utilized, the plug may be a USB style plug, headphone style, spring loaded pins/contact pads or other types of plugs, such a plug can be integrated into the housing 210 and electrically connected to the battery through either circuit board. Alternatively, a plug may be directly mounted onto one of the circuit boards. It is further contemplated that the charging plug can also be utilized both for charging as well as communication between multiple therapy providing devices 200 or the computing module 300 as described above using a compatible cable.
As described above, the present invention may utilize pins or pads disposed on or coupled to the first circuit board to enable charging of the battery disposed within the device. It is further contemplated that a non-contact charging assembly could be utilized with the present invention. If a non-contact charging arrangement is selected, then the charging pins 265 and/or openings within the first surface of the housing 210 may not be necessary. Instead, the therapy providing device 200 would include a charging coil (not shown) disposed about the perimeter of the first circuit board 500 . The use of a non-contact charging coil would further necessitate the inclusion of additional integrated circuits to enable and control the charging function. These additional circuits can be disposed on either of the two circuit boards. Suitable examples of a non-conductive or inductive charging would utilize an electromagnetic field to transfer energy between the charger and the battery pack. In this embodiment a charging station would be provided in which the therapy providing device 200 could be stored and charged simultaneously as will be described below. It is also contemplated that the storage/charging container may be a smart container that is it may contain a microprocessor and/or a wireless communication chipset. Thus, once the therapy device is removed from the storage container, the integrated wireless chipset within the storage container may cause the therapy device to power on. Suitable examples of components to enable non-contact charging are available from Wurth Electronics Inc., part numbers 760308201 wireless charging receiving coil and 760308101 wireless charging transmitting coil.
In accordance with the present invention, it is contemplated that the energy source 240 may be embodied in the form of an integrated generator, wherein the generator would be configured to create energy from movement of the therapy providing device 200 , much like and automatic watch movement.
As described above, the therapy providing device 200 shown in FIG. 5 includes two circuit boards, 500 and 550 . The circuit board 500 having been previously described above. Referring now to FIGS. 5 and 6 there are shown exemplary embodiments of the circuit board 550 in accordance with the therapy providing device 200 of the present invention. As described above, the second circuit board 550 is configured to be coupled with the first circuit board 500 , wherein components may be disposed on either of the two boards and interconnected through an appropriate connection as previously described using a header or solder holes formed in the circuit board 550 . Referring now to FIG. 6 , there is shown a general schematic of the second circuit board 550 , wherein the second circuit board 550 includes a processor 551 , optional memory chip 552 , an audio amplification circuit 553 and a communication port 554 . The communication port 554 may embodied as a physical port such as a mini-usb, micro-usb, firewire, thunderbolt or other known similar communication ports. The audio amplification circuit 553 may include one or two audio amplifiers, wherein the incoming signal from the processor 551 is amplified such that the amplified signal can then be connected to a driver assembly 220 as described below. As shown in FIGS. 5 and 6 , the second circuit board 550 may be shaped to be received within a shaped housing. As shown in FIGS. 5 and 6 , the second circuit board is shown having an elliptical shape with an aperture formed through the center thereof. The aperture can be sized to receive a portion of the driver assembly 220 , thereby allowing the overall size of the device to be reduced by allowing components to ‘nest’ when assembled. The second circuit board 550 may contain additional electronic components such as audio filters, booster circuits, timing circuit and data logging capability. In accordance with the present invention, the processor 551 may be sourced from CSR PLC, Churchill House, Cambridge Business Park, Cowley Road, Cambridge, CB4 0WZ Churchill House, Cambridge Business Park, Cowley Road, Cambridge, CB4 0WZ, having part number 8670.
The second circuit board 550 may further include a communications chipset (not shown) such: BLUETOOTH, WIFI, ZIGBEE, RFID, NFC, Ant+, infrared, 3G/4G, CDMA, TDMA or other known wireless communication protocols.
The first or second circuit board 500 / 550 may further include a clock circuit (not shown). The clock circuit generates and sets the timing of operations performing within the therapy providing device 200 . The clock generator may be utilized to activate the therapy providing device 200 , or may be utilized to record timed events, such as when the therapy providing device is on or off or in use.
Further still, either circuit board 500 / 550 may alternatively include an impedance sensor or pair of impedance sensors, the impedance sensors in association with the processor 551 can be used to determine if the housing 210 is coupled to a user's skin or if the housing is not coupled to the skin. If the housing 210 is coupled to a user's skin, then the impedance sensor would provide a signal to the processor 551 indicating such a condition, thereby the program stored in the memory of the processor or transmitted to the microprocessor could be initiated to conduct therapy according to the invention. If the impedance sensor is not coupled to the user's skin, then an open condition would occur, whereby the program would not be initiated and a visual signal may be generated through the program/processor to alert the user that the therapy providing device 200 is not placed properly and needs to be repositioned.
In yet another embodiment, the electronics module may include a microphone, whereby a test signal can be initiated and delivered by the driver assembly 220 or other audio/vibration device. The microphone would be utilized by the processor 551 to listen for a reflection of the test signal off of the user's clavicle, skin or other bone or structure to determine if the therapy providing device 200 has been placed properly. If the reflected sound matches that of one stored in memory, then the program can be run to provide therapy. If the reflected sound does not match the sound stored in memory, then an error message would be generated. The error message may be in the form of an audio signal or in the form of a visual signal such as a blinking light or a series of blinking lights.
Additionally, the microphone could be coupled with a blood pressure monitor, wherein the microphone would listen for Korotkoff sounds, whereby the data generated from the blood pressure monitor and specifically the Korotkoff sounds captured by the microphone can be utilized to enable a closed loop control system or closed loop feedback system. It is contemplated, that the therapy provided by the therapy providing device 200 can be dynamically modified in response to the data received from the microphone coupled to the processor 551 .
The circuit board 500 or 550 may further incorporate a pressure sensitive switch coupled to the processor 551 . In use, the pressure sensitive switch would be in a normally open position or off position. When the therapy providing device 200 is placed on the user's skin, the pressure sensitive switch would be depressed, thereby turning the therapy providing device 200 on. The actuation of the switch can also be associated with the clock circuit to associate a time with the on/off state of the switch. These events can be written to the memory of the processor 551 or other memory storage location. The data can then be transmitted, wired or wirelessly, to a personal computer for analysis/storage. By tracking the actual on/off time of the therapy providing device, user compliance may be tracked by the user or by a third party such as a health care provider.
In yet another embodiment, the circuit board 500 or 550 may include an optical sensor, wherein the optical sensor is utilized to detect whether the therapy providing device is affixed to a user's skin. In this embodiment, the optical sensor can include a light sensor, whereby when the therapy providing device 200 is affixed to the user's skin the light is blocked to the sensor. In another embodiment, the optical sensor can be a reflective sensor, wherein the color of the light reflected back indicates whether the device is affixed to a user's skin or not.
In another aspect of the present invention, the light sensor may be utilized to monitoring blood oxygen level, wherein data received from monitoring the user's blood oxygen level can be stored in memory or transmitted to another device such as a pulse-oximetry monitor or another computing device. Further still, the blood oxygen data may be utilized by a program of the therapy providing device to alter therapy provided to the user or otherwise control the therapy providing device 200 .
In another aspect of the present invention, the light sensor may be used to measure alteration in blood-reflectance color, whereby the program controlling the therapy providing device may utilize this signal as a representation of heart rate or heartbeat. Accordingly the program controlling the therapy providing device 200 may use this data to determine blood pressure and accordingly provide therapy to the user based on the received data.
It is further contemplated, that an accelerometer and/or compass and/or tilt sensor and/or GPS sensor can be incorporated into either of the circuit boards described above. The inclusion of such a sensor can be utilized to determine the position and/or orientation of the device. In use, as described below, a user would affix the housing 210 to their person using an adhesive patch, harness, specialized clothing article as will be described below. In this embodiment, the accelerometer/compass in communication with the processor 551 can be utilized to determine when to activate the therapy providing device or devices 200 . If the signal coming back from the accelerometer/compass/tilt sensor indicates that a therapy providing device 200 is in a vertical position, then the program contained within the memory of the processor 551 or computing device 800 would not be initiated. Once the signal from the accelerometer/compass/tilt/GPS sensor indicates that the user is in a prone position, likely a sleep position, then the program contained within the memory can be run. Additionally, the clock timer can be associated with the accelerometer/compass/tilt/GPS sensor such that a user's sleep pattern can be stored in memory of the processor 551 or computing device 800 . Data generated from such sensors could be stored in memory, of either the therapy providing device or the computing device to track usage of the device as well as the physical location of the devices. Such data could be transmitted to a third party using know wireless communication methods.
The circuit boards or the housing or therapy providing device 200 may be provided with a unique identifier such as a serial number or patient information identifier so that the therapy providing device 200 may be tracked. Additionally, using the unique identifier it may be possible for a physician or a user to utilize a computer program, such as a website which when placed in communication with the therapy providing device, either wired or wirelessly, would allow continuous monitoring of usage of the device, such as date and time monitoring, duration of use, patient compliance and the like. The website could also provide information regarding hypertension and additionally be configured to communicate with other devices such as a scale to track the user's weight, a blood pressure monitor to track blood pressure measurements, a glucose meter, a heart rate monitor or other fitness tracking device such as FITBIT or BODYBUG. Each of these devices would be interfaced with the website, such that data collected from these devices could be uploaded to the website where the data could be presented to the user or alternatively, the data could be shared with anyone that the user chooses to do so. For example, the user may desire to share the data with their health care provider, dietician or other individual(s).
In accordance with the invention, it is contemplated that one or both circuit boards along with the battery may be housed within a separate housing from the therapy providing device 200 . In this embodiment, the circuit board(s) and battery would be coupled to the therapy providing device either through a cable connection or through a wireless connection. If a wireless connection is utilized, then the therapy providing device would include the necessary electronics disposed within its housing to facilitate the communication between the electronics module and the therapy providing device as well as a power source such as the battery.
Referring to FIG. 5 , disposed below the second circuit board 550 is a driver assembly 220 . The driver assembly 220 is disposed within the volume 213 of the housing 210 . The driver assembly may comprise a conventional coil speaker, an ultrasonic generator, a piezoelectric speaker, a haptic speaker, a pneumatic device, a suction device, a mechanical vibratory device, a hydraulic actuation device, or a photo-acoustic excitation device. Examples of drivers assemblies 220 that can be used with the present invention may be purchased from HiWave Technologies PLC, Regus House, 1010 Cambourne Business Park, Cambourne, Cambridge CB23 6DP United Kingdom. Referring now to FIG. 7 there is shown an exemplary haptic speaker or haptic exciter 220 ′ which may be utilized with the therapy providing device 200 of the present invention. As shown in FIG. 7 , the haptic speaker 220 ′ includes a frame member 221 , a voice coil 222 and a plurality of flexible members 223 . Additionally, the haptic speaker 220 ′ includes electrical connections 224 , thereby allowing the haptic speaker 220 ′ to be electrically connected to the audio amplifier circuit as previously described. In use, the flexible members 223 allow the voice coil 222 of the haptic speaker 220 ′ to translate relative to the frame 221 , thereby producing sound or movement.
In yet another embodiment, the driver assembly 220 may be embodied as an electroactive polymer transducer 315 as shown in FIGS. 8-10 . Electroactive polymer transducers are made up of a first thin elastic polymer 320 , which is also referred to as a film or membrane, this is sandwiched between compliant electrodes 340 and 345 . When voltage is applied across the electrodes, the unlike charges in the two electrodes are attracted to each other, these electrostatic attractive forces compress the polymer film 320 (along the z-axis). The repulsive forces between like charges in each electrode stretch the film in the plane (along the X and Y axis′). As the transducer 315 deflects, the deflection can be utilized to perform work. In the present invention, the work that is performed is the development of vibrations, wherein the vibrations being developed by the transducer 315 are developed within a certain frequency range as will be discussed in greater detail below. Additional information regarding electrostatic transducers can be found in U.S. Pat. Nos. 7,898,159 and 7,608,989, the entireties of which are hereby incorporated by reference.
It is further contemplated that the transducer 315 as described above may be further coupled to another assembly, wherein the other assembly would have an increased mass. Through use, the transducer would be activated by providing a voltage to the electrodes, thereby exciting the polymer, wherein the weighted assembly would be excited thereby delivering greater vibrational energy.
In accordance with another aspect of the present invention, the electroactive polymer transducer 315 can be formed to have a curved shape, or be attached to a housing having a curved shape, such that the housing or curved excited can be readily received by a user's anatomy, specifically the user's clavicle or collarbone.
The electroactive polymer transducer 315 of the present invention may be embodied in different geometric shapes. It is contemplated that the transducer 315 may be embodied in the form a circular shape, oblong shape, square, rectangular or other known geometric shapes. Further still, it is contemplated that the transducer may be formed with at least one bar-arm type of arrangement as shown in FIG. 3D . In this embodiment, the bar-arm 347 is configured to vibrate in response to the charge placed on the electrodes. The number of bars and shape of the bars can be configured to adjust the acoustic/vibrational properties of the assembly.
Use of an electroactive polymer transducer as described above further includes a circuit driver 350 , the circuit driver 350 may be incorporated into the first or second circuit boards 500 / 550 as described above. Alternatively, the circuit driver 350 may be embodied as a separate circuit board (not shown) which may be electrically coupled with either the first or second circuit boards of the present invention. The circuit driver 350 further includes an audio input 360 and at least one output 370 , but preferably a pair of outputs 371 and 372 . The outputs 371 , 372 are coupled to the electrodes 340 , 345 of the transducer 315 .
The circuit driver 350 , may further include additional components such as an amplifier, a filter, a voltage step-up circuit, a charge controller, voltage step-down.
Further still it is contemplated that the driver assembly may be embodied as multiple elements, for example any combination of driver assemblies may be use, such as a combination of a haptic speaker and a piezo, a haptic speaker and an electro active polymer transducer, an electroactive polymer transducer and a piezo or multiples of the same driver type within the same housing. The examples provided herein should not be considered limiting in any manner. Alternatively, the driver assembly may be a vibrating motor or coin cell motor.
As described above and in accordance with the present invention, it is contemplated that two therapy providing devices 200 may be utilized together to provide therapy to a user, wherein the two therapy units may be interconnected with a physical connection. It is contemplated that one of the therapy devices may have a complete set of electronics disposed therein, wherein the complete set of electronics would include the communication, memory and other chipset(s) and associated circuitry. Wherein the other therapy providing module 200 could then include a simplified electronics module, wherein the simplified electronics module would not have the complete chipset of the complete electronics module. For example, the simplified electronics module would not need to have a battery charging circuit or other chips as well it may have less or no memory. By providing the other therapy providing device with a slimmed down electronics module a larger energy source may be fitted, through this arrangement the combined therapy providing devices 200 could be utilized for a longer time before the energy source would need to be replaced or recharged.
Referring now to FIG. 11 there is shown a charging/base station 570 in accordance with the present invention. As shown in FIG. 11 , the base station 570 includes a housing 571 , wherein the housing 571 includes recessed portions 572 configured to receive the therapy providing device 200 therein. The recessed portions 572 are configured to include charging pins 574 , which when the therapy providing device 200 is disposed within the recess will align with the charging pins/pads 265 of the therapy providing device. In addition to the charging pins 574 , other pins may be included both on the base 570 and the therapy providing device 200 which may be used for other purposes such as downloading data stored within memory of the therapy providing device(s) 200 . The base station 570 may further include a wired or wireless connection to the internet or other network such that the data received from the therapy providing device(s) can be transmitted or uploaded to a webpage as described above or transmitted to another location such as a health care provider or other location for storage. It is further contemplated that the base 570 may include additional features such as an alarm clock or clock 573 , a cellular telephone or tablet charging station. As will be described in greater detail below with regard to FIGS. 16A and 16B , the therapy providing device may include extensions 219 extending from the housing 210 each extension 219 containing a magnet 230 . It is contemplated that the recessed portions of the charging base 570 may be shaped to receive the extensions 219 of the housing 210 shown in FIG. 16A . The recessed portions 572 may be adapted to receive the extensions 219 or may further include a metallic member or a magnet disposed therein, such that when the therapy providing device is placed into the recessed portion, the magnets 230 within the housing 210 of the therapy providing device 200 are attracted to the metal or magnet of the charging station 570 , thus, temporarily affixing the therapy providing device 200 to the charging station. In addition to temporarily affixing the therapy providing device 200 to the charging station 570 , by temporarily affixing the therapy providing device 200 to the charging/base station 570 providing better contact between the therapy providing device 200 and the charging pins 574 . It is contemplated that other arrangements to increase contact between the therapy providing device and the charging pins of the charging/base station may be utilized. For example, the charging pins 574 in the base station 570 may be configured to move linearly and be held with a spring force, whereby the charging pins 574 retract or partially retract when a therapy providing device 200 is placed into the recessed portion 572 for charging. Additionally, another member (not shown), such as a plate or weights may be placed onto the therapy providing devices after the therapy providing devices have been disposed within the recessed portions. Further still, the charging pins 574 may be disposed on a lid (not shown) of the charging base 570 , such that the therapy providing device 200 is placed within a recessed portion 572 of the charging base 570 and the lid is closed, thereby completing the electrical connection between the charging pins 574 of the charging base and the charging pins/pads 256 of the therapy providing device 200 .
In accordance with the invention, the base 570 may be further embodied as another medical device or incorporate other medical devices. It is contemplated that the base 570 may incorporate, or be incorporated into another medical device such as a pulse-oximetry meter, a blood pressure monitoring device, a glucose meter, an infusion pump, a glucose pump, sleep tracking device, temperature measuring device, or a sleep apnea device such as those offered by ResMed and Respironics. Presently, sleep apnea devices utilize a console which houses the electronics necessary to control a blower to deliver pressurized air to a patient interface. The patient interface may be embodied in the form of a full-face mask, nasal mask, oro-nasal mask, mouth mask, nasal prongs, or other suitable configurations know in the art. Also, any suitable headgear arrangements may be utilized to comfortably support the patient interface in a desired position.
In yet another aspect of the present invention, referring now to FIG. 12 there is shown the therapy providing device 200 of the present invention, wherein the therapy providing device 200 has been adapted to interface with a sleep apnea patient interface. As shown in FIG. 12 , the therapy providing device 200 is configured to be received or engage or is integrated into the headgear arrangement of a sleep apnea patient interface device, wherein the therapy providing device of the present invention is configured to engage the patient's jawbone or skull.
In yet another aspect of the present invention, the therapy providing device 200 may be incorporated into other devices which are configured to engage a patient's tissue and skeletal bones such as bone conduction hearing aids, one such example is being offered by Sonitus Medical under the tradename SOUNDBITE.
Referring now to FIGS. 13A , 14 A, 14 B, 15 A, 15 B, 16 A and 16 B there are shown multiple embodiments of the housing 210 of the therapy providing device 200 in accordance with the present invention. As shown in these figures, the housing 210 is shown having a variety of mounting assemblies that can be utilized to affix the therapy providing device 200 to the patient.
As shown in FIG. 13A , one surface of the therapy providing device is provided with a slot 263 . A bandage 265 can be passed through the slot 263 , wherein a rib 261 formed by slot 263 retains the therapy providing device 200 onto the bandage 265 . The bandage 265 further includes a biocompatible adhesive, such that the therapy providing device 200 can be affixed to the patient as shown in FIG. 13B . The bandage may be a one-time use construction, wherein the bandage is disposed of after a single use. Alternatively, the bandage 265 may be a multiple-use product, wherein the biocompatible adhesive is selected such that the bandage can be placed and removed from a user's skin multiple times. Additionally, it is contemplated that the biocompatible adhesive may be renewed. The adhesive may be renewed by spreading new adhesive over the existing adhesive, washing the adhesive surface with a substance to renew the surface or the adhesive may be embodied having multiple thin layers, wherein the user removes the used layers and disposes of the used layer, thereby exposing a new layer of adhesive for use again. A suitable example of an adhesive for a reusable bandage are hydrogel adhesives, similar to those utilized on electrodes for electrical muscle stimulation devices, otherwise known as a TENS unit. Such electrodes are manufactured and sold by 3M as well as others. It is contemplated, that a temporary marking may be applied to the user's body initially to indicate the location of where the therapy providing device. For example, the temporary marking may be in the form of a temporary tattoo or a henna tattoo.
Alternatively, a bandage large enough to cover the entire housing of the therapy providing device 200 may be utilized. In this embodiment, the bandage would hang over the edge of the housing by a sufficient amount, such that when the therapy providing device 200 is placed against the tissue of the user, the bandage could be affixed to the tissue to hold the therapy providing device in a desired position. In this embodiment, the bandage may include an aperture, an opaque section or otherwise transparent section, such that when the bandage is placed over the therapy providing device 200 , the button 260 , LEDs 262 and charging pins/ports 265 on the top surface of the housing 210 of the therapy providing device 200 described above are visible and accessible if the housing includes such components. Such a bandage may be constructed to further include a one-way membrane, wherein moisture under the bandage may be transported or migrate from the tissue surface through the bandage, however, the bandage would not allow fluid to pass from the outside to the therapy providing device 200 or the user's tissue.
Referring now to FIGS. 14A-14C there is shown an alternative design for affixing the therapy providing device 200 to the patient. In this embodiment, one surface of the therapy providing device includes a first fitting 280 disposed on the second surface 215 of the housing 210 . A bandage 400 is provided, wherein the bandage 400 has a proximal surface 402 and a distal surface 401 . A biocompatible adhesive is disposed on the distal surface of the bandage 401 . A second fitting 281 is disposed on the proximal surface 402 of the bandage 400 . The first fitting 280 and the second fitting 281 are designed to be received by each other and to form a detachable locking attachment as shown in FIG. 14C . Suitable examples of such detachable fittings may be a screw thread, quarter turn fasteners, grooved pathways, a tapered fitting and the like. A safety lock (not shown) may be incorporated into either of the fittings, wherein the safety lock would engage after the two fittings are brought together in a locking arrangement. The safety lock would prevent the fittings from releasing without an additional application of force or motion to the safety lock to enable the fittings to be separated. The bandage 400 may be a single use product or may be a re-usable bandage as described above. In another aspect, the bandage of the present invention may be fabricated to include multiple layers, wherein each layer includes a new glue surface. After use, the layer of the bandage having been in contact with tissue is peeled off by the user and properly disposed of, thereby exposing a new glue layer for further use.
Referring now to FIGS. 15A and 15B there is shown another alternative design for affixing the therapy device 200 to a patient. In this embodiment, a surface of the therapy device 200 includes a magnet 290 disposed thereon or incorporated into the surface. As described above bandage 400 is provided, wherein the bandage 400 has a proximal surface 402 and a distal surface 401 . A biocompatible adhesive is disposed on the distal surface of the bandage 401 . A metallic member 292 is incorporated into the bandage 400 as shown in FIG. 15B . In use, the user would apply the bandage 400 to their body, wherein the center of the bandage would align with their clavicle. In one embodiment, the bandage 400 would be replaced daily. In another embodiment, the bandage 400 would be reused for a period of time and then replaced. Further still, in another embodiment, the glue surface of the bandage 400 may be refurbished after each use to prolong the useful life of the bandage 400 . Once the bandage 400 is affixed to the user, the therapy providing device 200 as shown in FIG. 15A and described above would then be coupled to the bandage through the magnetic coupling between the magnet 290 of the therapy providing device 200 and the metallic member 292 of the bandage 400 . It shall be understood that the combination of using a magnet 290 and a metallic member 292 could be reversed. For example, the bandage 400 may contain the magnet 290 and the therapy providing device 200 would have the metallic member 292 . Alternatively, both the bandage 400 and the therapy providing device 200 may include a magnet 290 , whereby the magnets 290 assist in self-aligning the therapy providing device to the bandage 400 . Further still, it is contemplated that the magnet or metallic member of either the bandage 400 or the therapy providing device 200 may be offset from an axis extending through the center of the bandage 400 , thereby providing for two different orientations in which the therapy providing device 200 may disposed upon the bandage 400 in for use. Further still, it is contemplated that the driver 220 of the therapy providing device may be offset within the housing 210 from an axis running longitudinally through the housing 210 . Offsetting the driver 220 within the housing 210 , achieves the same effect of providing multiple mounting orientations of the therapy providing device 200 during use. In yet another embodiment, the magnet 290 or metallic member 292 could be implanted under the user's skin, therefore eliminating the need for the bandage 400 . In this embodiment, the therapy providing device 200 could be coupled to the patient's skin directly.
In another embodiment (not shown) the bandage may include an aperture formed therethrough, wherein the metallic member 292 would be disposed about the aperture. The aperture is sized to receive a portion of the therapy providing device 200 therein. It is further contemplated that the therapy providing device may include a second bandage or an enlarged surface similar in size to the bandage 400 . The enlarged surface would contain magnets 290 as described above; therefore, when the therapy providing device 200 is disposed within the aperture of the bandage 400 , the enlarged surface covers the bandage.
In further embodiments, the magnets and the metallic members may be interchanged, wherein the bandage contains the magnets and the housing may be a metallic member, a portion may be metallic or a portion may be magnetic. Additionally, instead of utilizing magnets and metallic members, other known detachable systems may be utilized, for example a hook and loop configuration or reusable adhesive surface.
Referring now to FIGS. 16A and 16B there is shown a housing in accordance with the present invention, wherein the housing 210 includes extensions 219 . The extensions 219 further include magnets 230 disposed therein. Referring now to FIG. 16B there is shown a bandage 420 to be utilized with the housing shown in FIG. 16A . The bandage 420 further includes an aperture 431 formed therethrough, the aperture sized to accept a portion of the therapy providing device 200 . The bandage 420 further includes magnets 430 disposed therein. The bandage 420 may be formed of a multilayer construction, wherein the bandage may include a glue layer a glue support layer and a backing layer. It is contemplated that the magnets 430 could be disposed within the glue support layer, wherein the magnets 430 would be encapsulated in the bandage 420 by the glue layer and the backing layer. In use, the user would place the bandage 420 onto their skin, wherein the user can use the aperture 431 to properly align the bandage in the example where the therapy providing device is placed over the clavicle. The glue layer of the bandage 420 may be a re-usable adhesive, such as that described above and commonly utilized on tens electrodes, wherein the glue layer allows for repositioning of the bandage. After placement of the bandage 420 , the therapy providing device, having a housing shown in FIG. 16A is disposed over the bandage. The magnets 230 of the housing extensions 219 and the magnets 430 of the bandage act to attach and center the therapy providing device to the bandage. In accordance with the invention, it is contemplated that either the magnets 230 of the housing or the magnets 430 of the bandage may be replaced by metallic members.
In yet another aspect of the invention, as described herein the magnets, which may be positioned in the device housing, the bandage or both, may be utilized to control the function of the therapy providing device 200 . In this example, at least one of the magnets can be used as a switch to control or complete a power circuit. The power circuit can be activated such as to power the therapy providing device 200 on, thereby initiating therapy. If the magnetic connection is broken, then the therapy providing device would be powered off. It is further contemplated, that in addition to the above, the magnet within the device or bandage may be manufactured with specific properties, such that the therapy providing device will only operate with original equipment manufacturing products, thereby preventing the therapy providing device 200 from being utilized with non-approved or counterfeit bandages. A benefit of utilizing the magnets to switch the device on/off is that the user does not have to activate any buttons on the device, additionally, the device can be simplified through the eliminate of the button on the therapy providing device as described herein. Another benefit is the preservation of battery life of the device, as the device will be powered off as soon as the magnetic connection is broken. Additionally, if the therapy providing device is being utilized at night time during sleep and the device becomes dislodged from the user, the device will automatically power off, thus providing an additional safety feature.
Further still, it is contemplated, that the therapy providing device 200 and/or bandage may include a security feature, such as an optical scanner disposed within the therapy providing device, such that the optical scanner is configured to scan a QR code, bar code or other coded printed on the bandage or bandage packaging. As described above, this combination of a scanner and specific code can be utilized to control the activation of the therapy providing device 200 . Additionally, the use of a security code/barcode can be combined with the magnetic activation of the therapy providing device 200 as described above to ensure that the bandage being utilized is an approved product that has been designed to be specifically utilized with the therapy providing device 200 and that the bandage is not a third-party un-approved product or a counterfeit product. It is contemplated that other types of security systems can be utilized to achieve the same or similar functions. For example, the bandage may include a protrusion (not shown) that projects above the surface of the bandage, the protrusion would be received within an aperture of the second surface of the housing where it would activate a switch within the housing. Another example would be the use of an electronic circuit or chip disposed upon or within the bandage, the circuit or chip would interface with the therapy providing device, thereby completing a circuit to enable activation of the therapy providing device.
Referring now to FIG. 17 there is shown an alternative design for a mounting device to be utilized with the therapy system 100 in accordance with the present invention. As shown in FIG. 17 there is shown a support structure 600 . The support structure 600 can be configured to position therapy providing devices 200 according to the present invention in a preferred location over a user's clavicle. The user can also adjust the positioning of the location of the therapy providing devices 200 by adjusting both the angle of the arm about pivot 610 and buy adjusting the length through the telescoping assembly 620 .
The support structure 600 further includes a ball and cup joint 660 at the distal ends 640 of the arms 630 . The ball and cup joint 660 is arranged to hold the therapy providing device 200 and allows a user to align the therapy providing device 200 substantially parallel to a surface of the user at the desired location to insure that as much as possible of the therapy providing device 200 is in contact with the user.
The support structure 600 further includes a pad 650 connected to the arms 630 . In accordance with embodiments of the present invention, the pad may contain the electronics module 320 and the power source.
The arms 630 of the support structure 600 can also be configured to include a spring force to push the therapy providing device 200 against the body. For example, the arms 630 of the support structure 600 depicted in FIG. 17 are curved and are configured to apply a spring force between the therapy providing units 200 and the pad 650 when the support structure 600 is placed over a user's shoulders.
Referring now to FIG. 18 there is shown another example, of a support structure 700 in accordance with the present invention. As shown in FIG. 4H , the support structure 700 includes a pad 750 , a first arm 730 , and second arms 731 . The support structure 700 further includes joints 740 , the joints 740 join the first arm 730 to the second arms 731 . The joints 740 are configured to allow for rotational motion between the first arm 730 and the second arms 731 in order to allow a user to align the therapy providing devices 200 in accordance with the methods of the present invention. The second arms 731 further include telescoping sections 745 . The telescoping sections 745 allow the user to adjust the length of the second arms 731 to position the therapy providing units properly. The second arms 731 further include a ball joint assembly 760 disposed at their distal ends, the ball joint assemblies 760 couple the therapy providing units to the second arms 731 . The ball joint assemblies 760 allow the therapy providing units to lay flat against the user's collar bones and account for differences in anatomy. The support structure 700 further includes a pad 750 coupled to the first arm 730 . As described above the pad 750 may contain the electronics module 320 and the power source. In certain embodiments the electronics module and power source would be user replaceable. In other embodiments, the electronics module and battery would not be user replaceable and the entire assembly would be replaced including the therapy providing devices.
The support structures 600 and 700 can be made of an elastic material. The elasticity of the design provides for a spring or clamping force, such that the support structure and therapy providing devices remain in position during use.
The support structures described herein can be configured to fit snugly without being too compressive on the body, are straightforward to put on over the shoulders or around the torso, and can be worn underneath clothing without significantly altering the profile of the clothing.
Referring now to FIGS. 19A-19C , there are shown additional embodiments of the present invention. As shown in FIGS. 19A-19C , the therapy providing device 200 of the present invention may be incorporated into a support structure 800 , wherein the support structure 800 includes a proximal end 802 and a distal end 801 and an elongate member 803 extending between the two ends. The support structure further includes a control panel 810 , wherein the control panel 810 may include an indicator such as a light or LED 811 to indicate the function of the therapy providing devices 200 . The control panel 810 further includes a switch 813 , the switch 813 being in electrical communication with the therapy providing devices 200 and the electronics module 230 and the energy source 240 , each of which have been described above. The support structure 800 may be fabricated of fabric such as cotton, nylon, polyester or the like, wherein the body 803 is in the form of a tubular, square, rectangular or cylindrical shape, thereby forming an inner chamber. As shown in FIG. 19A , the therapy providing devices 200 and the electronics module 230 and energy source 240 are shown disposed within the inner chamber. These components may be held within the inner chamber through the use of pockets formed within the inner chamber. It is further contemplated that the inner chamber may be filled with a material to increase the weight of the overall device. Examples of materials that can be utilized to fill the chamber are rice, beans, sand, metallic materials, polymer materials and other such materials that are known to one skilled in the art.
As shown in FIGS. 19B and 19C , the support structure 800 can be worn around a user's neck and shoulders, wherein the therapy providing device 200 would be adjusted by the user to fall onto and make contact with the user's clavicle. The support structure 800 may be disposed over the top of a user's clothing as shown in FIG. 19B , or alternatively the support structure 800 may be disposed directly against a user's skin as shown in FIG. 19C .
In accordance with the embodiment shown in FIGS. 19A-19C , it is contemplated that the support structure may further include a removable cover (not shown), wherein the removable cover can be disposed about the support structure 800 . The removable cover may include a zipper, velcro or snaps to open and close the cover. Additionally, the removable cover may include additional items such as pads placed along a portion or a length thereof. For example, a pad may be disposed on the cover near the user's neck area.
It is further contemplated that the support structure 800 in accordance with the present invention may include additional features. For example, a heating element may be incorporated into the support structure 800 , whereby the heating element may be utilized by the user to address sore muscles or neck pain.
Referring now to FIGS. 20A and 20B , there are shown exemplary embodiments of clothing articles which can be utilized with the therapy providing device 200 of the present invention.
As shown in FIG. 20A , in one embodiment, the clothing article is embodied as a t-shirt 600 , wherein the t-shirt 600 includes pockets 602 formed therein to receive the therapy providing device 200 . The pockets 602 are aligned over the user's clavicle in order to provide treatment as will be described below.
Referring now to FIG. 20B there is shown an alternative embodiment of a piece of clothing configured to retain the therapy device 200 in accordance with the present invention. As shown in FIG. 5B the clothing can be embodied in the form of a sports bra 610 . The sports bra 610 further includes pockets 612 configured to receive the therapy device 200 . Alternatively, instead of pockets, other attachment mechanisms such as those described above, wherein instead of pockets, magnets, hook and loop fasteners, snap fasteners, twist and lock or similar types of fastening systems may be utilized to retain the therapy providing device 200 in position.
Additionally, the clothing devices described above may further include an additional pocket or pockets to receive the computing device, or in embodiments wherein the electronics or energy source are separate from the therapy providing device, pockets or other retention means to retain these additional components.
The clothing devices may further include a structure formed therein or attached thereto (not shown) wherein the structure is configured to apply a downward force upon the therapy providing device(s). Structures similar to those shown in FIGS. 17 , 18 and 19 may be utilized.
In accordance with the present invention, the therapy providing device 200 may include addition features. One such additional feature can be the inclusion of a thermometer to track the user's temperature during use. Another additional feature can be the inclusion of a sleep sensor or sleep tracking program, wherein the therapy providing device can be utilized to track the user's sleep. For example, the sleep program may utilize the GPS/accelerometer of the therapy providing device to track movement during sleep, wherein the sleep program could further utilize the temperature data as well. Another aspect of the invention could be to utilize the therapy providing device to be further utilized to diagnose sleep apnea, wherein the therapy providing device could further include a microphone to enable audio recording of the user's breathing during sleep. Additionally, the microphone recording of the breathing can be combined with the accelerometer data or GPS/tilt data to correlate the breathing recordings to the specific user.
Referring now to FIGS. 21A and 21B there is shown a computing device 300 in accordance with the present invention. The computing device 300 includes a processor, memory, energy source (such as a battery), and a display. The computing device may be a custom manufactured device for use with the therapy device 200 as described above, or alternatively, the computing device 300 may be a commercially available device such as a smartphone or tablet. Examples of such commercially available devices are iOS enabled devices such as the IPHONE, IPAD, IPOD, Android based phones and/or tablets, laptops or computers. As shown in FIG. 15B , the computing device may be configured to display a user's heart rate and blood pressure when connected to a therapy providing device having those measurement capabilities or where other compatible devices are utilized with the therapy providing device. Alternatively, the computing device may display data received from one or more therapy providing devices, this data may include start/stop times of therapy provided by the therapy providing device 200 , battery status of one or more therapy providing devices and the like.
In accordance with the present invention, the computing device 300 is configured to run a program 820 . In accordance with the present invention, the program 820 is configured to communicate with the therapy device 200 . The communication between the program 820 , computing device 300 and the therapy device 200 may be conducted using BLUETOOTH, WIFI, ZIGBEE, NFC, RFID, ANT+, 3G/4G, cellular connection or other known wireless communication protocols. Alternatively, the computing device may be coupled to at least one of the therapy devices through a cable connection.
In an alternative embodiment, the program 820 is stored on memory located within the memory of the therapy providing device 200 . The program maybe initiated manually through the use of a physical button pressed by the user. Alternatively, the program 820 may be initiated automatically by a timer located within the therapy providing device 200 . The timer may further utilize data inputs from an accelerometer/compass or tilt sensor to indicate when the user is in a prone position to initiate the program 820 . Further still, the timer may receive input from an impedance sensor indicating whether the therapy providing device 200 is in proper placement on the users body. The program would then be initiated based on the inputs received. The device may be activated further by the light sensor either from the darkness against the skin. The device may be activated from the reduced light from the users surroundings, for example when the user is sleeping.
In certain embodiments, the program 820 is pre-configured to deliver therapy using the therapy providing device through pre-programmed parameters. The HCP may adjust the therapy parameters within the program 820 , such that the therapy provided to the user may be customized to the user. The customization of the therapy may be changes to the wavelength, amplitude, duration, start/stop times. The customization may be done by the HCP while providing services to the patient, for example, the HCP may apply the therapy providing device to the patient, initiate therapy and monitor the patient's response. Through this active monitoring, the HCP may change the parameters of the program to elicit a response in the patient. For example, it is contemplated that certain patients may have different bone densities; therefore the therapy provided by the device may need to be adjusted accordingly. It is further contemplated, that once programmed, the user cannot change the therapy parameters of the program, or alternatively, certain parameters or all parameters may be open to change by the end user or remotely. Alternatively, the HCP, after determining the best therapy parameters, can choose from multiple programs stored within memory of the therapy providing device. Further still, the HCP may be provided with a dedicated programming device, or may couple the device to a personal computer, smartphone, tablet or other internet enabled device, such that the HCP can utilize the dedicated programmer or download over a secure internet connection, programs to be uploaded into the therapy providing device.
Referring now to FIG. 22 , there is shown a flow diagram illustrating the program 820 in accordance with one embodiment of the present invention. As shown in FIG. 22 , the program 820 may configured to be run on the computing device 800 to control the therapy applied to the user by the therapy providing device 200 . Alternatively, it is contemplated that the program 820 may reside within memory within the therapy providing device 200 as described above.
At Box 830 , the user activates the program on the computing device 800 or therapy providing device 200 .
At Box 840 , the program checks the time on the computing device 800 or internally from the clock circuit of the therapy providing device 200 .
At Box 850 , the program determines whether to turn the therapy providing device on based upon the time check in Box 840 . If the time is before a pre-programmed time or a user set time, then the program returns to Box 840 . If the time is after the pre-set time or user set time, then the program turns the therapy providing device on. In accordance with the invention, if the time is received from the computing device, a user may adjust the time of the computing device, for example if the computing device is moved from one time zone to another. Alternatively, the computing device may automatically update the time.
At Box 860 , the therapy providing device 200 is provided with a signal generated by the program and transmitted from the computing device 800 through a selected transmission method. In alternative embodiments, the therapy providing device contains a processor and memory, wherein a program is retained within the memory of the therapy providing device. In this embodiment, the signal provided by the computing device 800 , is a power on/off signal, wherein once powered on the program residing within the memory of the therapy providing device will begin to run.
At Box 870 , the therapy device provides therapy to the patient. In the process of providing therapy, a signal is transmitted to the therapy device 200 by the computing device 800 through as directed by the program 820 , or as described above, the program residing in the memory of the therapy providing device runs. In one embodiment, the therapy is applied for a set period of time. In alternative embodiments, the time duration of the therapy may be determined based upon data received from other sensors disposed upon the user or about the user. In yet another embodiment, the user may manually deactivate the therapy providing device/program.
At Box 880 , the therapy is stopped. The therapy may be stopped based upon a time event, motion event, manually by the user, automatically by the program.
During each of the steps described above and shown in the flow diagram of FIG. 22 , the user may be presented with displays on the screen 810 of the computing device. The screen 810 may display the start and stop times of the therapy, these times may be set by the user or may be set for the user by a health care provider. Alternatively, the times maybe automatically generated in response to data received from other sensors as will be described in detail below.
According to the invention, the program includes a non-transitory computer readable medium having computer executable program code embodied thereon, the computer executable program code configured to send appropriate signals to the circuit board(s) 500 / 550 to provide therapy in accordance with the methods of the present invention utilizing the therapy providing device 200 of the present invention.
Methods of Use
In accordance with the present invention, methods of use of the present invention will be described below. The methods described shall be considered to be exemplary and should not be considered limiting in any manner.
In accordance with one embodiment of the present invention, the therapy device includes a driver assembly, wherein the driver assembly is embodied as a speaker as shown in FIG. 5 . The speaker may be a haptic speaker, a piezoelectric speaker, an electroactive polymeric transducer, or a magnetic coil speaker. The computing device 800 and program 810 are configured to provide a signal to the speaker to cause the speaker to vibrate at certain frequencies or to oscillate or translate through a range of frequencies.
In accordance with embodiments of the present invention, the frequencies contemplated for use with the present invention range between 0 Hz to 20,000 Hz, 0 Hz and 10,000 Hz, 0 Hz and 5,000 Hz, 0 Hz and 2,500 Hz, 0 Hz and 1,750 Hz, 0 Hz and 875 Hz, 0 Hz and 435 Hz, 0 Hz and 200 Hz, 0 Hz and 150 Hz, 1 Hz and 150 Hz, 2 Hz and 150 Hz, 3 Hz and 150 Hz, 4 Hz and 150 Hz, 5 Hz and 150 Hz, 6 Hz and 150 Hz, 7 Hz and 150 Hz, 8 Hz and 150 Hz, 9 Hz and 150 Hz, 10 Hz and 150 Hz, 11 Hz and 150 Hz, 12 Hz and 150 Hz, 13 Hz and 150 Hz, 14 Hz and 150 Hz, 15 Hz and 150 Hz, 16 Hz and 150 Hz, 17 Hz and 150 Hz, 18 Hz and 150 Hz, 19 Hz and 150 Hz, 20 Hz and 150 Hz, 21 Hz and 150 Hz, 22 Hz and 150 Hz, 23 Hz and 150 Hz, 24 Hz and 150 Hz, 25 Hz and 150 Hz, 26 Hz and 150 Hz, 27 Hz and 150 Hz, 28 Hz and 150 Hz, 28 Hz and 150 Hz, 29 Hz and 150 Hz, 30 Hz and 150 Hz, 31 Hz and 150 Hz, 32 Hz and 150 Hz, 33 Hz and 150 Hz, 34 Hz and 150 Hz, 35 Hz and 150 Hz, 36 Hz and 150 Hz, 37 Hz and 150 Hz, 38 Hz and 150 Hz, 39 Hz and 150 Hz, 40 Hz and 150 Hz, 41 Hz and 150 Hz, 42 Hz and 150 Hz, 43 Hz and 150 Hz, 44 Hz and 150 Hz, 45 Hz and 150 Hz, 46 Hz and 150 Hz, 47 Hz and 150 Hz, 48 Hz and 150 Hz, 49 Hz and 150 Hz, 50 Hz and 150 Hz, 51 Hz and 150 Hz, 52 Hz and 150 Hz, 53 Hz and 150 Hz, 54 Hz and 150 Hz, 55 Hz and 150 Hz, 56 Hz and 150 Hz, 57 Hz and 150 Hz, 58 Hz and 150 Hz, 59 Hz and 150 Hz, 60 Hz and 150 Hz, 61 Hz and 150 Hz, 62 Hz and 150 Hz, 63 Hz and 150 Hz, 64 Hz and 150 Hz, 65 Hz and 150 Hz, 66 Hz and 150 Hz, 67 Hz and 150 Hz, 68 Hz and 150 Hz, 69 Hz and 150 Hz, 70 Hz and 150 Hz, 71 Hz and 150 Hz, 72 Hz and 150 Hz, 73 Hz and 150 Hz, 74 Hz and 150 Hz, 75 Hz and 150 Hz, 76 Hz and 150 Hz, 77 Hz and 150 Hz, 78 Hz and 150 Hz, 79 Hz and 150 Hz, 80 Hz and 150 Hz, 81 Hz and 150 Hz, 82 Hz and 150 Hz, 83 Hz and 150 Hz, 84 Hz and 150 Hz, 85 Hz and 150 Hz, 86 Hz and 150 Hz, 87 Hz and 150 Hz, 88 Hz and 150 Hz, 89 Hz and 150 Hz, 90 Hz and 150 Hz, 91 Hz and 150 Hz, 92 Hz and 150 Hz, 93 Hz and 150 Hz, 94 Hz and 150 Hz, 95 Hz and 150 Hz, 96 Hz and 150 Hz, 97 Hz and 150 Hz, 98 Hz and 150 Hz, 99 Hz and 150 Hz, 100 Hz and 150 Hz, 101 Hz and 150 Hz, 102 Hz and 150 Hz, 103 Hz and 150 Hz, 104 Hz and 150 Hz, 105 Hz and 150 Hz, 106 Hz and 150 Hz, 107 Hz and 150 Hz, 108 Hz and 150 Hz, 109 Hz and 150 Hz, 110 Hz and 150 Hz, 111 Hz and 150 Hz, 112 Hz and 150 Hz, 113 Hz and 150 Hz, 114 Hz and 150 Hz, 115 Hz and 150 Hz, 116 Hz and 150 Hz, 117 Hz and 150 Hz, 118 Hz and 150 Hz, 119 Hz and 150 Hz, 120 Hz and 150 Hz, 121 Hz and 150 Hz, 122 Hz and 150 Hz, 123 Hz and 150 Hz, 124 Hz and 150 Hz, 125 Hz and 150 Hz, 126 Hz and 150 Hz, 127 Hz and 150 Hz, 128 Hz and 150 Hz, 129 Hz and 150 Hz, 130 Hz and 150 Hz, 131 Hz and 150 Hz, 132 Hz and 150 Hz, 133 Hz and 150 Hz, 134 Hz and 150 Hz, 135 Hz and 150 Hz, 136 Hz and 150 Hz, 137 Hz and 150 Hz, 138 Hz and 150 Hz, 139 Hz and 150 Hz, 140 Hz and 150 Hz, 141 Hz and 150 Hz, 142 Hz and 150 Hz, 143 Hz and 150 Hz, 144 Hz and 150 Hz, 145 Hz and 150 Hz, 146 Hz and 150 Hz, 147 Hz and 150 Hz, 148 Hz and 150 Hz, 149 Hz and 150 Hz, 150 Hz and 150 Hz, 60 Hz and 100 Hz, 61 Hz and 100 Hz, 62 Hz and 100 Hz, 63 Hz and 100 Hz, 64 Hz and 100 Hz, 65 Hz and 100 Hz, 66 Hz and 100 Hz, 67 Hz and 100 Hz, 68 Hz and 100 Hz 69 Hz and 100 Hz, 70 Hz and 100 Hz, 60 Hz and 99 Hz, 61 Hz and 99 Hz, 62 Hz and 99 Hz, 63 Hz and 99 Hz, 64 Hz and 99 Hz, 65 Hz and 99 Hz, 66 Hz and 99 Hz 67 Hz and 99 Hz, 68 Hz and 99 Hz, 69 Hz and 99 Hz and 70 Hz and 99 Hz, and 61 Hz and 98 Hz, 62 Hz and 98 Hz, 63 Hz and 98 Hz, 64 Hz and 98 Hz, 65 Hz and 98 Hz, 66 Hz and 98 Hz, 67 Hz and 98 Hz, 68 Hz and 98 Hz, 69 Hz and 98 Hz and 70 Hz and 98 Hz.
In a preferred embodiment the signal causes the driver assembly to vibrate at a frequency or sweep through a range of frequencies between about 40 Hz and 150 Hz, more preferably between 50 Hz and 125 Hz, most preferably between about 60 Hz and 115 Hz. In accordance with the present invention, a therapeutic response has been achieved utilizing a frequency range between 65 Hz and 100 Hz.
It is further contemplated that these frequencies may be doubled and still achieve the therapeutic lowering of blood pressure in accordance with the present invention. It is further contemplated that these frequencies may be halved and still achieve the therapeutic lowering of blood pressure in accordance with the present invention.
In additional embodiment of the present invention, the driver assembly may vibrate or sweep or step between frequencies of between 60 Hz, 61 Hz, 62 Hz, 63 Hz, 64 Hz, 65 Hz, 66 Hz, 67 Hz, 68 Hz, 69 Hz, 70 Hz, 71 Hz, 72 Hz, 73 Hz, 74 Hz, 75 Hz, 76 Hz, 77 Hz, 78 Hz, 79 Hz, 80 Hz, 81 Hz, 82 Hz, 83 Hz, 84 Hz, 85 Hz, 86 Hz, 87 Hz, 88 Hz, 89 Hz, 90 Hz, 91 Hz, 92 Hz, 93 Hz, 94 Hz, 95 Hz, 96 Hz, 97 Hz, 98 Hz, 99 Hz and 100 Hz.
Referring now to FIGS. 23A and 23B , there is shown a further embodiment wherein the therapy is provided utilizing a combination of single frequencies and a sweeping frequency. For example, the driver assembly would be driven to vibrate at a single frequency, F1, for a period of time, then driven to sweep through a range of frequencies, F2, then driven at a single frequency, F3, different than the first single frequency, F1, and then finally driven backwards through the sweep of frequencies above, F4. This cycle may be repeated for a set period of time, turned off for a period of time and then repeated again, until an overall time period of therapy is reached.
It is further contemplated that multiple signals utilizing separate frequencies may be transmitted by the program to the speaker. For example, one signal may be transmitted at one frequency and a second signal at another frequency. The signals may be transmitted simultaneously, independently or in an alternating fashion. If at least two therapy providing devices 200 are utilized, then one therapy providing device 200 may receive a first signal and the other receives a second signal.
In one embodiment, at least two therapy providing devices 200 are utilized. In use a signal will be sent to one of the two therapy providing devices 200 , causing the speaker to emit a signal having a chosen frequency or range of frequencies. The signal is transmitted to a first therapy providing device 200 for a pre-determined period of time. After such time, the signal is terminated. Upon termination of the first signal, a second signal is generated and transmitted to the other therapy providing device. This second signal causes the speaker to emit a signal having a chosen frequency or range or frequencies. The chosen frequency may be the same as that transmitted to the first therapy providing device or it may be at a different frequency. The second signal will be transmitted to the second therapy providing device for a pre-determined period of time. After such time, the signal is terminated. The program will continued to run, however, during this time no signal will be transmitted to either therapy providing device 200 , thereby creating a pause between activation of the therapy providing devices 200 . After the pre-determined time period of the pause has passed, the program will then enter a loop and repeat the process described above. This pattern of therapy will repeat for as long as the program has been instructed to do so.
In the embodiment where two therapy providing devices 200 are utilized, each of the devices deliver a waveform to the user's left and right clavicle. The waveform is transmitted from the speaker in each of the therapy providing devices to the user's clavicles. The waveform is transmitted through the clavicle on the left and right side, where both waves meet at the sternum to create a standing wave.
Further still, in accordance with the present invention, the amplitude of the signal can be adjusted to adjust the sound pressure generated by the driver assembly 220 of the therapy providing device 200 . It is contemplated that the amplitude may be doubled or increased even more to deliver the therapy in accordance with the present invention. In accordance with the invention, the therapy providing device 200 may be configured to provide a sound pressure between: 0 to 150 decibels, 0 to 100 decibels, 0 to 99 decibels, 0 to 98 decibels, 0 to 97 decibels, 0 to 96 decibels, 0 to 95 decibels, 0 to 94 decibels, 0 to 93 decibels, 0 to 92 decibels, 0 to 91 decibels, 0 to 90 decibels, 0 to 89 decibels, 0 to 88 decibels, 0 to 87 decibels, 0 to 86 decibels, 0 to 85 decibels, 0 to 84 decibels, 0 to 83 decibels, 0 to 82 decibels, 0 to 81 decibels, 0 to 80 decibels, 0 to 79 decibels, 0 to 78 decibels, 0 to 77 decibels, 0 to 76 decibels, 0 to 75 decibels, 0 to 74 decibels, 0 to 73 decibels, 0 to 72 decibels, 0 to 71 decibels, 0 to 70 decibels, 0 to 69 decibels, 0 to 68 decibels, 0 to 67 decibels, 0 to 66 decibels, 0 to 65 decibels, 0 to 64 decibels, 0 to 63 decibels, 0 to 62 decibels, 0 to 61 decibels, 0 to 60 decibels, 0 to 59 decibels, 0 to 58 decibels, 0 to 57 decibels, 0 to 56 decibels, 0 to 55 decibels, 0 to 54 decibels, 0 to 53 decibels, 0 to 52 decibels, 0 to 51 decibels, 0 to 50 decibels, 0 to 49 decibels, 0 to 48 decibels, 0 to 47 decibels, 0 to 46 decibels, 0 to 45 decibels, 0 to 44 decibels, 0 to 43 decibels, 0 to 42 decibels, 0 to 41 decibels, 0 to 40 decibels, 0 to 39 decibels, 0 to 38 decibels, 0 to 37 decibels, 0 to 36 decibels, 0 to 35 decibels, 0 to 34 decibels, 0 to 33 decibels, 0 to 32 decibels, 0 to 31 decibels, 0 to 30 decibels, 0 to 29 decibels, 0 to 28 decibels, 0 to 27 decibels, 0 to 26 decibels, 0 to 25 decibels, 0 to 24 decibels, 0 to 23 decibels, 0 to 22 decibels, 0 to 21 decibels, 0 to 20 decibels, 0 to 19 decibels, 0 to 18 decibels, 0 to 17 decibels, 0 to 16 decibels, 0 to 15 decibels, 0 to 14 decibels, 0 to 13 decibels, 0 to 12 decibels, 0 to 11 decibels, 0 to 10 decibels, 0 to 9 decibels, 0 to 8 decibels, 0 to 7 decibels, 0 to 6 decibels, 0 to 5 decibels, 0 to 4 decibels, 0 to 3 decibels, 0 to 2 decibels, 0 to 1 decibels, 0 to 0.5 decibels, 0 to 0.25 decibels, 10 to 100 decibels, 20 to 100 decibels, 30 to 100 decibels, 40 to 100 decibels, 50 to 100 decibels, 60 to 100 decibels, 70 to 100 decibels, 80 to 100 decibels, 90 to 100 decibels, 10 to 75 decibels, 20 to 75 decibels, 30 to 75 decibels, 40 to 75 decibels, 50 to 75 decibels, 60 to 75 decibels, 70 to 75 decibels, 10 to 65 decibels, 20 to 65 decibels, 30 to 65 decibels, 40 to 65 decibels, 50 to 65 decibels and 60 to 65 decibels, 20 to 30 decibels, 30 to 40 decibels, 40 to 50 decibels, 50 to 60 decibels, 60 to 70 decibels, 70 to 75 decibels, 80 to 90 decibels, 50 to 75 decibels and 50 to 65 decibels.
Further still, in accordance with the present invention, the standing wave may be of half-octave, double octave, or reflective incidence. Thus the frequencies delivered at the collarbone may independently collide across the breastbone or sternum and create a new frequency which is of a different or same frequency as the generating waves.
In accordance with the present invention, the frequency selected for therapy may be held constant while the sound pressure level can be increased or decreased, alternatively, the sound pressure level may be held constant and the frequency varied. The measurement of a sound pressure level is related to the displacement of a portion of the delivery device 220 . The portion of the delivery device 220 may be displaced between: 0 mm and 20 mm, 0 mm to 10 mm, 0 mm to 9 mm, 0 mm and 8 mm, 0 mm to 7 mm, 0 mm to 6 mm, 0 mm to 5 mm, 0 mm and 4 mm, 0 mm and 3 mm, 0 mm and 2 mm, 0 mm and 1 mm, 0 mm and 0.5 mm, 0 mm to 0.05 mm, 0 mm to 0.005 mm, 0 mm to 0.0005 mm, 0.5 mm to 0.05 mm, 0.5 mm to 0.005 mm, 0.05 mm to 0.005. If the delivery device 220 is selected to be the haptic speaker 220 ′, then the portion of the haptic speaker 220 ′ being displaced is the coil of the haptic speaker.
In accordance with the present invention, it is contemplated that each therapy providing device may be activated to provide therapy for a time period between about 1 second and 24 hours. In other embodiments, the therapy providing devices may be activated to provide therapy for a time period of between about 1 second and 12 hours, 1 second and 11 hours, 1 second and 10 hours, 1 second and 9 hours, 1 second and 8 hours, 1 second and 7 hours, 1 second and 6 hours, 1 second and 5 hours, 1 second and 4 hours, 1 second and 3 hours 1 second and 2 hours, and 1 second and 1 hour, 1 second and 45 minutes, 1 second and 30 minutes, 1 second and 20 minutes, 1 second and 15 minutes, 1 second and 10 minutes, 1 second and 5 minutes and 1 second and 1 minute.
The overall therapy process may be conducted for a time period between 1 second and 24 hours, 1 second and 23 hours, 1 second and 22 hours, 1 second and 21 hours, 1 second and 20 hours, 1 second and 19 hours, 1 second and 18 hours, 1 second and 17 hours, 1 second and 16 hours, 1 second and 15 hours, 1 second and 15 hours, 1 second and 14 hours, 1 second and 13 hours, 1 second and 12 hours, 1 second and 11 hours, 1 second and 10 hours, 1 second and 9 hours, 1 second and 8 hours, 1 second and 7 hours, 1 second and 6 hours, 1 second and 5 hours, 1 second and 4 hours, 1 second and 3 hours, 1 second and 2 hours, 1 second and 1 hour, 1 second and 45 minutes, 1 second and 30 minutes, 1 second and 15 minutes, 1 second and 10 minutes, 1 second and 5 minutes, 1 second and 1 minute.
In an alternative embodiment, instead of activating one therapy providing device 200 at a time to conduct the therapy, both therapy providing devices 200 may be activated at the same time.
In accordance with the present invention, the therapy device may be factory programmed to utilize a certain frequency or range of frequencies to provide therapy. Alternatively, the frequencies may be selected and programmed or chosen from memory by a health care provider based upon a patient's response to a specific frequency or range of frequencies.
It is further contemplated that the computing device may be additionally in communication with other sensors, such as a blood pressure monitor, heart rate monitor, pulse oximetry monitor, electrocardiogram (EKG/ECG), or glucose sensor.
In one embodiment the computing device 800 would receive data from the blood pressure monitor, or other sensor, such that the user's blood pressure would be recorded before, during and after the application of therapy in accordance with the present invention. This data, along with the therapy data could be provided to the user and/or a health care provider. Based upon the data, the frequency or range of frequencies selected for therapy could be adjusted. The adjustments may be made automatically by the program, or by a health care provider or by the user themselves.
In another embodiment, the processor of the therapy providing device 200 may be in communication with other sensors, such as those described above, wherein the other sensors would be coupled in communication with the therapy providing device. The processor within the therapy providing device 200 can receive data from various other sensors, such as a blood pressure monitor. The data received from the blood pressure monitor may be utilized by the program within the memory of the electronics module to further control the therapy providing device 200 .
The signals generated by the program and transmitted to the therapy providing device are preferably in the form of a sine wave. However, other wave forms may be utilized, such as a square waveform, sawtooth waveform or triangle waveform.
It is further contemplated that additional sensors maybe utilized with the methods and devices in accordance with the present invention. For example, a blood pressure monitor may be affixed to the patient as described above. Other sensors, such as a sleep sensor, movement sensor, pulse oximetry sensor, temperature sensor, heart rate monitor, EKG, microphone, digital stethoscope, light sensor, sleep apnea device (CPAP) or camera may be used in combination with the therapy system 100 in accordance with the present invention. The sensors listed above could be used separately or in combination to provide additional data to the user or a health care provider as to the health of the user as well as to the response of the user to the therapy provided by the therapy system 100 .
It is further contemplated that any of the above sensors could be incorporated into the therapy providing device 200 in accordance with the present invention. If incorporated into the therapy providing device 200 , the data from each of the additional sensors could be utilized by the program to alter the therapy provided based upon data received from the various sensors. In an alternative embodiment, the data from each of the additional sensors could be stored on the resident memory contained within the therapy providing device 200 . The therapy providing device 200 could then be turned into a service center after a period of time, wherein the data contained within the memory can be retrieved and analyzed. In yet another embodiment, the data stored within the memory can be downloaded from the therapy providing device 200 each time the therapy providing device is placed on the inductive charging pad. The data can then be transmitted to a collection center and analyzed. Additionally, the data could be uploaded to a server or other internet/network connected personal computer, such that the data could be viewed by the user, a health care provider or others.
In another embodiment, the device will store the number of uses and durations of usage to allow the health care practitioner to determine compliance of the patient. As in sleep apnea devices, reimbursement is only allowed if the patient is 70 percent compliant, by tracking and recording the usage of the therapy providing device of the present invention, this data could be utilized for reimbursement purposes.
In another embodiment, the therapy system 100 of the present invention could be associated with a home health system, such as Honeywell's HOMMED system. In this embodiment, the therapy system 100 in accordance with the present invention would be coupled to a monitoring system. In this embodiment, a health care provider could remotely monitor users as well as their response to the therapy being provided. Further still, the therapy system 100 may be configured to recognize an emergency, such as excessively high blood pressure, excessively low blood pressure, high heart rate or low heart rate and generate an alert, such as an alarm or notification to an emergency response unit to request help for the user.
In accordance with the present invention, the therapy device 200 as described herein is disposed adjacent to or thereabout the clavicle just above the brachial plexus of the user. It is contemplated that the therapy providing device 200 may be placed at other locations on the user such as the sternum, jaw, scapula, kneecap, wrist or skull. When activated, the driver assembly 220 of the therapy device generates a frequency in the form of a sound wave; this sound wave is transmitted to the clavicle and the skin adjacent the clavicle. The sound waves transmitted to the clavicle are transmitted in the form of vibrations. The vibrations travel through the clavicle and into the skin, the arteries, vessels, nerves, sensory corpuscles, airways, bones near the clavicle, ligaments and tendons. As a result, the vibrations are eventually transmitted to the baroreceptors, the nociceptors, the proprioreceptors and other somatasory sensors. Here, the vibrations interact with the baroreceptors and other sensors in a manner to lower blood pressure. In a preferred embodiment, the clavicle is chosen because it's easily accessible location as well as its ability to transmit sound or vibrations. The clavicle is easy to identify by a health care provider and a patient as it resides close to the surface of the skin regardless of body mass.
In accordance with the methods and devices of the present invention, activation of both the carotid and aortic baroreceptors as well as other somatasory sensors can be achieved. It is believed that activation of both the carotid and aortic baroreceptors is beneficial in achieving lower blood pressure. It is believed that the methods provided according to the present invention mimic exercise, and therefore achieve a lowering of blood pressure.
In accordance with the invention, the therapy may be provided at night time either right before the patient enters a sleep cycle or during a sleep cycle of the patient. It may be beneficial to provide the therapy in accordance with the present invention at night time as it is believed that one of the most important times to lower blood pressure is during the night. By providing therapy at night time in accordance with the present invention, the therapy can be utilized to address nighttime hypertension. Additionally, at nighttime, systemic drug levels are at their lowest, therefore there is a need for additional blood pressure control at this time.
In accordance with another embodiment of the present invention, it is believed that through the use of a single therapy providing device instead of two therapy providing devices can be utilized to lower only Diastolic blood pressure, wherein the use of both therapy providing devices can be utilized to lower both Systolic and Diastolic blood pressure.
In accordance with the invention, the therapy may be provided prior to a user's sleep cycle and again in the morning either before they awake or shortly after they have woken up.
In accordance with the invention, the therapy providing device may be programmed with frequencies, wherein other frequencies may be utilized to raise blood pressure at such times whereby raising the blood pressure would be therapeutic and beneficial to a patient. It may be desirable to raise blood pressure after childbirth or to counteract episodes of hypotension.
It is further contemplated that the device and methods according to the present invention may be utilized at any time. For example, it may be desirable to utilize the device during the day time, where the device could be utilized in combination with a blood pressure monitor, or alternatively, incorporate a blood pressure monitor for closed loop control. In this embodiment, the program would monitor the user's blood pressure and apply therapy on an as needed basis. The user could select to turn the system off if desired, for example if they are planning to engage in physical activity which will raise their blood pressure.
Test Results
In accordance with the present invention, and referring to FIGS. 24A and 24B , the following blood pressure results were achieved through use of the device and methods described herein. FIGS. 24A and 24B illustrate ambulatory blood pressure readings over a 24 hour period. Line 910 is the European Society of Hypertension (ESH), the UK National Institute for Health and Clinical Excellence (NICE) and American Society of Hypertension (ASH) recommended limits for Systolic blood pressure. Between the hours of 10 pm and 7 am a blood pressure of below 125 mmHg is considered to be at goal. During the daytime between the hours of 7 am and 10 pm, a blood pressure below 140 mmHg is considered to be at goal. Line 930 is the ESH, NICE and ASH recommended limits for Diastolic blood pressure, similar to the Systolic line 910 , between the hours of 10 pm and 7 am an at-goal Diastolic pressure is considered to be 80 mmHg, and between the hours of 7 am to 10 pm a measurement of 90 mmHg is considered to be at goal.
As shown in FIG. 24A , lines 900 and 920 represent twenty-four (24) hour ambulatory blood pressure measurements of an individual, wherein blood pressure measurements were taken every fifteen (15) minutes. The user presented in FIG. 24B would be considered to be hypertensive, that is to have high blood pressure. This can be determined by looking specifically at lines 900 and lines 920 , wherein any time these lines are above the recommend guideline pressures, lines 910 and 930 the user would be considered to be hypertensive.
Referring now to FIG. 24A there is shown a graph of the same user after having received therapy in accordance with the present invention. In this instance, the user received therapy at twice for two hours (2 hours) each time as depicted items 940 and 950 . Comparing the user's actual blood pressure measurements, lines 900 and 920 of FIG. 24A , with the user's treated actual blood pressure measurements, lines 901 and 902 of FIG. 24A , it can be clearly seen that the user's blood pressure was significantly lowered through the application of therapy utilized the device and methods of the present invention.
To achieve the results depicted in FIG. 24A , two therapy providing devices were utilized, one on the left clavicle and one on the right clavicle. A frequency between 60 and 100 Hz was delivered by the speaker of each therapy providing device. The therapy providing devices were utilized for a total of 4 hours of therapy, wherein the frequency of 65 Hz was played for 8 seconds, followed by a sweep of frequencies from 65 Hz to 98 Hz lasting 1 second, afterwards 98 Hz was played for 8 seconds, followed by a sweep of frequencies from 98 Hz to 65 Hz lasting for 1 second. Therapy was provided, repeatedly for 120 minutes following this cycle. After 120 minutes the therapy was suspended for a period of 4 hours. After 4 hours of silence, an additional 120 minutes of therapy was delivered utilizing the cycle above.
Blood pressure measurements were taken before the application of the therapy, whereby the user's Systolic blood pressure averaged 131 mmHg at night time and 144 mmHg during the day. Diastolic blood pressure was 72 mmHg at night time and 87 mmHg during the day. After using the therapy for one evening (one 8 hour session as described above), Systolic blood pressure averaged 116 mmHg at nighttime and 131 mmHg at daytime and diastolic blood pressure averaged 66 mmHg at nighttime and 80 mmHg at daytime.
Method of Action
In accordance with the present invention, as described in detail above and with reference to the included publications, it is understood that baroreceptors and nerves affect blood pressure through a measured response generated by stretching or contraction of the arterial wall.
Nerve fibers, including baroreceptors, have the following input-output characteristics; threshold pressure, saturation, post-excitatory depression (PED), Asymmetric Rate Sensitivity and hysteresis.
As long as pressure within an artery remains below a certain level, no nerve firing occurs, this is referred to as the nerve threshold pressure. Above the threshold pressure, the fiber responds by producing action potentials, i.e., as signal. Individual fibers within humans and animals possess a wide range of pressure threshold values.
As pressure increases within the artery, the firing rate of individual fibers increases. However, at certain pressure, further increases in input yield no further increase in output frequency, thereby reaching the saturation of the baroreceptor nerve.
If pressure input within the artery is stepped from a low pressure, which is higher than the threshold pressure, to a higher pressure, then returning to a lower pressure level, will result in a brief period of shutoff, that is there will be no firing of the baroreceptor nerve, also referred to as post-excitatory depression (PED). The baroreceptor nerve will return to its original firing rate after time.
Baroreceptor nerve frequency response to rising pressure is more pronounced than the response to falling pressure, otherwise known as asymmetric rate sensitivity.
Lastly, periodic inputs produce looping in pressure-frequency plots, another indication of the asymmetry between responses to rising and falling pressures otherwise referred to as hysteresis.
In accordance with the present invention, utilization of the devices in accordance with the methods described herein cause an activation of the nervous system which affect blood pressure. The nerve terminal endings respond to stretch or acoustic vibration, and produce a frequency-modulated train of action potentials which can override the natural frequencies to elicit a response. Wherein the therapy provided by the invention, utilizes acoustic vibration of specific frequencies applied at specific time intervals to activate the body's nervous system to elicit a blood pressure response. The therapy of the present invention is applied in a cyclic manner as it is believed that the baroreceptors may become saturated if stimulated for too long of a period of time. If the therapy was applied continuously it is believed that the baroreceptors would stop responding.
According to a method of the present invention, the therapy providing device is disposed adjacent to a user's clavicle. The clavicle being a Dermal bone, is capable of transmitting vibrations. The clavicle lies above the cerviocoaxillary which holds auxiliary arteries, veins, airways and the brachial plexus of nerves that supply the upper limb of the arm. Vibrating the clavicle is believed to create micro-pulsations which travel to the Aortic Baroreceptors and the Carotid Bulb Baroreceptors. These micro-pulsations are believed to be perceived as an increase in heart rate by the baroreceptors which then send a signal to the brain. Thereby causing the body to lower blood pressure.
Selective stimulation of primary nerve endings can be obtained with careful control of the amplitude, displacement and the mode of application of the vibration or micro-pulsations.
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Devices, systems and methods are described which control blood pressure and nervous system activity by stimulating baroreceptors. By selectively and controllably activating baroreceptors and/or nerves, the present invention reduces blood pressure and alters the sympathetic nervous system; thereby minimizing deleterious effects on the heart, vasculature and other organs and tissues. A baroreceptor activation device or other sensory activation device is positioned near a dermal bone to provide the treatment.
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FIELD
The present description relates to a system and methods for improving vehicle drivability and driver controls. The systems and methods may be particularly useful for engines that may be frequently stopped and restarted to conserve fuel.
BACKGROUND AND SUMMARY
An engine of a vehicle may be automatically stopped without a driver providing input to a device that has a sole purpose or function of stopping engine rotation so that fuel may be conserved (e.g., engine stop/start devices). Fuel may be conserved when the engine is automatically stopped since the engine does not consume fuel when it is not operating. However, if the engine is restarted immediately after it is stopped, the fuel reduction may be less than desired. Further, the driver may be annoyed that the engine has stopped and is being restarted so quickly after being stopped. Thus, automatically stopping an engine may conserve fuel, but it may also be less than desirable during some driving conditions. Present implementation schemes for engine stop/start devices provide a switch for a driver override that inhibits the automatic engine stop feature. However, there may be conditions when the driver wishes to override the engine stop functionality only once, or desires to override the engine stop feature without looking away from the vehicle's route to locate and active the switch.
The inventors herein have recognized the above-mentioned disadvantages of automatic engine stopping and have developed a method for operating an engine, comprising: inhibiting automatic engine stopping in response to a secondary application or increased application of vehicle brakes following an initial application of vehicle brakes, the secondary application or increased application of vehicle brakes occurring after the initial application of vehicle brakes and without vehicle brakes being fully released.
By allowing a driver to communicate to an engine stop/start controller via application of vehicle brakes, it may be possible to reduce the possibility of aggravating the driver during conditions where the driver may have more information than the vehicle engine controller regarding whether or not conditions are desirable for automatically stopping the engine. For example, a driver of a vehicle may notice that traffic lights for opposing traffic are about to change and give right of way to the driver. The driver may apply vehicle brakes in a prescribed manner that allows the driver to communicate with the automatic engine stop controller so that automatic engine stopping is inhibited in response to the driver applying vehicle brakes. As a result, the vehicle may accelerate in a more timely manner when automatic engine stopping is inhibited, thereby improving driver satisfaction.
The present description may provide several advantages. In particular, the approach may improve driver satisfaction. Additionally, the approach may save fuel when fuel consumption may be increased by stopping and engine and restarting the engine shortly thereafter. Further, the approach may provide the driver improved vehicle control as compared to other systems where the driver cannot communicate with the engine stop controller.
The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages described herein will be more fully understood by reading an example of an embodiment, referred to herein as the Detailed Description, when taken alone or with reference to the drawings, where:
FIG. 1 is a schematic diagram of an engine;
FIG. 2 shows an example vehicle driveline;
FIG. 3 shows an example prophetic vehicle operating sequence;
FIGS. 4 and 5 show an example brake pressure and brake position threshold levels; and
FIG. 6 shows an example method for operating a stop/start engine.
DETAILED DESCRIPTION
The present description is related to controlling operation of an engine that may be automatically stopped and started in a vehicle. The engine may be a sole source of torque for propelling the vehicle. Alternatively, the vehicle may include an engine and a motor that both supply torque to propel the vehicle. FIG. 1 shows an example engine system. The engine may be part of a vehicle driveline as is shown in FIG. 2 . The engine may restart, automatically stop, or be prevented from being automatically stopped as shown in the engine operating sequence shown in FIG. 3 . Vehicle brake system conditions illustrated in FIGS. 4 and 5 may be the basis for judging whether or not to automatically stop and/or start an engine. The method of FIG. 6 may operate an engine and driveline according to FIGS. 1 and 2 to provide the operating sequence shown in FIG. 3 .
Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Flywheel 97 and ring gear 99 are coupled to crankshaft 40 . Starter 96 includes pinion shaft 98 and pinion gear 95 . Pinion shaft 98 may selectively advance pinion gear 95 to engage ring gear 99 . Starter 96 may be directly mounted to the front of the engine or the rear of the engine. In some examples, starter 96 may selectively supply torque to crankshaft 40 via a belt or chain. In one example, starter 96 is in a base state when not engaged to the engine crankshaft. Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 . Intake cam 51 and exhaust cam 53 may be moved relative to crankshaft 40 .
Fuel injector 66 is shown positioned to inject fuel directly into cylinder 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width of signal from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). In addition, intake manifold 44 is shown communicating with optional electronic throttle 62 which adjusts a position of throttle plate 64 to control air flow from air intake 42 to intake manifold 44 . In one example, a low pressure direct injection system may be used, where fuel pressure can be raised to approximately 20-30 bar. Alternatively, a high pressure, dual stage, fuel system may be used to generate higher fuel pressures. In some examples, throttle 62 and throttle plate 64 may be positioned between intake valve 52 and intake manifold 44 such that throttle 62 is a port throttle.
Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of catalytic converter 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 .
Converter 70 can include multiple catalyst bricks, in one example. In another example, multiple emission control devices, each with multiple bricks, can be used. Converter 70 can be a three-way type catalyst in one example.
Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 (e.g., non-transitory memory), random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing force applied by driver 132 ; a measurement of engine manifold pressure (MAP) from pressure sensor 122 coupled to intake manifold 44 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 ; brake pedal position from brake pedal position sensor 154 when driver 132 applies brake pedal 150 ; and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
In some examples, the engine may be coupled to an electric motor/battery system in a hybrid vehicle. Further, in some examples, other engine configurations may be employed, for example a diesel engine.
During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is shown merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
Referring now to FIG. 2 , an example vehicle driveline 200 is shown. Vehicle driveline 200 includes engine 10 as shown in greater detail in FIG. 1 . Engine 10 may include one or more torque actuators 204 . Torque actuator 204 may be an engine throttle, variable camshaft, fuel injector, ignition system, or other device that may affect engine torque. Engine torque may be increased or decreased via operating the torque actuator.
Engine 10 provides torque to torque converter 206 via crankshaft 40 . Torque converter 306 hydraulically couples engine 10 to transmission input shaft 251 . Automatic transmission 208 includes a forward clutch 212 and gear clutches 210 . Mechanical pump 214 supplies pressurized transmission fluid to torque converter 206 , gear clutches 210 , and forward clutch 212 .
Driveshaft 253 directs torque from transmission 208 to vehicle wheels 291 . Force may be supplied to vehicle wheels via hydraulic or air brakes 290 . Hydraulic brake pressure or air pressure applies force to activate brakes 290 and may be observed or measured via brake pressure sensor 234 . Brakes 290 may be applied while vehicle 290 is moving, is desired to be held in a stopped state, and as holding or parking brakes. Additionally, hydraulic brakes 290 may be applied when inclinometer 271 indicates a road grade greater than a threshold road grade when vehicle 290 is stopped. Brake system pressure and vehicle incline information may be input to controller 12 .
Thus, the system of FIGS. 1 and 2 provides for a vehicle system, comprising: an engine; a brake pedal; and a controller including non-transitory instructions executable to inhibit automatic stopping of the engine in response to a driver applying the brake pedal a plurality of times without fully releasing the brake pedal once the brake pedal is applied during a vehicle stop. The vehicle system includes additional instructions to automatically restart the engine when the engine is stopped in response to the driver applying the brake pedal a plurality of times. The vehicle system further comprises additional instructions to reactivate an engine that is rotating without being supplied fuel in response to the driver applying the brake pedal a plurality of times. The vehicle system includes where applying the brake pedal a plurality of times includes increasing brake fluid pressure by more than a predetermined pressure. The vehicle system includes where applying the brake pedal a plurality of times includes moving the brake pedal more than a predetermined distance. The vehicle system includes where the predetermined distance varies with a distance the brake pedal is applied a first time since the brake pedal is fully released.
Referring now to FIG. 3 , an example prophetic engine operating sequence according to the method of FIG. 6 is shown. Vertical markers T0-T11 represent times of interest during the sequence. Further, the sequence of FIG. 3 may be provided by the system of FIGS. 1 and 2 .
The first plot from the top of FIG. 3 is a plot of vehicle speed versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents vehicle speed and vehicle speed increases in the direction of the Y axis.
The second plot from the top of FIG. 3 is a plot of brake pedal position versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents brake pedal position and the brake pedal is applied further (e.g., commanding more braking force) in the direction of the Y axis arrow.
The third plot from the top of FIG. 3 is a plot of brake fluid pressure (e.g., hydraulic or air) versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents brake fluid pressure and brake fluid pressure increases in the direction of the Y axis arrow.
The fourth plot from the top of FIG. 3 is a plot of engine operating state versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents engine operating state. An engine operating state value of zero represents an engine that is commanded to stop rotation. An engine operating state value of one represents an engine that is commanded to rotate and combust an air-fuel mixture.
The fifth plot from the top of FIG. 3 is a plot of an automatic engine stop enable flag or indicator versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents a state of an automatic engine stop enable flag or indicator and a value of one indicates that the engine start/stop system is at operating conditions where automatic engine stopping is desired. A value of zero indicates that the engine stop/start system is operating at conditions where automatic engine stopping is not desired. The automatic engine stop enable flag may be set to a value of one when the vehicle is stopped, the vehicle brake pedal is applied, and when the engine is warm to conserve fuel. The automatic engine stop enable flag may be set to a value of one when the vehicle is traveling downhill or decelerating when the driver demand torque is at a low level or during other selected operating conditions. In one example, automatic engine stopping is allowed when the engine is stopped rotating based on vehicle operating conditions without a driver operating a switch or device that has a sole purpose of starting/stopping the engine (e.g., an ignition switch).
The sixth plot from the top of FIG. 3 is a plot of accelerator pedal position versus time. The X axis represents time and time increases from the left side of FIG. 3 to the right side of FIG. 3 . The Y axis represents vehicle accelerator pedal position and the accelerator pedal position increases and indicates an increase in driver demand torque in the direction of the Y axis arrow.
At time T0, the vehicle speed is at a middle level and the brake pedal position indicates that the brake is not applied. The brake pressure is at a lower level indicating that no pressure is applied to the vehicle brakes. The engine is operating and rotating and the vehicle is not presently at conditions for automatic engine stopping as indicated by the automatic engine stop enable flag being at a level of zero. The accelerator pedal is at a lower level indicating a lower level driver demand torque.
At time T1, the brake pedal is applied and the brake pedal position increases to indicate that the brake pedal is being applied. The vehicle speed decreases and the brake pressure increases in response to the brake pedal being applied. The engine continues to operate and the automatic engine stop enable flag is not asserted. Additionally, the accelerator pedal is released near time T1 and the accelerator pedal position goes to zero in response to the driver decelerating the vehicle.
At time T2, the driver applies the vehicle brake pedal to a further extent for a second time without fully releasing the brake pedal as indicated by the brake pedal position increasing. The brake pressure also increases as the brake pedal position increases and the vehicle decelerates at a higher rate. The engine continues to operate and the automatic engine stop enable flag is not activated. By increasing the brake pedal position after the brake pedal has been initially applied, the automatic engine stopping may be inhibited or stopped. Alternatively, or in addition, the automatic engine stopping mode may be inhibited or stopped in response to applying the brake pedal a plurality of times without fully releasing the brake pedal. When automatic engine stopping is deactivated, the engine may not be stopped during conditions where the engine would otherwise be automatically stopped.
Additionally, in some examples, method 400 may deactivate automatic engine stopping in response to brake fluid pressure or brake line pressure instead of brake position. For example, if brake pressure increases in response to an applied brake pedal, and if brake pressure increases by a predetermined amount of pressure over the brake pressure when the brake pedal is first applied, automatic engine stopping may be inhibited.
At time T3, vehicle speed is zero, the brake pedal continues to be applied, the brake pressure is at a higher level, and the automatic engine stop enable flag is asserted to indicate that conditions are present to automatically stop the engine. However, the engine is not stopped as indicated by the engine operating state remaining at a higher level to show that the engine is operating. The engine is not stopped even though the automatic engine stop enable flag is activated since the brake pedal or brake pressure has increased by more than a threshold amount after an initial brake application. In other words, application of the vehicle brake and applying more than a threshold amount of pressure to the brakes acts as a signal or condition to bypass or ignore the automatic engine stop enable flag so that the engine is not automatically stopped.
The driver may purposefully apply the vehicle brakes one or more times without fully releasing the vehicle brakes to communicate with the engine controller that the engine is not to be automatically stopped at the present time. The driver may apply the brakes twice or several more times when the driver knows that rapid vehicle acceleration will soon be desired, or during other conditions when the driver wishes to inhibit automatic engine stopping. Consequently, the engine is not stopped at time T3 even though the driver demand torque as indicated by the accelerator pedal position is at a lower level and the vehicle is stopped.
At time T4, the driver releases the brake pedal in response to driving conditions and brake pressure is reduced in response to the released brake pedal. The engine continues to operate and the automatic engine stop enable flag transitions to a low level to indicate that the engine is not to be automatically stopped. The accelerator pedal is applied shortly after the brake pedal is released and the vehicle begins to accelerate. The engine may be automatically stopped after the vehicle begins to accelerate. Alternatively, the engine may be automatically stopped in response to application of the accelerator pedal or other conditions that may be the basis for clearing inhibiting of automatic engine stopping.
Between time T4 and time T5, the vehicle accelerates in response to the released brake pedal and accelerator pedal application. Further, the automatic engine stop enable flag is not asserted and the accelerator pedal is released by the driver near time T5.
At time T5, the driver applies the brake pedal as indicated by the brake pedal position increasing in response to the driver's desired to stop the vehicle. The brake pressure increases in response to the brake pedal being applied and the vehicle slows in response to the vehicle brakes being applied via the brake pedal. The automatic engine stop enable flag remains in a not asserted state and the engine continues to operate as the vehicle decelerates.
At time T6, the vehicle brake is applied to a further extent for a second time. However, the vehicle brake is not applied to an extent where the brake pedal position exceeds a threshold level beyond the position the brake pedal assumed after initial brake pedal application or to an extent that the brake pressure exceeds a threshold level beyond the brake pressure assumed after initial brake pedal application. Consequently, automatic engine stopping is not inhibited. The automatic engine stop flag is not asserted and the engine continues to operate as indicated by the engine operating state.
At time T7, vehicle speed reaches zero speed in response to the accelerator pedal being released and the vehicle brake being applied. Shortly thereafter, the automatic engine stop enable flag is asserted and the engine is stopped as indicated by the engine operating state transitioning to a low level. The accelerator remains not applied and the brake pressure holds the vehicle in a stopped position.
At time T8, the driver releases the vehicle brake pedal in response to vehicle operating conditions as is indicated by the brake pedal position being reduced. The automatic engine stop enable flag transitions to a lower level to indicated the engine is no longer to be automatically stopped. The engine operating state changes to a higher level in response to the automatic engine stop flag transitioning to a lower level and the engine is started by cranking the engine and supplying spark and fuel to the engine. Shortly thereafter, the driver applies the accelerator pedal to accelerate the vehicle. In this way, the automatically stopped engine is restarted.
At time T9, the driver releases the accelerator and shortly thereafter applies the vehicle brake pedal in response to vehicle operating conditions. The brake pressure increases in response to the increase in brake pedal position and the vehicle begins to decelerate as indicated by the vehicle speed decreasing. The automatic engine stop enable flag is not asserted and the engine operating state is at a higher level indicating that the engine is continuing to operate. The brake pedal position and brake pressure remain at steady values shortly after the brake is applied.
Between time T9 and time T10, the vehicle stops in response to the brake pedal being applied and the accelerator pedal not being applied. The engine remains operating and rotating and the automatic engine stop enable flag remains not asserted.
At time T10, the automatic engine stop enable flag transitions to a higher level in response to automatic engine stopping conditions being present. The engine operating state transitions to a higher level to indicate that the engine is commanded to stop rotating in response to the automatic engine stop enable flag being asserted. Thus, the engine is automatically stopped in response to operating conditions. Operating conditions may include but are not limited to vehicle speed equal to zero, time since vehicle stop greater than a threshold time, and vehicle brake being applied.
At time T11, the driver applies the vehicle brake to a greater extent to signal the engine controller that the driver wishes the engine to start. The driver may depress the brake pedal to a further extent to restart the engine based on conditions the driver observes (e.g., traffic lights changing state), or the driver's intent to start the engine for other purposes (e.g., start the engine to keep the cabin heater operating at a higher level). The engine is inhibited or prevented from stopping after the engine is restarted until the vehicle accelerates or another condition occurs.
In these ways, the engine may be automatically restarted and stopped from being automatically stopped in response to a driver applying a brake pedal. In this example, the driver applies the brake pedal to move the brake pedal more than a threshold distance or angle to inhibit automatic engine stopping or to restart the engine. In other examples, the driver may apply the brake pedal a predetermined number of times to inhibit the engine from automatically stopping or to restart a stopped engine.
Referring now to FIG. 4 , a plot of a first example of a way to inhibit automatic engine stopping or to activate automatic engine starting in response to brake pressure or force during a braking event is shown. The plot of FIG. 4 includes an X axis that represents time and time increases from the left to right side of FIG. 4 . The Y axis represents brake pressure or brake force. Brake pressure may be measured via a pressure sensor or estimated. Line 401 represents brake pressure versus time for initial brake application. Line 403 represents brake pressure versus time for a first example second brake application that provides greater than a threshold brake pressure and that is sufficient to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. Line 405 represents brake pressure versus time for a second example second brake application that provides less than a threshold brake pressure and that is not sufficient to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. Lines 405 and 403 may be in a same braking event as line 401 , but only one of line 405 and 403 may be present in the same braking event. Lines 405 and 403 are shown together to distinguish between different braking conditions. Vertical lines at T20-T22 represent times of interest during the sequence of FIG. 4 .
At time T20, the brake pressure is at a value of zero indicating that the brake pedal is not applied. The driver increases brake pressure at time T21 via applying the vehicle brake pedal. Brake pressure stabilizes at a constant level between time T21 and time T22.
At time T22, the brake pressure in line 403 is shown increasing a second time since time T20 during a second brake application from the level of line 401 . The second brake application occurs without the brake being completely released between the first brake application and the second brake application. The brake pressure in line 405 is also shown increasing a second time since time T20 during a second brake application from the level of line 401 . A pressure increase from line 401 to line 403 is represented by the length of arrow 404 . A pressure increase from line 401 to line 405 is represented by the length of arrow 402 . The length of arrow 406 represents a minimum pressure change from the brake pressure of line 401 that may be a condition for inhibit automatic engine stopping or initiating starting of an automatically stopped engine. Thus, arrow 406 represents a threshold pressure to be exceeded in order to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine.
In this way, line 403 shows a brake pressure increase that is greater than the brake pressure of line 405 . Consequently, the brake pressure of line 403 relative to the brake pressure of line 401 is sufficient to provide conditions to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. On the other hand, the brake pressure of line 405 relative to the brake pressure of line 401 is insufficient to provide conditions to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. The threshold pressure represented by arrow 406 may be adjusted for vehicle operating conditions and based on initial applied brake pressure that is present before a second brake application.
Referring now to FIG. 5 , a plot of a first example of a way to inhibit automatic engine stopping or to activate automatic engine starting in response to brake pedal or actuator position is shown. The plot of FIG. 5 includes an X axis that represents time and time increases from the left to right side of FIG. 4 . The Y axis represents brake pedal position. Brake pedal position may be measured via a pressure sensor or estimated. Line 501 represents brake pedal position versus time for initial brake application. Line 503 represents brake pedal position versus time for a first example second brake application that provides greater than a threshold brake position increase and that is sufficient to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. Line 505 represents brake pedal position versus time for a second example second brake application that provides less than a threshold brake position increase and that is not sufficient to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. Lines 505 and 503 may be in a same braking event as line 501 , but only one of line 505 and 503 may be present in the same braking event. Lines 505 and 503 are shown together to distinguish between different conditions. Vertical lines at T30-T34 represent times of interest during the sequence of FIG. 5 .
At time T30, the brake position is at a value of zero indicating that the brake pedal is not applied. The driver increases brake position (e.g., applies the brake pedal) at time T31 via applying the vehicle brake pedal. Brake pedal position stabilizes at a constant level between time T31 and time T32.
At time T32, the brake pedal position shown in line 503 increases a second time since time T30 during a second brake application from the level of line 501 . The second brake application occurs without the brake pedal being completely released between the first brake application and the second brake application. The brake position shown in line 505 is also shown increasing a second time since time T30 during a second brake application from the level of line 501 . A brake pedal position increase from line 501 to line 503 is represented by the length of arrow 504 . A brake pedal position increase from line 501 to line 505 is represented by the length of arrow 502 . The length of arrow 506 represents a minimum brake pedal position change from the brake position of line 501 that may be a condition for inhibit automatic engine stopping or initiating starting of an automatically stopped engine. Thus, arrow 506 represents a threshold brake pedal position to be exceeded in order to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine.
In this way, line 503 shows a brake pedal position increase that is greater than the brake pedal position increase of line 505 . Consequently, the brake pedal position increase of line 503 relative to the brake pedal position of line 501 is sufficient to provide conditions to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. On the other hand, the brake pedal position increase of line 505 relative to the brake pedal position increase of line 501 is insufficient to provide conditions to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine. The threshold brake pedal position increase represented by arrow 506 may be adjusted for vehicle operating conditions and based on initial applied brake pedal position that is present before a second brake application.
FIG. 5 also shows a second application of the brake pedal beginning at time T33 after the brake pedal is released. In particular, at time T33, the brake pedal is applied and the brake pedal position 509 begins to increase. The brake pedal position stabilizes between time T33 and time T34.
At time T34, the brake pedal position shown in line 509 increases a second time since time T33 during a second brake application from the level of line 509 . The second brake application after time T33 occurs without the brake pedal being completely released between the first brake application and the second brake application.
A brake pedal position increase from line 509 to line 513 is represented by the length of arrow 514 . A brake pedal position increase from line 509 to line 511 is represented by the length of arrow 512 . Lines 511 and 513 represent different brake applications after the brake application of line 509 in a same braking event. Lines 511 and 513 are shown together to distinguish between different braking conditions.
The length of arrow 514 represents a minimum brake pedal position change from the brake position of line 509 that may be a condition for inhibit automatic engine stopping or initiating starting of an automatically stopped engine. Thus, arrow 514 represents a threshold brake pedal position to be exceeded in order to inhibit automatic engine stopping or to initiate starting of an automatically stopped engine.
It may be observed that the change in brake pedal position at time T34 that enables inhibiting automatic engine stopping or initiating starting of an automatically stopped engine requires a shorter or smaller change in brake pedal position than the brake pedal position change at time T32 that inhibits automatic engine stopping or initiating starting of an automatically stopped engine. Thus, different threshold changes in brake pedal position may enable inhibiting automatic engine stopping or initiating starting of an automatically stopped engine at different operating conditions. One reason for allowing a smaller change in brake pedal position to enable automatic engine stopping after a brake pedal has been applied a distance is that the brake pedal force increases as the brake pedal displacement increases. Further, much higher force must be applied to the brake pedal for the brake pedal to move after the brake pedal has been applied to a greater extent as compared to when the brake pedal is applied to a lesser extent. Therefore, in this example, a shorter or smaller change in brake pedal position enables inhibiting automatic engine stopping when the brake pedal has been initially applied to a greater extent. A larger or greater change in brake pedal position enables inhibiting automatic engine stopping when the brake pedal has been initially applied to a lesser extent.
Referring now to FIG. 6 , a method for operating a stop/start engine is shown. The method of FIG. 6 may be incorporated in to the system of FIGS. 1 and 2 as executable instructions stored in non-transitory memory. The method of FIG. 6 may provide the operating sequence shown in FIG. 3 .
At 602 , method 600 judges whether or not the vehicle brake is applied. In one example, the vehicle brake may be determined to be applied based on brake pedal position. In other examples, the vehicle brake may be determined to be applied based on brake line or brake fluid pressure. If method 600 judges that the vehicle brakes are applied, method 600 proceeds to 604 . Otherwise, method 600 proceeds to 622 .
At 604 , method 600 judges whether or not conditions for an automatic engine stop are present. In one example, conditions for an automatic engine stop are present when vehicle speed is less than a threshold speed, the vehicle brakes are applied, and the engine temperature is greater than a threshold temperature. In other examples, conditions for automatic engine stop may be present when vehicle brakes are applied and driver demand torque (e.g., torque demanded by the driver via the accelerator pedal) is less than a threshold amount of torque. If method 600 judges that conditions are present for an automatic engine stop, the answer is yes and method 600 proceeds to 610 . Otherwise, the answer is no and method 600 proceeds to 606 .
At 606 , method 600 restarts the engine if the engine is already stopped rotating. The engine may be restarted via engaging the engine starter, rotating the engine, and supplying spark and fuel to the engine. Method 600 proceeds to 622 after the engine is restarted.
At 610 , method 600 judges whether or not a secondary brake application greater than a threshold is present. In one example, a secondary brake application after a first brake application during a same or single braking event of a vehicle deceleration may be determined via monitoring brake pedal position. In other examples, secondary brake application after a first brake application during a vehicle deceleration may be determined via monitoring brake line or brake fluid pressure. Thus, the vehicle driver may communicate with the automatic engine stop/start controller via application of a brake pedal or actuator.
In examples where a secondary brake application is determined via brake pedal position, different brake position change amounts for different initial brake positions may be the basis for determining whether or not a secondary brake application (e.g., where brakes are applied or brake pedal position is increased a second time after brakes are initially applied without the brakes being released) brake position change amount is greater than a threshold amount. For example, as shown in FIG. 5 , inhibiting automatic engine stopping or restarting an automatically stopped engine may be performed in response to a change in brake pedal position after a brake pedal is applied to a greater extent (e.g., time after time T34 in FIG. 5 ) in response to a smaller change in brake pedal position as compared to a change in brake pedal position after the brake pedal is applied to a lesser extent (e.g., time between time T31 and time T33 in FIG. 5 ).
Similarly, in examples where a secondary brake application is determined via brake pressure or brake force, different brake pressure change amounts for different initial brake application pressures may be the basis for determining whether or not a secondary brake application (e.g., where brakes are applied or brake pedal position is increased a second time after brakes are initially applied without the brakes being released) brake pressure or force change amount is greater than a threshold amount.
If method 600 judges that a secondary brake pedal position or brake force change is greater than a threshold amount, the answer is yes and method 600 proceeds to 614 . Otherwise, the answer is no and method 600 proceeds to 612 .
At 612 , method 600 judges whether or not there have been a plurality of brake applications after the initial brake application in a same or single braking event without the vehicle brakes being released. For example, method 600 may judge whether the brake pedal has been applied and partially released twice to indicate the driver's intent to inhibit automatic engine stopping or to automatically restart an automatically stopped engine. Similarly, method 600 may judge whether or not the brake line or brake fluid pressure has increased and subsequently decreased to a value greater than zero a predetermined number of times to indicate the driver's intent to inhibit automatic engine stopping or to automatically restart an automatically stopped engine. If method 600 judges that a plurality of brake applications (e.g., increasing brake force) have occurred while the vehicle brakes are activated, the answer is yes and method 600 proceeds to 614 . Otherwise, the answer is no and method 600 returns to 604 .
It should be noted that the engine may be automatically stopped while portions of the method of FIG. 6 are executing. The engine may be automatically stopped based on conditions such as vehicle speed, brake pedal application, and absence of driver demand torque.
At 614 , method 600 judges whether or not the engine is stopped or being stopped. The engine may determined to be stopped when engine rotational speed is zero. The engine may be determined to be being stopped if spark and/or fuel supplied to the engine is deactivated while the engine continues to rotate. If method 600 determines that the engine is stopped or being stopped, the answer is yes and method 600 proceeds to 620 . Otherwise, the answer is no and method 600 proceeds to 616 .
At 616 , method 600 inhibits or stops automatic engine stopping until automatic engine stop conditions are cleared or not present and subsequently are indicated and present. For example, automatic engine stopping may not be allowed after the brake pedal is applied a second time after an initial brake application and until the vehicle moves and later reaches zero speed. In another example, automatic engine stopping may not be allowed after a brake pedal is applied three times without releasing the vehicle brake until the vehicle brake is fully released and subsequently applied three times without the brake pedal being released.
Inhibiting automatic engine stopping causes the engine to continue to combust air-fuel mixtures even though conditions are present for automatic engine stopping. Consequently, the engine does not have to be restarted to accelerate the vehicle or to provide power to vehicle accessories. Method 600 proceeds to 622 after automatic engine stopping is inhibited.
At 620 , method 600 restarts or reactivates a rotating engine and inhibits automatic engine stopping until automatic engine stopping conditions are cleared or not present and are subsequently present. For example, if engine speed is zero, the engine is cranked and restarted by supplying spark and fuel to the engine. The engine may not be automatically stopped until automatic engine stopping conditions are present after automatic engine starting conditions have been cleared. In another example, the engine may inhibited from automatically stopping until the vehicle speed has increased to a value greater than zero and returned to a value of zero. In yet another example, spark and/or fuel may be supplied to an engine that is rotating to reactivate the engine and combust air-fuel mixtures in the engine. The reactivated engine may not be automatically stopped until automatic engine stopping conditions are not present and are subsequently present. In this way, a deactivated decelerating engine may be restarted in response to a driver applying a brake pedal. Method 600 proceeds to 622 after the engine is restarted or reactivated.
At 622 , method 600 supplies a limited amount of engine torque in response to a driver demand torque while the vehicle brakes are applied. For example, if the driver is applying vehicle brakes and requesting 75 N-m of torque, method 600 may supply 30 N-m of torque. If the driver is not applying the vehicle brakes, the engine output torque follows the driver demand torque. Engine torque is adjusted via adjusting engine spark, air amount, and fuel amount based on the driver demand torque and engine torque limits. Method 600 proceeds to exit after engine torque is adjusted.
Thus, the method of FIG. 6 provides for a method for operating an engine, comprising: inhibiting automatic engine stopping in response to a secondary application of vehicle brakes following an initial application of vehicle brakes, the secondary application of vehicle brakes occurring after the initial application of vehicle brakes and without vehicle brakes being fully released. The method includes where inhibiting automatic engine stopping causes the engine to continue combusting air and fuel mixtures during conditions where automatic engine stopping is otherwise allowed. The method includes where the secondary application of vehicle brakes following the initial application of vehicle brakes includes changing a brake pedal position by more than a threshold amount.
In another example, the method further comprises not inhibiting automatic engine stopping when changing the brake pedal position by less than the threshold amount. The method further comprises inhibiting automatic engine stopping in response to a plurality of brake applications of vehicle brakes while the vehicle brakes are activated. The method includes where the plurality of brake applications comprises depressing a brake pedal a plurality of times. The method also includes where vehicle brakes are fully released when the brake pedal is fully released.
The method of FIG. 6 also includes a method for operating an engine, comprising: inhibiting automatic engine stopping in response to a secondary application of vehicle brakes following an initial application of vehicle brakes, the secondary application of vehicle brakes occurring after the initial application of vehicle brakes and without vehicle brakes being fully released; and automatically restarting the engine in response to the secondary application of vehicle brakes. The method includes where the engine is restarted without engaging a starter while the engine is rotating. The method includes where the engine is automatically restarted from an engine stop.
In some examples, the method further comprises inhibiting automatic engine stopping until automatic engine stopping conditions are not present. The method further comprises inhibiting automatic engine stopping until a vehicle in which the engine operates moves and stops after inhibiting automatic engine stopping. The method includes where the secondary application of vehicle brakes includes moving a brake pedal is greater than a threshold distance. The method includes where the secondary application of vehicle brakes includes increasing brake fluid pressure greater than a threshold brake pressure amount. The method also includes where the brake pedal is required to move a predetermined distance that varies with a distance the brake pedal is applied a first time since the brake pedal is fully released to inhibit automatic engine stopping.
As will be appreciated by one of ordinary skill in the art, method described in FIG. 6 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used. Further, the described actions, operations, methods, and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the engine control system.
This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, 13, 14, 15, V6, V8, V10, and V12 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage.
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Systems and methods for improving operation of a vehicle are presented. In one example, automatic engine stopping is inhibited in response to a driver communicating a desire to not automatically stop an engine. The driver communicates intentions to allow or inhibit automatic engine stopping via a brake pedal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
An apparatus for improving the formation of textile lap is described. More specifically the improvements of the instant invention concerns the assembly of fibers and tufts into lap without the use of very high compression forces and the present associated massive machinery. Lap edge uniformity as well as total uniformity and smooth surface texture is achieved by compressing a column of open tufts and fibers in one direction without disturbing their arrangement in the other two plains.
2. Description of the Prior Art
Heretofore, the principal manner of lap forming was by collecting fibers and tufts on the surface of two rotating condensers. The loosely formed mat was peeled from the condensers and passed through a series of high compression rollers. Thus, the retention of the fibers and tufts into a lap was completely dependent upon the high roller compression forces.
Cross-sectional uniformity and both long and short term lap variation is dependent upon (1) the rate at which fibers and tufts are air transferred to the condenser collection chamber, and (2) the random manner in which the fibers and tufts are drawn to the surface of the condenser screen by negative air pressure within the condenser.
A number of variables which are difficult to control are inherent in the process. The non-uniformity of the vacuum pressure across the condenser screen and distribution of fiber and tufts within the condenser collection chambers are the more serious examples that contribute to the variation in cross-sectional lap weight. Long and short term variations are controlled by an averaging device that controls the amount (average thickness) of textiles being metered to the condenser chamber.
Since a conventional textile lap is produced by compressing fibers and tufts through a series of metal rollers as the textile merges from between condenser cylinders, it is the force of several very high successive compressions that is the sole means by which the lap is held together.
SUMMARY AND OBJECTS OF THE INVENTION
The instant invention relates to an apparatus for using belts and rollers to interlock fibers and tufts, and flatten the mixture into a uniform lap, and does not rely on high compression but a technique of kneading or massaging the fibers and tufts which being held and conveyed between belts passed around rollers.
Using the apparatus of the instant invention, one can achieve lap formation in a unique and unusual manner. Textile fibers can be caused to interlock by restraining the fibers between two belts in a state of moderate compression and at the same time impart a small longitudinal movement of one belt relative to the other in both directions a number of times. Fibers and tufts are held and continuously conveyed between two thin flexible belts. The belts with fibers in-between, passes between and around a series of fluted rollers. The flutes are of sufficient size so as to cause the belts with fiber sandwiched in-between to undergo reverse bending as it passes between the rollers. Additional reverse bending is achieved by a small roller whose radius approximates the flute radius of the larger belt conveyor rollers. The smaller roller oscillates upon the fluted surface of one of the larger rollers. The bending and reversal of the belt fiber sandwich causes the necessary kneading action to interlock the fibers into a lap.
It is the primary object of this invention to produce a superior lap.
It is another object of this invention to impart a smooth surface texture to the lap.
It is a third object of this invention to provide a means for varying the lap weight.
It is a fourth object of this invention to maintain uniform cross-sectional density up to the edge of the lap.
It is a fifth object of this invention to eliminate long and short term variations in lap density.
It is a sixth object of this invention to provide a means of forming lap with a simple, light-weight and low-cost machine with low energy driving force.
Other objects and advantages of this invention will further become apparent hereinafter and in the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric drawing showing fiber lap forming machine and guide entry chute.
FIG. 2 is an upper external view of the lap forming machine showing the relationship of the movable sides and the method of adjusting the rollers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Turning now to the preferred embodiment of the invention illustrated in FIG. 1, and FIG. 2, wherein individual fibers and small tufts 1 are deposited in a chute 2 and maintained at a suitable level by a sensing and control system (not shown). Chute 2, being a rectangle at the top or entrance end to a point of intersection with a first set of rollers 5 and 10. Opposing sides 2a and 2c, held in place by bolts 23, terminate at and are tangent to rollers 5 and 10, and are in close proximity to belts 3 and 4, and form a first set of adjusting tension rollers at the top or entrance end. Belts 3 and 4 thus form the lower section of two opposing sides of the chute which will direct and transport the incoming textile fibers and tufts. The other two opposing sides 2b and 2d, held in place by bolts 23, complete the upper rectangular section as well as extend down to the intersection or vertex point of belts 3 and 4 from the said tangential points, thus completing the side closures from the top of the rectangle to the point of belt intersection at rollers 6 and 7. The chute thus directs and confines the downward movement of the fibers and tufts, forming a column of fibers and tufts. This column of fibers and tufts within the chute is transported by the converging downward movement of belts 3 and 4 in the direction indicated by arrows A and B. Belts 3 and 4 with fibers and tufts 1 sandwiched in-between forms a lap between said belts which passes between roller 6 and compression roller 7. Belts 3 and 4 with fiber and tuft composition 1 sandwiched between, follows the under periphery of roller 7 and then goes between a first drive roller 8 and compression roller 7. Rollers 6,7,8, and 11, are fluted in a manner depicted by the drawing. Flutes 16 of the fluted rollers interact with each other in the same manner as gear teeth interact. This interaction causes belts 3 and 4 to follow a serpentine course as belts 3 and 4 pass between each set of rollers. The bending of belts 3 and 4 by flutes 16 causes the belts to take on a slight forward and back movement in relation to each other. It is this small displacement of belt 3 with respect to belt 4 during this moderate compression which causes the fibers and tufts 1 to interlock and remain in an apparent compressed state after exiting from the apparatus. This fiber interlocking is further increased as belts 3 and 4 pass around the upper periphery of roller 8 and between oscillating compression roller 9 which is driven by bell-crank drive 17. Oscillating roller 9, which is parallel to and adjacent roller 8, oscillates back and forth rapidly as belts 3 and 4 pass their point, resulting in a thorough massaging action on the tufts and fibers between belts 3 and 4. Belts 3 and 4 then pass between driving roller 8 and a second compression roller 11 where the belts separate and discharge the fiber and tufts composition 1 which is now in the form of a lap 21, ready for further processing. Belt 3 then follows the under periphery of roller 8 and then around the under periphery of roller 6 and back to the starting point at roller 5. Belt 4 follows the under periphery of roller 11 and then to tensioning roller 12 and around adjustable roller 10. Lap 21 is weight changeable by moving adjustable roller 5 and 10 toward and away from center of chute. The tension in belt 4 is maintained by tension roller 12. Wall 2a and 2c of chute 2 are likewise adjustable, being capable of movement toward and back from the center of the chute. Bell crank 17 and rollers 5,6,7,8,10,11, and 12, are suitably mounted in structural frame 19. Compression rollers 7,9, and 11, are mounted in movable bearing block 20, and held against rollers by spring and guide unit 15 thus forming a means of maintaining compression between the first and second rollers, the second and third rollers, and the third and fourth rollers.
The means 15,20, maintains comprssion between roller 7 and rollers 6 and 8 while the means 15,20, for roller 11 maintains compression between rollers 11 and 8.
All rollers turn in directions as indicated by arrows shown on FIG. 1.
FIG. 2 being an upper external view shows the relationship of the movable sides 2a and 2c and the method of adjusting rollers 5 and 10 corresponding amounts to achieve lap weight variation. Rollers 5 and 10 are mounted in bearing blocks 20 and are positioned by guide and adjusting screw blocks 22.
Sides 2b and 2d are slotted to allow sides 2a and 2c to adjust inwardly or outwardly toward and away from the center of the chute 1. This will allow for changes in the cross-sectional area of chute 1 and thus the density of the lap since it will feed greater amounts of fiber into belts 3 and 4 when the cross-sectional area is lessened and smaller amounts when the cross-sectional area is increased.
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An apparatus for pressing textile fiber and tufts into lap through the use of converging belts around and between compression rollers thus improving the uniformity and surface texture of the lap is disclosed. The device comprises a series of driven rollers, belts and compression springs uniquely arranged to transform open fibers and tufts into a uniform, compressed and homogenous lap.
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FIELD OF THE INVENTION
This invention involves a woven tape, especially a woven tape used for the trimming of a brassiere (bra).
BACKGROUND OF THE INVENTION
Woven tapes are extensively used in the textile industry and other aspects of daily life. It is particularly widely used in the garment industry. For example, existing bras need narrow elastic woven tapes for the trimming of the bra body or for the shoulder straps for fixing the bra.
In general, there are two ways to connect the shoulder straps with the bra body. One of the methods is to integrate the straps with the bra body by direct sewing. The position of the shoulder straps of this kind of bra is fixed and cannot be detached. This will frequently bring inconvenience to a user wearing a thin-strap vest or a bare top. Another method is to use a movable device, in that the bra body is equipped with shackles and the shoulder straps are sewed with “9”-shaped hooks, so that the shoulder straps can be detached from or hooked on to the bra body according to different needs in use. This kind of bra is commonly called a dual-purpose brassiere.
Although this kind of dual-purpose bra solves, to a certain extent, the problem of the exposure of the shoulder straps when wearing a thin-strap vest or a bare top, it is obviously inconvenient to users of different body shapes or different wearing needs, because the user can only choose between detaching or attaching the shoulder straps, but it is impossible for her to adjust the positions where the shoulder straps are attached to the bra body as she pleases according to the current need. In addition, the shackles are left on the bra body of the dual-purpose bra after the straps are detached, which affects the appearance of the bra. At present, there is no woven tape which can satisfactorily solve the above mentioned problem by allowing a user, when using wearing a bra incorporating such a woven tape, to adjust the positions where the shoulder straps are engaged with the bra body.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a woven tape for use as trimming of a brassiere, said woven tape including a body portion provided with a plurality of openings along its warpwise centerline.
This invention is aimed at providing a woven tape which can be used for the trimming of a brassiere, allowing the hooking positions to be changed as the user pleases.
Advantageously, the openings may be formed integrally with said woven tape by weaving.
Conveniently, a position for engagement with a hook may be constituted by two adjacent openings.
Suitably, said woven tape may include a plurality of said engagement positions.
Said body portion of said woven tape may advantageously be of a double-layer structure folded along said warpwise centerline. The body portion of said woven tape may conveniently be sealed on both sides.
Said double-layer structure may suitably have a bottom section which is a sealed double layer.
Said tape edge may be a single-layer woven tape, or a double-layer woven tape. Said woven tape may be an elastic woven tape, or a non-elastic woven tape.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of woven tapes according to the present invention will now be described, by way of examples only, with reference to the accompanying drawings, in which:
FIG. 1 shows the schematic structure of a shuttleless loom which can be used for production of a woven tape according to the present invention;
FIG. 2 shows double weft needles;
FIG. 3 shows a binding method with a single latch needle and without binder threads;
FIG. 4 shows a binding method with a double latch needle and without binder threads;
FIG. 5 shows a binding method with both a single latch needle and binder threads;
FIG. 6 shows a binding method with both double latch needles and double binder threads;
FIG. 7 shows an opened double-layer structure of a woven tape according to an embodiment of the present invention;
FIG. 8 shows the structure of a woven tape according to a further embodiment of the present invention;
FIG. 9 a is a cross-sectional view taken along the line A-A in FIG. 8 ;
FIG. 9 b is a cross-sectional view taken along the line B-B in FIG. 8 ;
FIGS. 10A and 10B are cross sectional views of a woven tape taken along the lines A-A and B-B in FIG. 8 , respectively, according to the present invention.
FIG. 11 shows the weaving structure of the double-ply structure shown in FIG. 8 ;
FIG. 12 shows the weaving structure of the openings shown in FIG. 8 ;
FIG. 13 shows the weaving structure of the hooking positions shown in FIG. 8 ;
FIG. 14 shows the weaving structure of the double-layer structure and the openings integrated with the hooking positions by weaving;
FIG. 15 shows a woven tape according to the present invention when in actual use;
FIG. 16 shows a bra body sewn with a woven tape according to the present invention, when engaged with the shoulder straps in a first configuration;
FIG. 17 shows the bra body shown in FIG. 16 engaged with the shoulder straps in a second configuration; and
FIG. 18 shows the bra body shown in FIG. 16 engaged with the shoulder straps in a third configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A woven tape according to the present invention may be elastic or non-elastic, and their manufacturing methods are similar. An elastic woven tape according to a first embodiment of the present invention will be described first below.
elastic woven tapes according to the present invention, and as shown in FIG. 8 , FIG. 9 a , FIG. 9 b , FIG. 10A and FIG. 10B , include a double-layer structure 11 . Along the upper section of the woven tape are alternately arranged openings 13 and hooking positions 14 , and along a lower section of the woven tape is integrally woven with a sealed double-layer section 12 which is to be sewn with the bra body. FIGS. 10A and 10B show cross sectional views of an elastic woven tape, taken along the lines A-A and B-B in FIG. 8 , respectively. As depicted in FIGS. 10A and 10B , the double-layer section 12 of one embodiment of the woven tape has open lower sides. The hooking position 14 is used for attachment with a “9”-shaped hook and the opening 13 is used for entry or exit of the hook. The double-layer structure 11 , sealed double-layer section 12 , openings 13 and hooking positions 14 are integrally formed with one another by weaving instead of sewing, so there are no joints between the parts.
The sealed double layer section can be woven into the form of a single-layer elastic tape, as shown in FIG. 9 a and FIG. 9 b , or be woven into the form of a double-layer elastic tape, as shown in FIG. 10 .
FIG. 1 shows a schematic view of a Swiss Muller Model NF shuttleless loom used in the production of a woven tape according to the present invention. The weaving of this woven tape is realized in the matched binding way by means of the weaving structure of the fabric. A binding method, which can be used in this invention, is described below. A double weft needles method, as shown in FIG. 2 , must be used for this woven tape and there are many binding ways, e.g. a way with single latch needle and without binder threads as shown in FIG. 3 .
A diagram showing the specific weaving structure of the double-layer structure 11 is shown in FIG. 11 , in which “X” means the warp yarn is above two weft yarns; “◯” means the warp yarn is between two weft yarns; and “□” means the warp yarn is underneath two weft yarns.
The specific weaving structure of the opening 13 is shown in FIG. 12 , in which “X” means the warp yearn is above two weft yarns; “◯” means the warp yarn is between two weft yarns; and “□” means the warp yarn is underneath two weft yarns.
The specific weaving structure of a hooking position 14 is shown in FIG. 13 , in which “X” means the warp yarn is above two weft yarns; “◯” means the warp yarn between two weft yarns; and “□” means the warp yarn is underneath the two weft yarns.
The weaving structure of the integrally woven double-layer structure, openings 13 , and hooking positions 14 is shown in FIG. 14 , in which “X” means the warp yarn is above two weft yarns; “◯” means the warp yarn is between two weft yarns; and “□” means the warp yarn is underneath two weft yarns.
The lengths of the openings 13 and hooking positions 14 can be decided according to the size of the hook.
The woven tape can be woven with characters, patterns, graphic designs, numerals or letters according to the demand of the market so as to enhance its appearance.
Woven tapes according to this invention can be extensively used in the textile industry and other industries, and are especially suitable for the trimming of a lady's brassiere. A woven tape according to the present invention may be engaged with a bra body 2 in various configurations and positions, as shown in FIG. 15 , FIG. 16 , FIG. 17 and FIG. 18 . When an elastic fabric according to this invention is sewn onto the upper edge of the respective cup of the bra body 2 , which seems not to be different in appearance from an ordinary bra. However, as the woven tape 1 has a number of hooking positions 14 and openings 13 , the bra is equipped with a number of hidden hooking positions 14 for engagement with the shoulder straps 3 . Shoulder straps 3 with “9”-shaped hooks 4 can be hooked onto the hooking positions 14 of the woven tape as the user pleases so as to adjust the wearing of the bra.
As shown in FIG. 16 , a user may hook the shoulder straps 3 in the positions close to the middle 21 of the bra body 2 . This arrangement suits a lady wearing a high-collar bare-top blouse. As shown in FIG. 17 , a user may also hook the shoulder straps 3 in positions close to both sides 22 of the bra body 2 . This arrangement is suitable for a lady wearing a wide-collar blouse. As shown in FIG. 18 , a user may remove one shoulder strap 3 , with only one should strap 3 left. This arrangement is suitable for a lady wearing a dress with one shoulder bare.
As the bra with the shoulder straps 3 removed has no shackles left on it, it still looks neat and beautiful, and is natural and comfortable to wear. In a nutshell, this invention is used for the trimming of a bra, so as to allow flexibility and convenience in using the bra, and various ways and modifications may be taken according to different needs of the user.
As shown in FIG. 4 , the binding method of double weft needles in combination with double latch needles without binder threads can also be used for weaving the woven tape. A side view of a woven tape resulting from this binding method is shown in FIG. 9 b , whose edge is of a double-layer structure.
In addition, such a woven tape may also be formed by a binding method with both a single latch needle and binder threads as shown in FIG. 5 , or a binding method with both a double latch needle and double binder threads, as shown in FIG. 6 . The binding methods are not limited to those mentioned above and a larger number of ways of binding can be used for working this invention.
According to a second embodiment of the present invention, and as shown in FIG. 7 , the sealed double layer section of a woven tape according to the present invention may be cancelled and the lower edge of the original double-layer structure 11 is not sealed. The double-layer structure 11 is opened to form a main body 10 of a single-layer woven tape. At this time, the openings 13 and hooking positions 14 are now located along the centreline in the warpwise direction of the main body 10 of the woven tape.
The method of weaving this woven tape is basically identical to that discussed above, namely the lower section of the double-ply structure is not sealed and integrated with the opening positions and hooking positions by weaving. The double-layer structure so formed is then spread into the main body of a single-ply woven tape. In use, the tapes are superposed to attach the hooks onto the hooking positions 14 .
It can be seen from the foregoing that a woven tape in accordance with the present invention is provided with a number of openings, (which serve as hook positions) which are integrally woven with the tape, and allow releasable engagement with hooks. Such simplifies the working procedure and reduces the number of seaming joints, thus reducing the possibility of loose ends at the seaming joints irritating the skin of a user. The hooks can be engaged with the openings according to the wish of the user, thus allowing change of locations of engagement of the hooks with the body of the bra. As these openings are hidden on the inner side of the bra, the bra remains simple and aesthetically pleasing. Such an arrangement allows the possibility of using or removing one or both of the shoulder straps, and allows the engagement of the shoulder straps at different locations of the bra body in accordance with the body shape and habits of the user, thus satisfying a large number of fashion needs of ladies.
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A woven tape for use as a trimming of a brassiere is disclosed as including a body portion provided with a number of openings along its warpwise centerline. An advantage in the use of a woven tape according to this invention as a trimming of a brassiere is that its position relative to the bra body can be adjustable, thus allowing choices to a user, and offering both enhanced convenience and aesthetic appearance.
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This is a continuation-in-part of my co-pending patent application Ser. No. 06/372,134, filed Apr. 27, 1982 abandoned.
BACKGROUND
This invention pertains to valves and in particular to dual valve devices utilizing a sleeve valve and a cooperating ball valve, a valve positioner and an operator for the valves.
PRIOR ART
When operating earth wells, it is highly desirable to have apparatus in the well which may operate to maintain pressure control and prevent "blowouts" by closing off well outflow near the producing formation and providing means to introduce heavy fluid into the well to "kill" the well.
One such system, herein incorporated by reference, is shown on p. 813 of the 34th revision of the "Composite Catalog of Oilfield Equipment and Services" and described as a "block-kill" system. This system requires numerous downhole devices such as a block-kill actuator, an actuator mandrel, control line, and a block-kill valve, which are operated by pressure in the well annulus.
The valve devices of the present invention replace all the numerous devices required in the above described system and operate to close formation outflow and open wall flow passages to allow killing fluid to flow into the tubing from the well annulus.
A valve device of this invention is installed in well tubing, above a packer and lowered into the well casing, where the packer is set above a producing formation, creating an annulus in the well and sealing between the formation and annulus. The formation is then in pressure communication with the tubing and flow passage through the valve device, and the well annulus is in pressure communication with flow ports in the valve device wall.
Two embodiments of the invention devices utilize a ball valve controlling flow through the device, connected to a sleeve valve, controlling flow through wall flow ports between the annulus outside the valve and the flow passage through the valve, and include a lock, locking the sleeve valve closed and the connected ball valve open. The lock is releasable in response to predetermined pressures. As the ball valve is opened and the sleeve valve is closed mechanically, an operating spring is compressed to furnish operating force.
The lock release in one of these embodiments is a spring loaded differential piston which is moved by greater pressure outside the valve device to compress a spring and release a collet type lock.
The lock release in the other embodiment utilizes a number of precharged bellows which respond to higher pressure outside the valve and operate to release a ratchet type lock.
One of these valves is then installed at the desired depth in the well and when annulus pressure outside the valve exceeds formation pressure inside the valve by a preset amount, the lock is released and the compressed spring closes the ball valve, closing off flow through, and opens the sleeve valve and wall flow passages to flow pumped in from the well annulus to kill the well.
A third embodiment of the valve device of this invention contains cooperating ball and sleeve valves, a lock locking the ball valve closed, a piston responsive to pressure, which is movable to compress an operating spring, release the lock, open the ball valve and close the sleeve valve. Pressured fluid is conveyed from the surface through a conduit to a sealed chamber above the piston. This device is operated in a well by increasing or reducing pressure in the conduit at the surface. This embodiment includes structure similar to that shown in U.S. Pat. No. 3,384,337 to N. F. Brown, herein incorporated for reference. When the ball valve of this embodiment of the present invention is locked closed, higher pressure in the valve body above or below the valve ball biases the seat away from the higher pressure into sealing engagement with the valve ball. Structure in the Brown patent biases the seat nearer the high pressure into sealing engagement with the valve ball.
The chamber in the third embodiment valve device could be pressured sufficiently on the surface and sealed to move the piston to compress the operating spring, release the lock, open the ball valve and close the sleeve valve. If this valve is installed in well tubing above a packer set in well casing, the piston would respond automatically to a predetermined higher pressure in the well annulus and release the compressed operating spring, to close the ball valve and tubing flow and open the sleeve valve to killing fluid flow, from the well annulus.
A ball valve device of the type shown in U.S. Pat. No. 4,140,153 to Deaton, herein incorporated by reference, is utilized in embodiments of the present invention. The ball valve could be of the type disclosed in U.S. Pat. No. 4,289,165 to Fredd.
All embodiments of the invention valve device may be reset to operate repeatedly while in place in a well.
An object of this invention is to provide an improved safety and kill valve which automatically operates when well annulus pressure is increased a predetermined amount.
An object of this invention is to provide an improved safety and kill valve wherein operating pressures may be preset.
An object of this invention is also to provide an improved block and kill valve which may be reset to operate repeatedly without retrieving from the well.
Also an object of this invention is to provide a safety and kill valve operable by conduit from the surface.
BRIEF DRAWING DESCRIPTION
FIGS. 1A and 1B together show an elevational view of an embodiment of the invention valve device, half sectioned, showing the valves positioned to operate after installation in a well.
FIGS. 2A and 2B together show a view of the valve device of FIGS. 1A and 1B after operation.
FIGS. 3A and 3B together show another embodiment of the dual valve device of the present invention in elevation, half sectioned, wherein the two valves are positioned to operate.
FIGS. 4A and 4B together show the valve device of FIGS. 3A and 3B after operation.
FIG. 5 is a fragmentary enlarged view of the lock mechanism of the embodiment of FIG. 3 in the locked position.
FIG. 6 is a fragmentary enlarged view of the lock mechanism of the embodiment of FIG. 3 in the unlocked position.
FIGS. 7A, 7B, 7C, 7D and 7E together show a half section elevation view of a third embodiment of the dual valve device of this invention, wherein the valves are in operating postion.
FIGS. 8A, 8B, 8C, 8D and 8E together show the valve device of FIGS. 7A, 7B, 7C, 7D and 7E after operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an invention valve device 10, locked in position for installation in a well, whereon is provided an appropriate top connection 11 and bottom connection 12 for connecting the valve 10 into a well pipe string to be lowered into a well. An internal profile 13 is provided in upper connector 14. The upper end of operator tube 15 is slidably received in upper connector bore 16. A downward facing shoulder 15a is provided on operator tube 15 to compress operating spring 17, and a longitudinal bore and flow passage 15b is provided therethrough. Upper connector 14 is connected to upper housing 18 at thread 19 and sealed with seal 20. Housing 18 is provided with internal shoulder 21 on opposite sides of which press operator spring 17 and piston spring 22. The lower end of piston spring 22 presses through ring 23 on the upper end of piston 24. A seal 25 is provided in internal shoulder 26 in lower housing 27 slidably sealing piston 24 to housing 27. At least one port 27a is provided in housing 27. A seal 28 is also provided for sealing upper housing 18 to lower housing 27 above their connecting threads 29. Another seal 30 in piston 24 slidably seals it to the outside of operator tube 15. An internal bore 31 is provided in the lower end of piston 24, and groove 32 is formed in the outside of operator tube 15. Collet 33 with arm lug portions 34 is installed over the upper end of insert 35 and retained thereon by set screws 36. Seal 37 slidably seals insert 35 to operating tube 15. Lower connector 38 is connected to lower housing 27 at threads 39 and sealed to insert 35 with seal 40. At least one port 41 is provided in operating tube 15. A chamfered shoulder 42 is formed on the lower end of insert 35, engageable by secondary valve surface 43a formed on seat member 43. Seat member 43 is connected to operator tube 15 with threads 44.
The construction and operation of ball valve device 45, housed in lower connection 38, is described in U.S. Pat. No. 4,140,153. The ball valve device 45 includes shoulder 42, seat member 43, control arms 46 fitted to ball member 47 in frame 48, seat 43b formed on the lower end of seat member 43, and shoulder 49 in lower connector 38.
FIG. 3 shows another embodiment of the invention valve device 50 utilizing a pair of bellows 51 with lower ends joined to body connector 52. The upper ends of bellows 51 are joined to ring 53. Ring 53 is secured to latch tube 54 with screws 55 when bellows 51 are in slots 56 provided for the bellows in latch tube 54. Bellows 51 and ring 53 may be gas pressure charged internally by loosening screw seals 57, opening passages 58 to admit pressured gas into bellows 51 and ring passage 53a, and tightening seals 57 to seal the charge in the bellows and passages. Slots 59 are cut near the lower end of latch tube 54 through which pawls 60 may engage teeth 61 on operating tube 65 (see also FIGS. 5 and 6). Pawls 60 are positioned in opposed slots 62 in the lower end of body connector 52 and are retained by and pivot around pins 63. Camming surfaces 64 and 66 are formed at either end of slots 59 to cam pawls 60 into and out of engagement with teeth 61. The lower end of latch tube 54 is enlarged to extend camming surface 66. A longitudinal flow passage 67 is provided through operating tube 65. An operating spring 68 biases operator tube 65 upwardly. At least one port 69 is provided in tube 65. A seal 70 slidably seals tube 65 in connector 72. At least one port 71 is provided in lower housing 73.
FIG. 7 depicts a third embodiment 74 of the block and kill valve device of this invention, preferred by the inventor, shown in ball valve open position and having an appropriate thread 75 in top connection 76. The top connection has an internal profile 77, a thread 78 for connection of a control conduit from suface or a plug and connecting flow passages 79 and 80. The lower end of the top connection is provided with a thread 81 connecting the top connection to upper housing 82. Resilient seal 83 seals the top connection to the upper housing. The upper end of upper operator tube 84 is slidably received in bore 85 in the top connection and sealed to it with resilient seal 86. Formed on the upper operator tube is a piston 87 slidably received in bore 88 in the upper housing and sealed to it with resilient seals 89. A variable volume chamber C, in communication with flow passage 80, is formed by seal 83, bore 88, seal 89, piston 87 and seal 86. A compressed spring 90 is positioned in the upper housing bore around the upper operator tube between lower piston surface 87a and internal shoulder 82a in the upper body.
An intermediate housing 91 is connected to the lower end of the upper housing with thread 92 and has at least one flow port 93. Upper operating tube 84 extends through a bore in the lower end of the upper housing and is connected to lower operator tube 94 with threads 95 and is sealed to the lower tube with resilient seal 96.
The larger outside of the lower operator tube is slidable into bore 91a in the intermediate housing and is sealed to the intermediate housing when inside by resilient seal 97. Also slidably mounted in bore 91a is dog carrier 98 to which are pivotally connected a number of dogs 99 by pins 100. Interrupting bore 91a is a recess 91b. The lower tube has a groove 94a and is provided with at least one port 94b. Carrier 98 is connected to an upper seat 102 with thread 103. The upper seat is slidably sealed in the upper housing by resilient seal 104. Bore 97a houses a spring 105 which receives an expander 106. An annular seat 102a is formed at the lower end of the upper seat and the annular upper seat is held in slidable contact with the outside sealing surface 107a on valve ball 107 by an opposed pair of control connections 108, each having a pin portion 108a protruding into holes 107b centered in flats on opposite sides of the valve ball. Control connections 108 are slidably housed in frames 109.
Connected to the intermediate housing with thread 110 is a lower housing 111. These housings are sealed together by resilient seal 112. Lower seat 113 has a annular seat 113a, formed in its upper end, which is also held in slidable contact with the outer sealing surface on the valve ball by the control connections. Connected to the lower housing with thread 114 is a lower connector 115, having an appropriate lower thread 116 for connecting into well tubing. Each frame is positioned in lower housing 111 between the lower end of intermediate housing 91 and the upper end of lower connector 115. Each frame has a pin 109a which protrudes into a slot 107c in each ball flat, eccentric to the holes for connector pins 108a. Longitudinal movement of the upper seat slides the valve ball, control connectors and lower seat in the frames, and the valve ball is rotated about pins 108a by stationary frame pins 109a, between open and closed positions. Resilient seal 117 slidably seals the lower seat in lower connector bore 115a and seal 118 seals the lower connector to the lower housing. The upper and lower seat diameters sealed by seals 104 and 117 are equal and smaller than the equal seal diameters of ball 107 on annular seats 102a or 113a. Longitudinal flow passage 119 extends through valve device 74.
One embodiment of the present invention may be preferred by a well operator depending on conditions in a particular well.
To utilize the embodiment of this invention shown in FIGS. 1 and 2, the valve 10, if not in running and operating position shown in FIG. 1, is placed in position on the surface by pushing down on the upper end of operating tube 15, to move operating tube 15 downwardly (disengaging valve 43a from shoulder 42), compressing spring 17, rotating ball valve 45 to open flow passage 15b to flow while moving ports 41 below seal 37 to close flow through ports 41. When groove 32 on tube 15 is opposite lugs 34, spring force in the collet arms 33 moves lugs 34 into groove 32 and compressed spring 22 moves ring 23 and piston 24 down and bore 31 over lugs 34 to lock lugs 34 in groove 32 and operator tube 15 and the valve 10 in running and operating position.
The valve 10 is then connected into a well tubing string above a packer and lowered to desired depth in the well where the packer is set in the well casing, sealing between the well annulus and formation. As ball valve 45 is open, two-way formation flow may occur freely through tubing and flow passage 15b, and no flow may occur through ports 41 as they are below seal 37. In the event pressure in the well annulus outside the valve 10 acting through ports 27a on the sealed differential piston area between the inside of seal 30 and the outside of seal 25 produces an upward force on piston 24 sufficient to overcome the combined downward forces of compressed spring 22 and force produced by pressure in flow passage 15b acting down on sealed differential piston area from the outside of seal 25 to the inside of seal 30, piston 24 moves up compressing spring 22. The rate of spring 22 may be preselected to determine a desired pressure difference between well tube pressure in valve flow passage 15b and greater well annulus pressure outside of valve 10 to move piston 24 up. Upward movement of piston 24 continues until bore 31 is above the upper end of lugs 34 unlocking lugs 34 to be moved out of groove 32. Compressed spring 17 maintains an upward bias on operating tube 15 sufficient to cam lugs 34 outward from groove 32 with cam surface 32a, releasing the tube 15 to be moved up until ports 41 are above seal 37 and in pressure communication with ports 27a, and ball valve 45 has rotated to close flow passage 15b and well outflow (FIG. 2). If required, fluid may be pumped down the well annulus through ports 27a and 41 into flow passage 15b and up in the well tube to a level sufficient to overcome well pressure on the lower side of the closed ball valve 45, "killing" the well.
To reposition the valve 10 to operating position, reopening ball valve 45 and closing ports 41 to flow, an appropriate tool may be lowered in the well tubing to contact the upper end of operator tube 15 and push it down to reposition valve 10 in locked operating position.
To utilize the embodiment shown in FIGS. 3 and 4, bellows 51 are pressure charged and sealed to a predetermined pressure and will automatically operate the valve device 50 in the well when pressure outside the valve is greater by a predetermined amount than pressure in bellows 51. If valve 50 is in the operated position as shown in FIG. 4, it must be repositioned to run and operate position as shown in FIG. 3 by pushing down on the upper end to move operator tube 65 down, "ratcheting" teeth 64 by pawls 60, compressing spring 68, moving ports 69 below seal 70, and rotating ball valve 45 open. The pressure charge in bellows 51 maintains the bellows extended and exerting a constant upward pull on latch tube 54. Cam surfaces 66 on tube 54 are constantly urging pawls 60 into engagement with teeth 64 on tube 65. Operator tube 65, therefore, is automatically locked in down position by pawls 60 engaging a tooth 64 (see FIG. 5). Ports 69 are now below seal 70 and closed to flow, and ball valve 45 is open for flow through flow passage 67, as shown in FIG. 3. The valve 50 is then connected in well tubing above a packer and lowered into the well to the desired depth at which the packer is set, sealing between the formation and well annulus. When well annulus pressure outside the valve 50, acting through ports 71 in housing 73 up through clearances between outside latch tube 54 and inside housing 73 and connector 52, overcomes the pressure charge in bellows 51, the well annulus pressure compresses and shortens the bellows and moves latch tube 54 down. Cam surfaces 66 are moved out of engagement with pawls 60 and cam surfaces 64 contact and cam pawls 60 around pins 63 out of engagement with teeth 61 (FIG. 6), unlocking tube 65 to be moved up by compressed spring 68. Upward movement of tube 65 moves ports 69 above seal 70 and rotates ball valve 45. Valve 45 has closed flow passage 67 to upflow and ports 69 are above seals 70 and open to flow through ports 71 into and up flow passage 67 as shown in FIG. 4.
An appropriate tool may later be lowered in the well tubing to engage the upper end of and move operating tube 65 down repositioning the dual valve 50 for repeated operation.
To install and use the block and kill valve embodiment 74 shown in FIG. 7 and 8, the variable volume chamber C of an operated valve (FIG. 8) may be pressure charged at the surface through flow passages 79 and 80 with a predetermined pressure and sealed by screwing an ordinary pipe plug into thread 78. The pressure charge acting on piston 87 operates and positions the dual valves for automatic operation in a well, when pressure exterior of the valve is sufficiently greater than pressure in valve device flow passage 119. If surface control of the operation of the valve device 74 is desired, chamber C is not pressure charged at the surface and a control conduit is connected to thread 78. The control conduit may be pressured at the surface to increase pressure in chamber C and operate the valve device.
The pressure charged or control conduit valve device 74 is then connected in well tubing above a packer and lowered into the well to the desired depth, where the packer is set to anchor and seal with well casing above a producing formation in the well and form a tubing-casing annulus above the packer.
Pressure in the well tubing-casing annulus, exterior of the pressure charged valve device 74, enters ports 93 and acts downwardly on the annular sealed area between seals 96 and 97 and also acts upwardly on the annular sealed area between seals 96 and 89. Seal 89 is larger than seal 97, so the net force is upward on operator tubes 84 and 94. Compressed spring 90 exerts an upward force on piston 87 and the operator tubes and the charged pressure in chamber C exerts a downward force on the piston. When annulus pressure exterior of the valve device is increased sufficiently to overcome downward forces on the operating tubes, the operating tubes move upwardly compressing the charge in chamber C, moving dogs 99, carrier 98, upper seat 102, control connections 108 and lower seat 113 while rotating valve ball 107 closed. The upward travel of the dog carrier, upper seat, control connectors and lower seat is stopped when the upper end of the connectors contact the lower end of intermediate housing 91 and valve ball 107 has rotated to close flow passage 119 to flow. At this time, dogs 99 are aligned with intermediate housing recess 91b and on continued upward movement of the operating tubes, the lower end of lower operating tube 94 disengages the upper end of expander 106 and releases spring 105 to push the expander inside the dogs expanding and locking them into engagement in recess 91b and valve ball 107 closed. Upward movement of the upper operator tube is stopped by the top side of piston 87 contacting the lower end of top connection 76. The lower operator tube has moved out of sealing engagement with intermediate housing seal and ports 94b are in pressure communication with intermediate housing ports 93 and the well annulus exterior of the valve device 74, as shown by FIG. 8. Well fluid of a gradient sufficient to overcome formation pressure may now be pumped from the well annulus through ports 93 and 94b into valve device flow passage 119. Closed valve ball 107 seals on annular seat 102 a or 113a effectively preventing higher pressure leakage in flow passage 119 from above or below the closed valve ball 107.
When the ball valve is locked closed, higher pressure in flow passage 119 above the valve ball acting on the sealed annular area between the larger upper seat seal diameter on valve ball 107 and smaller seal 104 biases the upper seat up. As there are very small operational clearances between movable parts, the upper seat is moved upwardly by the bias, out of sealing engagement with the ball, and minute flow may now occur through operational clearances between seat 102a and ball seal surface 107a and connectors 108 and ball 107, increasing pressure on the lower seat annular area between the larger lower seat seal on valve ball 107 and seal 117 and biasing the lower seat upwardly to sealingly engage lower seat seal surface 113a and ball seal surface 107a. The control connectors now prevent downward movement of the valve ball and lower seat, and forces tending to distort the valve ball are greatly reduced. If the higher pressure is below the locked closed valve ball in flow passage 119, the upper seat is biased into sealing engagement with the valve ball in a like manner, and the valve ball seals on the seat away from higher pressure and valve ball distorting forces are reduced. The pressure charged valve device will be automatically repositioned to operate on sufficient reduction of pressure exterior of the valve in the well annulus.
If surface operational control is desired for valve device 74, a control line is connected to thread 78 and the valve device with control line extending to the surface is installed in the well. With no pressure in chamber C, spring 90 closes valve ball 107 and opens ports 93 and 100 to flow between flow passage 119 and the valve device's exterior. Valve 74 may be placed in operating position as shown in FIG. 7 by pressuring the control line at surface. When pressure in chamber C and down forces are sufficient, the operating tubes are moved downwardly by piston 87, opening the ball valve for flow through passage 119 and closing ports 93 and 100 to flow between passage 119 and the valve device exterior. When operation of the control line valve device is desired, pressure in the control line is reduced or annulus pressure increased sufficiently for spring 90 to move the operating tubes upwardly, opening ports 93 and 100 to flow and closing passage 119 to flow and locking valve ball 107 closed. The control line valve device may be repositioned to operate by repressuring the control conduit at the surface or reducing pressure in the annulus.
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Disclosed is a safety and kill valve device useful in tubing above a packer set above a producing formation in a well, operable to shut off tubing flow and open wall flow passages to the well annulus through which heavy formation killing fluid may be pumped into the tubing. A lower ball valve is used to shut off tubing flow and an upper sleeve valve, cooperable with the ball valve, controls flow through the wall flow passage. An operating tube moves downwardly, opening the ball valve and closing the sleeve valve while compressing a spring. The compressed spring furnishes operating force to move the operating tube upwardly, closing the ball valve and opening the sleeve valve. Two embodiments operate automatically in response to higher well annulus pressures. Another embodiment may be controlled through conduit from the surface or operate automatically in response to higher annulus pressures. All embodiments may operate repeatedly without retrieving from a well.
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RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 USC 119(e) of U.S. Provisional Patent Application Nos. 61/272,436 and 61/245,333, both filed on Sep. 24, 2009, and of 61/232,494 filed on Aug. 10, 2009. The contents of the above applications are hereby incorporated by reference as if fully set forth herein.
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to a device for printing and, more particularly, but not exclusively to a high-speed printing machine for printing directly onto textiles including the application of print directly onto garments, built in a two dimensional matrix structure.
[0003] Screen printing and digital printing are both known methods in the art of garment printing. Mass production of garment decoration is performed today by screen printing press machines as described above, that are complex, inflexible, and require a specific set-up for each different print and color. First, an image file undergoes a mechanical spot-color separation process in which each color is printed in black and white on a separate sheet of paper or film. Then, the image is developed in a long optical process, into a fine mesh or screen, which is pressed during the printing process against the media. Before printing, each screen has to be set in the proper station and adjusted with reference to the other screens. Ink is transferred to the garment through the mesh by mechanical means, generally wiping a squeegee along the screen. Garment screen-printing technology requires a special press station for each color level.
[0004] Print quality is limited due to the high registration requirements between stations; hence printing resolution is relatively low. Thus, conventional screen-printing technology is not cost effective for short run processes, especially for sample printing stages.
[0005] In a simple screen printing operation the garment or cloth substrate placed on tray is first printed with one color, then moved to a next screen and printed with a second color, etc. To achieve high speed and high efficiency, a modern screen-printing machine has several stations, each station prints one color, and the printed substrates are moved in a sequence from station to station.
[0006] Digital printing employs a printing head having several ink injectors, each injector applying one color, so that a single printing head prints all the colors in a single operation. A controller moves the functional unit over the garment (or the garment may move under the functional unit) and instructs the ink injectors when to inject ink. To speed up the printing process, a digital printing system may employ several printing heads concurrently, and a printing head may have hundreds of injectors of the same color.
[0007] In screen printing, the fabrication of the screens and the setup of the printing machine, e.g. the mounting of the screens, is relatively slow and expensive. However, the printing itself is fast and inexpensive. Screen printing is therefore suitable for large product quantities. Screen printing can easily employ special colors and special effects such as glitter particles.
[0008] Digital printing creates images of higher spatial resolution (i.e. smaller pixel size) and higher color resolution (i.e. many more shades) of each color. The result is an image of much higher quality. Digital printing requires very short preparation prior to printing, however the printing itself is slow and inefficient relative to screen printing.
[0009] Printing processes often involve several stages. With textiles in particular, a pre-printing process such as a wetting process may be required; a post printing process such as ironing may be also required.
[0010] US patent application No 2005/0179708 A1 by Ofer Ben Zur, Published on Aug. 18, 2005 herein incorporated by reference discloses a digital printer having one digital printing head and two printing tables to allow loading and unloading of a garment as the other garment is printed. Thus down-time of the print head while the printing table is prepared is reduced or eliminated.
[0011] U.S. patent application Ser. No. 11/123,201 filled on 6 May 2005 by Feldman Alon et al, herein incorporated by reference, discloses a carousel printer for combining stencil and digital printing. The carousel allows for screen printing stations and digital printing stations together.
[0012] Digital garment printers, like the Brother GT541, that print directly on the garment are commonly used for short batches only.
[0013] However the fixed size of the carousel allows only for serial operation and requires a complete redesign for addition of stations to suit particular operations.
SUMMARY OF THE INVENTION
[0014] The present embodiments may provide an improved speed digital printing machine permitting accurate, high resolution printing on a substrate with relatively high efficiency, for decoration of garments and other rigid or flexible substrates.
[0015] The present embodiments may provide a printing matrix of modules arranged together. The matrix may thus combine required numbers of trays and printing stages on rails to allow flexible configurations for different printing operations.
[0016] A variation creates the matrix from printing modules in series and in parallel.
[0017] In such matrix structure, garments etc. to be printed may pass through each printing or accessory process in parallel, hence actual printing time is reduced.
[0018] Printing heads and other accessory process devices, hereinafter functional units, are provided as needed to each garment being printed on the matrix in a flexible manner.
[0019] According to one embodiment, the frame and matrix are made up of modular units assembled to build a customized configuration of the matrix in different matrix sizes such as 1×1, 6×4.
[0020] According to one aspect of the present invention there is provided a textile printing machine comprising a plurality of printing modules arranged in an m×n matrix, the matrix having a longitudinal direction and a transverse direction, the matrix having m first rails in said transverse direction for supporting printing functional units, and n second rails in said longitudinal direction for supporting printing trays that carry textiles to be printed, each module defining a meeting point between one of said first rails and one of said second rails for a textile printing related operation to take place, and wherein both m and n are integers of at least two, the matrix thereby providing linear printing sequences.
[0021] In an embodiment, said matrix is held together by a frame.
[0022] In an embodiment, said printing related operations comprise at least two of digital printing, screen printing, pre-printing and post-printing operations.
[0023] An embodiment may comprise a programmable controller, wherein each of said n transverse rails carries textiles for undergoing parallel printing sequences, and wherein said programmable controller comprises a process timer for ensuring that textiles on different ones of said transverse rails arrive at given stages of said parallel sequences at different times.
[0024] Embodiments may comprise a programmable controller, wherein each of said n transverse rails carries textiles for undergoing different printing sequences, and wherein said programmable controller comprises a process timer for ensuring that textiles on different ones of said transverse rails require the same functional units at different times.
[0025] In an embodiment at least one of m and n is at least three, or at least four or at least five or at least six.
[0026] In an embodiment, said textile printing trays are respectively independently controllable.
[0027] In an embodiment, one of said printing functional units is a digital printing head, wherein said inkjet nozzles further comprise drop-on-demand piezoelectric inkjet nozzles or continuous piezoelectric inkjet nozzles.
[0028] In an embodiment, one of said printing functional units comprises one member of the group consisting of an array of sprayers, a curing unit for curing ink on said item to be printed, an infrared curing unit, a hot air blowing curing unit, a microwave curing unit, an ironing unit for ironing said item to be printed, a stencil printing unit, an array of valve jet nozzles for performing digital printing, and a heat press.
[0029] According to a second aspect of the present invention there is provided a method for building a matrix for textile printing; comprising:
[0030] a. providing m first rails for bearing respective printing functional units and n second rails for bearing respective printing trays for holding a textile to be printed; and
[0031] b. Placing said first rail substantially perpendicularly to each of said second rails to form an m×n printing matrix therefrom, both m and n being integers greater than 1.
[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting.
[0033] The word “exemplary” is used herein to mean “serving as an example, instance or illustration”. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments.
[0034] The word “optionally” is used herein to mean “is provided in some embodiments and not provided in other embodiments”. Any particular embodiment of the invention may include a plurality of “optional” features unless such features conflict.
[0035] Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. This refers in particular to tasks involving the control of the printing equipment and printing operations.
[0036] Moreover, according to actual instrumentation and equipment of embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.
[0037] For example, hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to exemplary embodiments of method and/or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic hard-disk and/or removable media, for storing instructions and/or data. Optionally, a network connection is provided as well. A display and/or a user input device such as a keyboard or mouse are optionally provided as well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in order to provide what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0039] In the drawings:
[0040] FIGS. 1 a - 1 e which are simplified schematic diagrams illustrating the construction of a printing matrix as an extension of printing trays and printing function stages, according to embodiments of the present invention.
[0041] FIG. 2 is a simplified diagram illustrating embodiments of a two dimensional matrix;
[0042] FIG. 3 is a diagram illustrating a two-table printing module, of which the matrix is an extension; and
[0043] FIGS. 4 a - 4 c are respective side, front and top views of a two table one printing head printing module, of which the matrix is an extension;
[0044] FIGS. 5 a - 5 c are respective front side and plan views of a two table-two printing head matrix according to embodiments of the present invention; and
[0045] FIG. 6 is a diagram describing an exemplary printing scenario, using an embodiment of a two dimensional matrix.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] The present embodiments provide a matrix textile or garment printing machine which may combine a plurality of printing trays in parallel and a plurality of stages in series and in parallel to be useful for varying printing operations.
[0047] The principles and operation of an apparatus and method according to the present invention may be better understood with reference to the drawings and accompanying description.
[0048] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
[0049] Reference is now made to FIGS. 1 a - 1 e which are simplified schematic diagrams illustrating the construction of a printing matrix as an extension of printing trays and printing function stages, according to embodiments of the present invention. According to embodiments of the present invention, there is provided a first rail for bearing a printing functional unit and a second rail for bearing a printing tray for holding an item to be printed, the tray being mobile along the rail to bring the item in proximity with the functional unit. The first rail is optionally positioned at a lower level then the second rail. By a functional unit is meant a print head or a wetting unit or a curing unit or a unit for providing any other function required in garment printing of any kind. More generally the functional unit is a unit capable of providing printing or other operations related to printing. Operations include pre-printing operations, post-printing operations as well as the printing operations themselves. A pre printing function can be, for example, wetting the garment before performing digital printing. A post printing function can be, for example, a curing function. A print tray may travel along the second rail to meet different functional units for different stages of a printing operation, and likewise the printing functional unit can move along the first rail to provide the same operations to different print trays. The travel of the trays and the travel of the functional units is optionally controlled by a computer so that print tray and functional unit meet as intended and any programmed printing operation is carried out. The trays may have different sizes.
[0050] FIG. 1 a is a simplified diagram illustrating a module for a matrix according to one embodiment of the present invention. Matrix module 100 comprises first rail 101 for bearing a functional unit (not shown) and second rail 102 for bearing a tray (not shown). First rail 101 is orientated in the direction pointed by arrow 103 for allowing movement of the functional unit. Second rail 102 is orientated in the direction pointed by arrow 104 for allowing movement of the tray. The first rail may be placed substantially perpendicularly to the second rail. The functional unit may comprise an array of inkjet nozzles for performing digital printing, wherein each inkjet nozzle may be a drop-on-demand piezoelectric inkjet nozzle or a continuous piezoelectric inkjet nozzle. The functional unit may be for providing other operations related to printing, or for the printing itself. Thus functional units may be for preprinting or post printing, as discussed above. The functional units may be an array of sprayers, a curing unit for curing ink, an ironing unit for ironing the item to be printed, and a heat press. The curing unit can be an infrared curing unit, a hot air blowing curing unit or a microwave curing unit. The functional unit may be a printing unit, in which case it may be a stencil printing unit or a digital printing head, for example having an array of valve jet nozzles for performing digital printing.
[0051] FIG. 1 b is a simplified diagram illustrating two of the modules 100 fixed side by side to form printing matrix 200 . The matrix 200 comprises two rails 202 and 203 for bearing parallel trays (not shown) and one rail 201 for bearing a printing functional unit (not shown). Printing module 100 is illustrated in greater detail in FIG. 3 . The two-module printing matrix 200 is illustrated in greater detail in FIG. 4 . First rail 201 is orientated in the direction indicated by arrow 104 for allowing movement of the functional unit. Rails 202 and 203 are orientated in the direction indicated by arrow number 205 for allowing movement of the tray.
[0052] FIG. 1 c is a simplified diagram illustrating a four module matrix 300 having two rails for bearing trays and two rails for bearing functional units. Printing matrix 300 is illustrated in greater detail in FIGS. 5A , 5 B and 5 C, which are discussed below.
[0053] It should be noted that two rails for bearing trays and two rails for bearing functional units are shown for the purpose of illustration only and without wishing to be limited. In principle the matrix can always be built to any suitable size. For example and without wishing to be limited, adding a rail having an ironing unit provides the ability to perform an ironing stage before or after existing printing stages. Matrix for printing 300 comprises a rail 301 for bearing a printing functional unit (not shown), a further rail 306 also for bearing a printing functional unit (not shown) and two rails 307 and 308 for bearing printing trays (not shown).
[0054] FIG. 1 d is a simplified diagram illustrating another matrix for printing 400 . Matrix for printing 400 comprises a rail 401 for bearing a printing functional unit (not shown) and four rails 403 and 404 , 405 and 406 for bearing printing trays (not shown). It should be noted that one rail for bearing a functional unit is shown for the purpose of illustration only and without wishing to be limited and a matrix can be build with a plurality of rails for bearing functional units to more printing stages. The matrix can be built from any number of stages for bearing functional units to provide more garments or textile items to be printed asynchronously and to provide additional series of printing functions.
[0055] FIG. 1 e is a simplified diagram illustrating a matrix for printing 500 . Matrix for printing 500 comprises rails 501 and 502 for bearing printing functional units (not shown) and rails 506 , 503 , 508 and 513 for bearing printing trays (not shown).
[0056] Reference is now made to FIG. 2 , which is a simplified diagram illustrating an embodiment of a matrix 600 comprising a plurality of printing trays in parallel and a plurality of printing stages.
[0057] Matrix 600 features rail 601 for bearing functional unit 623 and functional unit 622 , rail 602 for bearing functional unit 621 and functional unit 620 , rail 603 for bearing functional unit 619 and functional unit 618 , rail 604 for bearing functional unit 617 and functional unit 616 , rail 605 for bearing functional unit 615 and functional unit 614 and rail 606 for bearing functional unit 612 and functional unit 613 . Matrix 600 also features rail 608 for bearing printing table (tray) 627 , rail 609 for bearing printing table (tray) 626 , rail 610 for bearing printing table (tray) 625 and rail 611 for bearing printing table (tray) 624 .
[0058] In the exemplary diagram the rails that carry the functional units widthwise across the matrix are referred to as transverse rails, and those that carry the trays along the sequence of functional units which make up the length of the matrix are referred to as longitudinal rails. Matrix 600 features a modular frame unit for holding the modules together.
[0059] The modular matrix printer is programmable so that operations can be varied. Furthermore the two different paths down the matrix may or may not carry out the same operation, depending on their programming.
[0060] The two or more rails in parallel may at times perform the same process. The actual printing time for an individual item is not shortened by having parallel rails for the same process. However a single digital printing head can get on with printing an item on one rail while an item on the other rail is being handled by pre printing or post printing processes, or is being set up on a tray. Thus the overall time for the total number of garments which are printed in parallel is shortened, and/or the utilization of the functional units is increased.
[0061] The different rails may alternatively be engaged on different printing processes at the same time.
[0062] FIG. 3 is a schematic diagram illustrating an embodiment of a printing module comprising one table and one functional unit. The module may serve as a building block for the matrix. Printing module 10 comprises a rigid frame 12 in which a linear motion X axis rail 14 is installed. According to one embodiment, X-axis rail 14 is a linear motor driven stage, and may be a conventional linear stage. Alternatively, X-axis rail 14 may be any other type of linear rail, such as a belt-driven rail, or ball screw driven rail. A printing table assembly 16 is connected to X axis rail 14 . Substantially perpendicular to the X axis direction, a linear motion Y axis rail 18 is installed above printing table assembly 16 , for example on a bridge 13 . Functional unit 20 is mounted to Y axis rail 18 by mounting 22 . The functional unit 20 may be a printing head, and may comprise an array of inkjet nozzles for performing digital printing, wherein each inkjet nozzle may be a drop-on-demand piezoelectric inkjet nozzle or a continuous piezoelectric inkjet nozzle. The functional unit may alternatively be for preprinting or post printing or other printing related activities. The rails in the X and Y axes can be provided using known-in-the-art products, for example, including linear rails marketed by THK Co., Ltd., Tokyo, Japan, a linear encoder such as that sold by RSF Elektronik Ges.m.b.H., Tarsdorf, Austria, and a moving plate supported on the rails.
[0063] According to a preferred embodiment of the invention, the X-axis rail 14 and the Y-axis rail 18 are linear motor driven rails. A printing table assembly 16 may be mobile along X axis rail 14 to bring garments or textile cloth or the like (not shown) in proximity with the functional unit. Printing module 10 is configured to be placed or fixed within a frame alongside other modules, by juxtaposing the rails to corresponding rails on other modules, to provide continuity of travel between the modules.
[0064] It is noted that during the printing process the functional unit generally scans over the item to be printed. However in one variation the functional unit is stationary over the item to be printed and the tray scans under the functional unit.
[0065] Referring now to FIGS. 4 a , 4 b and 4 c , respective side, front and top views of a two module matrix 110 according to an embodiment of the invention, and corresponding to FIG. 1 b , are presented. The matrix may be formed by placing two of the modules of FIG. 3 side by side and fixing within a frame. In the matrix of FIG. 4 two independent linear X axis rails 114 are installed side by side. A single Y axis rail 118 is substantially the same as Y axis rail 8 in FIG. 3 and is mounted on bridge 124 . Matrix 110 may accommodate two printing table assemblies 160 , and a functional unit 126 such as a printing head. The X axis rails may operate independently from one another, either on the same process or on different processes. The rather time consuming process of loading a garment on the printing tray, which may require careful folding, can be carried out on one printing table assembly at the same time that printing is being carried out on the second printing table assembly. As a result, the array operates substantially continuously, dramatically improving throughput of the machine. Each table can be accessed from the same edge, thereby permitting a single worker to operate two printing assemblies. A main computer may control both X axis rails for independent operation.
[0066] Reference is now made to FIGS. 5A , 5 B and 5 C which are schematic front, side and plan views respectively of a matrix printing machine according to an embodiment of the present invention and corresponding to FIG. 1C above. In textile printing machine 500 of FIGS. 5A to 5C are two X axis rails 502 and 504 , each with printing trays 506 and 508 respectively.
[0067] At right angles to the two X axis rails are two Y axis rails 510 and 512 . The two Y-axis rails each have respective functional units 514 and 516 , typically print heads or curing units or the like. Each functional unit can operate on either of the print trays 506 and 508 as required.
[0068] FIG. 6 is a simplified diagram describing an exemplary printing scenario, using an embodiment of a two dimensional matrix. The figure illustrates a scenario in which two trays are being used for performing asynchronous printing processes on two textile items or garments. The exemplary diagram shows two processes each using a different number of stages. Each process is of different length and takes a different amount of time. The two processes take place side by side, but may nevertheless share some of the functional units within the matrix. First of all, each garment is placed on a tray. Stages 1 - 7 describe a printing sequence carried out on an item (a garment or a textile) placed on tray 1 . In stage 1 , tray 1 is located below a screen printer, which prints a red color on the item to be printed. When stage 1 is completed, tray 1 moves to the next functional unit in line, which is another screen printer. In stage 2 , tray 1 is located below the second screen printer, which adds a blue color on the item to be printed. When stage 2 is completed, the tray moves to the next functional unit in line, which is a third screen printer. In stage 3 , tray 1 is located below the third screen printer, which adds a green color on the item to be printed. When stage 3 is completed, tray 1 moves to the next functional unit in line, which is a wetting unit. In stage 4 , tray 1 is located below the wetting unit, which wets the item to prepare the item for digital printing. When stage 4 is completed, tray 1 moves to the next functional unit in line, which is a digital printer. In stage 5 , tray 1 is located below the digital printer, which prints one or more digital images on the garment etc. When stage 5 is completed, tray 1 moves to the next functional unit in line, which is a curing unit. In stage 6 , tray 1 is located below the curing unit which cures the printed item.
[0069] Stages 8 - 12 are performed using tray 2 which holds a second garment etc. to be printed. Stage 8 is performed asynchronously to stages 1 - 3 . In stage 8 tray 2 is located below a further screen printing unit of a second series, which is now located over the horizontal rail carrying tray 2 . The further screen printer prints the item which is located on tray 2 in white. In stage 9 , a curing unit may be used for curing the item on tray 2 . When stage 9 is completed, the tray moves to the next functional unit in line, which is a wetting unit. In stage 10 , tray 2 is positioned below a wetting unit for wetting the item before performing digital printing. A single wetting unit may be shared by both processes, and use of the same wetting unit by each tray can be achieved by moving the wetting unit along its corresponding Y-axis rail.
[0070] When stage 10 is completed, the tray moves to the next functional unit in line, which is a digital printing unit for digital printing in stage 11 . The digital printing unit used for stage 11 may be the same as that used for stage 5 and the first tray.
[0071] After digital printing the tray moves to a curing stage 12 , and again the curing unit used may be shared with the first tray. In general, using a matrix of modules allows flexible printing processes which may use different numbers of stages, and which are able to share functional units. Variation is possible both by programming and by adding additional rails.
[0072] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.
[0073] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents, and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
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A textile printing machine comprises a plurality of printing modules arranged in an m×n matrix, the matrix having m first rails in a transverse direction for supporting printing functional units such as print heads, and n second rails in a longitudinal direction for supporting printing trays that carry textiles to be printed, each module defining a meeting point for a textile printing related operation to take place. The matrix size is at least two by two and provides flexible linear printing sequences that are able to share resources such as print heads.
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REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. Ser. No. 08/944,183, filed Oct. 6, 1997 and now U.S. Pat. No. 5,962,776, issued Oct. 5, 1999, which is hereby incorporated by reference. Reference is also made to U.S. application Ser. No. 08/944,471 of the same applicant filed at the same time as U.S. application Ser. No. 08/944,183.
FIELD OF THE INVENTION
The present invention relates to a method for producing liquid content-filled containers involving tightness testing of closed receptacles, at least partially filled with flowable filling, in which a pressure differential relative to the environment is produced between the receptacle interior and the receptacle environment, a test chamber which is closable in a vacuum-tight manner for practicing the method, as well as a test system with such a test chamber, and finally a tester with a plurality of the test systems.
BACKGROUND AND SUMMARY OF THE INVENTION
Tightness testing methods are known for closed containers in which a pressure differential relative to the environment is produced between the interior of the container and its surroundings, in a test chamber, by applying a suction source to the test chamber. Leaking containers are identified as follows: following application of a given pressure differential, a suction source required for the purpose is uncoupled from the test chamber and the change as a function of time in the pressure differential between the interior of the container and its environment is observed and/or recorded in basic fashion. This is accomplished for example by measuring the pressure values in the environment of the container at at least two points in time. Depending on the size of a leak, pressure equalization between the interior of the container and its environment proceeds faster or slower. Information on such a technique can be found for example in W094/05991 of the same applicant as for the present application.
The claimed procedure, especially according to the abovementioned W094/05991, makes it possible to detect extremely small leaks in containers. Problems arise when containers to be tested are filled at least partially with a flowable filling, especially with a leak between a liquid filling and the environment, and the effect of suction, if a leak is present, causes liquid filling to escape into the environment through the leak, in other words at the outside wall of the container. Because of the sealing action of the escaping liquid filling, a leak in a container wall area exposed to a fluid can only be detected, if at all, by measuring pressure for relatively long periods of time, which is highly disadvantageous especially when testing containers are arriving sequentially on a production line.
The goal of the present invention is therefore to propose a method of the species recited at the outset in which the disadvantages of the abovementioned pressure measurement test are eliminated. For this purpose, the said method according to the invention is characterized by the following: if, as in the case described above, liquid filling escapes to the exterior through a leak in the container wall because of the applied pressure differential, this is detected by an electrical impedance measurement as proposed by the invention.
The liquid filling escaping in the immediate vicinity of the outside wall of the container produces a change in the electrical impedance between at least one pair of impedance measuring electrodes applied in this area, and an impedance measurement makes it possible to detect the change in this impedance produced by the filling.
While it is appropriate in certain cases to determine the escape of the filling by measuring the electrical alternating voltage impedance, especially when testing containers with electrically insulating walls, like those with plastic walls, and fillings that are electrical conductors, it is proposed to perform DC and preferably low-voltage DC resistance measurement as impedance measurement, using for example DC voltages below 50 V.
Although in cases when very specific locations on the container/receptacle under test are to be tested for leaks, a single impedance-measurement location in the vicinity of the container section to be tested may suffice, it is also proposed to provide a plurality of impedance measurement sections connected in parallel and to arrange these along the container to be tested in order to detect leaks anywhere in the container.
This tightness testing method based on impedance measurement can now be combined according to the invention in a highly advantageous manner with the abovementioned pressure measurement test. Namely, when containers are to be tested which, as is usually the case, are only partially filled with flowable filling, so that basically there are air inclusions in the container in addition to the liquid filling, it is never certain where the air is located in the container and where the liquid is located. The fact that in addition to impedance measurement for differentiating between tightness and leakiness, the time curve of a pressure differential is recorded especially by tracking the pressure in an encapsulated container environment, regardless of whether air inclusions are present or where said inclusions are located at the moment in the container, whereby a combined determination of the leakage state of a container can be obtained: at those parts of the container wall currently exposed to the filling, the electrical impedance measurement is representative of leakage, while as far as the wall parts that are currently in contact with air inclusions are concerned, the pressure differential that is recorded is representative of leakage. Here again, the known highly precise technique from W094/05991 is used to distinguish between tightness and leakiness on the basis of the pressure differential that develops, wherein, after establishing a predetermined vacuum between the interior of the container and the encapsulated environment and after disconnecting the system from a vacuum source, the pressure in the encapsulated environment is recorded at at least two points in time and the pressure differential is evaluated as an indication of tightness. To create an extremely sensitive measurement method, at the first point in time, with the recorded pressure value stored as a reference signal, a zero-deviation signal is also measured and at the second point in time the pressure differential is recorded relative to the zero-corrected value for the first point in time. This makes it possible to amplify the abovementioned differential or the evaluation signal corresponding to this differential in order to achieve high resolution.
It is highly advantageous in this connection to evaluate a signal indicating the existence of an impedance differential by using the same method as for evaluating any pressure differential that develops.
A test chamber according to the invention for tightness testing of closed containers with flowable filling, comprises a test chamber closable in a vacuum-tight manner, at least one impedance-measuring section being provided in the test chamber. The impedance-measuring section has at least one pair of spaced electrodes. In a disclosed embodiment, a plurality of distributed electrode pairs is provided in the test chamber. The pairs are, preferably, connected in parallel. In one form of the invention, the chamber inside wall is formed by a pattern of electrically conducting electrode sections and insulating sections separating the electrode sections from one another. A further feature of the invention involves providing at least one pressure sensor on the test chamber. There is also at least one cleaning gas connection terminating in the chamber.
A test system with at least one such test chamber is defined according to the invention with at least one electrode pair of the test chamber being effectively connected with an impedance measuring unit. In one embodiment, the impedance-measuring unit is a DC resistance measuring unit, preferably a low-voltage resistance measuring unit. The distinction between non-leaking and leaking is made using a threshold-value-sensitive unit on an evaluation unit. The at least one test chamber has a plurality of electrode pairs which are connected effectively in parallel with the input impedance-measuring unit. The impedance-measuring unit comprises a threshold-value-sensitive unit on the output side.
The test system further comprises a pressure sensor on the test chamber. The output of the pressure sensor is actively connected with an evaluation unit that preferably records the output signal at a first point in time and also at a second subsequent point in time, and feeds the recorded pressure sensor output signals to a differential unit whose output acts on the threshold value-sensitive unit. The two inputs of the differential unit receive the output signal of the sensor recorded at the first point in time and a zero-differential signal is formed and stored as the output signal of the differential unit. Both the pressure sensor and electrode pair are effectively connected with the same evaluation unit which, preferably switchably, generates a signal as a function of the impedance at the electrode pair and the sensor output signal.
A highly advantageous design of this test system is achieved by virtue of the fact that in the most preferred version, with both an impedance measurement and a pressure measurement, one and the same evaluation unit is used. For example, if a DC voltage is applied across a measuring resistance and the voltage across the measuring resistance is evaluated as the measurement signal for impedance measurement in the section between the preferably several electrode sections connected in parallel, the evaluation unit is supplied with a voltage, namely the voltage that depends on the fixed measuring resistance and the current that varies with the measurement section resistance. The evaluation unit itself is then a voltage-measuring device. By switching to a pressure-measuring sensor provided on the test chamber, this same evaluation unit can be used to measure pressure-dependent sensor output voltage.
A tester of the type according to the invention comprises a plurality of the testing systems. A central impedance-measuring unit is provided for the testing systems. The unit is switchable to individual testing systems. A central evaluation unit is effectively connectable in a switchable fashion with pressure sensors of the test chambers of the test systems and their electrode pair. It is especially advantageous that an evaluation unit is provided centrally for pressure measurement by several test systems provided with at least one test chamber, and an evaluation unit is provided for impedance measurement, each unit being switchable between the test systems or a single evaluation unit being provided that can be switched between the individual test systems and each of the individual test systems can be switched between pressure measurement and impedance measurement.
The method according to the invention, the test chamber, the test system, and the tester are preferably used for producing liquid content-filled containers with electrically insulating walls, preferably glass or plastic walls, especially containers in the medical field, such as plastic ampoules. At the same time, the method is advantageously performed on several containers forming a set of containers, with leaks in one of these containers or one of these ampoules resulting in nonselective rejection of the entire set.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the figures.
FIG. 1 is a schematic view of a schematic diagram according to the invention, explaining the method according to the invention from its general aspect;
FIG. 2 is a schematic view showing the design of a test chamber and/or test system according to the invention for working the method according to the invention in a greatly preferred embodiment;
FIG. 3 is a preferred evaluation configuration of the system according to the invention and/or the method according to the invention according to FIG. 2;
FIG. 4 shows a preferred embodiment of an evaluation unit according to FIG. 3 in the form of a signal flow/function block diagram for processing the output signal from the pressure sensor or from the measuring resistance section;
FIG. 5 shows, in a simplified perspective view, an embodiment of the test chamber according to the invention for testing sets of ampoules, with only half of the test chamber according to the invention being shown, and
FIG. 6 is a schematic view of a signal flow/function block diagram of a tester according to the invention in the preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
According to FIG. 1, between interior I and the environment U of a container 1 to be tested, a pressure differential Δ p , is created relative to environment U. In the vicinity of the outside wall of the container, at least one impedance measurement section is provided, with several being provided according to FIG. 1, as indicated by the complex impedances Z x . The impedance measurement sections are each formed between a pair of measuring electrodes 3 a and 3 b , said electrodes being electrically connected alternately with conductors 5 a and 5 b as shown schematically. As a result, impedance measuring sections Z x are connected in parallel between leads 5 a and 5 b . Tap leads 5 a and 5 b are connected to an impedance measuring unit 7 whose output acts on a threshold-value-sensitive unit 39 . If a leak causes a filling liquid to escape from container I into environment U, at least one of section impedances Z x changes as a result. The impedance or the change therein is detected by impedance measuring unit 7 . If the impedance changes by more than the specified amount as indicated by at least one threshold value on unit 39 , the container 1 just tested is considered to be leaking and is discarded.
Although, depending on the application, very complex alternating voltage impedances in impedance measuring sections can be detected and evaluated by means of unit 7 , in a far more preferable manner and especially for testing containers with electrically insulating walls and with electrically conducting fillings, impedance measurement is performed as a DC resistance measurement, with impedance measuring unit 7 being actually used as an ohmmeter.
As will be explained later on with reference to FIG. 2, the method explained in principle in FIG. 1, based on impedance measurement, can be combined in a highly optimum fashion, and also with considerable significance for the present invention, with a previously known tightness testing method, considered separately, based on pressure measurement.
According to FIG. 2, a test chamber 9 according to the invention for accommodating container or containers 1 , comprises at least two parts, preferably an upper and a lower half, as indicated schematically by 9 o and 9 u . Test chamber 9 together with the container I it contains defines an encapsulated container environment U. On the wall of interior chamber 11 inside the test chamber, a pattern of electrically conducting surfaces is provided that forms electrodes 3 b and 3 a according to FIG. 1 . Of course, electrodes 3 a and 3 b are separated from one another by insulating wall material. As a result, regular distribution of impedance measurement sections over the entire test chamber interior is preferably provided directly along container 1 .
In addition, at least one pressure sensor 13 shown schematically in FIG. 2 is provided that is in an active relationship with the interior of the test chamber. It measures the pressure P u that prevails in this interior, corresponding to environment U. Following insertion of container 1 to be tested, preferably with an insulating wall, the test chamber is sealed and the pressure differential Δ p plotted in FIG. 1 is created by means of a pump 15 for example. Usually the container wall then presses tightly against electrode area 3 a and 3 b at the inside wall of test chamber 9 . If liquid filling F in a wall area of container 1 escapes, as shown schematically at 17 , the impedance between the associated electrodes 3 a and 3 b changes, and this is detected by impedance-measuring unit 7 ′, preferably designed as an ohmmeter. Detection is performed at threshold value unit 39 ′ to determine whether the measured resistance changes by at least a predetermined threshold value. If so, the container just tested is then declared to be leaky. Areas G of the container filled by air inclusions undergo a pressure rise in environment U if a leak is present in these areas, as a result of the pressure equalization between area G and environment U that takes place through the leak. This pressure change is detected by a pressure-measuring unit 19 connected with sensor 13 , with the output signal from said unit 19 being fed to another threshold-value-sensitive unit 21 . Preferably, the ambient pressure is measured at a first point in time t 1 and, after a predetermined time interval, at a later point in time t 2 , and the resultant pressure differential Δp u is recorded. If this differential falls below a threshold value set on threshold value unit 21 , container 1 under test will be deemed to be leaky. The wall of the test chamber interior chamber is then advantageously designed in such fashion that when the pressure differential causes the wall of the container to press against this wall, a continuous ambient space 23 extends around container 1 . This is accomplished basically by supports shown individually at 25 , which are most preferably produced by roughening inside wall 11 . This creates a situation in which, completely independently of where areas G and F are located in the container, tightness is always detected throughout the container. As far as the technology is concerned, in order to ensure that there is a continuous ambient space 23 despite the pressing of the container wall against the inside wall of the chamber, reference is made to EP-A-0 379 986 of the same applicant.
While in the embodiment according to FIG. 2 one evaluation unit 7 ′ is provided for impedance measurement and another is provided for pressure differential recording, 19 ; according to FIG. 3 a single evaluation unit 197 is preferentially provided. Basically, this is made possible by the fact that the same measuring signals are made available for impedance measurement and measurement of the output signal from pressure sensor 13 . According to FIG. 3, this can be accomplished for example by connecting measurement sections 3 a / 5 a and 3 b / 5 b corresponding to the resistance to be measured, shown in FIG. 3 as R x on the one hand with DC voltage source 27 , preferably in the low voltage range, for example 15 V, and on the other hand to a measuring resistance R M . The evaluation unit 197 , in this case designed as a voltmeter, is alternately switched on the input side by means of a manually or automatically operated switch 29 to the output of sensor 13 and measuring resistance RM. In one case, it measures the output voltage of sensor 13 , and in the other case it measures the voltage as a function of Rx at measuring resistances R M , U M .
As far as the pressure-measuring technique employed is concerned, reference is made in full to the abovementioned W094/05991. The evaluation unit described therein, however, as shown in the present case in FIG. 4, in accordance with the procedure shown in FIG. 3, is also used for highly accurate impedance and/or resistance measurement. The output signal from sensor 13 or from measuring resistance R M , or from the resistance-measuring section in general is supplied to a converter stage 121 that has an analog/digital converter 121 a on the input side followed immediately downstream by a digital/analog converter 121 b . The output e 1 0 digital/analog converter 121 b is supplied to a differential amplifier unit 123 constructed in known fashion, in the same way as the output signal e 1 from the pressure- and resistance-measuring devices 13 and Rm. The output of differential amplifier unit 123 is connected to an additional amplifier stage 125 whose output is superimposed through a storage element 127 on the input signal to amplifier 125 , at 128 . Converter unit 121 , like storage unit 127 , is controlled by a clock 129 . With this arrangement, pressure differential, impedance differential, and/or resistance differential measurement can be performed. For resistance measurement, at a first point in time, the measuring voltage is applied through converter unit 121 and simultaneously, possibly through an additional converter unit 122 b via switch S 1 , to both inputs of amplifier unit 123 : ideally, a zero signal appears on the output side of amplifier 123 . If a signal appears that differs from zero, this signal value is stored in storage unit 127 as a zero compensation signal. If the resistance measurement is repeated again at a later point in time to form a resistance differential signal, the value stored previously in storage unit 127 acts as a zero compensation signal and the value stored in unit 121 serves as the reference signal. Thus, a level of amplification that drastically increases resolution can be set on amplifier unit 125 . This same zero compensation principle is used in pressure differential measurement at two points in time, as described in detail in W 0 94/05991. Storage unit 127 is appropriately designed to store both a resistance-differential zero-compensation signal and a pressure-differential zero-compensation signal, with unit 121 being duplicated for storing the assigned reference values. Depending on whether the measurement cycle is measuring pressure or resistance, the assigned compensation signal value is switched to differential unit 128 or the assigned reference signal value is stored and/or switched to the corresponding unit 121 as shown by ref 1 in FIG. 4 .
In FIG. 5, in a simplified perspective view, one half 9 a or 9 b of the test chamber is shown, especially designed for testing sets of ampoules, like those used especially in medical technology. The sets of ampoules are placed in the roughened recess 30 provided for the purpose and then chamber 9 is sealed by applying a second chamber half. As shown, the chamber is composed for example of conducting strips 34 separated with a sealing action from one another by insulating material 32 , into which strips recesses 30 are machined. As a result, on the inside walls of recesses 30 , a continuous pattern of impedance-measuring electrodes is produced. These electrodes are connected alternately with conducting leads 5 a and 5 b as shown.
FIG. 6 shows the preferred design of a tester according to the invention with reference to a signal flow functional block diagram as disclosed in the aforementioned U.S. application Ser. No. 08/944,183. It comprises a plurality of test chambers 9 , whose pressure sensor and impedance section outputs, marked 13 and Rm in FIG. 6, are each guided to switching units 36 . Sequentially, these inputs are connected to one output of units 36 , said unit being connected to an actual multiplexer unit 38 . On multiplexer unit 38 , the inputs supplied by units 36 are preferably selectively connected to an evaluation unit 40 designed as shown for example in FIG. 4. A time-control unit 50 controls the chamber-specific switching cycles—pressure sensor/impedance measurement—and on multiplexer 38 , the connection of the individual test chambers 9 to unit 40 that serves as the impedance and pressure evaluation unit. In this way it is possible, optimally with fewer electronic units, to determine the tightness of containers in several test chambers 9 and on the basis of impedance and pressure measurements, i.e. independently of whether liquid-filled or gas-filled volumes are in respective containers 1 and if so, where they are.
In addition, preferably at least one cleaning gas line 35 (FIG. 5) is provided in test chamber 9 to blow out the test chamber and dry it after testing a leaking container.
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In order to obtain a reliable idea of the state of tightness for tightness testing of containers filled with liquids in which a pressure differential Δp is created between the interior of the container and its exterior, and also relative to the container wall in contact with the filling, an impedance measurement ( 7 ) is performed using measuring electrodes ( 3 a , 3 b ) on the exterior of container ( 1 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for applying a liquid agent (such as photoresist and passivation) on a surface of a substrate (such as a semiconductor substrate, a ceramic substrate, a glass substrate or the like) while supporting the substrate by a spinchuck and while rotating the spinchuck in a cup which prevents the liquid agent from scattering. In particular, the present invention relates to an apparatus in which liquid agent which would otherwise adhere to the inside of the circumferential wall of the cup or to a member for regulating air flow in the cup can be efficiently rinsed.
2. Description of the Related Art
An apparatus of this kind is generally referred to as a "spinner". A spinner, as is well-known in the art, is used in a photoresist applying process, a developing process, an etching process and the like.
In the above described processes, when the liquid agent is applied to a rotating substrate, the liquid agent tends to adhere to the inside of a circumferential wall of the cup, to a member for regulating air flow in the cup and to other members. When the liquid agent adhering to the inside of the circumferential wall dries out and cakes, it changes into fine powder dust and scatters in the cup due to vibration of the rotating substrate, or the like. The scattered dust adheres to a surface of the substrate being processed, and thereby reduces production yield.
A spinner which is disclosed in Japanese Utility Model Application Laid Open No. 58-40275 is designed to eliminate the above-described disadvantage. Referring to FIGS. 1 and 2, the apparatus includes a cup 101 for preventing treatment solution from scattering and a spinchuck 110 provided at the center of the cup 101 for supporting a substrate W and for rotating the same. The cup 101 surrounds the spinchuck 110 and includes a circumferential wall 103 for preventing the treatment solution from scattering. A bottom wall 105 is located below the spinchuck 110 for receiving the dropping treatment solution.
The bottom wall 105 includes a ring-shaped bottom plate 106 protruding toward the center of the bottom wall 105 and a slant bottom surface 107 for catching the dropping treatment solution and for letting the same flow in the direction of the bottom plate 106. The bottom plate 106 has a ventilation duct 118 and a drain 119 for waste liquid. The slant bottom portion 107 is horn-shaped with a slant surface 116. A peripheral portion of the bottom portion 107 is connected to the bottom plate 106. The central portion of the bottom portion 107 is located near the top of the spinchuck 110.
The apparatus further includes a ring-shaped rinse agent conduit 117 provided around an upper edge portion of the slant bottom portion 107 for supplying rinse agent on the slant surface 116, and a ring-shaped rinse agent conduit 104 provided on an inner surface of an upper portion of the circumferential wall 103 for supplying the rinse agent on the inner surface of the circumferential wall 103.
In operation, the substrate W is fed to the spinchuck 110 by a substrate transporter (not shown) and is supported on the spinchuck 110 by vacuum suction or the like. After a nozzle (not illustrated) supplies photoresist to an upper surface of the substrate W, the spinchuck 110 is rotated by a motor (not illustrated) at a high speed. Excess photoresist is scattered around the substrate W by centrifugal force such that a uniform photoresist layer is formed on the upper surface of the substrate W.
The photoresist scattered around the substrate W adheres to the inner surface of the circumferential wall 103, to the slant surface 116 and the like. The conduit 104 supplies organic solvent to the inner surface 108 of the circumferential wall 103. The photoresist dissolves in the organic solvent and goes down toward the bottom plate 106 along the inner surface of the circumferential wall 103.
The conduit 117 supplies the organic solvent to the slant surface 116 of the slant bottom portion 107. Photoresist adhering to the slant surface 116 dissolves in the organic solvent and flows down the slant surface 116 toward the bottom plate 106.
A slope is formed on the upper surface of the bottom plate 106 for flowing waste liquid toward the drain 119. The waste liquid flows to the drain 119, from which it is externally discharged.
The air in the apparatus is forcibly discharged from the ventilation duct 118 to the outside.
The organic solvent is continuously supplied to the inner surface 108 of the circumferential wall 103 and the slant surface 116 through the rinse agent conduits 104 and 117, thereby preventing the photoresist from adhering to the inner surface 108 and the slant surface 116. Thus, the photoresist cannot dry to the surfaces 108 and 116, turn into fine dust and scatter around in the cup to adhere to the substrate W.
However, the conventional apparatus cannot completely eliminate the disadvantages of the prior art. Namely, the rinse agent is not supplied around the conduits 104 and 117. As a result, liquid agent adhering to the conduits 104 and 117 is never rinsed therefrom. The liquid agent adhering to the conduits 104 and 117 soon dries out and turns into powder, which is scattered in the cup and adheres to the substrate W. If this disadvantage were overcome, production yield would be improved.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide an apparatus in which liquid agent is applied more efficiently to a substrate, thereby increasing production yield.
Another object of the present invention is to increase production yield by reducing particles of dried liquid agent scattering in a cup.
Another object of the present invention is to provide an apparatus in which liquid agent adhering to the inside of a cup and drying out can be reduced.
Another object of the present invention is to further reduce drying liquid agent by rinsing more of the liquid agent.
Another object of the present invention is to prevent liquid agent from adhering to a rinse agent conduit provided in a cup.
The present invention relates to an apparatus for applying liquid agent to a substrate, the apparatus including: (a) means for supporting and rotating a substrate; (b) means for applying liquid agent to the substrate while rotating the substrate; (c) a cup member for preventing liquid agent from scattering, the cup member including a circumferential wall, the circumferential wall including an inner circumferential surface and an upper portion, the upper portion of the circumferential wall including an inner surface and an outer surface, the inner surface of the upper portion including a plurality of openings; (d) first cleaning agent supplying means for supplying cleaning agent to the inner circumferential surface of the circumferential wall by supplying cleaning agent through the openings, the cleaning agent supplying means being ring shaped, the cleaning agent supplying means being integrally formed on the outer surface of the upper portion of the circumferential wall; (e) a slanted member with a slanted upper surface for regulating and guiding air, liquid agent and cleaning agent downwardly through the cup member, the slanted surface being lower than the supporting means, the slanted surface including an upper portion, the upper portion of the slanted surface including a plurality of openings, the slanted member including a lower surface and a lower edge, the lower surface including an upper portion; and (f) second cleaning agent supplying means for supplying cleaning agent to the slanted surface by supplying cleaning agent through the openings of the slanted surface, the second cleaning agent supplying means being ring shaped, the second cleaning agent supplying means being integrally formed on the upper portion of the lower surface of the slanted member.
Preferably, the apparatus further includes: (g) a waste liquid zone for collecting liquid agent and cleaning agent drained from the inner circumferential surface and the slanted surface; (h) a ventilation zone for collecting air which is guided by the slanted member; and (i) a separating wall for separating the ventilation zone from the waste liquid zone, the separating wall being located radially within the lower edge of the slanted member, the separating wall having an upper edge which is located above the lower edge of the slanted member.
Preferably, the openings of the cup member and of the slanted member are angled such that cleaning liquid is directed substantially horizontally out of the openings of the cup member and substantially horizontally out of the openings of the slanted member so as to cover the inner circumferential surface and the slanted surface with cleaning agent.
Preferably the apparatus includes fine irregularities for spreading cleaning agent.
Thus, according to the present invention, liquid agent applied to the substrate cannot scatter and adhere to the first and second ring-shaped conduits, and dried liquid agent adhering thereto cannot turn into fine powder to contaminate the surface of the substrate. Thus, production yield is improved compared to the conventional apparatus.
The foregoing and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a conventional apparatus.
FIG. 2 is a sectional view taken in the direction of the arrow II--II of FIG. 1.
FIG. 3 is a partially sectional view of an apparatus according to a preferred embodiment of the present invention.
FIG. 4 is a plan view taken in the direction of the arrow IV--IV of FIG. 3.
FIG. 5 is a plan view of a member for regulating the air flow in a cup of the apparatus of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 3 and 4, an apparatus according to a preferred embodiment of the present invention includes a cup 1 for collecting liquid agent and for preventing splashed droplets of the liquid agent from scattering, a horizontally rotatable spinchuck 10 provided at the central portion of the cup 1, for supporting a lower surface of the substrate W by suction and for horizontally rotating the same about a spin axis, a nozzle 11 provided above the spinchuck 10 for supplying liquid agent (such as photoresist) to an upper surface of the substrate W, and a member 15 provided below and around the spinchuck 10 for regulating the downward airflow from above the substrate W.
The cup 1 includes a lower cup 1B and an upper cup 1A which is detachably attached to the lower cup 1B. The upper cup 1A includes a circumferential wall 3A which forms a horn opening downward. The circumferential wall 3A has an inner surface 3a which is opposed to the spinchuck 10 and a circumferential surface 3b which faces the opposite side of the spinchuck 10. A cylindrical air intake 2 is formed in the upper portion of the circumferential wall 3A. A large number of discharge openings 5 are formed in an upper end portion of the circumferential wall 3A. The discharge openings 5 penetrate through the circumferential surface to the inner surface of the circumferential wall 3A for discharging the rinse agent.
The upper cup 1A further includes a ring-shaped hollow conduit 4 which surrounds the air intake 2 along the upper portion of the circumferential surface of the circumferential wall 3A. The conduit 4 supplies the rinse agent to the inner surface 3a through the discharge openings 5. The conduit 4 is in fluid communication with the inner portion of the upper cup 11A through the discharge openings 5. The discharge openings 5 each extend slightly slanted with respect to a direction tangent to the inner surface 3a of the circumferential wall 3A. The rinse agent 6 flowing out from the discharge openings 5 spreads in a generally direction downward and circumferential direction along the inner surface 3a towards the inner surface 3b.
The lower cup 1B includes a circumferential wall 3B. The wall 3B is in engagement with the opening in the lower portion of the horn formed by the circumferential wall 3A and a bottom wall 7 which is integrally formed with a lower end of the circumferential wall 3B. The bottom wall 7 defines the bottom of the cup 1. The circumferential walls 3A and 3B form a circumferential wall 3 of the cup 1.
The inner surfaces of the circumferential walls 3A and 3B are "satin-finished". Namely, a lot of fine irregularities are formed on the inner surfaces of the circumferential walls 3A and 3B. The irregularities accelerate the spread of the rinse agent on the inner surfaces of the circumferential walls 3A and 3B. The irregularities also reduce the speed at which the rinse agent flows and covers or coats the inner surfaces 3a and 3b. Thus, the satin finish prevents the splashed droplets of the scattered liquid agent from adhering to the inner surfaces 3a and 3b and reduces the consumption of the rinse agent.
The bottom wall 7 has a waste liquid drain for discharging the waste liquid. The drain 8 is formed near a periphery of the bottom wall 7. The bottom wall 7 further includes a ventilation duct 9 for venting the air in the cup 1. The ventilation duct 9 is formed on the opposite side of the waste liquid drain 8 with respect to the center of the bottom wall 7. The ventilation duct 9 is nearer to the central portion of the bottom wall 7 than the waste liquid drain 8. The ventilation duct 9 is connected to a forcible ventilation device (not illustrated).
The central portion of the bottom wall 7 surrounding the spinchuck 10 is raised above the other and an upper surface 7a thereof forms a ring-portions shaped plane surface which surrounds the spinchuck 10. A ring-shaped protruding wall 7b is formed on the upper surface of the bottom wall 7. The wall 7b surrounds the spinchuck 10. The waste liquid drain 8 is located outside the protruding wall 7b. The ventilation duct 9 is located inside the protruding wall 7b. The protruding wall 7b divides the lower portion of the cup 1 into a waste liquid zone Z1 and a ventilation zone Z2. The waste liquid zone Z1 is on the outward side of the wall 7b. The ventilation zone Z2 is on the inward side of the wall 7b.
Referring to FIGS. 3 and 5, the member 15 for regulating the air flow is provided below the spinchuck 10 and seated on the upper surface 7a of the central protruding portion of the bottom wall 7 in the lower cup 1B. The member 15 has a slanted surface 16 for regulating the air flow A entering from the air intake 2 and flowing down along the periphery of the substrate W and for guiding the air flow A to the lower cup 1B. The central portion of the slanted surface 16 is concaved to form a central bottomed opening 20. The member 15 guides splashed droplets of the liquid agent guided downward by the slant inner surface 3a of the upper cup 1A toward the lower cup 1B by means of the air flow A.
The member 15 further includes an integrally formed ring-shaped conduit 17. The conduit 17 is located along the upper half portion of the lower surface of the member 15. The conduit 17 supplies the rinse agent to the slanted surface 16. The member 15 has a large number of discharge openings 18 for discharging the rinse agent. The openings 18 are formed in the upper portion of the surface 16. The conduit 17 and the member 15 are structured such that the externally supplied rinse agent S flows from the discharge openings 18 downward to and along the slanted surface 16.
Like the discharge openings 5, each discharge opening 18 extends slightly slanted with respect to a direction tangent to the inner surface 3a of the circumferential wall 3A. The rinse agent 19 flowing out onto the surface 16 spreads along the surface 16 in a generally downward and circumferential direction and slowly flows down the surface 16.
A region 16a (FIG. 5) of the surface 16 on an upstream side of the discharge openings 18 is "mirror-finished". The upstream region 16a prevents the rinse agent from entering the central bottom opening 20 of the member 15. A region 16b of the surface 16 on a downstream side of the discharge openings 18 is satin-finished, thereby allowing the region 16b to be coated entirely by the rinse agent, like the inner surfaces 3a and 3b.
The member 15, the discharge openings 18 and the conduit 17 prevent splashed droplets of the scattered liquid agent from adhering to the surface 16 and reduce consumption of the rinse agent.
Referring to FIG. 3, the member 15 extends outwardly of the protruding wall 7b from above the ventilation duct 9. The bottom wall 7 of the lower cup 1B is bent downward near its periphery to form a ring-shaped groove in the cup 1. The portion of the member 15 which extends over the ring-shaped groove causes the air flow A flowing down along the surface 16 to change direction and flow through the waste liquid zone Z1 to the ventilation zone Z2. This minimizes the penetration of splashed droplets of the liquid agent into the ventilation zone Z2, thereby reducing the amount of liquid agent which adheres to the inside of the ventilation duct 9. The apparatus can normally operate with a longer interval between the rinsing of the ventilation duct 9.
In operation, the substrate W is placed on the spinchuck 10 by a substrate transporter (not illustrated). The spinchuck 10 supports the central portion of the lower surface of the substrate W by vacuum suction or the like. The nozzle 11 supplies the liquid agent (such as photoresist) onto the substrate W. The spinchuck 10 rotates about the spin axis such that excess photoresist is scattered from the substrate W. The remaining photoresist forms a uniform layer on the substrate W. Rinse agent S (such as organic solvent) is externally supplied to the conduits 4 and 17 at a predetermined rate. The rinse agent S supplied to the conduit 4 flows out of the discharge openings 5 in a generally downward and circumferential direction along the inner surface 3a. Since there are a large number of the discharge openings 5, a uniform layer of the rinse agent S is formed on the inner surfaces 3a and 3b.
The rinse agent S supplied to the conduit 17 flows out of the discharge openings 18 in a generally downward and circumferential direction and spreads and flows down the surface 16. Since there are a large number of the discharge openings 18, a uniform layer of the rinse agent S is formed on the surface 16.
The air in the cup 1 is forcibly discharged from the ventilation duct 9. The air enters the cup 1 through the air intake 2.
A part of the photoresist scattered from the substrate W adheres to the inner surfaces 3a and 3b of the circumferential wall 3. But this photoresist dissolves in the rinse agent and falls down to the bottom wall 7 of the cup 1. Some of the splashed droplets of photoresist are transported downwardly by the air flow A and reach the bottom wall 7 directly. Other droplets adhere to the surface 16. However, the photoresist adhering to the surface 16 dissolves in the rinse agent 5 and flows down the surface 16 to the bottom wall 7.
The collected photoresist and rinse agent in the groove of the bottom wall 7 flow to the waste liquid drain 8 and are discharged therethrough. The air in the cup 1 is forcibly discharged from the ventilation duct 9 to the outside.
Since the conduit 4 is formed on the outside of the wall 3A, photoresist cannot adhere to and dry out on the conduit 4. The conduit 17 is formed in the upper half portion of the lower surface of the member 15. In addition, the member 15 and the groove formed in the bottom wall 7 essentially prevent photoresist from entering the space surrounded by the member 15. Therefore, it is very unlikely that splashed droplets of photoresist will adhere to and dry out on the conduit 17.
The present invention greatly reduces the possibility that photoresist will dry out and scatter in the cup 1, compared to the conventional apparatus wherein the conduit for supplying the rinse agent is exposed in the cup 1. Accordingly, the possibility that particles of dried photoresist will adhere to the substrate is reduced. Production yield in terms of forming a layer of liquid agent (such as a layer of photoresist) on the substrate W is thereby increased.
The present invention is not limited to the above-described preferred embodiment. For example, the cup 1 may be integrally formed. The cup 1 need not be formed of detachable cups 1A, 1B.
Moreover, in the above-described embodiment, the air flow regulating member 15 is provided in addition to the bottom wall 7, and the conduit 17 for supplying rinse agent is integrally formed with the member 15 thereunder. However, the present invention is not limited thereto. A bottom wall 107 of FIGS. 1 and 2 may be used to regulate air flow, and a conduit for rinsing the slanted surface may be provided below the bottom wall 107.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention should be limited only by the appended claims.
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An apparatus for applying liquid agent to a substrate includes a cup member for preventing liquid agent from scattering. Cleaning agent is supplied to an inner circumferential surface of the cup member through openings located at an upper portion of the inner circumferential surface. The structure for supplying the cleaning agent is integrally formed on an outer circumferential surface of the cup member. The apparatus also has a slanted surface for regulating and guiding air, liquid agent and cleaning agent downwardly through the cup member. Cleaning agent is supplied to the slanted surface through openings which are located at an upper portion thereof. Preferably, the openings are angled so that cleaning agent is directed substantially horizontally therefrom. Preferably, the apparatus has fine irregularities for spreading cleaning agent on the inner circumferential and slanted surfaces.
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[0001] The present invention relates to targeting of glycans in cancer and monoclonal antibodies (mAbs) that bind glycans.
[0002] Glycan structures are present on both protein and glycolipid backbones and can be massively over-expressed in cancer due to altered expression of glycosyltransferases. Glycolipids consist of a lipid tail with a carbohydrate head and constitute about 5% of lipid molecules in the outer monolayer. Examples of tumour associated glycolipids are gangliosides such as GM2, GD2, GD3 and fucosyl GM1. Glycolipids are postulated to be very good targets due to their high surface density, mobility, and association with membrane microdomains; all of which contribute to strong cellular interactions. However, generating anti-glycolipid antibodies is a challenging task as there is no T cell help and the mAbs are usually of low affinity and of the IgM subclass [1, 2]. Although generating mAbs to glycans expressed on proteins overcome this problem, they present new challenges as the mAbs rarely see just the small glycan but usually recognise the glycan on the specific protein giving a very restrictive expression.
[0003] Only a limited number of antibodies recognising glycans have been described. Several anti-Lewis (Le) carbohydrate antigen mAbs have been generated to date but they often have cross reactivity with a range of glycans expressed on normal tissues. Lewis carbohydrate antigens are formed by the sequential addition of fucose onto oligosaccharide precursor chains on glycoproteins or glycolipids through the action of a set of glycosyltransferases [3]. They can be divided into 2 groups, type I (Le a and Le b ) and type II (Le x and Leg). Le a and Le b antigens are regarded as blood group antigens whereas Le x and Le y are viewed as tumour associated markers [4]. Le x is overexpressed in breast and gastrointestinal carcinomas. Normal expression of Le x is restricted to human polymorphonuclear neutrophils (PMNs). FC-215 (IgM) is a murine anti-Le x mAb which in a phase I clinical trial induced transient anti-tumour responses but profound neutropenia was observed and it has been suggested crosslinking of Le x epitopes on PMNs induced homotypic aggregation of PMNs [5]. A range of Le y antibodies have also been identified but a consistent problem with these has been the degree of cross reactivity with Le x , and H type 2 structures causing red blood cell agglutination and gastrointestinal toxicity [6-8]. The mAb GNX-8 (human IgG1), which recognises Le b -Le a has been generated. Based on the authors studies, it is predicted to be useful in the immunotherapy of human colorectal cancer [9]. Similarly the mAb 692/29 recognises Le b/y and shows anti-tumour responses against colonic tumours [10].
[0004] The sialylation of Le a is a key event in tumour progression, invasion and metastasis [11]. The antigen belongs to the neolactoseries and is a ligand of E-selectin expressed by endothelium. It is expressed on normal fibroblasts, on the luminal side of ductal epithelial cells and some parenchymatous cells, and is normally present on the inner surface of ductal epithelium, preventing accessibility to antibodies and immune effector cells. However, sialyl Le a (SLe a ) is found to be aberrantly expressed on the surface of a broad range of carcinomas such as breast [12], ovarian [13, 14], melanoma, colon [15], liver, lung and prostate. It is used as a serum marker in a range of cancers, including colorectal cancer to measure a patient's response to therapy [16]. Treatment with an anti-SLe a mAb against SLe a positive cancers has proven to be efficient in inhibiting pancreatic tumour metastasis in mouse models [17]. A human anti-SLe a mAb was produced using peripheral blood lymphocytes isolated from a breast cancer patient undergoing SLe a -keyhole limpet hemocyanin (KLH) vaccination [11]. This mAb has shown specific binding to SLe a alone and promisingly induces ADCC and CDC of antigen positive cell lines as well as anti-tumour activity in a xenograft model. Recognition of SLe a can be achieved with commercial mAbs such as CA19-9 (also known as carbohydrate antigen 19-9; Abcam, Cambridge, UK, [13]) whilst the mAb 7-Le recognises Le a and the mAb 225-Le, Le b (Abcam). International patent application number WO 2005/108430 discloses an anti-cancer mouse mAb designated SC104. SC104 is a murine IgG1 mAb recognising sialyl-di-Le a . The mAb has the ability to induce ADCC and CDC as well as direct tumour cell death without the need for immune effector cells through an apoptotic mechanism. In vivo studies demonstrated SC104 could inhibit tumour growth [18].
[0005] There is a need for further and improved cancer markers and therapies. The inventors have provided a new glycan, referred to herein as LecLe x , described in more detail below. The inventors have also provided mAbs which demonstrate potent in vivo anti-tumour activity. The mAbs not only display potent immune-mediated cytotoxic activity against human colon cancer cells in vitro via antibody-dependent cell-mediated cytotoxicity (ADCC) and complement dependent cytotoxicity (CDC), but also have the ability to directly induce cell death without the need for immune effector cells. The inventors have unexpectedly found that a family of new mAbs, referred to herein as FG88 mAbs, recognise Le a−x related carbohydrates namely LecLe x , Le a Le x , Le x containing glycans, Di-Le a and Le a containing glycans. Surprisingly, the inventors have found that these epitopes are highly expressed on tumours but have limited expression on normal tissues.
[0006] According to a first aspect of the invention, there is provided a glycan having the structure galβ1-3GLcNacβ1-3Galβ1-4(Fucα1-3)GlcNAc (LecLe x ) which is attached to a lipid or protein backbone.
[0007] According to a second aspect of the invention, there is provided isolated specific binding members capable of binding LecLe x glycan.
[0008] The invention also provides isolated specific binding member capable of binding LecLe x , Le a Le x , Di-Le a , Le x containing glycans and Le a containing glycans and directly inducing cell death without the need for immune effector cells. Such binding members may be for use in a method for treating cancer. The invention also provides for the use of such a binding partner in the manufacture of a medicament for the treatment of cancer. The invention also provides a method of treating cancer, comprising administering a binding partner of the invention to a subject in need of such treatment.
[0009] In one aspect, the present invention provides the mAb FG88.2 which binds to LecLe x , Le a Le x , Le x containing glycan, Le a containing glycan, Le a and Di-Le a .
[0010] In another aspect, the present invention provides for the mAb FG88.7 which binds to LecLe x , Di-Le a , Le a , Le a containing glycans, Le x containing glycan and Le a Le x .
[0011] In this invention we show two murine IgG3k mAbs, FG88.2 and FG88.7, which bind to LecLe x and were generated by immunising Balb/c mice with tumour plasma membrane lipid extracts. Interestingly, they do not recognise PMNs. Although they can bind Le a they prefer more complex glycans and importantly, do not bind or lyse red blood cells. Evidence suggests that Le a and Le b antigens found in the secretions of various tissue types, have the capability of binding to the surface of erythrocytes [21]. The term ABH secretor refers to secretion of ABO blood group antigens; one of the differences in physiology between secretors and non-secretors being the secretion of these components in their body fluids [22]. If the antigen is derived from both the Le and Se alleles, Le a is converted to Le b , which can be absorbed to the erythrocyte membrane, resulting in Le a−b+ phenotype. If the antigen derives from only the Le allele, the antigenic form of Le a will be expressed, giving rise to the Le a+b− phenotype. If the Lewis antigen does not carry the Le allele, regardless of the presence or absence of Se allele, the erythrocyte phenotype will be Le a−b− [23] . Among Lewis antigen positive individuals, ABH secretors are always Le a−b+ whereas ABH non-secretors are always Le a+b− [22]. In Caucasians, it was reported that approximately 80% are secretors and 20% are non-secretors. However, in another study in Negroes, 60% are secretors and 40% are non-secretors, suggesting the phenomenon may be due to racial variation [24].
[0012] Immunohistochemical binding of FG88 to colorectal (208 tumours), gastric (93 tumours), pancreatic (89 tumours), Lung (275 tumours), breast (902 tumour) and ovarian (186 tumours) tumour tissue microarrays (TMAs) revealed that FG88 mAbs stained 69% colorectal, 56% of gastric, 23% of lung, 27% of all breast types, 25% of ER negative breast cancer and 31% ovarian tumours. FG88.2 and FG88.7 showed weak staining on human jejunum, thymus and rectum; moderate staining on oesophagus, tonsil and pancreas; and strong staining on gall bladder, ileum and liver. In addition to the tissues stained by both mAbs, FG88.7 also stained rectum weakly. No staining was seen on placenta, skin, adipose, heart, skeletal, bladder, spleen, brain, stomach, breast, kidney, testis, cerebellum, cervix, lung, ovary, diaphragm, uterus, duodenum and thyroid.
[0013] A further aspect of the invention provides an isolated specific binding member comprising one or more binding domains selected from the amino acid sequence of residues 27 to 38 (CDRH1), 56-65 (CDRH2) and 105 to 121 (CDRH3) of FIG. 1 a or 2 a.
[0014] The binding domain may comprise an amino acid sequence substantially as set out as 1-133 (VH) of FIG. 1 a or 2 a.
[0015] In one embodiment, the member comprises a binding domain which comprises an amino acid sequence substantially as set out as residues 105 to 121 (CDRH3) of the amino acid sequence of FIG. 1 a or 2 a . In this embodiment, the isolated specific binding member may additionally comprise one or both, preferably both, of the binding domains substantially as set out as residues 27 to 38 (CDRH1) and residues 56 to 65 (CDRH2) of the amino acid sequence shown in FIGS. 1 a and 2 a.
[0016] In another aspect, the present invention provides an isolated specific binding member comprising one or more binding domains selected from the amino acid sequence of residues 27 to 38 (CDRL1), 56-65 (CDRL2) and 105 to 121 (CDRL3) of FIG. 1 b or 2 b.
[0017] The binding domain may comprise an amino acid sequence substantially as set out as residues 105 to 121 (CDRL3) of the amino acid sequence of FIGS. 1 b and 2 b . In this embodiment, the isolated specific binding member may additionally comprise one or both, preferably both, of the binding domains substantially as set out as residues 27 to 38 and (CDRL1) residues 56 to 65 of (CDRL2) the amino acid sequence shown in FIGS. 1 b and 2 b.
[0018] Specific binding members which comprise a plurality of binding domains of the same or different sequence, or combinations thereof, are included within the present invention. Each binding domain may be carried by a human antibody framework. For example, one or more binding regions may be substituted for the complementary determining regions (CDRs) of a whole human antibody or of the variable region thereof.
[0019] One isolated specific binding member of the invention comprises the sequence substantially as set out as residues 1 to 133 (VL) of the amino acid sequence shown in FIG. 1 b or 2 b.
[0020] In some embodiments binding members having sequences of the CDRs of FIG. 1 a or FIG. 2 a may be combined with binding members having sequences of the CDRs of FIG. 1 b or 2 b.
[0021] In a further aspect, the invention provides a binding member comprising residues 1 to 133 (VH) of the amino acid sequence of FIG. 1 a or 2 a , and residues 1 to 123 (VL) of the amino acid sequence of FIG. 1 b or 2 b.
[0022] The invention also encompasses binding partners as described above, but in which the sequences of the binding domains are substantially as set out in FIG. 1 or 2 . Thus, binding partners as described above are provided, but in which in one or more binding domains differ from those depicted in FIG. 1 or 2 by from 1 to 5, from 1 to 4, from 1 to 3, 2 or 1 substitutions.
[0023] The invention also encompasses binding partners having the capability of binding to the same epitopes as the VH and VL sequences depicted in FIGS. 1 and 2 . The epitope of a mAb is the region of its antigen to which the mAb binds. Two antibodies bind to the same or overlapping epitope if each competitively inhibits (blocks) binding of the other to the antigen. That is, a 1×, 5×, 10×, 20× or 100× excess of one antibody inhibits binding of the other by at least 50% but preferably 75%, 90% or even 99% as measured in a competitive binding assay compared to a control lacking the competing antibody (see, e.g., Junghans et al., Cancer Res. 50:1495, 1990, which is incorporated herein by reference).
[0024] The invention therefore further provides a binding member which competes for binding to LecLe x , Le a Le x , Di-Le a , Le x containing glycans or Le a containing glycans with an antibody comprising a VH chain having the amino acid sequence of residues 1 to 133 of FIG. 1 a or 2 a and a VL chain having the amino acid sequence of residues 1 to 123 of FIG. 1 b or 2 b.
[0025] In a preferred embodiment the competing binding partner competes for binding to LecLe x with an antibody comprising a VH chain having the amino acid sequence of residues 1 to 133 of FIG. 1 a or 2 a and a VL chain having the amino acid sequence of residues 1 to 123 of FIG. 1 b or 2 b.
[0026] In a further embodiment the competing binding partner competes for binding to LecLe x , Le a Le x , Di-Le a , Le x containing glycans or Le a containing glycans with an antibody comprising a VH chain having the amino acid sequence of residues 1 to 133 of FIG. 1 a and a VL chain having the amino acid sequence of residues 1 to 123 of FIG. 1 b , or with an antibody comprising a VH chain having the amino acid sequence of residues 1 to 133 of FIG. 2 a and a VL chain having the amino acid sequence of residues 1 to 123 of FIG. 2 b.
[0027] Preferably, competing binding partners are antibodies, for example monoclonal antibodies, or any of the antibody variants or fragments mentioned throughout this document.
[0028] Once a single, archtypal mAb, for example an FG88 mAB, has been isolated that has the desired properties described herein, it is straightforward to generate other mAbs with similar properties, by using art-known methods. For example, the method of Jespers et al., Biotechnology 12:899, 1994, which is incorporated herein by reference, may be used to guide the selection of mAbs having the same epitope and therefore similar properties to the archtypal mAb. Using phage display, first the heavy chain of the archtypal antibody is paired with a repertoire of (preferably human) light chains to select a glycan-binding mAb, and then the new light chain is paired with a repertoire of (preferably human) heavy chains to select a (preferably human) glycan-binding mAb having the same epitope as the archtypal mAb.
[0029] MAbs that are capable of binding LecLe x , Le a Le x , Di-Le a , Le x containing glycans and Le a containing glycans and directly inducing cell death without the need for immune effector cells, and are at least 90%, 95% or 99% identical in the VH and/or VL domain to the VH or VL domains of FIG. 1 or 2 , are included in the invention. Preferably such antibodies differ from the sequences of FIG. 1 or 2 by a small number of functionally inconsequential amino acid substitutions (e.g., conservative substitutions), deletions, or insertions.
[0030] In any embodiment of the invention, the specific binding pair may be an antibody or an antibody fragment, Fab, (Fab′) 2 , scFv, Fv, dAb, Fd or a diabody. In some embodiments the antibody is a polyclonal antibody. In other embodiments the antibody is a monoclonal antibody. Antibodies of the invention may be humanised, chimeric or veneered antibodies, or may be non-human antibodies of any species.
[0031] In one embodiment the specific binding partner of the invention is mouse antibody FG88.2 which comprises a heavy chain as depicted in FIG. 1 a and a light chain as depicted in FIG. 1 b.
[0032] In another embodiment the specific binding partner of the invention is mouse antibody FG88.7 which comprises a heavy chain as depicted in FIG. 2 a and a light chain as depicted in FIG. 2 b.
[0033] In another embodiment the specific binding partner of the invention is chimeric FG88.2 which comprises a heavy chain as depicted in FIG. 1 d and a light chain as depicted in FIG. 1 e.
[0034] In another embodiment the specific binding partner of the invention is chimeric FG88.7 which comprises a heavy chain as depicted in FIG. 2 d and a light chain as depicted in FIG. 2 e.
[0035] Specific binding members of the invention may carry a detectable or functional label.
[0036] In further aspects, the invention provides an isolated nucleic acid which comprises a sequence encoding a specific binding member of the aspects of the invention, and methods of preparing specific binding members of the invention which comprise expressing said nucleic acids under conditions to bring about expression of said binding member, and recovering the binding member.
[0037] Specific binding members according to the invention may be used in a method of treatment or diagnosis of the human or animal body, such as a method of treatment of a tumour in a patient (preferably human) which comprises administering to said patient an effective amount of a specific binding member of the invention. The invention also provides a specific binding member of the present invention for use in medicine, as well as the use of a specific binding member of the present invention in the manufacture of a medicament for the diagnosis or treatment of a tumour.
[0038] The invention also provides the antigen to which the specific binding members of the present invention bind. In one embodiment, a LecLe x which is capable of being bound, preferably specifically, by a specific binding member of the present invention is provided. The LecLe x may be provided in isolated form, and may be used in a screen to develop further specific binding members therefor. For example, a library of compounds may be screened for members of the library which bind specifically to the LecLe x . The LecLe x may on a lipid backbone (i.e. a LecLe x ceramide) or on a protein backbone. When on a protein backbone, it may have a molecular weight of about 50-150 kDa, as determined by SDS-PAGE.
[0039] In a further aspect the invention provides an isolated specific binding member capable of binding LecLe x , Le a Le x , Di-Le a , Le x containing glycans and Le a containing glycans for use in the diagnosis or prognosis of colorectal, gastric, pancreatic, lung, ovarian and breast tumours.
[0040] The invention further provides a method for diagnosis of cancer comprising using a specific binding partner of the invention to detect LecLe x , Le a Le x , Di-Le a , Le x containing glycans or Le a containing glycans in a sample from an individual. In some embodiments, in the diagnostic method the pattern of glycans detected by the binding partner is used to stratify therapy options for the individual.
[0041] These and other aspects of the invention are described in further detail below.
[0042] As used herein, a “specific binding member” is a member of a pair of molecules which have binding specificity for one another. The members of a specific binding pair may be naturally derived or wholly or partially synthetically produced. One member of the pair of molecules has an area on its surface, which may be a protrusion or a cavity, which specifically binds to and is therefore complementary to a particular spatial and polar organisation of the other member of the pair of molecules. Thus, the members of the pair have the property of binding specifically to each other. Examples of types of specific binding pairs are antigen-antibody, biotin-avidin, hormone-hormone receptor, receptor-ligand, enzyme-substrate. The present invention is generally concerned with antigen-antibody type reactions, although it also concerns small molecules which bind to the antigen defined herein.
[0043] As used herein, “treatment” includes any regime that can benefit a human or non-human animal, preferably mammal. The treatment may be in respect of an existing condition or may be prophylactic (preventative treatment).
[0044] As used herein, a “tumour” is an abnormal growth of tissue. It may be localised (benign) or invade nearby tissues (malignant) or distant tissues (metastatic). Tumours include neoplastic growths which cause cancer and include oesophageal, colorectal, gastric, breast and endometrial tumours, as well as cancerous tissues or cell lines including, but not limited to, leukaemic cells. As used herein, “tumour” also includes within its scope endometriosis.
[0045] The term “antibody” as used herein refers to immunoglobulin molecules and immunologically active portions of immunoglobulin molecules, i.e., molecules that contain an antigen binding site that specifically binds an antigen, whether natural or partly or wholly synthetically produced. The term also covers any polypeptide or protein having a binding domain which is, or is homologous to, an antibody binding domain. These can be derived from natural sources, or they may be partly or wholly synthetically produced. Examples of antibodies are the immunoglobulin isotypes (e.g., IgG, IgE, IgM, IgD and IgA) and their isotypic subclasses; fragments which comprise an antigen binding domain such as Fab, scFv, Fv, dAb, Fd; and diabodies. Antibodies may be polyclonal or monoclonal. A monoclonal antibody may be referred to as a “mAb”.
[0046] It is possible to take monoclonal and other antibodies and use techniques of recombinant DNA technology to produce other antibodies or chimeric molecules which retain the specificity of the original antibody. Such techniques may involve introducing DNA encoding the immunoglobulin variable region, or the CDRs, of an antibody to the constant regions, or constant regions plus framework regions, of a different immunoglobulin. See, for instance, EP-A-184187, GB 2188638A or EP-A-239400. A hybridoma or other cell producing an antibody may be subject to genetic mutation or other changes, which may or may not alter the binding specificity of antibodies produced.
[0047] As antibodies can be modified in a number of ways, the term “antibody” should be construed as covering any specific binding member or substance having a binding domain with the required specificity. Thus, this term covers antibody fragments, derivatives, functional equivalents and homologues of antibodies, humanised antibodies, including any polypeptide comprising an immunoglobulin binding domain, whether natural or wholly or partially synthetic. Chimeric molecules comprising an immunoglobulin binding domain, or equivalent, fused to another polypeptide are therefore included. Cloning and expression of chimeric antibodies are described in EP-A-0120694 and EP-A-0125023. A humanised antibody may be a modified antibody having the variable regions of a non-human, e.g., murine, antibody and the constant region of a human antibody. Methods for making humanised antibodies are described in, for example, U.S. Pat. No. 5,225,539.
[0048] It has been shown that fragments of a whole antibody can perform the function of binding antigens. Examples of binding fragments are (i) the Fab fragment consisting of VL, VH, CL and CH1 domains; (ii) the Fd fragment consisting of the VH and CH1 domains; (iii) the Fv fragment consisting of the VL and VH domains of a single antibody; (iv) the dAb fragment [25] which consists of a VH domain; (v) isolated CDR regions; (vi) F(ab′) 2 fragments, a bivalent fragment comprising two linked Fab fragments; (vii) single chain Fv molecules (scFv), wherein a VH domain and a VL domain are linked by a peptide linker which allows the two domains to associate to form an antigen binding site [26, 27]; (viii) bispecific single chain Fv dimers (PCT/US92/09965) and; (ix) “diabodies”, multivalent or multispecific fragments constructed by gene fusion (WO94/13804; [28]).
[0049] Diabodies are multimers of polypeptides, each polypeptide comprising a first domain comprising a binding region of an immunoglobulin light chain and a second domain comprising a binding region of an immunoglobulin heavy chain, the two domains being linked (e.g., by a peptide linker) but unable to associated with each other to form an antigen binding site: antigen binding sites are formed by the association of the first domain of one polypeptide within the multimer with the second domain of another polypeptide within the multimer (WO94/13804).
[0050] Where bispecific antibodies are to be used, these may be conventional bispecific antibodies, which can be manufactured in a variety of ways [29], e.g., prepared chemically or from hybrid hybridomas, or may be any of the bispecific antibody fragments mentioned above. It may be preferable to use scFv dimers or diabodies rather than whole antibodies. Diabodies and scFv can be constructed without an Fc region, using only variable domains, potentially reducing the effects of anti-idiotypic reaction. Other forms of bispecific antibodies include the single chain “Janusins” described in [30].
[0051] Bispecific diabodies, as opposed to bispecific whole antibodies, may also be useful because they can be readily constructed and expressed in E. coli . Diabodies (and many other polypeptides such as antibody fragments) of appropriate binding specificities can be readily selected using phage display (WO94/13804) from libraries. If one arm of the diabody is to be kept constant, for instance, with a specificity directed against antigen X, then a library can be made where the other arm is varied and an antibody of appropriate specificity selected.
[0052] An “antigen binding domain” is the part of an antibody which comprises the area which specifically binds to and is complementary to part or all of an antigen. Where an antigen is large, an antibody may only bind to a particular part of the antigen, which part is termed an epitope. An antigen binding domain may be provided by one or more antibody variable domains. An antigen binding domain may comprise an antibody light chain variable region (VL) and an antibody heavy chain variable region (VH).
[0053] “Specific” is generally used to refer to the situation in which one member of a specific binding pair will not show any significant binding to molecules other than its specific binding partner(s), and, e.g., has less than about 30%, preferably 20%, 10%, or 1% cross reactivity with any other molecule. The term is also applicable where e.g., an antigen binding domain is specific for a particular epitope which is carried by a number of antigens, in which case, the specific binding member carrying the antigen binding domain will be able to bind to the various antigens carrying the epitope.
[0054] “Isolated” refers to the state in which specific binding members of the invention or nucleic acid encoding such binding members will preferably be, in accordance with the present invention. Members and nucleic acid will generally be free or substantially free of material with which they are naturally associated such as other polypeptides or nucleic acids with which they are found in their natural environment, or the environment in which they are prepared (e.g., cell culture) when such preparation is by recombinant DNA technology practised in vitro or in vivo. Specific binding members and nucleic acid may be formulated with diluents or adjuvants and still for practical purposes be isolated—for example, the members will normally be mixed with gelatin or other carriers if used to coat microtitre plates for use in immunoassays, or will be mixed with pharmaceutically acceptable carriers or diluents when used in diagnosis or therapy. Specific binding members may be glycosylated, either naturally or by systems of heterologous eukaryotic cells, or they may be (for example if produced by expression in a prokaryotic cell) unglycosylated.
[0055] By “substantially as set out” it is meant that the CDR regions of the invention will be either identical or highly homologous to the specified regions of FIG. 1 or 2 . By “highly homologous” it is contemplated that from 1 to 5, from 1 to 4, from 1 to 3, 2 or 1 substitutions may be made in the CDRs.
[0056] The invention also includes within its scope polypeptides having the amino acid sequence as set out in FIG. 1 or 2 , polynucleotides having the nucleic acid sequences as set out in Figure A or B and sequences having substantial identity thereto, for example, 70%, 80%, 85%, 90%, 95% or 99% identity thereto. The percent identity of two amino acid sequences or of two nucleic acid sequences is generally determined by aligning the sequences for optimal comparison purposes (e.g., gaps can be introduced in the first sequence for best alignment with the second sequence) and comparing the amino acid residues or nucleotides at corresponding positions. The “best alignment” is an alignment of two sequences that results in the highest percent identity. The percent identity is determined by comparing the number of identical amino acid residues or nucleotides within the sequences (i.e., % identity=number of identical positions/total number of positions×100).
[0057] The determination of percent identity between two sequences can be accomplished using a mathematical algorithm known to those of skill in the art. An example of a mathematical algorithm for comparing two sequences is the algorithm of Karlin and Altschul (1990) [31], modified as in Karlin and Altschul (1993) [32]. The NBLAST and XBLAST programs of Altschul et al. (1990) [33] have incorporated such an algorithm. BLAST nucleotide searches can be performed with the NBLAST program, score=100, word length=12 to obtain nucleotide sequences homologous to a nucleic acid molecules of the invention. BLAST protein searches can be performed with the XBLAST program, score=50, word length=3 to obtain amino acid sequences homologous to a protein molecules of the invention. To obtain gapped alignments for comparison purposes, Gapped BLAST can be utilized as described in Altschul et al. (1997) [34]. Alternatively, PSI-Blast can be used to perform an iterated search that detects distant relationships between molecules (Id.). When utilizing BLAST, Gapped BLAST, and PSI-Blast programs, the default parameters of the respective programs (e.g., XBLAST and NBLAST) can be used. See http://www.ncbi.nlm.nih.gov. Another example of a mathematical algorithm utilized for the comparison of sequences is the algorithm of Myers and Miller, [35]. The ALIGN program (version 2.0) which is part of the GCG sequence alignment software package has incorporated such an algorithm. Other algorithms for sequence analysis known in the art include ADVANCE and ADAM as described in Torellis and Robotti (1994) [36]; and FASTA described in Pearson and Lipman (1988) [37]. Within FASTA, ktup is a control option that sets the sensitivity and speed of the search.
[0058] Isolated specific binding members of the present invention are capable of binding to a LecLe x carbohydrate, which may be a LecLe x ceramide or may be on a protein moiety. In one embodiment, the CDR3 regions, comprising the amino acid sequences substantially as set out as residues 105 to 121 (CDRH3) of FIGS. 1 a and 2 a and 105 to 121 of FIGS. 1 b and 2 b , are carried in a structure which allows the binding of these regions to a LecLe x carbohydrate.
[0059] The structure for carrying the CDR3s of the invention will generally be of an antibody heavy or light chain sequence or substantial portion thereof in which the CDR3 regions are located at locations corresponding to the CDR3 region of naturally-occurring VH and VL antibody variable domains encoded by rearranged immunoglobulin genes. The structures and locations of immunoglobulin variable domains may be determined by reference to http://www.imgt.org/. The amino acid sequence substantially as set out as residues 105 to 121 of FIGS. 1 a and 2 a may be carried as the CDR3 in a human heavy chain variable domain or a substantial portion thereof, and the amino acid sequence substantially as set out as residues and 105 to 121 of FIGS. 1 b and 2 b may be carried as the CDR3 in a human light chain variable domain or a substantial portion thereof.
[0060] The variable domains may be derived from any germline or rearranged human variable domain, or may be a synthetic variable domain based on consensus sequences of known human variable domains. The CDR3-derived sequences of the invention may be introduced into a repertoire of variable domains lacking CDR3 regions, using recombinant DNA technology.
[0061] For example, Marks et al., (1992) [38] describe methods of producing repertoires of antibody variable domains in which consensus primers directed at or adjacent to the 5′ end of the variable domain area are used in conjunction with consensus primers to the third framework region of human VH genes to provide a repertoire of VH variable domains lacking a CDR3. Marks et al. (1992) [38] further describe how this repertoire may be combined with a CDR3 of a particular antibody. Using analogous techniques, the CDR3-derived sequences of the present invention may be shuffled with repertoires of VH or VL domains lacking a CDR3, and the shuffled complete VH or VL domains combined with a cognate VL or VH domain to provide specific binding members of the invention. The repertoire may then be displayed in a suitable host system such as the phage display system of WO92/01047 so that suitable specific binding members may be selected. A repertoire may consist of from anything from 10 4 individual members upwards, for example from 10 6 to 10 8 or 10 10 members.
[0062] Analogous shuffling or combinatorial techniques are also disclosed by Stemmer (1994) [39] who describes the technique in relation to a β-lactamase gene but observes that the approach may be used for the generation of antibodies.
[0063] A further alternative is to generate novel VH or VL regions carrying the CDR3-derived sequences of the invention using random mutagenesis of, for example, the SC104 VH or VL genes to generate mutations within the entire variable domain. Such a technique is described by Gram et al., (1992) [40], who used error-prone PCR.
[0064] Another method which may be used is to direct mutagenesis to CDR regions of VH or VL genes. Such techniques are disclosed by Barbas et al., (1994) [41] and Schier et al., (1996) [42].
[0065] A substantial portion of an immunoglobulin variable domain will generally comprise at least the three CDR regions, together with their intervening framework regions. The portion may also include at least about 50% of either or both of the first and fourth framework regions, the 50% being the C-terminal 50% of the first framework region and the N-terminal 50% of the fourth framework region. Additional residues at the N-terminal or C-terminal end of the substantial part of the variable domain may be those not normally associated with naturally occurring variable domain regions. For example, construction of specific binding members of the present invention made by recombinant DNA techniques may result in the introduction of N- or C-terminal residues encoded by linkers introduced to facilitate cloning or other manipulation steps, including the introduction of linkers to join variable domains of the invention to further protein sequences including immunoglobulin heavy chains, other variable domains (for example in the production of diabodies) or protein labels as discussed in more detail below.
[0066] One embodiment of the invention provides specific binding members comprising a pair of binding domains based on the amino acid sequences for the VL and VH regions substantially as set out in FIG. 1 , i.e. amino acids 1 to 133 (VH) of FIGS. 1 a and 2 a and amino acids 1 to 133 (VL) of FIGS. 1 b and 2 b . Single binding domains based on either of these sequences form further aspects of the invention. In the case of the binding domains based on the amino acid sequence for the VH region substantially set out in FIGS. 1 a and 2 a , such binding domains may be used as targeting agents since it is known that immunoglobulin VH domains are capable of binding target antigens in a specific manner.
[0067] In the case of either of the single chain specific binding domains, these domains may be used to screen for complementary domains capable of forming a two-domain specific binding member which has in vivo properties as good as or equal to the FG88 antibodies disclosed herein.
[0068] This may be achieved by phage display screening methods using the so-called hierarchical dual combinatorial approach as disclosed in WO92/01047 in which an individual colony containing either an H or L chain clone is used to infect a complete library of clones encoding the other chain (L or H) and the resulting two-chain specific binding member is selected in accordance with phage display techniques such as those described in that reference. This technique is also disclosed in Marks et al., [38].
[0069] Specific binding members of the present invention may further comprise antibody constant regions or parts thereof. For example, specific binding members based on the VL region shown in FIGS. 1 b and 2 b may be attached at their C-terminal end to antibody light chain constant domains including human Cκ or Cλ, chains. Similarly, specific binding members based on VH region shown in Figure b and 2 b may be attached at their C-terminal end to all or part of an immunoglobulin heavy chain derived from any antibody isotype, e.g., IgG, IgA, IgE and IgM and any of the isotype sub-classes, particularly IgG1, IgG2 and IgG4.
[0070] Specific binding members of the present invention can be used in methods of diagnosis and treatment of tumours in human or animal subjects.
[0071] When used in diagnosis, specific binding members of the invention may be labelled with a detectable label, for example a radiolabel such as 131 I or 99 Tc, which may be attached to specific binding members of the invention using conventional chemistry known in the art of antibody imaging. Labels also include enzyme labels such as horseradish peroxidase. Labels further include chemical moieties such as biotin which may be detected via binding to a specific cognate detectable moiety, e.g., labelled avidin.
[0072] Although specific binding members of the invention have in themselves been shown to be effective in killing cancer cells, they may additionally be labelled with a functional label. Functional labels include substances which are designed to be targeted to the site of cancer to cause destruction thereof. Such functional labels include toxins such as ricin and enzymes such as bacterial carboxypeptidase or nitroreductase, which are capable of converting prodrugs into active drugs. In addition, the specific binding members may be attached or otherwise associated with chemotherapeutic or cytotoxic agents, such as maytansines (DM1 and DM4), onides, auristatins, calicheamicin, duocamycin, doxorubicin or radiolabels, such as 90 Y or 131 I.
[0073] Furthermore, the specific binding members of the present invention may be administered alone or in combination with other treatments, either simultaneously or sequentially, dependent upon the condition to be treated. Thus, the present invention further provides products containing a specific binding member of the present invention and an active agent as a combined preparation for simultaneous, separate or sequential use in the treatment of a tumour. Active agents may include chemotherapeutic or cytotoxic agents including, 5-Fluorouracil, cisplatin, Mitomycin C, oxaliplatin and tamoxifen, which may operate synergistically with the binding members of the present invention. Other active agents may include suitable doses of pain relief drugs such as non-steroidal anti-inflammatory drugs (e.g., aspirin, paracetamol, ibuprofen or ketoprofen) or opitates such as morphine, or anti-emetics.
[0074] Whilst not wishing to be bound by theory, the ability of the binding members of the invention to synergise with an active agent to enhance tumour killing may not be due to immune effector mechanisms but rather may be a direct consequence of the binding member binding to cell surface bound LecLe x , Le a Le x , Di-Le a and Le a glycans.
[0075] Specific binding members of the present invention will usually be administered in the form of a pharmaceutical composition, which may comprise at least one component in addition to the specific binding member. The pharmaceutical composition may comprise, in addition to active ingredient, a pharmaceutically acceptable excipient, diluent, carrier, buffer, stabiliser or other materials well known to those skilled in the art. Such materials should be non-toxic and should not interfere with the efficacy of the active ingredient. The precise nature of the carrier or other material will depend on the route of administration, which may be oral, or by injection, e.g., intravenous.
[0076] It is envisaged that injections will be the primary route for therapeutic administration of the compositions although delivery through a catheter or other surgical tubing is also used. Some suitable routes of administration include intravenous, subcutaneous, intraperitoneal and intramuscular administration. Liquid formulations may be utilised after reconstitution from powder formulations.
[0077] For intravenous injection, or injection at the site of affliction, the active ingredient will be in the form of a parenterally acceptable aqueous solution which is pyrogen-free and has suitable pH, isotonicity and stability. Those of relevant skill in the art are well able to prepare suitable solutions using, for example, isotonic vehicles such as Sodium Chloride Injection, Ringer's Injection, Lactated Ringer's Injection. Preservatives, stabilisers, buffers, antioxidants and/or other additives may be included, as required. Pharmaceutical compositions for oral administration may be in tablet, capsule, powder or liquid form. A tablet may comprise a solid carrier such as gelatin or an adjuvant. Liquid pharmaceutical compositions generally comprise a liquid carrier such as water, petroleum, animal or vegetable oils, mineral oil or synthetic oil. Physiological saline solution, dextrose or other saccharide solution or glycols such as ethylene glycol, propylene glycol or polyethylene glycol may be included. Where the formulation is a liquid it may be, for example, a physiologic salt solution containing non-phosphate buffer at pH 6.8-7.6, or a lyophilised powder.
[0078] The composition may also be administered via microspheres, liposomes, other microparticulate delivery systems or sustained release formulations placed in certain tissues including blood. Suitable examples of sustained release carriers include semi-permeable polymer matrices in the form of shared articles, e.g., suppositories or microcapsules. Implantable or microcapsular sustained release matrices include polylactides (U.S. Pat. No. 3,773,919; EP-A-0058481) copolymers of L-glutamic acid and gamma ethyl-L-glutamate [43], poly (2-hydroxyethyl-methacrylate). Liposomes containing the polypeptides are prepared by well-known methods: DE 3,218, 121A; Epstein et al, PNAS USA, 82: 3688-3692, 1985; Hwang et al, PNAS USA, 77: 4030-4034, 1980; EP-A-0052522; EP-A-0036676; EP-A-0088046; EP-A-0143949; EP-A-0142541; JP-A-83-11808; U.S. Pat. Nos. 4,485,045 and 4,544,545. Ordinarily, the liposomes are of the small (about 200-800 Angstroms) unilamellar type in which the lipid content is greater than about 30 mol. % cholesterol, the selected proportion being adjusted for the optimal rate of the polypeptide leakage.
[0079] The composition may be administered in a localised manner to a tumour site or other desired site or may be delivered in a manner in which it targets tumour or other cells.
[0080] The compositions are preferably administered to an individual in a “therapeutically effective amount”, this being sufficient to show benefit to the individual. The actual amount administered, and rate and time-course of administration, will depend on the nature and severity of what is being treated. Prescription of treatment, e.g., decisions on dosage etc, is within the responsibility of general practitioners and other medical doctors, and typically takes account of the disorder to be treated, the condition of the individual patient, the site of delivery, the method of administration and other factors known to practitioners. The compositions of the invention are particularly relevant to the treatment of existing tumours, especially cancer, and in the prevention of the recurrence of such conditions after initial treatment or surgery. Examples of the techniques and protocols mentioned above can be found in Remington's Pharmaceutical Sciences, 16 th edition, Oslo, A. (ed), 1980 [45].
[0081] The optimal dose can be determined by physicians based on a number of parameters including, for example, age, sex, weight, severity of the condition being treated, the active ingredient being administered and the route of administration. In general, a serum concentration of polypeptides and antibodies that permits saturation of receptors is desirable. A concentration in excess of approximately 0.1 nM is normally sufficient. For example, a dose of 100 mg/m 2 of antibody provides a serum concentration of approximately 20 nM for approximately eight days.
[0082] As a rough guideline, doses of antibodies may be given weekly in amounts of 10-300 mg/m 2 . Equivalent doses of antibody fragments should be used at more frequent intervals in order to maintain a serum level in excess of the concentration that permits saturation of the LecLe x carbohydrate.
[0083] The dose of the composition will be dependent upon the properties of the binding member, e.g., its binding activity and in vivo plasma half-life, the concentration of the polypeptide in the formulation, the administration route, the site and rate of dosage, the clinical tolerance of the patient involved, the pathological condition afflicting the patient and the like, as is well within the skill of the physician. For example, doses of 300 μg of antibody per patient per administration are preferred, although dosages may range from about 10 μg to 6 mg per dose. Different dosages are utilised during a series of sequential inoculations; the practitioner may administer an initial inoculation and then boost with relatively smaller doses of antibody.
[0084] This invention is also directed to optimise immunisation schedules for enhancing a protective immune response against cancer.
[0085] The binding members of the present invention may be generated wholly or partly by chemical synthesis. The binding members can be readily prepared according to well-established, standard liquid or, preferably, solid-phase peptide synthesis methods, general descriptions of which are broadly available (see, for example, in J. M. Stewart and J. D. Young, (1984) [46], in M. Bodanzsky and A. Bodanzsky, (1984) [47]; or they may be prepared in solution, by the liquid phase method or by any combination of solid-phase, liquid phase and solution chemistry, e.g., by first completing the respective peptide portion and then, if desired and appropriate, after removal of any protecting groups being present, by introduction of the residue X by reaction of the respective carbonic or sulfonic acid or a reactive derivative thereof.
[0086] Another convenient way of producing a binding member according to the present invention is to express the nucleic acid encoding it, by use of nucleic acid in an expression system.
[0087] The present invention further provides an isolated nucleic acid encoding a specific binding member of the present invention. Nucleic acid includes DNA and RNA. In a preferred aspect, the present invention provides a nucleic acid which codes for a specific binding member of the invention as defined above. Examples of such nucleic acid are shown in FIGS. 1 and 2 . The skilled person will be able to determine substitutions, deletions and/or additions to such nucleic acids which will still provide a specific binding member of the present invention.
[0088] The present invention also provides constructs in the form of plasmids, vectors, transcription or expression cassettes which comprise at least one nucleic acid as described above. The present invention also provides a recombinant host cell which comprises one or more constructs as above. As mentioned, a nucleic acid encoding a specific binding member of the invention forms an aspect of the present invention, as does a method of production of the specific binding member which method comprises expression from encoding nucleic acid therefor. Expression may conveniently be achieved by culturing under appropriate conditions recombinant host cells containing the nucleic acid. Following production by expression, a specific binding member may be isolated and/or purified using any suitable technique, then used as appropriate.
[0089] Systems for cloning and expression of a polypeptide in a variety of different host cells are well known. Suitable host cells include bacteria, mammalian cells, yeast and baculovirus systems. Mammalian cell lines available in the art for expression of a heterologous polypeptide include Chinese hamster ovary cells, HeLa cells, baby hamster kidney cells, NSO mouse melanoma cells and many others. A common, preferred bacterial host is E. coli . The expression of antibodies and antibody fragments in prokaryotic cells such as E. coli is well established in the art. For a review, see for example Plückthun (1991) [48]. Expression in eukaryotic cells in culture is also available to those skilled in the art as an option for production of a specific binding member, see for recent review, for example Reff (1993) [49]; Trill et al., (1995) [50].
[0090] Suitable vectors can be chosen or constructed, containing appropriate regulatory sequences, including promoter sequences, terminator sequences, polyadenylation sequences, enhancer sequences, marker genes and other sequences as appropriate. Vectors may be plasmids, viral e.g., ‘phage, or phagemid, as appropriate. For further details see, for example, Sambrook et al., (1989) [51]. Many known techniques and protocols for manipulation of nucleic acid, for example in preparation of nucleic acid constructs, mutagenesis, sequencing, introduction of DNA into cells and gene expression, and analysis of proteins, are described in detail in Ausubel et al., (1992) [52].
[0091] Thus, a further aspect of the present invention provides a host cell containing nucleic acid as disclosed herein. A still further aspect provides a method comprising introducing such nucleic acid into a host cell. The introduction may employ any available technique. For eukaryotic cells, suitable techniques may include calcium phosphate transfection, DEAE-Dextran, electroporation, liposome-mediated transfection and transduction using retrovirus or other virus, e.g., vaccinia or, for insect cells, baculovirus. For bacterial cells, suitable techniques may include calcium chloride transformation, electroporation and transfection using bacteriophage. The introduction may be followed by causing or allowing expression from the nucleic acid, e.g., by culturing host cells under conditions for expression of the gene.
[0092] In one embodiment, the nucleic acid of the invention is integrated into the genome (e.g., chromosome) of the host cell. Integration may be promoted by inclusion of sequences which promote recombination with the genome, in accordance with standard techniques.
[0093] The present invention also provides a method which comprises using a construct as stated above in an expression system in order to express a specific binding member or polypeptide as above.
[0094] Preferred features of each aspect of the invention are as for each of the other aspects mutatis mutandis. The prior art documents mentioned herein are incorporated to the fullest extent permitted by law.
[0095] The inventors have unexpectedly found that a family of mAbs FG88 recognises LecLe x , Le a Le x , Di-Le a and Le a containing glycans induced non apoptotic direct cell death without immune effector cells.
[0096] In one aspect, of the present invention it provides drugs which bind to LecLe x , Le a Le x , Le a containing glycan, Le a and Di-Le a and induce non apoptotic cell death.
[0097] FG88 mAbs induced membrane damage to cells resulting in cell clumping, loss of microvilli, uptake of small molecular weight dyes and pore formation. The cell death was not inhibited by pan-caspase inhibitors and did not induce DNA fragmentation suggesting that the death was not mediated via apoptosis. Over time cells developed larger pores and lysed in a mechanism similar to oncosis. This is similar to a number of mAbs recognising other glycan but has not been described for mAbs recognising LecLe x , Le a Le x , Le a containing glycan, Le a and Di-Le a [53-58]. The FG88 mAbs also exhibited potent in vitro cytotoxic activity through antibody dependent cellular cytotoxicity (ADCC) and complement cellular cytotoxicity (CDC). The administration of FG88.2 and FG88.7 mAbs (0.1 mg intravenous (i.v.) twice a week for 9 weeks) to mice with established metastases in the liver and peritoneal cavity results in complete tumour eradication and cure of 40% of the mice. The potential of FG88.2 and FG88.7 mAbs in eradicating well-established tumours without concomitant chemotherapy indicates their potential as monotherapeutic agents for the treatment of multiple LecLe x , Le a Le x , Di-Le a and Le a expressing human solid tumours.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure Legends
[0098] FIG. 1 a : Amino acid and nucleotide sequence for the mouse IgG3 heavy chain of the FG88.2 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 1 b : Amino acid and nucleotide sequence for the mouse kappa chain of the FG88.2 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 1 c : The chimeric version of the FG88.2 mAb (original murine variable regions linked to human constant region sequence), produced by a transfected cell line, binds the target cell line (C170). FIG. 1 d : Amino acid and nucleotide sequence for the human IgG1 heavy chain of the FG88.2 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 1 e : Amino acid and nucleotide sequence for the human kappa chain of the FG88.2 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59].
[0099] FIG. 2 a : Amino acid and nucleotide sequence for the mouse IgG3 heavy chain of the FG88.7 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 2 b : Amino acid and nucleotide sequence for the mouse kappa chain of the FG88.7 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 2 c : The chimeric version of the FG88.7 mAb (original murine variable regions linked to human constant region sequence), produced by a transfected cell line, binds the target cell line (C170). FIG. 2 d : Amino acid and nucleotide sequence for the human IgG1 heavy chain of the FG88.7 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. FIG. 2 e : Amino acid and nucleotide sequence for the human kappa chain of the FG88.7 mAb. Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59].
[0100] FIG. 3 a : Binding of FG88 hybridoma supernatant to the colorectal cancer cell line Colo205 shown by indirect immunofluorescence staining and flow cytometric analysis. The panels represent (a) FG88.2 (neat supernatant); (b) FG88.7 (neat supernatant); (c) the positive control W6/32 (5 μg/ml), a mAb directed against human class I histocompatibility antigens (HLA-A,B,C); and (d) the negative control mouse immunoglobulin (IgG) (5 μg/ml). Results are expressed as geometric mean values (Gm).
[0101] FIG. 3 b : Assessment of FG88 hybridoma supernatant binding to healthy donor blood by indirect immunofluorescence staining and flow cytometric analysis. The CEACAM6 (anti-CEACAM6; binds granulocytes; 10 μg/ml) and W6/32 (anti-HLA-A,B,C; 5 μg/ml) mAbs are included as positive controls and normal mouse serum and medium alone (RPMI), as the negative.
[0102] FIG. 3 c : Binding of FG88.2 hybridoma supernatant to lipid antigens as assessed by thin layer chromatography (TLC). FG88.2 hybridoma supernatant (1/20 dilution) binding lipid antigens of 1) AGS (total lipid extract from 2×10 6 cells), 2) C170 (total lipid extract from 2×10 6 cells), 3) Colo205 (total lipid extract from 2×10 6 cells) or, 4) the chloroform methanol control.
[0103] FIG. 4 : Binding of FG88.2 and FG88.7 were screened against The Consortium for Functional Glycomics glycan array which is composed of 610 mammalian glycan targets. The fine specificity between (a) FG88.2 and (b) FG88.7 are compared; where Le a =Lewis a , Le x =Lewis x , Le a --=Lewis a containing glycan and Le x --=Lewis x containing glycan. The corresponding details of glycans bound are shown where ▪ represents glucosylamine, represents galactose, ▴ represents fucose, and represents mannose. Sp denotes the length of spacer between glycan and slide.
[0104] FIG. 5 : Binding of FG88.2 and FG88.7 to protein and lipid antigens as assessed by Western blot analysis. Lanes 1) Colo205 cell lysates (1×10 5 cells equivalent), 2) Colo205 plasma membrane (1×10 6 cells equivalent), 3) Colo205 total lipid extract (1×10 6 cells equivalent), 4) Colo205 plasma membrane lipid extract (1×10 6 cells equivalent) and 5) C170 cell lysates (1×10 5 cells equivalent) using a) FG88.2 (5 μg/ml) b) FG88.7 (5 μg/ml) and c) 505/4 (5 μg/ml).
[0105] FIG. 6 : Binding of FG88.2 and FG88.7 to lipid antigens as assessed by TLC. Total lipid extracts from 1) AGS, 2) Colo205, 3) MKN45 and 4) C170 tumour cells (each 2×10 6 cells equivalent) using a) FG88.2 (5 μg/ml), b) 505/4 (5 μg/ml), c) FG88.7 (5 μg/ml) and d) CA19-9 (5 μg/ml). The 505/4 and CA19-9 mAbs were included in the panel for comparison.
[0106] FIG. 7 : Assessment of CH88.2 and CH88.7 binding to Colo205 cells by indirect immunofluorescence staining and flow cytometric analysis at a range of concentrations. 1×10 5 Colo205 cells were incubated with CH88.2 and CH88.7 mAbs at a range of concentrations from 0.1-10 μg/ml. Medium alone (RPMI) was used as the negative control.
[0107] FIG. 8 a : Binding of FG88.2, FG88.7, CH88.2 and CH88.7 mAbs to normal human whole blood, and the panel of comparative mAbs; 505/4, CA19-9 and 7-Le, as assessed by indirect immunofluorescence staining and flow cytometric analysis. Binding of these mAbs to normal human blood was compared to the positive controls: W6/32, anti-HLA-A,B,C mAb; CEACAM6, an anti-CEACAM6 mAb and OKT3, an anti-CD3 mAb. Mouse immunoglobulin (IgG) and medium alone (RPMI) were the negative controls
[0108] FIG. 8 b : Sandwich ELISA using FG88.2 for the detection of secreted Lea in saliva. Saliva from nine healthy donors was collected, heat inactivated and analyzed for the presence of Lea. Three out of nine donors tested strongly positive.
[0109] FIG. 8 c : Evaluation of FG88 binding to erythrocytes from Le a -positive donor by flow cytometry. Absence of erythrocyte binding by FG88.2 (i) and FG88.7 (ii) was compared to control mAbs: 7-Le, anti-Le a (iii) and 225-Le, anti-Le e (iv). MAb 791T/36, anti-CD55 (v) and (vi) IgG isotype control were used as positive and negative controls, respectively. Representative result from three Le a -positive donors.
[0110] FIG. 9 a : Confocal microscope analysis of the internalisation of FG88.2 and FG88.7 mAbs on C170 cells. C170 cells were grown on coverslips and incubated with a) Alexa-488 labelled FG88.2 (A-FG88.2; 5 μg/ml) mAb, b) Alexa-488 labelled FG88.7 (A-FG88.7; 5 μg/ml) mAb and c) medium alone (negative control) for 2 hrs and processed as described in the ‘methods’.
[0111] FIG. 9 b : Assessment of the internalisation of FITC-labelled FG88.2 (FG88.2FITC) and FG88.7 (FG88.7FITC) mAbs into Colo205 cells at 4° C. and 37° C. by acid wash flow cytometric analysis. Internalisation of FG88.2FITC and FG88.7FITC mAbs to Colo205 cells were compared to PE-labelled Epcam mAb (EpcamPE) which was used as positive control. PBS at pH2, and pH7 were used as wash buffers to wash away mAbs bound to cell surface antigens. Medium alone (RPMI) was used as negative control. FITC-labelled samples were analysed via the FL1 channel and PE-labelled samples, the FL2 channel.
[0112] FIG. 9 c : Time-lapse confocal microscopy of Alexa Fluor® 488 labelled FG88 mAbs internalizing into live C170 cells. Merged images taken every 20 minutes demonstrate FG88 internalization and co-localization with lysosomal compartments (arrows). The nucleus was labelled with Hoechst 33258, lysosomal compartments with LysoTracker® Deep Red and the plasma membrane with CellMask™ Orange. Magnification 60×.
[0113] FIG. 9 d : Targeted toxin (saporin) delivery by internalized FG88 mAbs in a panel of cancer cell lines [C170 (i), Panc 1 (ii), ST16 (iii) and HT29 (iv)]. The anti-proliferative effect of internalized FG88 mAbs preincubated with a saporin-linked anti-mouse IgG Fab fragment was evaluated using 3 H-thymidine incorporation. Results (mean±STD from three independent experiments) are presented as a percentage of proliferation of cells treated with primary mAbs only; normalized values are shown for C170 and Panel [FG88.7 (∘); FG88.2 (▴)].
[0114] FIG. 10 a : ADCC killing of Colo205 cell line by FG88.2 and FG88.7. 51 Cr-labeled cells were cultured at 5×10 3 cells/50 μl with increasing concentrations of antibodies in the presence of PBMCs. The cells were incubated for 18 hrs at 37° C. 51 Cr released in the supernatant was measured as percentage of total 51 Cr released with 10% Triton-X. PBMCs plus Colo205 cells were included as a negative control.
[0115] FIG. 10 b : ADCC activity of FG88 mAbs on a panel of tumor cell lines. FG88 mAbs and control (791T/36) were used at 10 μg/ml.
[0116] FIG. 10 c : CDC killing of C170 cell line by FG88.2 and FG88.7 mAbs. C170 cells were incubated at 5×10 3 cells/50 μl in the presence of increasing concentrations of FG88.2 and FG88.7 in the presence of human serum. The percentage cell lysis was measured after 18 hrs at 37° C. 51 Cr released in supernatant was measured as percentage of total 51 Cr released with 10% Triton-X. Serum plus Colo205 cells were included as a negative control.
[0117] FIG. 10 d : CDC activity of FG88 mAbs on a panel of tumor cell lines. FG88 mAbs and control (791T/36) were used at 10 μg/ml. Significance (Panels B and D) was established by multiple t-tests versus PBMC or serum control repectively, with Holm-Sidak correction for multiple comparisons and α=0.05 (GraphPad Prism 6).
[0118] FIG. 11 a : FG88.2 and FG88.7 induced PI uptake (suggestive of direct cell death) into C170 cells at both 37° C. and 4° C. C170 cells were incubated with 10 and 20 μg/ml of FG88.2 and FG88.7 at 37° C. and 4° C. 505/4 and medium alone were included as positive and negative controls respectively.
[0119] FIG. 11 b : FG88.2 and FG88.7 induced PI uptake (suggestive of direct cell death) into C170 cells occurs even in the presence of the caspase inhibitor Z-FMK-VAD. The panels A1-D1 and A3-D3 show the FACS dot plots corresponding to histograms of C170 cells incubated with FG88.2 at 10 μg/ml+/−Z-FMK-VAD (A2 and A4), FG88.2 at 30 μg/ml+/−Z-FMK-VAD (B2 and B4), FG88.7 at 10 μg/ml+/−Z-FMK-VAD (C2 and C4) and FG88.7 at 30 μg/ml+/−Z-FMK-VAD (D2 and D4).
[0120] FIG. 12 : Chimeric FG88.2 (CH88.2) induced PI uptake of C170 cells at 37° C. C170 cells were incubated with 30 μg/ml of CH88.2 at 37° C. FG88.2 (30 μg/ml) and FG88.7 (30 μg/ml) were included for comparison. Isotype control and medium alone (RPMI) were included as negative controls. 0.5% H 2 O 2 and 0.4% saponin were used as positive controls.
[0121] FIG. 13 : Measurement of apoptosis associated DNA fragmentation. DNA was extracted from FG88.2-treated C170 cells (lane 2), FG88.2+Z-FMK-VAD-treated C170 cells (lane 3), FG88.7-treated C170 cells (lane 4), FG88.7+Z-FMK-VAD-treated C170 cells (lane 5), untreated C170 cells (lane 6), anti-Fas mAb treated Jurkat cells (lane 7) and anti-Fas+Z-FMK-VAD-treated Jurkat cells (lane 8) and analysed on a 0.8% agarose gel, with DNA equivalent to 1.25×10 6 cells per lane. FG88.2 and FG88.7 were used at 30 μg/ml and the anti-Fas mAb at 0.5 μg/ml. Pan-caspase inhibitor Z-FMK-VAD was used at a final concentration of 20 μM. The DNA samples were prepared from untreated or mAb pre-treated cells after treatment for 20 hrs at 37° C. The relative mobility of a 1 kb DNA ladder is shown as molecular weight standards (lane 1).
[0122] FIG. 14 : Inhibition of 3 H-thymidine incorporation into DNA by FG88.2 and FG88.7 in the presence or absence of the pan-caspase inhibitor Z-FMK-VAD in exponential growing C170 human colorectal tumour cells. C170 cells were incubated with FG88.2 (a) and FG88.7 (b) at a range of concentrations from 0.03-3 μg/ml for 48 hrs. Medium alone was used as a negative control. Jurkat cells (c) treated with anti-Fas mAb at a concentration range from 0.003 to 0.3 μg/ml in the presence or absence of pan caspase inhibitor Z-FMK-VAD was used as a positive control.
[0123] FIG. 15 : Inhibition of C170 cell growth by FG88.2 and FG88.7. At day 0, 1×10 5 C170 cells were incubated with 10 μg/ml of FG88.7 and FG88.2 at 37° C. for 4 days. 505/4 mAb and medium alone (RPMI) was included as positive and negative controls respectively.
[0124] FIG. 16 : Scanning electron microscope (SEM) analysis of the C170 cell surface after mAb treatment. C170 cells were grown on coverslips for 24 hr to establish adherent cells and then incubated with a-b) medium alone, c-d) 0.4% saponin, e-f) FG88.7 (30 μg/ml), g-h) FG88.2 (30 μg/ml) and i-j) 0.5% H 2 O 2 for 20 hrs at 37° C. and processed as described in the ‘methods’. Magnifications are at ×2000 (bar=10 μm) and ×10,000 (bar=1 μm). White arrows indicate pores formed on C170 cell surface.
[0125] FIG. 17 : FG88.2 mAb induced 3KDa and 40 Kda dextran uptake (suggestive of induced direct cell death) in C170 cells. C170 cells were incubated with 3KDa and 40 KDa fluorochrome-labelled dextran and treated with 30 μg/ml of FG88.2 mAb at 37° C. for 2 hr. 0.5% H 2 O 2 and 0.4% (w/v) saponin was used as positive controls. Medium alone (RPMI) was included as negative control. (Green histogram represents single cell population and red histogram represents the aggregated cell population).
[0126] FIG. 18 a : Binding of FG88.2 and FG88.7 mAbs to cells with different antigen expression level. Exponentially growing tumour cells were harvested and stained by indirect immunofluorescence and analysed by flow cytometry analysis. W6/32 (anti-HLA-A,B,C) and medium alone (RPMI) were used as positive and negative controls, respectively. 505/4, CA19-9 and 7-Le were included in the same panel for comparison. Results are expressed as geometric means (y-axis; labelled MLF).
[0127] FIG. 18 b,c : Uptake of PI by HT29, Panc-1 and OVCAR4 tumour cells at b) 37° C. and c) 4° C. with FG88.2, FG88.7, 505/4, CA19-9 and 7-Le mAbs at 10 μg/ml. Medium alone (RPMI) was included as a negative control.
[0128] FIG. 19 a : Binding of FG88.2, FG88.7 and CH88.2 to a panel of tumour cell lines. Binding of FG88.2, FG88.7 and CH88.2 at 30 μg/ml to C170, Colo205, AGS, HT29 and Panc1 was assessed by immunofluorescence staining and flow cytometric analysis. In all cell lines, binding was compared to the positive control, Erbitux (anti-EGFR). An anti-Leg mAb (30 μg/ml) was included for comparison. Medium alone (RPMI) was used as negative control. Results are expressed as geometric means (Gm).
[0129] FIG. 19 b : Uptake of PI by C170, Colo205, AGS, HT29 and Panc1 tumour cells at 37° C. with CH88.2. Cells were incubated with 30 μg/ml of CH88.2 for 2 hr at 37° C. FG88.2, FG88.7, anti-Leg mAb and Erbitux were included in same panel at 30 μg/ml for comparison. 0.5% H 2 O 2 and medium alone (RPMI) were included as positive and negative controls respectively. Results are expressed as geometric means (Gm).
[0130] FIG. 20 : In vivo anti-tumour activity of FG88 mAbs. a) Percentage tumour growth is shown with the C170HM2 bioluminescence mouse tumour model used to assess the anti-tumour activity of FG88.2 and FG88.7 compared to the positive control mAbs and vehicle only control (PBS). In this model bioluminescence represents tumour cell viability. Group n≧8; the treatment with FG88.2 produced a significant reduction in percentage tumour growth by day 59 (p=0.016). Treatment was halted on day 120. b) Analysis by Log Rank Mantel-Cox test demonstrates significant survival in the FG88.7 (p=0.0037) treatment group compared to the vehicle only control.
DETAILED DESCRIPTION OF THE INVENTION
[0131] The invention will now be described further in the following non-limiting examples and accompanying drawings.
Methods
[0132] Binding to Tumour Cell Lines:
[0133] 1×10 5 cancer cells were incubated with 50 μl of primary antibodies at 4° C. for 1 hr. Cells were washed with 200 μl of RPMI 10% new born calf serum (NBCS: Sigma, Poole, UK) and spun at 1,000 rpm for 5 min. Supernatant was discarded and 50 μl of FITC conjugated anti-mouse IgG Fc specific mab (Sigma; 1/100 in RPMI 10% NBCS) was used as secondary antibody. Cells were incubated at 4° C. in dark for 1 hr then washed with 200 μl RPMI 10% NBCS and spun at 1,000 rpm for 5 min. After discarding supernatant, 0.4% formaldehyde was used to fix the cells. Samples were analysed on a Beckman coulter FC-500 flow cytometer (Beckman Coulter, High Wycombe, UK). To analyse and plot raw data, WinMDI 2.9 software was used.
[0134] Binding to Blood:
[0135] 50 μl of healthy donor blood was incubated with 50 μl primary antibody at 4° C. for 1 hr. The blood was washed with 150 μl of RPMI 10% NBCS and spun at 1,000 rpm for 5 min. Supernatant was discarded and 50 μl FITC conjugated anti-mouse IgG Fc specific mAb (1/100 in RPMI 10% NBCS) was used as the secondary antibody. Cells were incubated at 4° C. in the dark for 1 hr then washed with 150 μl RPMI 10% NBCS and spun at 1,000 rpm for 5 min. After discarding the supernatant, 50 μl/well Cal-Lyse (Invitrogen, Paisley, UK) was used followed by 500 μl/well distilled water to lyse red blood cells. The blood was subsequently spun at 1,000 rpm for 5 min. Supernatant was discarded and 0.4% formaldehyde was used to fix the cells. Samples were analysed on a FC-500 flow cytometer (Beckman Coulter). To analyse and plot raw data, WinMDI 2.9 software was used.
[0136] Erythrocyte Assays:
[0137] Healthy donor erythrocytes were washed 3 times in PBS and then resuspended in 10 times the packed cell volume of PBS. 50 μl of washed erythrocytes were then incubated with 50 μl primary antibodies at 37° C. for 1 hr. Cells were washed with 150 μl of PBS and spun at 2,000 rpm for 5 min. Supernatant was discarded and cells resuspended in 50 μl FITC-conjugated anti-mouse IgG Fc-specific secondary antibody (Sigma, 1/100 dilution in PBS, 1% BSA). Cells were incubated at 37° C. in the dark for 1 hr then washed with 150 μl PBS and spun at 2,000 rpm for 5 min. Supernatant was discarded and cells were resuspended in 500 μl PBS. Samples were analysed on a MACSQ flow cytometer (Miltenyi Biotech, Bisley, UK) using MACSQ software.
[0138] Plasma Membrane Glycolipid Extraction:
[0139] Colo205 cell pellet (5×10 7 cells) was resuspended in 500 μl of Mannitol/HEPES buffer (50 mM Mannitol, 5 mM HEPES, pH7.2, both Sigma) and passed through 3 needles (23G, 25G, 27G) each with 30 pulses. 5 μl of 1M CaCl 2 was added to the cells and passed through 3 needles each with 30 pulses as above. Sheared cells were incubated on ice for 20 min then spun at 3,000 g for 15 min at room temperature. Supernatant was collected and spun at 48,000 g for 30 min at 4° C. and the supernatant was discarded. The pellet was resuspended in 1 ml methanol followed by 1 ml chloroform and incubated with rolling for 30 min at room temperature. The sample was then spun at 1,200 g for 10 min to remove precipitated protein. The supernatant, containing plasma membrane glycolipids, was collected and stored at −20° C.
[0140] TLC Analysis of FG88 Glycolipid Binding:
[0141] Lipid samples were blotted onto silica plates and developed in chloroform/methanol/distilled water (60:30:5 by volume) twice followed by hexane:diethyl ether:acetic acid (80:20:1.5 by volume) twice. The dried plates were sprayed with 0.1% polyisobutylmethacrylate (Sigma) in acetone. After drying in air, the plates were blocked with PBS 2% BSA for 1 hr at room temperature. The plates were then incubated overnight at 4° C. with primary antibodies diluted in PBS 2% BSA. The plates were then washed 3 times with PBS and incubated with biotin-conjugated anti-mouse IgG Fc specific secondary antibody (Sigma) diluted 1/1000 in PBS 2% BSA for 1 hr at room temperature. The plates were subsequently washed again in PBS before incubating with IRDye 800CW streptavidin (LICOR Biosciences, Cambridge, UK) diluted 1/1000 in PBS 2% BSA for 1 hr at room temperature in the dark. The plates were washed a further 3 times with PBS and air dried in the dark. Lipid bands were visualized using a LICOR Odyssey scanner.
[0142] Glycome Analysis:
[0143] To clarify the fine specificities of the FG88 mAbs further, the antibodies were FITC labelled and sent to the Consortium for Functional Glycomics where they were screened against ≧600 natural and synthetic glycans. Briefly, synthetic and mammalian glycans with amino linkers were printed onto N-hydroxysuccinimide (NHS)-activated glass microscope slides, forming amide linkages. Printed slides were incubated with 1 μg/ml of antibody for 1 hr before the binding was detected with Alexa488-conjugated goat anti-mouse IgG. Slides were then dried, scanned and the screening data compared to the Consortium for Functional Glycomics database.
Affinity Analysis
[0144] Surface Plasmon Resonance (SPR, Biacore X, GE Healthcare) analysis was used to investigate real-time binding kinetics of the FG88 mAbs. Polyvalent Le a -HSA was coupled onto a CM5 biosensor chip according to the manufacturer's instructions and a reference cell was treated in a similar manner, but omitting the Le a conjugate. FG88 mAbs diluted in HBS-P buffer (10 mmol/L HEPES, pH 7.4, 150 mmol/L NaCl, 0.005% (v/v) surfactant P20) were run across the chip at a flow rate of 30 μl/min and BIAevaluation software 4.1 was used to determine the kinetic binding parameters from which affinities are calculated.
[0145] SDS-PAGE and Western Blot Analysis:
[0146] Briefly, 1×10 5 or 10 6 cell equivalents of Colo205 cell lysate, plasma membrane, total lipid extract, plasma membrane lipid extract or C170 cell lysates were analysed for FG88 binding. Tumour cell total and plasma membrane lipid extracts and cell lysates were reduced with dithiothreitol (DTT; Pierce Biotechnology, ThermoFisher, Loughborough, UK) and subjected to SDS-PAGE using NOVEX 4% to 12% Bis-Tris gels (Invitrogen), and transferred to Hybond-P PVDF membranes (GE Healthcare, Amersham, UK) using lx transfer buffer (20×, Invitrogen) and 20% (v/v) methanol at 30V for 1 hr. Membranes were blocked with 5% (w/v) non-fat dry milk in 0.05% (v/v) Tween-PBS for 1 hr then probed with primary antibodies diluted in Tween-PBS, 2% BSA for 1 hr. Primary antibody binding was detected using biotin-conjugated anti-mouse IgG Fc specific secondary antibody (Sigma; 1/2000 dilution in Tween-PBS, 2% BSA) for 1 hr, and visualized using IRDye 800CW streptavidin (LICOR Biosciences, UK; 1/1000 in Tween-PBS 2% BSA).
[0147] Identification of FG88.2 and FG88.7 Heavy and Light Chain Variable Regions.
[0148] Cell Source and Total RNA Preparation:
[0149] Approximately 5×10 6 cells from hybridomas FG88.2 and FG88.7 were taken from tissue culture, washed once in PBS, and the cell pellet treated with 5000 Trizol (Invitrogen). After the cells had been dispersed in the reagent, they were stored at −80° C. until RNA was prepared following manufacturer's protocol. RNA concentration and purity were determined by Nanodrop. Prior to cDNA synthesis, RNA was DNase I treated to remove genomic DNA contamination (DNase I recombinant, RNase-free, Roche Diagnostics, Burgess Hill, UK) following manufacturer's recommendations.
[0150] cDNA Synthesis:
[0151] First-strand cDNA was prepared from 3 μg of total RNA using a first-strand cDNA synthesis kit and AMV reverse transcriptase following manufacturer's protocol (Roche Diagnostics). After cDNA synthesis, reverse transcriptase activity was destroyed by incubation at 90° C. for 10 mins and cDNA stored at −20° C. GAPDH PCR to Assess cDNA Quality:
[0152] A PCR was used to assess cDNA quality; primers specific for the mouse GAPDH house-keeping gene (5′-TTAGCACCCCTGGCCAAGG-3′ and 5′-CTTACTCCCTTGGAGGCCATG-3′) were used with a hot-start Taq polymerase (NEB, Hitchen, UK) for 35 cycles (95° C., 3 mins followed by 35 cycles of 94° C./30 secs, 55° C./30 secs, 72° C./1 min; final polishing step of 10 mins at 72° C.). Amplified products were assessed by agarose gel electrophoresis.
[0153] PCR Primer Design for Cloning FG88.7 Variable Regions:
[0154] Primers were designed to amplify the heavy and light chain variable regions based upon the PCR product sequence data. Primers were designed to allow cloning of the relevant chain into unique restriction enzyme sites in the hIgG1/kappa double expression vector pDCOrig-hIgG1. Each 5′ primer was targeted to the starting codon and leader peptide of the defined variable region, with a Kozak consensus immediately 5′ of the starting codon. Each 3′ primer was designed to be complementary to the joining region of the antibody sequence, to maintain reading frame after cloning of the chain, and to preserve the amino acid sequence usually found at the joining region/constant region junction. All primers were purchased from Eurofins MWG.
[0155] Heavy Chain Variable Region PCR:
[0156] Immunoglobulin heavy chain variable region usage was determined using PCR with a previously published set of primers [60]. Previous results using a mouse mAb isotyping test kit (Serotec, Oxford, UK) had indicated that FG88.2 and FG88.7 were both mouse IgG3 antibodies. Appropriate constant region reverse primers were therefore used to amplify from the constant regions. PCR amplification was carried out with 12 mouse VH region-specific 5′ primers and 3′ primers specific for previously determined antibody subclass with a hot-start Taq polymerase for 35 cycles (94° C., 5 min followed by 35 cycles of 94° C./1 min, 60° C./1 min, 72° C./2 min; final polishing step of 20 min at 72° C.). Amplified products were assessed by agarose gel electrophoresis. Positive amplifications resulted for the VH4 primer.
[0157] Light (κ) Chain Variable Region PCRs:
[0158] Immunoglobulin light chain variable region usage was determined using PCR with a previously published set of primers [60]. Previous results using a mouse mAb isotyping test kit had indicated that both FG88.2 and FG88.7 used κ light chains. PCR amplification was carried out with mouse Vκ region-specific 5′ and 3′ mouse Cκ specific primers with a hot-start Taq polymerase for 35 cycles (94° C., 5 mins followed by 35 cycles of 94° C./1 min, 60° C./1 min, 72° C./2 mins; final polishing step of 20 mins at 72° C.). Amplification products were assessed by agarose gel electrophoresis. Positive amplifications resulted with the Vκ1 and Vκ2 primers for both FG88.2 and FG88.7.
[0159] PCR Product Purification and Sequencing:
[0160] PCR products were purified using a Qiaquick PCR purification kit (Qiagen, Crawley, UK). The concentration of the resulting DNA was determined by Nanodrop and the purity assessed by agarose gel electrophoresis. PCR products were sequenced using the originating 5′ and 3′ PCR primers at the University of Nottingham DNA sequencing facility (http://www.nottingham.ac.uk/life-sciences/facilities/dna-sequencing/index.aspx). Sequences were analysed (V region identification, junction analysis) using the IMGT database search facility (http://www.imgt.org/IMGT_vquest/vquest?livret=0&Option=mouseIg). Sequencing indicated that FG88.2 and FG88.7 shared near identical heavy and light chain variable regions (heavy chain; IGHV6-6*01, IGHJ1*01, light chain; IGKV12-41*01, IGKJ1*01). Sufficient residual constant region was present in the heavy chain sequences to confirm that FG88.2 and FG88.7 were of the mIgG3 subclass, indicating clearly that the two clones had come from two independent splenocyte-NSO fusion events.
[0161] Cloning Strategy:
[0162] Direct cloning of the PCR products into the pDCOrig-hIgG1 vector using the restriction sites incorporated into the PCR primers was known to be relatively inefficient from previous Scancell experience. A dual cloning strategy was therefore adopted; the PCR product generated using a proof-reading polymerase was cloned into both pDCOrig-hIgG1 and a TA vector (pCR2.1; Invitrogen) simultaneously, with the TA vector-cloned product acting as an easily expanded backup source of material for cloning should the initial pDCOrig-hIgG1 cloning fail.
[0163] FG88.7 Heavy/Light Chain PCR for Cloning:
[0164] PCR amplification was carried out using a proof-reading polymerase (Phusion; NEB) and the cloning primers described above using the FG88.7 cDNA template previously described for 35 cycles (98° C., 3 min followed by 35 cycles of 98° C./30 sec, 58° C./30 sec, 72° C./45 sec; final polishing step of 3 min at 72° C.). Successful amplification was confirmed by agarose gel electrophoresis.
[0165] Method 1—Direct Light Chain Cloning:
[0166] Amplified FG88.7 light chain was digested sequentially with the restriction enzymes BsiWI and BamHI according to manufacturer's instructions (NEB). Vector (pDCOrig-hIgG1, containing V regions from a previously cloned antibody) was simultaneously digested. Vector DNA was agarose gel purified using a QIAquick gel extraction kit (Qiagen) and insert DNA purified using a PCR purification kit. After DNA quantification by Nanodrop, vector DNA was phosphatase treated according to manufacturer's recommendations (Antarctic Phosphatase, NEB) and light chain insert ligated into the vector (T4 DNA ligase, NEB). Ligated DNA was transformed into chemically competent TOP10F′ cells (Invitrogen) and spread on 35 μg/ml Zeocin (Invitrogen, Toulouse, France) supplemented LB agar plates which were then incubated overnight at 37° C.
[0167] Method 2—TOPO Light Chain Cloning:
[0168] Amplified FG88.7 light chain was treated with Taq polymerase (NEB) for 15 min at 72° C. to add ‘A’ overhangs compatible with TA cloning. Treated PCR product was incubated with the TOPO TA vector pCR2.1 (Invitrogen) and transformed into chemically competent TOP10F′ cells according to manufacturer's instructions. Transformed bacteria were spread on ampicillin (80 μg/ml) supplemented LB agar plates which were then incubated overnight at 37° C. Colonies were grown in liquid culture (LB supplemented with 80 μg/ml ampicillin) and plasmid DNA prepared (spin miniprep kit, Qiagen). Presence of an insert was confirmed by sequential digestion with BsiWI and BamHI and agarose gel electrophoresis. Sequencing was carried out on miniprep DNA from colonies using T7 and M13rev primers. The DNA insert from one such colony had the predicted FG88.7 light chain sequence; a 300 ml bacterial LB/ampicillin culture was grown overnight and plasmid DNA prepared by maxiprep (plasmid maxi kit, Qiagen). Maxiprep DNA insert was confirmed by sequencing.
[0169] TOPO Heavy Chain Cloning:
[0170] Amplified FG88.7 heavy chain was treated with Taq polymerase (NEB) for 15 mi at 72° C. to add ‘A’ overhangs. Treated PCR product was incubated with the TOPO TA vector pCR2.1 and transformed into chemically competent TOP10F′ cells as above. Transformed bacteria were spread on ampicillin supplemented LB agar plates which were then incubated overnight at 37° C. Colonies were grown in liquid culture (LB/ampicillin) and plasmid DNA prepared (spin miniprep kit). Presence of an insert was confirmed by digestion with HindIII and AfeI and agarose gel electrophoresis. Sequencing was carried out on miniprep DNA from a number of colonies using T7 and M13rev primers. The DNA insert from one such colony had the predicted FG88.7 heavy chain sequence; a 300 ml bacterial LB/ampicillin culture was grown overnight and plasmid DNA prepared by maxiprep (plasmid maxi kit, Qiagen). Maxiprep DNA insert was confirmed by sequencing.
[0171] pDCOrig-hIgG1 Double Expression Vector Light Chain Cloning:
[0172] The FG88.7 light chain was digested from the TOPO vector pCR2.1 by sequential digestion with BsiWI and BamHI and the 400 bp insert DNA agarose gel purified using a QIAquick gel extraction kit (Qiagen) following manufacturer's recommendations. This insert was ligated into previously prepared pDCOrig-hIgG1 vector (see above) and transformed into chemically competent TOP10F′ cells. Transformations were spread on 35 μg/ml Zeocin supplemented LB agar plates which were then incubated overnight at 37° C. Colonies were grown in liquid culture (LB supplemented with 35 μg/ml Zeocin) and plasmid DNA prepared (spin miniprep kit, Qiagen). Sequencing was carried out on miniprep DNA from all colonies using the P6 sequencing primer sited in the human kappa constant region. The DNA insert from a colony had the predicted FG88.7 light chain sequence correctly inserted in pDCOrig-hIgG1; a 300 ml bacterial LB/zeocin culture was grown overnight and plasmid DNA prepared by maxiprep (plasmid maxi kit, Qiagen).
[0173] pDCOrig-hIgG1 Double Expression Vector Heavy Chain Cloning:
[0174] The FG88.7 heavy chain insert was digested from the TOPO vector pCR2.1 by digestion with HindIII and AfeI. Vector (pDCOrig-hIgG1-27.18k) containing the FG88.7 kappa light chain (prepared above) was also digested with HindIII and AfeI. The vector DNA was then phosphatase treated according to manufacturer's recommendations (Antarctic Phosphatase, NEB). After agarose gel electrophoresis, the 6.5kb pDCOrig-hIgG1 vector band and 400 bp FG88.7H insert band were isolated using a QIAquick gel extraction kit (Qiagen) following manufacturer's recommendations. The insert was ligated into the pDCOrig-hIgG1 vector and transformed into chemically competent TOP10F′ cells. Transformations were spread on 35 μg/ml Zeocin supplemented LB agar plates which were then incubated overnight at 37° C. Colonies were grown in liquid culture (LB supplemented with 35 μg/ml Zeocin) and plasmid DNA prepared (spin miniprep kit, Qiagen). Presence of an insert was confirmed by digestion with HindIII and AfeI and agarose gel electrophoresis. Sequencing was carried out on miniprep DNA from a number of the colonies using the P3rev sequencing primer sited in the human IgG1 constant region. The DNA insert from one of the colonies had the predicted FG88.7 heavy chain sequence correctly inserted in pDCOrig-hIgG1; a 300 ml bacterial LB/zeocin culture was grown overnight and plasmid DNA prepared by maxiprep (plasmid maxi kit, Qiagen). Sequencing was used to confirm that both heavy and light chain loci.
[0175] Expression, Purification and Characterisation of the Chimeric Antibody Constructs;
[0176] The methodology for the expression and purification of chimeric antibody described in the present invention can be achieved using methods well known in the art. Briefly, antibodies can be purified from supernatant collected from transiently, or subsequently stable, transfected cells by protein A or protein G affinity chromatography based on standard protocols, for example Sambrook et al. [61].
[0177] Immunohistochemistry Assessment for FG88:
[0178] To determine the therapeutic value of FG88, it was screened on gastric, ovarian, colorectal cancer tissue microarrays by immunohistochemistry (IHC).
[0179] Methodology: Immunohistochemistry was performed using the standard avidin-biotin peroxidise method. Paraffin embedded tissue sections were placed on a 60° C. hot block to melt the paraffin. Tissue sections were deparaffinised with xylene and rehydrated through graded alcohol. The sections were then immersed in 500 ml of citrate buffer (pH6) and heated for 20 min in a microwave (Whirlpool) to retrieve antigens. Endogenous peroxidase activity was blocked by incubating the tissue sections with endogenous peroxidase solution (Dako Ltd, Ely, UK) for 5 min. Normal swine serum (NSS; Vector Labs, CA, USA; 1/50 PBS) was added to each section for 20 min to block non-specific primary antibody binding. All sections were incubated with Avidin D/Biotin blocking kit (Vector Lab) for 15 min each in order to block non-specific binding of avidin and biotin. The sections were re-blocked with NSS (1/50 PBS) for 5 mins. Then tissue sections were incubated with primary antibody at room temperature for an hour. Anti-β-2-microglobulin (Dako Ltd; 1/100 in PBS) mAb and PBS alone were used as positive and negative controls respectively. Tissue sections were washed with PBS and incubated with biotinylated goat anti-mouse/rabbit immunoglobulin (Vector Labs; 1/50 in NSS) for 30 min at room temperature. Tissue sections were washed with PBS and incubated with preformed 1/50 (PBS) streptavidin-biotin/horseradish peroxidase complex (Dako Ltd) for 30 min at room temperature. 3, 3′-Diaminobenzidine tetra hydrochloride (DAB) was used as a substrate. Each section was incubated twice with 100 μl of DAB solution for 5 min. Finally, sections were lightly counterstained with haematoxylin (Sigma-Aldrich, Poole Dorset, UK) before dehydrating in graded alcohols, cleaning by immersing in xylene and mounting the slides with Distyrene, plasticiser, xylene(DPX) mountant (Sigma).
[0180] Confocal Microscopy:
[0181] FG88.2 and FG88.7 mAbs were labelled with Alexa-488 fluorophore (A-FG88.2 and A-FG88.7) according to manufacturer's protocol (Invitrogen). 1.5×10 5 C170 cells were grown on sterile circular coverslips (22 mm diameter, 0.16-0.19 mm thick) in 6 well plate for 24 hr in 5% CO 2 at 37° C. 24 hours later, cells on coverslips were treated with 5 μg/ml of A-FG88.2 and A-FG88.7 mAbs for 2 hr at 37° C. in dark. 2 hours later, excess/unbound mAbs were washed away using PBS. The cells were then fixed using 0.4% paraformaldehyde for 20 min in dark. 0.4% paraformaldehyde was washed away using PBS. The coverslips were mounted to slides with PBS:glycerol (1:1). The coverslip edge was sealed with clear nail varnish. Localisation of the A-FG88.2 and A-FG88.7 mAbs was visualised under a confocal microscope (Carl Zeiss, Jena, Germany).
[0182] ADCC and CDC:
[0183] Cells (5×10 3 ) were co-incubated with 100 μl of PBMCs, 10% autologous serum or media alone or with mAbs at a range of concentrations. Spontaneous and maximum releases were evaluated by incubating the labeled cells with medium alone or with 10% Triton X-100, respectively. After 4 hr of incubation, 50 μl of supernatant from each well was transferred to 96 well lumaplates. Plates were allow to dry overnight and counted on a Topcount NXT counter (Perkin Elmer, Cambridge, UK). The mean percentage lysis of target cells was calculated according to the following formula:
[0000]
Mean
%
lysis
=
100
×
mean
experimental
counts
-
mean
spontaneous
counts
mean
maximum
counts
-
mean
spontaneous
counts
[0184] [3H] Thymidine Incorporation Assay:
[0185] Cancer cells (1×10 3 /well) were incubated on a 96-well flat bottom microtitre plate for 24 hours to establish an adherent monolayer. Next day, mAbs were added 100 μl/well in quadruplicate (0.003 μg/ml to 3 μg/ml) in the presence or absence of 20 μM of a pan-caspase inhibitor Z-FMK-VAD (carbobenzoxy-valyl-alanyl-aspartyl-[O-methyl]-fluoromethylketone; Promega, Eastleigh, UK) for 48 hours. Cells were then exposed to 0.5 μCi/well of 3 H-thymidine during the final 24 hours of the 48-hour period. The incorporation of 3 H-thymidine into cells of the culture was measured using a liquid scintillation counter (Microscint 0 liquid scintillant on a Topcount NXT, both Perkin Elmer).
[0186] PI Uptake Assay:
[0187] FG88.2 and FG88.7 were incubated with C170 cells and tested for uptake of the small molecular weight dye propidium iodide (PI, Sigma) at various temperatures. Tumour cells (5×10 4 ) were incubated on a 96-well round bottom microtitre plate with 50 μl of primary antibodies at 37° C. or 4° C. for 2 hr. 1 μg of PI was added and cells were incubated at 37° C. or 4° C. for 30 min. 0.4% formaldehyde was used to fix the cells. Samples were analysed on a FC-500 flow cytometer (Beckman Coulter). To analyse and plot raw data WinMDI 2.9 software was used. For comparison, mAb 505/4 which is known to induce membrane damage was also included. Medium alone was included as a negative control.
[0188] Dextran Uptake Assay:
[0189] FG88.2 mAb was incubated with C170 cells and tested for uptake of fluorochrome-labelled 3KDa and 40KDa molecular weight dextran (Invitrogen) at 37° C. Tumour cells (5×10 4 ) were incubated on a 96-well flat bottom microtitre plate with 50 μl of primary antibodies at 37° C. for 2 hr. 1 μg of dextran was added and cells were incubated at 37° C. for 30 min. For comparison, 0.5% H 2 O 2 and 0.4% saponin, which are known to induce membrane damage, were also included. Medium alone (RPMI) was included as a negative control. Samples were analysed on a MACSQ flow cytometer (Miltenyi Biotech) using MACSQ software.
[0190] DNA Fragmentation:
[0191] C170 or Jurkat cells (1.25×10 6 ) were incubated with 30 μg/ml of FG88.2 or FG88.7 or 0.5 μg/ml of anti-Fas (Promega) mAbs in the presence or absence of the pan-caspase inhibitor Z-FMK-VAD (20 μM final concentration) at 37° C. 20 hours later, cells were collected by centrifugation at 14,000 rpm for 5 min at room temperature. Cell pellets were resuspended gently in 500 μl of lysis buffer (10 mM Tris-HCL pH8.5, 5 mM EDTA, 200 mM NaCl, 0.5% SDS, all Sigma) and incubated at 60° C. for 5 min. RNAse was added to each sample (Sigma; final concentration of 4 μg/ml) and incubated at 37° C. for 15 min. Proteinase K was added to each sample (Active Motif, La Hulpe, Belgium; final concentration of 2 ng/ml) and incubated at 60° C. for 1 hr. 350 μl of 5M NaCl was added to each sample and incubated on ice for 5 min. Samples were spun at 14,000 rpm for 15 min at 4° C. Supernatants were collected and an equal volume of ice cold phenol:chloroform (1:1 v/v) was added to each sample. Samples were spun at 14,000 rpm for 5 min at 4° C. The aqueous phase of each sample was collected and 20 μl of sodium acetate, pH 5.2 (Sigma; final concentration of 120 mM) was added to each sample. 500 μl of 100% ethanol (pre-chilled to −20° C.) was added to each sample and incubated at −80° C. for 1 hr. Samples were spun at 14,000 rpm for 10 min at 4° C. Supernatants were discarded and pellets were washed with 500 μl of pre-chilled 70% ethanol. Samples were spun at 14,000 rpm for 10 min at 4° C. Supernatants were removed, DNA pellets were allowed to air dry, resuspended in 20 μl of 10 mM Tris/HCl, pH8.5 buffer and analysed on a 0.8% agarose gel.
[0192] Scanning Electron Microscopy:
[0193] C170 cells (1×10 5 ) were grown on sterile circular coverslips (13 mm diameter, 0.2 mm thick; Thermanox, Nunc, Roskilde, Denmark) in a 6 well plate at 37° C., 5% CO 2 . 24 hours later, cells on coverslips were treated with 30 μg/ml of FG88.2 and FG88.7 mAbs, medium alone, 0.5% H 2 O 2 and 0.4% saponin (Sigma) for 20 hours at 37° C. 20 hours later, cells were washed with pre-warmed 0.1M sodium cacodylate buffer (pH7.4). Then washed cells were fixed with pre-warmed glutaraldehyde (final concentration of 12.5% w/v) for 24 hr. Fixed cells were washed twice with 0.1M sodium cacodylate buffer and post-fixed with 1% osmium tetroxide (pH 7.4) for 45 min. Subsequently, the cells were washed twice with deionised water. After the final wash, the cells were dehydrated in increasing concentration of ethanol from 40% to 100%. The prepared cells were exposed to critical point drying then sputtered with gold prior to SEM analysis (JSM-840 SEM, JEOL).
[0194] In Vivo Model:
[0195] The study was conducted under a UK Home Office Licence. NCRI guidelines for the welfare and use of animals in cancer research, LASA good practice guidelines and FELAS working group on pain and distress guidelines was also followed. Endotoxin free (<10 EU/ml) FG88 mAb was supplied in pre-formulated aliquots ready for dosing and stored at −20° C. until use. Age matched male MF-1 nude mice were obtained from Harlan Laboratories (Bichester, UK) with each group, FG88, control mAbs or the vehicle control, consisting of n>8 animals.
[0196] Mice were implanted with C170HM2 DLuX cells and monitored by optical imaging to determine tumour establishment and suitability to be entered into the study. Mice were dosed with either FG88 or the positive control mAb, 505/4 (1 mg/ml) dosed at 0.1 mg 2 x weekly 1000 intravenously (i.v.) until termination, or PBS, the vehicle control for the mAb, 1000 2× weekly i.v. until termination. Weekly bioluminescent imaging was carried out on all mice to obtain pre and post dosing tumour measurements. In this way each mouse provided pre-dose control readings against which tumour growth could be compared.
[0197] All measurements and readouts were transferred from the original dictation/notation to excel (tab delineated) format for data processing in SPSS v16.0. Data integrity was checked using explore and descriptive functions. Erroneous points when identified were cross referenced against the original data and corrected accordingly. The data was screened for outliers and distribution profile; data-points falling outside the 95% confidence limit (outliers) were removed from analysis, but kept in the datasheet for reference purposes.
[0198] Mice were imaged weekly for bioluminescent tumour burden (BLI) over the duration of the study as follows; 60 mg/kg D-Luciferin substrate was administered subcutaneously (s.c.), the mice were anesthetised and BLI readings taken 15 mins post substrate administration on open filter block (2D) and sequential emission filters (for DLIT, 3D reconstruction). Ventral and dorsal imaging was undertaken; the optimum position for imaging was abdomen uppermost. BLI was measured over the entire abdominal area, one Region of Interest (ROI) for each mouse in order to include all lesions present. Each mouse had a pre-dosing or baseline image taken to allow calculation of percentage tumour growth over time; these data were averaged per group. BLI readings were also taken after termination to identify tumours in PM tissue.
Example 1
Generation and Initial Characterisation of FG88 mAbs
[0199] FG88 was raised by immunisation with glycolipid antigens from the colorectal cell line, Colo205.
[0200] Analysis of antibody response to immunisations: Antibody titres were initially monitored by lipid enzyme-linked immunosorbent assay (ELISA). Thin layer chromatography (TLC) analysis using Colo205 total and plasma membrane lipid extracts, flow cytometry analysis (FACS) using Colo205 tumour cells and Western blot using Colo205 whole cell extract, total and plasma membrane lipid extracts were subsequently performed. The mouse considered to have the best response, compared to the pre-bleed serum control was boosted intravenously (i.v.) with Colo205 plasma membrane lipid extract prior to fusion.
[0201] 8 days after fusion, supernatants were collected and screened against fresh Colo205 tumour cells. Hybridomas which demonstrated cell surface binding, using an indirect immunofluorescence assay, were harvested, washed in complete media and spread across 96 well plates at 0.3 cells per well to acquire a clone. The plate was then screened for positive wells and these grown on until a sufficient number of cells was obtained to spread across a 96 well plate at 0.3 cells per well for a second time. If the resulting number of colonies equalled ˜30 and all hybridomas were positive, the hybridoma was considered a clone. Methods for clonal expansion, bulk culture and antibody purification of antibodies or antibody fragments are available using conventional techniques known to those skilled in the art.
[0202] Binding of FG88 hybridoma supernatant to Colo205 cells: FG88.2 and FG88.7 were analysed for their ability to bind to Colo205 cells by indirect immunofluorescence and FACS analysis ( FIG. 3 a ). Both hybridomas bound with strong intensity to the cell surface of Colo205 cells (FG88.2 Gm 4539; FG88.7 Gm 2897) when compared to positive control mAb anti-HLA mAb W6/32 (eBioscience, CA, USA), and the negative controls of and isotype control In contrast, FG88.2 and FG88.7 hybridoma supernatants did not bind to any normal blood cells ( FIG. 3 b ). FG88.2 bound lipid antigens from C170 and Colo205 but not those from AGS (ATCC accession # CRL-1739; FIG. 3 c ).
Example 2
Defining the Epitopes Recognised by FG88 mAbs
[0203] To clarify the fine specificities of the FG88 mAbs, they were screened against >600 natural and synthetic glycans. Binding of FG88.2 and FG88.7 mAbs to the glycan array showed that both mAbs bound to LecLe x , Le a Le x , Le x containing glycan, Le a containing glycans, Le a and Di-Le a ( FIG. 4 a,b ). Subtle differences were observed between the two antibodies with FG88.2 binding most strongly to LecLe x and Le a Le x , followed Le a containing glycan, Le a , Di-Le a and Le x containing glycan. FG88.7 bound most strongly to LecLe x and Di-Le a , followed by Le a containing glycans, Le a Le x and Le x containing glycan.
[0204] Additionally, the mAbs bound simple Le a on the array but not Le c or Le x . This was corroborated by competition experiments where preincubation of both mAbs with a Le a -HSA conjugate, but not a Le x -HSA conjugate, abolished Colo205 binding (data not shown). The Le a -HSA binding kinetics of the mAbs was examined using SPR (Biacore X). Fitting of the binding curves revealed strong apparent functional affinity (Kd ˜10 −10 M) with fast association (˜10 5 1/Ms) and slow dissociation (˜10 −5 l/s) rates for both mAbs.
[0000]
TABLE 1
Determination of kinetic Le a -binding parameters by SPR.
Association rate
Dissociation rate
Equilibrium dissociation
mAb
k on (1/Ms)
k off (1/s)
constant Kd (M)
FG88.2
1.9 × 10 5
11.8 × 10 −5
6.3 × 10 −10
FG88.7
1.7 × 10 5
5.8 × 10 −5
3.4 × 10 −10
[0205] To confirm that these sugars were expressed on proteins from tumour cells, FG88 mAbs were screened for binding to glycoproteins by SDS-PAGE/Western blotting ( FIG. 5 ). FG88.2 and FG88.7 recognise low, intermediate (MW between 10-230 kDa) and high (molecules that do not enter the separation gel) molecular weight molecules by Western blot analysis of Colo205 whole cell extract, C170 whole cell extract, Colo205 plasma membrane, Colo205 plasma membrane lipid and total lipid extracts. FG88.2 and FG88.7 also recognised a band at the dye front in Colo205 total lipid extract and Colo205 plasma membrane lipid extract lanes which is presumed to be glycolipid. The mAb 505/4 recognising sialyl-di-Le a was included as positive control and demonstrated a similar blotting pattern to FG88.2 and FG88.7, recognising high, intermediate and low molecular weight proteins and the glycolipid band at the dye front.
[0206] To confirm that LecLe x , Le a Le x , Le a containing glycans, Le a and Di-Le a glycans are expressed on lipids, the mAbs were screened for binding to tumour associated lipids by thin layer chromatography (TLC). FG88.2 mAb bound lipid antigens from Colo205, MKN45 (ATCC accession # CCL-171) and C170 but not those from AGS ( FIG. 6 ). Two glycolipids were stained by FG88.2 in Colo205 cells (R f =0.21 and 0.14). In addition, FG88.2 stained another glycolipid with less polarity (R f =0.46). In contrast, although FG88.7 also bound the same tumour cell lines as FG88.2, one of the glycolipids stained in the Colo205 sample demonstrated an intermediate mobility (R f =0.19). FG88.7 also stained an extra glycolipid with less polarity (R f =0.29).
Example 3
Immunohistochemistry Assessment for FG88
[0207] To determine the therapeutic value of FG88, it was screened on colorectal, gastric, pancreatic, lung, ovarian and breast tumour tissue microarrays (TMAs) by immunohistochemistry (IHC).
[0208] To assess the binding of FG88 to human tissues, a number of tumour TMAs were stained; 69% of colorectal ( 142/208), 56% of gastric ( 52/93), 74% of pancreatic ( 658/890), 23% of lung ( 62/275), 31% of ovarian ( 58/186) and 27% of breast ( 241/902) tumour tissues were stained (Table 2). Whilst FG88 recognised only 27% of the 902 breast tumour tissues stained, 34% were triple negative breast cancer (TNBC) and 32% of tumours with a basal phenotype stained. Further, the staining of the ER negative breast TMA using FG88.2 at 0.3 ug/ml (staining for FG88.7 not determined) showed 25% positive staining ( 84/338). Stained ER negative breast tissues correlated to all basal type significantly. With TNBC being such a challenging disease with the poorest prognosis of all breast cancer subtypes, and currently cytotoxic chemotherapy is the only systemic treatment option available, FG88 could provide a valued immunotherapeutic agent for this group of patients
[0000]
TABLE 2
Binding of FG88.2 (0.3 μg/ml) mAb to human colorectal,
gastric, pancreatic, lung, ovarian and breast tumour tissues
as assessed by immunohistochemistry. Staining of these tissue
microarrays were analysed via new viewer software 2010 and
given a semi-quantitative score according to intensity of
staining of tumour tissue. Strong staining was given a score
of 3, moderate staining a score of 2, weak staining a score
of 1 and a negative score of 0.
Tissue
Number of
Percent
Tumour TMA
number
positive
positive (%)
Colorectal
208
142
69
Gastric
93
52
56
Pancreatic
890
658
74
Lung
275
62
23
Ovarian
186
58
31
Breast (whole array)
902
241
27
Breast ER negative
338
84
25
[0209] To assess the possible toxicity of mAbs FG88.2 and FG88.7, human and Cynologous monkey normal tissue TMAs were stained. For human normal tissue TMA, FG88.2 did not stain placenta, rectum, skin, adipose, heart, skeletal, bladder, spleen, brain, stomach, breast, kidney, testis, cerebellum, cervix, lung, ovary, diaphragm, uterus, duodenum and thyroid. Staining was seen against oesophagus (moderate squamous epithelium staining), gall bladder (strong columnar epithelium staining), Ileum (strong columnar mucosa staining), jejunum (weak columnar mucosa staining), liver (strong bile duct staining), thymus (weak staining), colon (strong glandular epithelium staining), tonsil (moderate squamous epithelium staining) and pancreas (moderate staining) (Table 3). FG88.7 showed the same staining pattern as FG88.2 except that it also stained normal rectum (weak glandular epithelium stainin. For the monkey normal tissue TMA, staining was seen against small intestine, skin, colon, stomach, ovary, liver and thymus for both FG88.2 and FG88.7 (data not shown).
[0000]
TABLE 3
Binding of FG88 to normal human tissues as assessed by
immunohistochemistry. Staining of these tissue microarrays
were analysed via new viewer software 2010 and given
a semi-quantitative score according to intensity of staining
of tumour tissue. Strong staining was given a score of
3, moderate staining a score of 2, weak staining a score
of 1 and a negative score of 0. The results for FG88
also demonstrate differential staining of specific cell
types within these tissues.
Tissue type
FG88.2
FG88.7
Placenta
0.0
0.0
Oesophagus
1.1 (squamous epithelium)
0.1
Rectum
0.0
2.1
Gall bladder
1.3 (columnar epithelium)
1.2
Skin
0.0
0.0
Adipose
0.0
0.0
Heart
0.0
0.0
Skeletal
0.0
0.0
Bladder
0.0
0.0
Ileum
3.3 (columnar mucosa)
2.3
Spleen
0.0
0.0
Brain
0.0
0.0
Jejunum
2.1 (columnar mucosa)
1.1
Stomach
0.0
0.0
Breast
0.0
0.0
Kidney
0.0
0.0
Testis
0.0
0.0
Cerebellum
0.0
0.0
Liver
1.1 (bile duct)
1.1
Thymus
1.1 (keratin)
1.1
Cervix
0.0
0.0
Lung
0.0
0.0
Small intestine
3.0 (intestinal epithelium)
0.2
Colon
2.0 (glandular epithelium)
2.0
Ovary
0.0
0.0
Tonsils
2.1 (squamous epithelium)
2.1
Diaphragm
0.0
0.0
Pancreas
2.2 (?)
0.1
Uterus
0.0
0.0
Duodenum
0.0
0.0
Thyroid
0.0
0.0
Example 4
Chimeric mAb
[0210] The term “chimeric antibody” is intended to refer to antibodies in which the variable region sequences are derived from one species and the constant region sequences are derived from another species, such as an antibody in which the variable region sequences are derived from a mouse antibody and the constant region sequences are derived from a human antibody. Chimeric (or humanised) antibodies of the present invention can be prepared based on the sequence of a murine mAb prepared as described above. The amino acid and nucleotide sequence for the variable region of the heavy ( FIG. 1 a ) and light chains ( FIG. 1 b ) of the FG88.2 mAb and the amino acid and nucleotide sequence for the variable region of the heavy ( FIG. 2 a ) and light chains ( FIG. 2 b ) of the FG88.7 mAb are shown in FIGS. 1 and 2 . Numbers refer to the standardised IMGT system for the numbering of antibody sequences [59]. The CDR1, CDR 2 and CDR 3 regions are indicated. FG88.2 and FG88.7 both belong to the IGHV6-6*01 heavy chain and IGKV12-41*01 gene families. FG88.2 has 10 mutations from IGHV6-6*01 and FG88.7 eight. FG88.2 has 11 mutations from IGKV12-41*01 and FG88.7 twelve.
[0211] FG88.2 and FG88.7 heavy and light chain variable regions were cloned into human IgG1 expression vector. This was transfected into CHO-S cells and human antibody purified on protein G. The chimeric mAbs CH88.2 and CH88.7 bound to the colorectal cell line, Colo205 ( FIGS. 1 c and 2 c and FIG. 7 ). The amino acid and nucleotide sequence for the heavy ( FIG. 1 d ) and light chains ( FIG. 1 e ) of the human FG88.2 mAb and the amino acid and nucleotide sequence for the human heavy ( FIG. 2 d ) and light chains ( FIG. 2 e ) of the FG88.7 mAb are shown in FIGS. 1 and 2 .
Example 5
FG88 Binding Studies
[0212] FG88.2 and FG88.7 were screened by indirect immunofluorescence staining and flow cytometric analysis for binding to the cell surface of a panel of tumour cell lines Table 4. FG88.2 bound strongly (Gm>500) to C170, Colo205, Colo201, ST16, DU4475 and Panc-1, moderately (Gm 100-500) to HT29, H69 and OVCAR-3, weakly (Gm<100) to AGS, OVCAR-4 and OAW42 and failed to bind MKN45, ASPC-1, OVCA433, MCF-7 and MDA-MB-231 cell lines. FG88.7 showed a similar binding pattern as FG88.2, except that it bound moderately to MKN45.
[0213] In order to establish whether binding was tumour cell specific and not cross reactive with normal blood cells, the FG88.2, FG88.7, CH88.2 and CH88.7 mAbs were incubated with healthy normal donor whole blood. Neither the murine (FG88.2 and FG88.7) nor the chimeric mAbs (CH88.2 and CH88.7) bound to peripheral blood mononuclear cells (PBMCs, lower left quadrant) or granulocytes (upper left quadrant) ( FIG. 8 a ).
[0214] The need to determine normal red blood cell binding was further necessitated as within the literature, there is an indication that Le a antigens found in the secretions of various tissue types have the capability of adsorbing to the surface of erythrocytes. The term ABH secretor refers to the secretion of ABO blood group antigens into the individual's body fluids. Among Lewis antigen positive individuals, ABH secretors are always Le a−b+ whereas ABH non-secretors are always Le a+b− . In Caucasians, it was reported that approximately 80% are of secretor status and 20% are non-secretors. The secretor status of nine healthy human donors was determined by saliva sandwich ELISA ( FIG. 8 b ), followed by binding analysis of the FG88 mAbs to erythrocytes from a Le a -positive donor. Neither FG88 mAb bound to the erythrocytes ( FIG. 8 c ).
[0000]
TABLE 4
Binding of FG88.2 and FG88.7 (5 μg/ml) to a panel of tumour cell lines as assessed by FACS. 505/4, CA19-9, 7-Le
(5 μg/ml). 791T/36 (5 μg/ml) and W6/32 (1 μg/ml) were used as positive controls and media alone as the negative.
Gm value
W6/32
FG88.2
FG88.7
505/4
CA19-9
7-Le
791T/36
(anti-HLA-
Cell line
(anti-Le )
(anti-Le )
(anti-sDLe )
(anti-sLe )
(anti-Le )
(anti-CD55)
A, B, C)
RPMI
Colorectal
C170
2553.83
3096.03
8220.66
7667.27
8692.18
858.47
16.52
17.62
Colo205
831.25
723.61
3260.9
3212.15
5058.59
44.44
1300.62
9.07
Colo201
720.72
503.92
2471.68
1647.5
3350.2
22.26
603.08
21.74
HT29
204.91
190.8
585.12
ND
ND
916.22
1162.5
18.84
Pancreatic
ASPC1
19.2
19.05
19.96
21.01
47.41
7008.83
1775.04
18.73
Panc1
750.5
597.2
5339.55
4114.72
4328.87
471.84
20.09
18.24
Lung
H69
129.71
97.74
1116.4
358.26
142.96
28.09
109.02
17.69
Gastric
AGS
67.26
33.85
28.19
20.82
29.72
1877.02
1563.61
19.39
ST16
806.94
698.76
4226.31
2045.5
3615.76
902.58
33.55
27.53
MKN45
1.37
134.24
79.2
14.47
154.61
230.97
15.42
17.25
Ovarian
OVCAR3
120.96
68.19
154.48
26.67
48.5
411.72
633.41
21.19
OVCAR4
47.41
25.69
14.34
14.16
15.08
327.91
16.38
13.42
OVCA433
20.56
19.93
18.94
19.23
24.74
686.37
6785.04
17.88
OAW42
32.78
31.74
33.77
28.79
42.09
400.73
317.67
28.33
Breast
MCF7
34.75
31.86
17.97
ND
ND
460.6
514.99
30.99
MB-MDA-231
22.04
23.58
14.87
ND
ND
1161.68
757.94
16.96
DU4475
1462.03
720.20
1325.76
ND
ND
ND
1358.12
8.62
ND = not determined.
Results are expressed as Gm.
indicates data missing or illegible when filed
Example 6
FG88 Internalisation Studies
[0215] FG88 mAbs were analysed for cellular internalisation via confocal microscopy. They were labelled with Alexa-488 fluorophore following the manufacturer's protocol and the labelling efficiency checked via direct flow cytometric analysis of the mAb binding to the C170 cell surface. Confocal microscopy was then used to follow the cellular internalisation of FG88 mAbs by C170 cells over a two-hour incubation period. Cross-sectional images were obtained at 0.8 μm intervals and showed efficient internalisation after a two-hour incubation period. In addition, clustering of FG88 mAbs on C170 cell surface was observed, suggesting the heterogeneous distribution of the antigen in the C170 plasma membrane ( FIG. 9 a ).
[0216] A more quantitative analysis was performed using direct flow cytometry on Colo205 cells after acid wash and FITC-labelled murine FG88 mAbs. The results showed that wash buffer at pH2.0 strips any surface-remaining antibody (as seen by the near complete removal of Epcam PE fluorescence), but FG88-FITC labelled cells remain fluorescent after acid wash at pH 2.0, indicating the internalisation of the FITC-labelled FG88 mAbs (and thus protection from the acid wash). Colo205 cells internalised FG88.7 and FG88.2 to a similar degree at 37° C. and 4° C. ( FIG. 9 b ).
[0217] Over time, internalised FG88 mAbs co-localised with lysosomal compartments ( FIG. 9 c ). Similar results were obtained with FG88.7 (data not shown). Importantly, internalization was validated through toxicity of Fab-ZAP-FG88 immune complexes containing saporin. Internalization of the Fab-ZAP-FG88.2 and Fab-ZAP-FG88.7 complexes, but not the Fab-ZAP alone or the Fab-ZAP preincubated with a control mAb (data not shown), led to a dose-dependent decrease in cell viability of the high glyco-epitope expressing C170, Panc1 and ST16 cells ( FIG. 9 d ). The moderately binding HT29 cells were more refractory.
[0218] In summary, Colo205, C170 Panc 1 and ST16 cells efficiently internalise the murine FG88 antibodies and this may be linked to their direct cell killing ability.
Example 7
In Vitro Anti-Tumour Activity of FG88
[0219] ADCC and CDC:
[0220] The ability of murine and chimeric FG88 mAbs to induce tumour cell death through ADCC was screened. Human PBMCs were used as the source of effector cells while Colo205 cells served as target cells. The number of cells killed by mAbs FG88.2, FG88.7, CH88.2 and CH88.7 was measured after 18 hr incubation at 37° C. As shown in FIG. 10 a , Colo205 cells were susceptible to FG88.2, FG88.7, CH88.2 and CH88.7 mAbs killing showing a maximum of 57%, 56%, 64% and 59% lysis respectively. A range of tumor cell lines were analyzed for their susceptibility to FG88-mediated ADCC. The FG88 mAbs significantly lysed the high glyco-epitope expressing Colo205, C170, ST16 and Panc1 cells above the killing observed with PBMCs alone ( FIG. 10B ). The mAb 791T/36, a murine IgG2b that cannot bind human CD16 (32), showed no significant killing over the background observed with PBMCs alone. PBMC killing in the absence of FG88 mAbs was highest for cell lines lacking MHCI such as C170, ST16, Panc1 and AGS and probably reflects NK killing. Noticeably less immune-mediated killing was seen with the FG88 mAbs on the moderate-binding HT29 and DMS79 cells even at high mAb concentration of 10 μg/ml; the weak-binding OVCAR3 and AGS were refractory.
[0221] CDC is known to be an important mechanism involved in eliminating tumour cells in vivo. The capacity of the C170 cells to be killed by CDC induced by mAbs FG88.2 and FG88.7 in the presence or absence of human serum as source of complement at 37° C. for 18 hr was assayed. FG88.2 and FG88.7 showed a maximum of 80% and 91% lysis respectively ( FIG. 10 c ). The FG88 mAbs displayed significant CDC activity against Colo205 and Panc1 cells and to a lesser degree ST16 and DMS79 cells ( FIG. 10D ). No or little CDC was seen on the low- to moderate-binding cell lines HT29, OVCAR3 and AGS (data not shown). The low level of CDC killing of the high-binding ST16 cells could be due to higher levels of membrane complement regulatory proteins (MCRPs) (33). Additionally, the efficient FG88-mediated ADCC of ST16 cells under the same conditions, rules out the possibility that the reduced complement activation was due to suboptimal mAb binding.
[0222] In summary, FG88 strongly induced ADCC using human PBMCs as effector cells as well as significant CDC with human serum as a complement source.
[0223] Direct Cell Killing:
[0224] FG88.2 and FG88.7 induced membrane damage resulting in the uptake of the small molecular weight dye propidium iodide (PI; FIG. 11 a ). At 37° C., FG88.2 induced 76% (20 μg/ml) and 76% (10 μg/ml) and FG88.7 induced 82% (20 μg/ml) and 82% (10 μg/ml). Cells incubated with medium alone showed 21% PI uptake. Interestingly even at 4° C., FG88.2 induced 85% (20 μg/ml) and 85% (10 μg/ml) and FG88.7 induced 92% (20 μg/ml) and 86% (10 μg/ml) of the cells to take up PI. Cells incubated with medium alone showed 13% PI uptake. Cells incubated with chimeric FG88.7 induced 54% (30 μg/ml) PI uptake ( FIG. 11 b ).
[0225] It has been shown that at temperature lower than 15° C., apoptosis cannot occur. This would suggest that both FG88.2 and FG88.7 induced cell death independent of apoptotic mechanisms. Further evidence for an alternative mechanism of apoptotic induced cell death comes from experiments with the caspase inhibitor Z-FMK-VAD which failed to prevent the direct cell killing of the colorectal cell line, C170, at 4° C. (data not shown although almost identical to those at 37° C.) or 37° C., by the mAb ( FIG. 12 ). Classical apoptotic cell death can be defined by certain morphological and biochemical characteristics which distinguish it from other forms of cell death. One of the hallmarks of apoptosis is DNA fragmentation. In apoptotic cells, DNA is fragmented by endonuclease activity. DNA of C170 cells treated with FG88 mAbs (30 μg/ml) in the presence or absence of pan-caspase inhibitor (Z-FMK-VAD) were analysed using conventional agarose gel electrophoresis. Jurkat cells treated with anti-Fas mAb (0.5 μg/ml) in the presence or absence of Z-FMK-VAD were used as controls for apoptosis. Anti-Fas mAb-treated Jurkat cells showed strong DNA fragmentation and Z-FMK-VAD was shown to inhibit apoptosis induced by anti-Fas mAb (no DNA fragmentation). In contrast, neither FG88.2 or FG88.7 induced DNA fragmentation with or without Z-FMK-VAD again suggesting that these mAbs were not inducing apoptosis ( FIG. 13 ).
[0226] Inhibition of C170 cell growth by FG88.2 and FG88.7: PI uptake assays were performed on cells in suspension. To ensure that the mAbs also inhibited growth of adherent cells, they were exposed to FG88.2 and FG88.7 mAbs and cell growth was assessed by 3 H-thymidine incorporation ( FIG. 14 ). Both mAbs significantly inhibited adherent cell growth with IC 50 's of 3 μg/ml. Similarly an anti-Fas mAb inhibited the growth of Jurkat tumour cells ( FIG. 14 a ). However, in contrast to anti-Fas whose growth inhibition was abrogated by a pan-caspase inhibitor, the pan-caspase inhibitor Z-FMK-VAD (carbobenzoxy-valyl-alanyl-aspartyl-[O-methyl]-fluoromethylketone; Promega) failed to inhibit growth induced by the FG88 mAbs suggesting they inhibited cell growth via a non-apoptotic mechanism ( FIG. 14 b,c ).
[0227] To confirm that the PI assay truly reflect cell death in growing cells, C170 cells (Day 0: 1×10 5 cells/well) were treated with FG88.2 and FG88.7 and were observed microscopically. C170 cells exhibited monolayer disruption, cell rounding and cell detachment within 30 min after the addition of FG88.2, FG88.7 or 505/4 mAbs. However, these phenomena did not develop when C170 cells were incubated with medium alone. As shown in FIG. 15 ; FG88.2, FG88.7 and 505/4 mAbs inhibited C170 cell growth at day 1, 2 and 3. At day 4, C170 cells treated with FG88.7 (1.9×10 5 cells) and FG88.2 (9.4×10 4 cells) mAbs started to regrow. Cells incubated with media alone did not show growth inhibition and achieved 80% confluency at day 3. To confirm the morphological changes observed under the light microscope, C170 cells were exposed to FG88.2 and FG88.7 mAbs for 20 hr prior to analysis under a scanning electron microscope (SEM). Pronounced cell aggregation of C170 adherent cells after incubation with FG88 mAbs was observed. These cell aggregates displayed a loss of surface microvilli, the formation of membrane blebs and surface wrinkles. Most importantly, these clumped cells showed evidence of membrane pores which is reminiscent of oncosis. The sizes of these pores were heterogeneous with diameters ranged from 0.2 μm to 1 μm (white arrows) ( FIG. 16 ). To further confirm that FG88 mAbs induced oncosis, C170 cells were treated with FG88.2 mAb and then the uptake of dextran of different molecular weights (3 kDa and 40 kDa) was assessed. FG88.2 mAb induced uptake of both 3 and 40KDa molecular weight dextran in 2 hr ( FIG. 17 ).
[0228] To assess direct killing on cells with varying expression of glycans at 37° C. and 4° C., PI uptake assay was carried out using FG88.2 and FG88.7 mAbs with Panc-1, HT29 and OVCAR-4 cells ( FIG. 18 ). 505/4 and medium alone were included as positive and negative controls respectively. 7-Le and CA19-9 mAbs were included for comparison. FG88.2 and FG88.7 mAbs induced direct cell death on Panc-1 at both 37° C. and 4° C. whereas 505/4 induced Panc-1 cell death only at 37° C. suggesting FG88.2 and FG88.7 induced direct cell death independent of an apoptotic mechanism. Interestingly, FG88.2, FG88.7 and 505/4 mAbs did not induce HT29 cell death despite binding moderately to HT29 cells. The LecLe x related glycan negative cell line, OVCAR-4, was not killed. These results revealed a correlation between killing efficiency and the level of LecLe x related glycan expression with cells expressing moderate/low levels not being killed. Chimeric FG88.2 also induced PI uptake in cells expressing high (C170, Colo205 and Panc1) but not low or negative density (HT29 and AGS) antigen ( FIG. 19 ).
[0229] Experiments with different antigen negative human colorectal tumour cells, whole blood (PBMCs and granulocytes) or erythrocytes from normal human donors displayed no binding and no direct killing activities for mouse and/or chimeric FG88 mAbs. Taken together the chimeric FG88 mAb had similar potency and specificity when compared with parental mouse FG88 mAb. Examination of FG88 treated tumour cell surface by scanning electron microscopy (SEM) revealed pore formation. This mechanism of cell death resembles that described for oncosis.
Example 8
In Vivo Anti-Tumour Activity of FG88
[0230] Comparison of the therapeutic effect of the mAb FG88 in the C170HM2 DLuX human hepatic metastasis model: The mouse C170HM2 DLuX human hepatic metastasis tumour model was used to investigate the anti-tumour activity of the murine FG88 mAb. The C170HM2 DLuX cell line is a bioluminescent variant of a liver metastasising colon tumour cell line passaged to invade the liver parenchyma when implanted into the peritoneal cavity. Growth and distribution/location of such labelled cells and tissue can be assessed non-invasively in real time and in excised tissue at post mortem (PM) in a suitable optical imaging system. These cells were implanted for use as an experimental peritoneal metastasis model.
[0231] Anti-tumour data: FG88.2, FG88.7 and 505/4, administered twice a weekly (100 μg i.v). reduced peritoneal cavity and associated tumour growth compared to the vehicle control as assessed by bioluminescent intensity ( FIG. 20 ). At day 96 there is a significant difference between vehicle and F88.7 (p=0.037 by log rank (mantel-cox) test). In addition, these mAbs managed to completely eradicate established metastatic tumours in 30% of animals leading to significantly long term survival. F88.2 v vehicle p=0.06; F88.7 v vehicle p=0.0037.
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A glycan having the structure galβ1-3GLcNacβ1-3Galβ1-4(Fucα1-3)GlcNAc (LecLe x ) which is attached to a lipid or protein backbone, and isolated binding members capable of binding thereto.
| 2
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BACKGROUND OF THE INVENTION
The present invention relates to a shutter, preferably to ventilate in buildings and structures, and a slat for the shutter.
A shutter whose upper section is opened so as to ventilate storehouses in which foodstuffs such as grains are stored.
In the shutter having the opening for mere ventilation, noxious insects, etc. sometimes enter the storehouse through the opening, they eat the grain or other foodstuffs stored therein. With mere opening in the upper section of the shutter, ventilating the storehouse cannot be executed. A shutter, whose opening is covered with a screen is also known. The screen is fixed by rivets, etc. but fixing work is troublesome and increases manufacturing steps, so that the manufacturing cost of the shutter is raised.
A shutter having windows for lighting has existed. This shutter is composed of base slat members in which through-holes are bored and a transparent plate is fixed at each through-hole to cover it. In this shutter, the transparent plates are manually and respectively fixed at each through-hole bored in slats. The manual work is also troublesome and manufacturing efficiency becomes low.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a shutter, which is capable of fully ventilating a building, and a slat for the shutter.
To achieve the object, the present invention provides following structures.
A slat for a shutter according to the invention comprises, a having a through-hole for ventilation, a plurality of guides formed by cutting parts of the base member and forming the parts cut, each of the guides having an inserting section which opens in the longitudinal direction thereof, and a shutting plate having a window for opening and shutting the through-hole and being inserted from the inserting sections of the guides, the shutting plate being capable of sliding along a screen, which is inserted from the inserting sections of the guides which is fixed on the rear face of the basic material and which covers the through-hole, and/or is capable of sliding with guiding by the guides whereby the shutting plate opens and shuts the through-hole.
In the slat, the height or the width of the opening on the inserting side, from which the screen and/or the shutting plate is inserted, of each of the guides may be higher than the other side thereof.
Further, a shutter according to the invention has multiple slats which are mutually connected in the up-down direction, a slat in the upper section of the shutter comprising a base slat member having a through-hole for ventilation, a plurality of guides formed by cutting parts of base slat member and forming the parts cut, each of the guides having an inserting section which is open in the longitudinal, i.e., lengthwise, direction, and a screen inserted through the guides from the inserting sections so as to cover the through-hole and fixed on the rear face of the base member, and a slat in the lower section of the shutter comprising a base member having a through-hole for ventilation, a plurality of guides formed by cutting parts of the basic material and forming the parts cut, each of the guides having an inserting section which opens in the longitudinal direction of the base member a screen inserted from the inserting section of the guides and covering the through-hole, the screen being fixed on the rear face of the base member and a shutting plate having a window for opening and shutting the through-hole and being inserted from the inserting sections of the guides, the shutting plate being capable of sliding along the screen with guiding by the guides.
In this shutter, fresh air is able to enter a building from the through-hole of the slat in the lower section and air in the building flows out from the through-hole of the slat in the upper section when the window of the shutting plate of the slat in the lower section coincides with the through-hole of the slat thereof, so that ventilation is executed. Note that by bringing the window of the shutting plate into partial registry with to the through-hole of the slat, the amount of ventilating air can be adjustable.
If the slats in the upper and the lower sections have screens enough ventilation can be provided while noxious insects are prevented from entering the building.
Further, the screen and the shutting plate can be attached easily, because the seats include the guides.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be apparent from the following description, reference being had to the accompanying drawings wherein preferred embodiments of the present invention are clearly shown.
In the drawings:
FIG. 1 is a front view an entire of the present invention;
FIG. 2 is a rear view of a part of a slat;
FIG. 3 is a longitudinal sectional view of the basic material of the slat;
FIG. 4 is a side view of the basic slat;
FIG. 5 is a partial transverse sectional view of the basic slat;
FIG. 6 is a partial transverse sectional view of another basic slat;
FIG. 7 is a partial rear view of the basic slat whose through-holes are covered with screen;
FIG. 8 is a rear view of the slat having the screen and a shutting plate wherein windows of the shutting plate do not coincide with the through-holes of the slat;
FIG. 9 is a front view of the shutting plate;
FIG. 10 is a transverse sectional view of the slat of FIG. 8.;
FIG. 11 is a rear view of the slat wherein guides are provided between the through-holes, and the screen and the shutting plate are assembled;
FIG. 12 is a partial rear view of the slat wherein the width of the inserting side of the guides is made wider than the other side;
FIG. 13 is a front view of the slat wherein the guides are of another configuration;
FIG. 14 is a sectional view of the slat of FIG. 13;
FIG. 15 is a sectional view of a basic slat having other guides; and
FIG. 16 is a rear view of the slat wherein the shutting plate is inserted through the insert-holes of the guides.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
A shutter 10 is composed of a plurality of slats, which are connected by connecting sections, as shown in FIG. 1.
The shutter 10 is supported by two rails 10a, which guide both edges of the slats 11. There is provided an accommodating box 10b, which rolls up the shutter 10 and accommodates it, above the shutter 10.
Each slat 11 has connecting sections 12a and 12b along the upper and the lower end section of the base member 12 of the slat 11. The slats in the upper and the lower parts of the shutter 10 respectively have a plurality of through-holes 20. In this embodiment, four slats 11 in the upper part and two slats 11 in the lower part respectively have the through-holes 20.
First, the slat 11 in the upper part will be explained.
Guides 22 are provided in the slat 11 so as to cover parts of the through-hole 20 (see FIG. 2). The guides 22 are formed to project backward. Namely, both edges of the base member 12 are not cut away perhaps of the base member intended to form the guides 22 and those portions are formed backward at said section so as to form the guides 22. With this structure, a clearance "l" is kept between the rear face of the basic material 12 and the guide 22 and an insert-hole 23 is formed. A band-like screen 24 can be inserted through the insert-hole 23 of the guide 22 along the rear face of the basic material 12 from one end side of the basic material 12.
To easily insert the screen 24, the height of the inserthole 23a on the inserting side, from which the screen 24 is inserted, may be higher than the other side (see FIG. 6).
If clearance "K" between the through-holes 20 (see FIG. 2) is narrower than the width of the through-hole 20 and the through-holes 20 are closely arranged, the efficiency of ventilation can be raised.
If the width of the insert-hole 23 is reduced after the net 24 is inserted therethrough, the movement of the screen 24 can be prevented.
One example of forming the guide 22 will be explained.
Two cuts are formed in the transverse direction of the basic material 12. The part between the cuts is transformed to be the guide 22 with plastic deformation. After then, the through-hole 20 is formed. In this case, forming the guide 22 and the through-hole 20 can be executed in one action by press forming.
In the above noted embodiment, the guide 22 corresponds to the through-hole 20, so that the guide 22 certainly presses the screen 24 to the fringe of the through-hole 20. With this pressing, it is hard to make a gap between the screen 24 and the rear face of the basic material 12.
The guides 22 may be located at positions shifted from the through-hole 20 of the basic material 12 as shown in FIG. 7. The guide 22 is formed by cutting the basic material 12 is the longitudinal direction to make two cuts and transforming the part between the cuts with plastic deformation. Note that, sliding the screen 24 is the longitudinal direction can be prevented by cutting the screen 24 and piling the part 24a cut. The part 24a of the screen 24 piled cannot pass through the guide 22 and the location of the screen 24 is fixed.
Successively, the slats 11 in the lower section will be explained with reference to FIGS. 8 and 9.
As similar to the slats 11 in the upper section, there are formed the guides 22 and the through-holes 20 in the slats 11 in the lower section. The screen 24 and shutting plate 27, which are stacked together, are inserted through the insert-holes 23 of the guides 22 of the slats 11 in the lower section. Namely, similar to the slats 11 in the upper section, the screen 24 is inserted through the insert-holes 23 along the rear face of the basic material 12, and then the shutting plate 27 is inserted between the screen 24 and the basic material 12. With this structure, the shutting plate is clipped by the basic material 12 and the screen 24 and is capable of sliding.
There are opened windows 27a, whose positions correspond to the through-holes 20 of the slat 11, in the shutting plate 27. It is preferable to provide two reinforcing plates 27b at the mid section of each window 27a so as to reinforce the shutting plate 27 (see FIG. 9).
The status in which the through-holes 20 of the basic material 12 coincide with the windows 27a of the shutting plate 27 and in which ventilation can be executed is shown in FIG. 10; the status is which the windows 27a are shifted from the through-holes 20 to close the through-holes 20 is shown in FIG. 8.
It is necessary that the length (n) of the through-holes 20 or the windows 27a is longer than the distance (m) between the through-holes 20 or between the windows 27a, viz., n>m. Note that, shutting plate 27 is slidably inserted between the screen 24 and the basic material 12 but the screen 24 may be inserted between the shutting plate 27 and the basic material 12.
Guides 22s, whose structure is the same as the above noted guides 22, may be provided between the through-holes 20 in case that the distance between the through-holes 20 is long (see FIG. 11). In case of FIG. 11, the screen 24 and the shutting plate 27 never slacken at the midway section thereof. Further, similar to the example shown in FIG. 7, the piled part 24a (see FIG. 7) of the screen 24 may be formed in the vicinity of the guides 22s so as to prevent the screen 24 from sliding.
The shutter is preferably made of thin metal such as stainless steel. The metal shutting plate 27 shields the light but the shutting plate 27 made of transparent material can introduce the light inside.
Successively, the function of the shutter will be explained.
The through-holes 20 for ventilation through the slats 11 in the upper section of the shutter 10 are covered with the screen 24. The slats 11 in the lower section of the shutter 10 can be changed between ventilation mode and non-ventilation mode by shifting the shutting plate 27.
When the slain 11 in the lower section are changed to the ventilation mode, the windows 27a coincide with the through-holes 20, so that fresh air is introduced through the through-holes 20 of the lower slats 11; the air inside is exhausted through the through-holes 20 of the upper slats 11. The air in a building can be ventilated smoothly.
When a part of the windows 27a coincide with the through-holes 20, the opening area of the through-hole 20 can be adjustable, so that the amount of ventilation can be adjustable.
When the shutting plate 27 is further slided to close the through-holes 20 as the non-ventilation mode, introducing fresh air through the through-holes 20 of the lower slats 11 is stopped, so that the ventilation of the building stops then.
Note that, the slats 11 of the lower section may have only the shutting plate 27 for ventilation without the screen 24.
Successively, other examples of the guide will be explained.
FIGS. 12-15 show front views and sectional side views of the slat.
In FIG. 12, the width of the opening on the inserting side 23a of the guides 22 is wider than the other side thereof. The screen 24 or the shutting plate 27 can be inserted easily.
In FIGS. 13 and 14, the mid section of the guides 22 described above is cut. Namely, L-shaped guide pieces 32a are mutually projected upward and downward to compose the guides 32. The guide pieces 32a are formed, as same as the above noted guides 22, by cutting and transforming a part of the basic material 12.
In FIG. 15, the guides 42 are formed into a long L shape. The lower end of the guide 42 is fixed at the basic material 12; the upper end is opened. In this case, too, the screen 24 and the shutting plate 27 can be inserted through the guides 42. The screen 24 and the shutting plate 27 can be assembled from the open end of the guides 42. Therefore, this guide 42 has function and effectiveness similar to the above noted guides. The guide 42 is, similar to the above noted guide 22, formed by cutting and transforming a part of the basic material 12.
In the above described example, the guides 22, 22s, 32 and 42 are formed by cutting and transforming a part of the basic material 12, but the guides may be formed by fixing guide pieces, which are separately prepared, on the rear face of the basic material 12. In the case of using the guide pieces, the similar function and effectiveness can be got.
A transparent plate 26 can be inserted through the guides 22 as the shutting plate. In this case the light can be introduced inside.
Preferred embodiments of the present invention have been described in detail. The present invention, however, is not limited to the above described embodiments. Many modifications, of course, can be allowed without deviating from the spirit of the invention.
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The present invention relates to a shutter which is capable of ventilating air in a building. There is provided a slat, which has a through-hole covered with a net, in the upper section of the shutter; there is provided a slat, which is capable of adjusting the amount of ventilating air, in the lower section of the shutter. With this combination, fresh air is able to enter the building from the lower slat and air inside is able to flow out from the upper slat when the lower slat makes possible to ventilate.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 USC 119 from US Provisional Application Ser. No. 61/894,912 filed on Oct. 24, 2013, titled METHOD AND APPARATUS FOR ALLOWING BUYERS TO PLACE INTENDED PURCHASE OFFERS AND REWARD THE BUYERS FOR THEIR INTENDED PURCHASE OFFERS by NGUYEN, Vinh, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] There are several systems that buyers and sellers exchange or trade services and/or goods. The majority of them are seller-driven, meaning that sellers advertise, display the products or service to sell and initiate a price for their products or services. The buyers then search for the products or service that they want, compare prices and quality, contact sellers to complete the transaction.
[0003] In addition, there are limited numbers of systems where the buyer posts purchase offers. However, they are not popular because of the following reasons. First, buyers have no incentive to place purchase offers. Second, once buyers posts such purchase offers, they could be inundated with irrelevant emails or calls from sellers. The two mentioned reasons discourage buyers from posting what they plan to buy.
SUMMARY
[0004] The present invention provides a method and apparatus to reward buyers for placing their purchase offers in a system, to display the purchase offers globally for sellers to see and to search for relevant purchase offers and to bind or negotiate with and then bind the buyer to a contract with the buyer's intended purchase offers.
[0005] The present invention is similar to a job board in which the buyer is a business or a company, looking for an employee and the employee who is a service provider or a seller. In the job board, the business or the company posts its job posting on a job board and the employee acting as a seller searches for the relevant job offer, submit a resume and interview or negotiate with the company to bind an employment contract.
[0006] In present invention, the buyer posts or places the purchase offer. The purchase offer is comprised of subject, category, city, quantity, price, expiration date, conditions, buyer id, etc. The purchase offer is then stored in the database and displayed on display monitors globally for sellers to see and also sent to subscribed sellers. The seller then searches for the relevant purchase offer, either accepts the offer or makes a counter-offer in such a way that binds the buyer with a contract.
[0007] The buyer gets rewarded whenever contacted by the seller by either email, phone calls or any other means like postal mails. The reward can be points, credits, cash or others and can be applied toward the buyer's current or future purchase offers.
[0008] The goal of the present invention is to reward buyers to express or place their purchase offers. Buyers get rewarded when they are contacted by the sellers. When the buyer places a price in the purchase offer, then the offer is bound when accepted by the first seller. When the buyer does not place a price in the purchase offer, then the offer is open for negotiation. The buyer can be contacted by several sellers simultaneously and get rewarded every time being contacted by the sellers.
[0009] Another goal of the present invention is to create a “heaven” for sellers since we create and display a centralized purchase offers from buyers. The seller can search for relevant purchase offers, contact the buyer or accept the offer, or counter offer.
[0010] Another goal of the present invention is to shorten the transaction cycle between the buyer and the seller. In the case that the buyer places a price in the purchase offer, the buyer is ready to purchase. Once the seller accepts the buyer's offer, a bind contract is established. Even in the case that the buyer does not place a price in the purchase offer, the buyer has already intention to purchase. Once the seller offers a right price and the buyer accepts it, a binding contract is established.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The specification disclosed includes the figures, wherein like numbers in the figures represent like numbers in the description and the figures are represented as follows:
[0012] FIG. 1 is a block diagram of the system showing the central controller unit, buyer interface, seller interface, display monitor and database.
[0013] FIG. 2 is a block diagram of the central controller unit.
[0014] FIG. 3 is a block diagram of the seller interface.
[0015] FIG. 4 is a block diagram of the buyer interface.
[0016] FIG. 5 is a block diagram of the database.
[0017] FIG. 6 illustrates the process of how the buyer generates the purchase offer.
[0018] FIG. 7 illustrates the interaction between the buyer and the seller about the purchase offer and the buyer get paid after being contacted by the seller.
DETAILED DESCRIPTION
[0019] In accordance with the various aspects of the present invention, the computing devices of the present invention may include a central processing unit, memory, input devices (e.g., keyboard and pointing devices), output devices (e.g., display devices), and storage devices (e.g., disk drives). The memory and storage devices are computer-readable media that may contain instructions. In addition, the data structures and message structures may be stored or transmitted via a data transmission medium, such as a signal on a communications link. Various communications links may be used, such as the Internet, a local area network, a wide area network, or a point-to-point dial-up connection.
[0020] The systems of the present invention, in accordance with various aspects and embodiments, may use various computing systems or devices including personal computers, server computers, hand held or laptop devices, multiprocessor systems, microprocessor based systems, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. The systems may also provide services to various computing systems such as personal computers, cell phones, personal digital assistants, consumer electronics, home automation devices, and so on.
[0021] The systems may be described in the general context of computer-executable instructions, such as program modules, executed by one or more computers or other devices. Generally, program modules include routines, programs, objects, components, data structures, and so on that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various embodiments. For example, the user interface component may be implemented on a server separate from the computer system that generates the information or data.
[0022] FIG. 1 is a general diagram of the components of the apparatus used in this invention. It is comprised of a central controller unit 200 , a seller interface 300 , a buyer interface 400 , a database 500 , and a display monitor 600 . A buyer from the buyer interface 400 submits a purchase offer 110 which is received by the central controller unit 200 . The purchase offer information 140 is then stored in the database 500 . The central controller unit 200 might retrieve purchase offer information 150 to display information 160 at the display monitor 600 . The central controller unit 200 will notify sellers of the pending purchase offers 120 to the sellers through seller interface 300 . The sellers from seller interface 300 respond to purchase offers 130 to the central controller unit 200 which sends the seller's response to purchase offers 130 to the buyers at the buyer interface 400 .
[0023] FIG. 2 is a general diagram of the components of the central processing unit 200 . It is comprised of a central processing unit (CPU) 205 , a random access memory (RAM) 210 , a read only memory (ROM) 220 , a clock 230 , an operating system 240 , and a math processor 250 .
[0024] FIG. 3 is a general diagram of the components of the seller interface 300 . It is comprised of a central processing unit (CPU) 305 , a random access memory (RAM) 310 , a read only memory (ROM) 320 , a clock 330 , an operating system 340 , and a math processor 350 .
[0025] FIG. 4 is a general diagram of the components of the buyer interface 400 . It is comprised of a central processing unit (CPU) 405 , a random access memory (RAM) 410 , a read only memory (ROM) 420 , a clock 430 , an operating system 440 , and a math processor 450 .
[0026] FIG. 5 is a general diagram of the components of the database 500 . It is comprised of a buyer database 510 , a seller database 520 , a buyer's purchase offers database 530 , a seller's counter offers database 540 , a buyer's payment database 550 , a seller's payment database 560 , a buyer's purchase database 570 , a seller's promotion database 580 and a miscellaneous database 590 .
[0027] FIG. 6 illustrates how buyers submit purchase offers 110 . Using the buyer interface 400 , the buyer logs into the central processing unit 200 at step 610 . Then at step 620 , the buyer enters the subject of the goods or service that is desired to purchase. At step 630 , the buyer enters the quantity. The buyer has the option of entering a price at step 640 . If the price is entered, then the purchase offer is binding. If the price is not entered, then the purchase offer is not binding. At step 650 , the buyer enters an expiration date with the default value of today's date. The buyer must enter details of goods or service and any conditions if any at step 660 . For example, in buying an automobile, the buyer might enter the color of the automobile, whether it is an all-wheel drive, fully loaded with all equipment, etc. At step 680 , the buyer submits the purchase offer and the central controller 200 receives it. At step 690 , the purchase offer is displayed on the display monitor 600 and stored in the buyer's purchase offers database 530 .
[0028] FIG. 7 illustrates the flow of purchase offers made by the buyer and responded by the seller. After the buyer submits the purchase offers 110 at step 710 , the purchase offer is displayed in the display monitor 600 and stored the information 140 in the database 500 at step 720 . The central controller unit 200 retrieves information 150 from the database 500 and notified sellers of the pending purchase offers 120 at step 730 . At step 740 , the seller responds to the purchase offers 130 . Once the seller responds to the purchase offers 130 , the buyer get paid at step 760 . At step 770 , the seller carries out the transaction with the buyer online at a website or offer through email or telephone.
[0029] In accordance with the teachings and aspects of the invention a computer and a computing device are articles of manufacture. Other examples of an article of manufacture include: an electronic component residing on a mother board, a server, a mainframe computer, or other special purpose computer each having one or more processors (e.g., a Central Processing Unit, a Graphical Processing Unit, or a microprocessor) that is configured to execute a computer readable program code (e.g., an algorithm, hardware, firmware, and/or software) to receive data, transmit data, store data, or perform methods.
[0030] The article of manufacture (e.g., computer or computing device) includes a non-transitory computer readable medium or storage that may include a series of instructions, such as computer readable program steps or code encoded therein. In certain aspects of the invention, the non-transitory computer readable medium includes one or more data repositories. Thus, in certain embodiments that are in accordance with any aspect of the invention, computer readable program code (or code) is encoded in a non-transitory computer readable medium of the computing device. The processor, in turn, executes the computer readable program code to create or amend an existing computer-aided design using a tool. In other aspects of the embodiments, the creation or amendment of the computer-aided design is implemented as a web-based software application in which portions of the data related to the computer-aided design or the tool or the computer readable program code are received or transmitted to a computing device of a host.
[0031] An article of manufacture or system, in accordance with various aspects of the invention, is implemented in a variety of ways: with one or more distinct processors or microprocessors, volatile and/or non-volatile memory and peripherals or peripheral controllers; with an integrated microcontroller, which has a processor, local volatile and non-volatile memory, peripherals and input/output pins; discrete logic which implements a fixed version of the article of manufacture or system; and programmable logic which implements a version of the article of manufacture or system which can be reprogrammed either through a local or remote interface. Such logic could implement a control system either in logic or via a set of commands executed by a processor.
[0032] It can be seen that the invention provides a convenient and economical method for changing the function of a holder based on the user's needs. While particular embodiments of the present invention have been shown and described, those of ordinary skill will appreciate that modifications may be made that fall within the scope and spirit of the invention. In addition, the present invention should not be considered limited to the dimensions of the preferred embodiment described herein.
[0033] It is to be understood that this invention is not limited to particular embodiments described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
[0034] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
[0035] Certain ranges are presented herein with numerical values being preceded by the term “about.” The term “about” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number.
[0036] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, representative illustrative methods and materials are now described.
[0037] All publications and patents cited in this specification are herein incorporated by reference as if each individual publication or patent were specifically and individually indicated to be incorporated by reference and are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
[0038] It is noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
[0039] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present invention. Any recited method can be carried out in the order of events recited or in any other order which is logically possible.
[0040] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.
[0041] Accordingly, the preceding merely illustrates the principles of the invention. It will be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof.
[0042] Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. The scope of the present invention, therefore, is not intended to be limited to the exemplary embodiments shown and described herein. Rather, the scope and spirit of present invention is embodied by the appended claims.
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The invention is a method and apparatus for allowing buyers to place intended purchase offers and rewarding them whenever they receive counter offers from sellers even before they make the purchases. The invention allows prospective buyers of goods or services to communicate their intended purchase offers, to display their offers on the apparatus for sellers to see and to allow sellers to accept or and counter offer. Buyers get rewarded whenever they receive offers from sellers. The apparatus in the invention consists of a central controller to process purchase offers and counter offers, a database to store information about buyers, sellers, their purchase offers and counter offers, an interface for buyers and an interface for sellers.
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BACKGROUND OF THE INVENTION
a) Field of the Invention
The invention relates to a device for stretching an inserted filling-yarn, in particular for an airjet loom, and comprising a channel adjoining a filling-yarn insertion-conduit of a reed, a blow nozzle discharging into said channel and pointing to a branch channel which intersects in substantially a perpendicular manner said channel and which comprises at least one filling-yarn deflecting location.
b) Related Technology
As regards airjet looms, a device to stretch the inserted filling yarn (here-after filling) is mounted at the end of the filling insertion conduit formed by a plurality of reed lamellas in order to prevent the filling from recoiling after being inserted. Such devices are fitted with a channel running as a straight extension of the filling insertion conduit, a blow nozzle issuing into said channel and pointing at a branch channel intersecting substantially perpendicularly into the channel. A deflection location is located at the inlet of the said branch channel which also can be made to return to the channel along a curved path (EP 0 493 847 A1).
The objective of the invention is to improve a device of the above kind.
This problem is solved in that the at least one deflection location consists of a wear-resistant element mounted substantially transversely to the filling's direction of insertion.
BRIEF SUMMARY OF THE INVENTION
The invention is based on the consideration that the deflection location(s) are subject to wear caused by the filling running over it (them), whereby, after a given time of operation, the effect of the device will change and possibly the filling entering the device and held in it will be damaged. Because of the wear-resistant element(s) at the deflection location(s), constant and proper operation is assured by the said element(s) at the deflection location(s) and at the same time the danger of damaging the fillings is reduced.
In a preferred embodiment of the invention, the branch channel follows a curved path and joins again the channel. Two wear-resistant elements, each forming a deflection site for the filling, are mounted at the inlet of the branch channel. In this embodiment the filling's friction at the deflection locations and the applied pneumatic forces oppose filling-recoil, whereby the extant conditions also are preserved over a substantial length of operation because the deflection locations are wear-resistant elements and thereby do not incur any significant wear even over lengthy operation.
DESCRIPTION OF THE DRAWINGS
Further advantages and features of the invention are elucidated in the following description of the embodiment schematically shown in the drawing.
FIG. 1 is a partial view of an airjet loom with a section of a stretching device of the invention,
FIG. 2 is a cross-section of the stretching device approximately along line II--II of FIG. 1, and
FIG. 3 is an enlarged detail F3 of FIG. 1.
DETAILED DESCRIPTION
The stretching device 1 is mounted together with a reed 3 on a batten 2. The reed 3 consists of a plurality of lamellas forming a unilaterally open U-shaped filling insertion conduit 4.
The stretching device 1 comprises a housing fitted with a main filling yarn receiving channel 5 directly adjoining the exit end of the filling insertion conduit 4 of the reed 3, said housing also having a U-shaped cross-section substantially corresponding to the filling insertion conduit 4 and running along the insertion direction A from its inlet as an extension of the filling insertion conduit 4.
A branch channel 6 intersects the channel 5 directly behind its inlet and the first segment of said branch channel runs approximately perpendicularly to the channel 5 away from the batten 2 and then merges at an approximately cylindrical curvature to and intersecting a second segment returning into the channel 5. A first blow nozzle 8 discharges towards the inlet orifice of the branch channel 6 and also discharges into the lower side 13 of said channel 5 somewhat offset from the insertion conduit 4 and towards the batten 2. The blowing-in of the arriving filling is facilitated because of this offset configuration. The branch channel 6 is separated by a partition defining a filling yarn guide from the channel 5, said yarn guide being cross-sectionally pear- or droplet-shaped. Towards the inlet of the branch channel 6, the yarn guide comprises a wear-resistant element 7 of cylindrical structure and forms an apical deflection for a filling 14. Said wear-resistant element 7 is mounted substantially transversely to the direction of insertion A of the filling 14 and is adjoined by a support element 12 which may be part of the housing or a separate part. A wear-resistant element 11 is located at the outlet of the branch channel 6 on the side facing the channel 5. The support element 12 is configured to be recessed from the a straight line connecting the peripheries of wear-resistant elements 7 and 11 engaged by the filling 14. Consequently the support element 12 does not touch the filling and hence cannot damage it even if burred. The two wear-resistant elements 7 and 11 run substantially transversely to the blow-direction of the blow nozzle 8 and comprise convex surfaces.
Another blow nozzle 9 is located approximately above the apex line of the wear-resistant element allowing the filling 14 to loop around by an angle of about 90°. The blow nozzle 9 essentially runs toward the second segment of the branch channel 6 returning to the channel 5. The air jet issuing from the blow nozzle 9 ensures that the filling 14 shall reliably rest against the wear-resistant element 7 and also against the wear-resistant element 11. Although the blow nozzle 8 comprises two or more small blow orifices delivering compressed air with well directed jets, the blow nozzle 9 comprises only one more substantial blow aperture.
As shown in particular in FIG. 3, another wear-resistant element 10 is mounted in the vicinity of the front edge of the inlet of the branch channel 6 and runs essentially transversely to the direction of insertion A of the filling 14 while forming a first deflection area for the filling 14. The sizing, that is the diameter of this element 10, is comparatively small in order that the inlet to the branch channel 6 can be placed as close as possible to the filling insertion conduit 4.
The cross-section or curvature of the wear-resistant element 7 essentially corresponds to that of the branch channel 6 and consequently the yarn rests along a comparatively long path against the wear-resistant element 7. In a variation of the shown embodiment, the wear-resistant elements 7 and 11 as well as the support element 12 are one integral component having a pear- or droplet-shaped cross-section.
As shown by FIG. 2, a fitting 20 is present at the housing of the device 1 to affix a compressed-air supply line. Supply conduits 15, 16 and 17 made in the housing lead from said fitting to the blow nozzles 8 and 9. The housing may be made for instance by injection molding, the shapes of the channel 5 and of the branch channel 6 as well as of the blow nozzles 8 and 9 and of the supply conduits 15, 16 and 17 being implemented during injection molding. In another design, only the housing's exterior is injection molded, the channel 5 and the branch channel 6 being milled. The supply conduits 15, 16 and 17 as well as the blow nozzles 8, 9 then are in the form of boreholes, the supply conduits 16 and 17 being sealed by stoppers 18 and 19.
The wear-resistant elements 7, 10 and 11 form the deflection locations for a filling 14 and comprise rounded peripheral rest surfaces for this filling. Preferably they are cylindrical, being easily manufactured and installed. Being wear-resistant, their wear is comparatively slight, and the danger of damaging the yarn end of a filling 14 is thus reduced. The wear-resistant elements 7, 10 and 11 are made of ceramic in a first embodiment. In another embodiment they are basically made of metal or plastic and fitted with a peripheral coating.
As seen in FIG. 1, a detector 21 is mounted in the extension and at the outlet end of the channel 5, a filling 14 being blown into said detector. Illustratively, it is possible using this detector 21, which may be affixed also to the batten 2, to identify an excessively long filling 14.
In the device for stretching the filling 14, which in known manner is blown by main blow nozzles and inserting nozzles through the filling insertion conduit 4 of the reed 3, the filling 14 will first be deflected by the blow nozzle 8 around the wear-resistant element 7 and then by the further blow nozzle 9 around the wear-resistant element 7. Recoil of the filling 14 following filling insertion is precluded because of the air jet blown out of the blow nozzles 8 and 9 and because of the friction of the filling 14 especially at the wear-resistant element 7 and also at the wear-resistant element 10.
The scope of protection of the device of the invention is not restricted to the above embodiment but instead is determined by the attached claims. In particular variations in shape and/or configuration of the wear-resistant elements 7, 10 and 11 as well as in the geometry of the branch channel 6 are possible.
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A device for stretching an inserted filling (14), in particular for use in an airjet loom, includes a channel (5) adjoining a filling insertion conduit (4) of a reed (3), a blow nozzle directed at a branch channel intersecting the channel (5) in substantially perpendicular manner discharging into the channel (5), and at least one deflection location for the filling (14). The deflection location consists of a wear-resistant element (7, 10, 11) that extends substantially transversely to the direction of insertion (A) of the filling.
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FIELD OF THE INVENTION
[0001] The present invention relates to new intelligent electrical current switching devices and more particularly, to microchip controlled electrical current switching devices. The invention further relates, in one embodiment, to intelligent batteries having embedded therein a microchip for use with a variety of electrical devices to add heretofore unknown functionality to existing electrical devices. The invention also relates, according to another embodiment, to intelligent hand-held electronic devices, and in a preferred embodiment to hand-held light sources, and more particularly, to flashlights. According to one embodiment of the present invention, the invention relates to intelligent hand-held flashlights having microchip controlled switches wherein said switches can be programmed to perform a variety of functions including, for example, turning the flashlight off after a pre-determined time interval, blinking, or dimming, etc. According to a still further embodiment, the invention relates to low current switches controlled by microchips of the present invention for use in building lighting systems.
BACKGROUND OF THE INVENTION
[0002] In conventional flashlights, manually-operated mechanical switches function to turn the flashlight “on” and “off.” When turned “on,” battery power is applied through the closed switch to a light bulb, the amount of power then consumed depends on how long the switch is closed. In the typical flashlight, the effective life of the battery is only a few hours at most. Should the operator, after using the flashlight to find his/her way in the dark or for any other purpose, then fail to turn it off, the batteries will, in a very short time, become exhausted. Should the flashlight be left in a turned-on and exhausted condition for a prolonged period, the batteries may then leak and exude corrosive electrolyte that is damaging to the contact which engages the battery terminal as well as the casing of the flashlight.
[0003] When the flashlight is designed for use by a young child the likelihood is greater that the flashlight will be mishandled, because a young child is prone to be careless and forgets to turn the flashlight “off” after it has served its purpose. Because of this, a flashlight may be left “on” for days, if not weeks, and as a result of internal corrosion may no longer be in working order when the exhausted batteries are replaced.
[0004] Flashlights designed for young children are sometimes in a lantern format, with a casing made of strong plastic material that is virtually unbreakable, the light bulb being mounted within a reflector at the front end of the casing and being covered by a lens from which a light beam is projected. A U-shaped handle is attached to the upper end of the casing, with mechanical on-off slide switch being mounted on the handle, so that a child grasping the handle can readily manipulate the slide actuator with his/her thumb.
[0005] With a switch of this type on top of a flashlight handle, when the slide actuator is pushed forward by the thumb, the switch “mechanically” closes the circuit and the flashlight is turned “on” and remains “on” until the slide actuator is pulled back to the “off” position and the circuit is opened. It is this type of switch in the hands of a child that is most likely to be inadvertently left “on.”
[0006] To avoid this problem, many flashlights include, in addition to a slide switch, a push button switch which keeps the flashlight turned on only when finger pressure is applied to the push button. It is difficult for a young child who wishes, say to illuminate a dark corner in the basement of his home for about 30 seconds, to keep a push button depressed for this period. It is therefore more likely that the child will actuate the slide switch to its permanently-on position, for this requires only a monetary finger motion.
[0007] It is known to provide a flashlight with a delayed action switch which automatically turns off after a pre-determined interval. The Mallory U.S. Pat. No. 3,535,282 discloses a flashlight that is automatically turned off by a delayed action mechanical switch assembly that includes a compression spring housed in a bellows having a leaky valve, so that when a switch is turned on manually, this action serves to mechanically compress the bellows which after a pre-determined interval acts to turn off the switch.
[0008] A similar delayed action is obtained in a flashlight for children marketed by Playskool Company, this delayed action being realized by a resistance-capacitance timing network which applies a bias to a solid-state transistor switch after 30 seconds or so to cut off the transistor and shut off the flashlight. Also included in the prior art, is a flashlight previously sold by Fisher-Price using an electronic timing circuit to simply turn off the flashlight after about 20 minutes.
[0009] It is also known, e.g. as disclosed in U.S. Pat. No. 4,875,147, to provide a mechanical switch assembly for a flashlight which includes a suction cup as a delayed action element whereby the flashlight, when momentarily actuated by an operator, functions to connect a battery power supply to a light bulb, and which maintains this connection for a pre-determined interval determined by the memory characteristics of the suction cup, after which the connection is automatically broken.
[0010] U.S. Pat. No. 5,138,538 discloses a flashlight having the usual components of a battery, and on-off mechanical switch, a bulb, and a hand-held housing, to which there is added a timing means and a circuit-breaking means responsive to the timing means for cutting off the flow of current to the bulb, which further has a by-pass means, preferably child-proof, to direct electric current to the light bulb regardless of the state of the timing means. The patent also provides for the operation of the device may be further enhanced by making the by-pass means a mechanical switch connected so as to leave it in series with the mechanical on-off switch. Furthermore, the patent discloses a lock or other “child-proofing” mechanism may be provided to ensure that the by-pass is disabled when the flashlight is switched off.
[0011] Most conventional flashlights, like those described above, are actuated by mechanical push or slide button-type switches requiring, of course, mechanical implementation by an operator. Over time, the switch suffers “wear and tear” which impairs operation of the flashlight as a result of, for example, repeated activations by the operator and/or due to the fact that the switch has been left “on” for a prolonged period of time. In addition, such mechanical switches are vulnerable to the effects of corrosion and oxidation and can cause said switches to deteriorate and to become non-functioning. In addition, these prior art devices having these mechanical switches are generally “dumb,” i.e. they do not provide the user with convenient, reliable, and affordable functionalities which today's consumers now demand and expect.
[0012] The prior art switches typically provide two basic functions in prior art flashlights. First, the mechanical switches act as actual conductors for completing power circuits and providing current during operation of the devices. Depending upon the type of bulb and wiring employed, the intensity of electrical current which must be conducted by the switch is generally quite high leading to, after prolonged use, failure. Second, these mechanical switches must function as an interface between the device and its operator, i.e. the man-machine-interface (“MMI”) and necessarily requires repeated mechanical activations of the switch which over time mechanically deteriorate.
[0013] Also, currently the electrical switches used in buildings/houses for control of lighting systems are of the conventional type of switches which must conduct, i.e. close the circuit, upon command, thus also providing the MMI. These prior art switches suffer from the same disadvantages as the switches described above in relation to portable electronic devices, like flashlights. Moreover, the switches are relatively dumb in most cases and do not provide the user with a variety of functions, e.g but not limited to timing means to enable a user, for example, a shop owner or home owner to designate a predetermined shut off or turn on point in time.
[0014] There is a need for inexpensive, reliable, and simple intelligent electronic devices which provide increased functionality and energy conservation.
SUMMARY OF THE INVENTION
[0015] According to one embodiment of the present invention, there is provided a microchip controlled switch to manage both the current conducting functions and the MMI functions in an electronic device, such as a flashlight, on a low current basis i.e. without the MMI device having to conduct or switch high current. According to one aspect of the invention, the MMI functions are controlled by very low current signals, using touch pads, or carbon coated membrane type switches. These low current signal switches of the present invention can be smaller, more reliable, less costly, easier to seal and less vulnerable to the effects of corrosion and oxidation. Moreover, since the switch is a solid state component, it is, according to the present invention, possible to control the functions of the device in an intelligent manner by the same microchip which provides the MMI functions. Thus, by practicing the teachings of the present invention, more reliable, intelligent, and efficient electrical devices can be obtained which are cheaper and easier to manufacture than prior art devices.
[0016] According to another embodiment of the invention, there is provided a microchip which can be embedded in a battery that will lend intelligence to the battery and thus, the device it is inserted into, so that many functions, including but not limited to, delayed switching, dimming, automatic shut off, and intermittent activation may be inexpensively realized in an existing (nonintelligent) product, for example a prior art flashlight.
[0017] According to a further embodiment, the invention provides a power saving microchip which, when operatively associated with an electronic device, will adjust the average electric current through a current switch, provide an on and off sequence which, for example, but not limited to, in the case of a flashlight, can be determined by an operator and may represent either a flash code sequence or a simple on/off oscillation, provide an indication of battery strength, and/or provide a gradual oscillating current flow to lengthen the life of the operating switch and the power source.
[0018] According to one embodiment of the invention, an intelligent flashlight, having a microchip controlled switch is provided comprising a microchip for controlling the on/off function and at least one other function of the flashlight. According to a further embodiment of the invention, an intelligent flashlight having a microchip controlled switch is provided comprising an input means for sending activating/deactivating signals to the microchip, and a microchip for controlling the on/off function and at least one other function of the flashlight. According to a further embodiment of the invention, there is provided an intelligent flashlight having a microchip controlled switch comprising an input means for selecting one function of the flashlight, a microchip for controlling at least the on/off function and one other function of the flashlight, wherein the microchip control circuit may further comprise a control-reset means, a clock means, a current switch, and/or any one or combination of the same.
[0019] According to another embodiment of the invention, there is provided a battery for use with an electrical device comprising a microchip embedded in the battery. According to still a further embodiment of the invention, a battery for use with an electronic device is provided comprising a microchip embedded in the battery wherein said microchip is adapted such that an input means external to the microchip can select the on/off function and at least one other function of the electronic device.
[0020] According to one embodiment of the present invention, there is provided an intelligent battery for use with an electronic device, the battery having positive and negative terminal ends and comprising a microchip embedded in the battery, preferably in the positive terminal end, for controlling on/off functions and at least one other function of the electronic device.
[0021] According to another embodiment of the invention, there is provided a portable microchip device for use in serial connection with a power source, e.g. an exhaustible power source, and an electronic device powered by said source wherein said electronic device has an input means for activating and deactivating said power source, and said microchip comprising a means for controlling the on/off function and at least one other function of the electronic device upon receipt of a signal from said input means through said power source.
[0022] According to a still further embodiment of the invention, there is provided a microchip adapted to control lighting in buildings. According to this embodiment, the normal switch on the wall that currently functions as both a power-switch, i.e. conduction of electricity, and MMI can be eliminated, thus eliminating the normal high voltage and high current dangerous wiring to the switch and from the switch to the load or light. Utilizing the present invention, these switches can be replaced with connecting means suitable for low current DC requirements.
[0023] According to another embodiment, the present invention is directed to a battery comprising an energy storage section, a processor, e.g. a microchip and first and second terminal ends. The first terminal end being connected to the energy storage section, the second terminal end being connected to the processor, and the processor being connected to the second terminal end and the energy storage section. The processor controls the connection of the second terminal end to the energy storage section.
[0024] According to another embodiment, the present invention provides an electronic apparatus which includes an electrical device, comprising a power supply, an activating/deactivating means, and a processor. The activating/deactivating means is connected to the processor and the processor is connected to the power supply. The processor controls the on/off function of the device and at least one other function of the device in response to signals received from the activation/deactivation means.
[0025] The present invention, according to a still further embodiment, provides a flashlight comprising a light source, an energy storage means, a switch means, and a processor means. The switch means being in communication with the processor means and the processor means being in communication with the energy storage means which is ultimately in communication with the light source. The processor controls the activation/deactivation of the light source and, in some embodiments, further functions of the flashlight, in response to signals received from the switch means.
[0026] While the present invention is primarily described in this application with respect to either a flashlight or a battery therefore, the embodiments discussed herein should not be considered limitative of the invention, and many other variations of the use of the intelligent devices of the present invention will be obvious to one of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a schematic of a device having a microchip controlled push button or sliding type input activation/deactivation switch according to one embodiment of the present invention;
[0028] [0028]FIG. 2 is a block diagram of a microchip for use in association with a push button or sliding input activation/deactivation switch according to one embodiment of the invention;
[0029] [0029]FIG. 3 is a schematic of a second type of intelligent device having a microchip controlled push button or sliding type input activation/deactivation switch according to another embodiment of the invention;
[0030] [0030]FIG. 4 is a schematic of a device having a microchip controlled touch pad or carbon coated membrane activation/deactivation switch according to a still further embodiment of the invention;
[0031] [0031]FIG. 5 is a block diagram of a microchip for use in association with a touch pad or carbon coated membrane activation/deactivation switch according to one embodiment of the invention;
[0032] [0032]FIG. 6 is a schematic of a second type of device having a microchip controlled touch pad or carbon coated membrane activation/deactivation switch according to one embodiment of the invention;
[0033] [0033]FIG. 7 is a schematic of a battery having embedded therein a microchip according to a further embodiment of the invention;
[0034] [0034]FIG. 8A is a block diagram of a microchip for use in a battery according to one embodiment of the present invention;
[0035] [0035]FIG. 8B is a block diagram of a second type of microchip for use in a battery according to another embodiment of the present invention;
[0036] [0036]FIG. 9 is a schematic of a device having a microchip controlled switch according to one embodiment of the invention;
[0037] [0037]FIG. 10 is a schematic of a device having a microchip controlled switch according to one embodiment of the invention;
[0038] [0038]FIG. 11 is a schematic of a device having a microchip controlled switch according to one embodiment of the present invention;
[0039] [0039]FIG. 12 is a schematic of a flashlight having therein a microchip controlled switch according to one embodiment of the present invention;
[0040] [0040]FIG. 13 illustrates a possible position, according to one embodiment of the present invention of a microchip in a battery;
[0041] [0041]FIG. 13 b illustrates one embodiment of the present invention wherein a microchip is in single wire connection to the battery cells inside the battery (a virtual or ground reference level will have to be created and is not shown);
[0042] [0042]FIG. 13 c illustrates one embodiment of the present invention wherein a microchip is in a two wire connection to the cells within the battery (a power or ground reference can be obtained from the cells);
[0043] [0043]FIG. 14 is a schematic of one embodiment of the present invention of a low current switching device suitable for lighting systems in buildings;
[0044] [0044]FIG. 15 is a block diagram of one embodiment of the present invention, i.e. microchip 1403 of FIG. 14;
[0045] [0045]FIG. 16 is a flow diagram for a microchip as shown in FIGS. 4 and 5 for a delayed shut off function embodiment of one embodiment of the present invention; and
[0046] [0046]FIG. 17 is a flow diagram for a microchip as shown in FIGS. 7 and 8 a for a delayed shut off function embodiment of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0047] According to one embodiment or aspect of the present invention, and referring to FIG. 1, a schematic depiction of main circuit 100 of an electronic device, for example, a flashlight, is provided, wherein the device has a microchip 103 and a microchip controlled input activator/deactivator 102 , for example, a push button or sliding switch. Main circuit 100 of the device is powered by a current supplied by power source 101 . Power source 101 may be any power source, e.g a DC battery, as is well known to those of ordinary skill in the art. While the following discussion is limited to specific electronic devices, that is flashlights, it is to be understood that the following description is equally applicable to other electronic devices including portable radios, toys, for example but not limited to battery operated cars, boats, planes, and/or other electrically powered toys.
[0048] Referring to FIG. 1, when an operator activates input push button or sliding command switch 102 to the “on” position, the microchip 103 receives a signal. Switch 102 is a direct electrical input to microchip 103 . Microchip 103 is grounded by grounding means 104 . Microchip 103 is in series between power source 101 and load 105 . Microchip 103 also transfers sufficient power through means of a current switch (not shown in FIG. 1) to load 105 which can be, for example, a resistor-type bulb in the case of a flashlight to provide illumination.
[0049] The microchip 103 , and other microchips of the present invention, can have its/their intelligence embedded in combinational or sequential logic, a PLA or ROM type structure feeding into a state machine or a true microcontroller type structure. The memory for the above will normally be non-volatile, but should there be a need for selectable options, EE or flash memory structures may be used.
[0050] The structure and operational parameters of such a microchip 103 are explained in greater detail below with respect to FIG. 2. As shown in FIG. 1, power is supplied to microchip 103 by power source 101 . When an operator activates input switch 102 to the “on” position it represents a command which is communicated to microchip 103 . Input means 102 requires very low current in preferred embodiments. In one embodiment of the invention, microchip control/reset means 201 simply allows the current switch 202 to pass current provided from power source 101 to load 105 in an unimpeded manner when the MMI switch 102 is activated, and, in the case of a flashlight, illumination is obtained. It is important to recognize, however, that it is control circuit 201 which activates current switch 202 upon acting on an input from MMI switch 102 . Unlike heretofore known prior art devices, activating switch 102 does not conduct current to load 105 , but is only a command input mechanism which can, according to the invention, operate on very low current. For example, according to the invention, touch sensor input or carbon coated membrane type switch devices are preferred.
[0051] If, for example, an emergency notification function is desired, the flashlight may be designed to alternately flash on and off every second. First, the operator activates input 102 into the appropriate position to indicate such a function is desired. During the “on” segment of the flashing routine, control/reset means 201 commands current switch 202 to close and let current flow through to load 105 , thereby causing, in the case of a flashlight, the bulb to illuminate. Simultaneously, control/reset means 201 uses the timing means 203 as a clock for timing. After control/reset means 201 determines one second has elapsed, control/reset means 201 instructs current switch 202 to open and interrupt the current flow through to load 105 , and bulb illumination is discontinued. It is important to note that both control/reset means 201 and current switch 202 are still active and fully powered; however, current delivery is now latent with respect to load 105 . When another second has elapsed, a command is passed from control/reset means 201 which again allows current to be delivered through current switch 202 to load 105 , and in the case of a flashlight, bulb illumination is immediately resumed. The device continues an alternating current delivery routine until either the operator switches the setting of the activating input switch 102 to the “off” position, or until the conditions pre-programmed into the microchip, e.g. into the control/reset means 201 , are satisfied and current delivery is permanently discontinued.
[0052] Similar operating routines can be employed to generate other conspicuous flashing functions such as the generation of the universal distress signal S.O.S. in Morse code. Again, such a function would require that the microchip, e.g. control/reset means 201 , be pre-programmed with the appropriate code for creating such a signal, and to permit current transmission from switch 202 to load 105 in accordance with the code with the assistance of timing means 203 . For example, it may be desirable to have an S.O.S. sequence wherein flashes representing each individual letter are separated by time intervals ranging from one-half (½) second to one (1) full second, while the interval between each letter in the code comprises two (2) full seconds. After a certain number of repetitions of the routine, again determined by the operator or as pre-programmed within the microchip, e.g. within the control/reset means 201 , the signal is discontinued.
[0053] As shown in FIG. 3, it is possible to remove grounding means 104 from main circuit 100 . However, it is then necessary to intermittently provide an alternative power source for microchip 103 and to create a virtual ground reference level. A suitable microchip 103 for this configuration is described in greater detail below with respect to FIGS. 8A and 8B.
[0054] Referring now to FIG. 4, utilizing the circuits in the microchip of some embodiments of the present invention, carbon coated membrane or touch pad type switches are preferred. Carbon coated membrane switches and touch pad switches have many advantages over conventional high current switches, such as those currently used in flashlights. According to the present invention, carbon coated membrane type switches, low current type switches, and touch pad type switches can be used which may be smaller, less costly, easier to seal, and less vulnerable to corrosion and oxidation than conventional switches which also transfer energy or current to the load. Moreover, according to one embodiment of the present invention, carbon coated membrane type switches, touch pad switches, or low current type switches can be formed structurally integral with the product, for example, with the casing of a flashlight.
[0055] A block diagram showing microchip 103 for use, in accordance with one embodiment of the present invention, in association with a carbon coated membrane, a touch pad switch, or a low current type switch 106 is now explained in greater detail in respect to FIG. 5. According to this one embodiment of the present invention, current switch 202 is powered directly by grounded power source 101 . However, output of current from current switch 202 to load 105 is dependent on control/reset means 201 . When an operator depresses touch pad 106 , carbon coated membrane switch 106 or low current type switch 106 , control/reset means 201 allows current switch 202 to flow current through to load 105 . However, in more intelligent applications according to certain embodiments of the present invention, control/reset means 201 will coordinate, based on clock and/or timing means 203 , to execute timing routines similar to those described above such as, but not limited to, intermittent flashing, the flashing of a conspicuous pattern such as Morse code, dimming functions, battery maintenance, battery strength/level, etc.
[0056] As shown in FIG. 6, grounding means 104 can be removed from the system as a matter of design choice. A more detailed description of a suitable microchip 103 for this type of configuration is provided below with respect to FIGS. 8A and 8B.
[0057] Referring to FIG. 7, certain embodiments of the present invention also provide for a battery having a microchip embedded for use in association with an electronic device. As shown, direct current is provided to microchip 103 by power source 101 . When activating input switch 102 is closed, current is complete and power is transferred to load 105 at the direction of microchip 103 . Microchip 103 embedded in the battery can have any number of intelligent functions pre-programmed therein, such as, for example but not limited to, battery strength monitoring, recharging, adjustment of average current through a current switch, intermittent power delivery sequences, and so on. Examples of suitable microchips 103 for this type of application are discussed below with reference to FIGS. 8A and 8B.
[0058] [0058]FIGS. 8A and 8B are block diagrams of two different further embodiments of the present invention. Microchip 803 is especially suitable for applications wherein microchip 803 is not grounded through the body of the electrical device or where a ground cannot otherwise be established because of design considerations. This embodiment is useful to provide sufficient operating power to the microchip and can be achieved by periodically opening and closing current switch 202 when activation input switch 102 is closed. For example, referring to FIG. 8A, when input switch 102 is closed but current switch 202 does not conduct (that is, the switch is open and does not allow current to flow to load 105 ), then voltage drop over load 105 is zero and in the case of a flashlight, no illumination is provided from the bulb. Instead, the full voltage drop is over current switch 202 and in parallel with the diode 204 and capacitor 205 . Once capacitor 205 becomes fully charged, current switch 202 can close and circuit 103 will be powered by capacitor 205 . When circuit 803 is adequately powered, it functions in a manner identical to the circuits described previously with respect to the functions provided by control/reset means 201 and timing means 203 .
[0059] When the charging capacitor 205 starts to become depleted, control/reset means 201 will recognize this state and reopen the current switch 203 , thus briefly prohibiting the flow of current to load 105 , in order to remove the voltage drop from load 105 and allow capacitor 205 to recharge and begin a new cycle. In a flashlight application, the time period wherein current flow from current switch 202 is discontinued can be such that the dead period of the light is not easily or not at all detectable by the human eye. In the case of a high current usage load, such as a flashlight, it means the ratio of the capacitance of the capacitor having to power the microchip and the current consumption of the microchip, must be such that the capacitor can power the microchip for a long time relative to the charging time ( 202 open). This will enable the flashlight's “off” time to be short and the “on” time to be long, thus not creating a detectable or intrusive switching of the flashlight to the user.
[0060] According to another embodiment of the present invention, e.g. in relation to another product of low current consumption, such as a FM radio, the designer may opt for a capacitive (reservoir) device externally to the microchip (see FIG. 11). In this case, the electrical device may function for a time longer than the time required for charging the capacitor ( 205 , 207 ) which is when the current switch ( 202 ) is open and not conducting current.
[0061] According to another embodiment of the present invention, an output may be provided to indicate a condition, e.g. a battery is in good or bad condition. It may also be suitable to assist in locating a device, e.g. but not limited to a flashlight, in the dark. This may be a separate output pin or may be, according to another embodiment, shared with the MMI switch input. (See FIG. 11) This output or indicator may be a LED. Referring to FIG. 11, indicator/output device 1104 may, for example, be an LED. When microchip 1113 pulls the line 1114 to high, the LED 1104 shines. LED 1104 may also shine when switch 1111 is closed by the user. However, since that is only a momentary closure, this should not create a problem.
[0062] According to a further specific embodiment of the invention, referring to FIG. 11, microchip 1113 can activate the LED 1104 for a short time, e.g. every 100 milliseconds, every 10 seconds. This indication will let potential users know the device is in a good state of functionality and will enable fast location of the device in the dark, e.g. in times of emergency. The low duty cycle will also prevent unnecessary battery depletion.
[0063] With an alternative embodiment of the present invention, FIG. 8B illustrates the charging and discharging of capacitor 207 to provide power to circuit 803 , wherein the diode and capacitor structure establishes a ground reference for circuit 803 .
[0064] Each of the embodiments explained with respect to FIGS. 8A and 8B are suitable for use, according to the present invention, depending upon the application. Indeed, the embodiments shown in FIGS. 8A and 8B can be directly embedded into a battery and/or can be separately constructed in another portable structure, e.g but not limited to, in the shape of a disc, about the size of a quarter, to be inserted at the end of the battery between the output means or positive terminal of the battery and the current receiving structure of the electronic device. As described, the embodiments shown in FIGS. 8A and 8B can be utilized with the prior art high current switches currently being utilized in simple non-intelligent electronic devices, for example flashlights, radios and toys. For example, in the case of a portable simple radio without any intelligence, an automatic shut “off” may be achieved by using the intelligent battery or portable microchip of the present invention having a timing function to automatically shut off the radio after a given period of time, i.e. after the user is asleep.
[0065] The architecture of the two embodiments of the present invention shown in FIGS. 8A and 8B provide certain advantages over the simple dumb architecture in current simple electrical devices, for example, flashlights. Due to the unique design of the microchips, as shown in FIGS. 8A and 8B, after the device (into which the microchip is incorporated) is shut off the microchip remains powered for an additional period of time which allows for said microchip to thus receive additional commands, for example, a second “on” activation within a given period after a first “on” and “off” activation, may be programmed into the microchip (control/reset means) to indicate a power reduction or dimming function or any other function as desired by the designer of said device. This is accomplished by the inventive designs of the present invention without having to utilize substantial energy from what are typically small exhaustible power sources, e.g. DC batteries in the case of flashlights.
[0066] According to some embodiments of the present invention, more intelligent devices include many other useful functions pre-programmed within the microchip, e.g. in control/reset means 201 and may, e.g. be assisted by a timing means 203 . Referring to FIG. 2, commands can be entered through switch 102 in several different ways. First, various time sequences of closed and open activations may represent different commands. For example, but not limited to, a single closure may instruct microchip 103 to activate current switch 202 continuously for a pre-determined length of time. Alternatively, two successive closures may instruct the microchip 103 to intermittently activate current switch 202 for a pre-determined length of time and sequence, for example, a S.O.S. sequence.
[0067] Secondly, referring to FIG. 9, commands may be communicated to microchip 903 through the use of various voltages recognizable by microchip 903 to represent various commands. For example, but not limited to, according to one embodiment of the present invention, it may include multiple activating switches 901 and 902 connecting different voltages to the command input structure of microchip 903 .
[0068] Thirdly, referring to FIG. 10, commands may be communicated to microchip 1103 through the use of multiple specific switches ( 1004 , 1005 , 1006 , 1007 ) which when activated either singularly or in combination is/are recognizable by microchip 1103 as representing various different commands.
[0069] As can be seen by FIG. 9, switch 901 and 902 and in FIG. 10, switches 1004 , 1005 , 1006 , and 1007 , power or ground may be used as a command reference voltage level. For example, the switches in FIG. 10 may be connected to another ground instead of point 1008 depending on the internal structure of the microchip.
[0070] The control/reset means included in the inventive microchips of the present invention may and in some instances, depending upon the application, should in addition to the many possible user functions described above, include means for adjusting the average current over a switch and/or a means for providing a gradual “on”/“off” current flow, so that the operator does not appreciably perceive the increase and decrease in light provided by the device. These features allow for an ongoing variable level of lighting as desired by an operator, and may also lengthen the life span of the activation switch, the bulb, and the power source. Moreover, several functions can now be added to an existing device, like a flashlight, through the use of a battery having embedded therein a microchip according to the present invention.
[0071] In another embodiment of the invention, the microchip is adapted to control lighting in buildings. The normal switch on the wall that currently functions as both a power-switch and MMI can be replaced by a low current switching device like a membrane switch, touch pad or carbon coated switching device. Since very low currents are required by the MMI switch (device) that replaces the normal wall mounted (A/C) switch, it is possible to replace the normal high voltage/current (dangerous) wiring to the switch and from the switch to the lead (light), with connectivity means suitable to the new low current DC requirements. As such, in the case of normal A/C wiring (110V/220V), the dangerous wiring can now be restricted to the roof or ceiling and all switches (MMI's) can inherently be safe. This may make the expensive and regulated safety piping required for the wiring of electricity to wall switches redundant.
[0072] In a specific embodiment, the traditional wiring between the light and the wall switch is replaced by flexible current conducting tape that can be taped from the roof and down the wall to the required location. In another embodiment, the connections can be made by current conducting paint or similar substances. In both cases above, it can be painted over with normal paint to conceal it. This makes changing the location of a wall switch or the addition of another switch very easy.
[0073] The microchip according to the present invention can be located in the power fitting of the light. The microchip having the low current (MMI) input and a power switch to block or transfer the energy to the load (light, fan, air conditioner). It reacts to the inputs received to activate or disable, or control other functions, of whatever device it is controlling.
[0074] The microchip may be adapted to contain the high current/voltage switch or control an external switching device or relay. The microchip may also, as in the other embodiments discussed, have some intelligence to control functions like dimming, delayed shut off, timed activation/deactivation, timed cycles, flashing sequences and gradual on/off switching. The microchip may also be adopted, as in a specific flashlight embodiment discussed, to provide a location/emergency signal for lighting/flashing an LED.
[0075] The power input 101 in FIG. 14 may be DC (eg 12V) as is commonly used for some lights or A/C (110V or 240V). The device shown as 1403 may be monolithic or be a multichip unit having a relay (solid state or mechanical), a regulator (eg: 110AC volt to 12V DC) and a microchip as discussed in this application.
[0076] In a specific embodiment, Ic pin 1406 can normally be high and a closure of input means 1402 , e.g. any of the low current switching devices described above, can be detected as Ic pin 1405 also goes too high. To flash the LED 1404 the microchip will reverse the polarities so that Ic pin 1405 becomes high with regards to Ic pin 1406 . During this time, it may not be possible to monitor the closure of the input 1402 switch and the LED 1404 may not shine should the input 1402 be closed. In another embodiment, microchip 1403 is able to detect closure of input 1402 before reversing the voltage polarity as discussed and if it detects closure, it does not proceed with reversing the polarity.
[0077] In FIG. 15, microchip 1503 does not contain a current switch (eg switch 102 ) as shown in FIG. 2. However, if desired the regulator and relay can be integrated into a single monolithic microchip 1503 . In case of a 12V (DC) local voltage this may be done in any event unless the current/power considerations is too high to make it practical.
[0078] In another embodiment, the microchips 1403 and 1503 are adapted to receive commands not only via the MMI input but also over the load power (electricity) wiring. This would allow a central controller to send out various commands to various power points, controlled by a microchip according to this invention, by using address information of specific microchips or using global (to all) commands.
[0079] While the preferred embodiments of the present invention have been described in detail, it will be appreciated by those of ordinary skill in the art that changes and modifications may be made to said embodiments without, however, departing from the spirit and scope of the present invention as claimed.
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The present invention provides for a unique microchip or circuit which can, inter alia, handle both current conducting functions and man-machine-interface functions in an electrical device, for example, such as a flashlight. The man-machine-interface functions, according to the present invention, may be controlled by very low current signals, touch pads, carbon coated membrane type switches, or other low current type switches. These low current switches are smaller, more reliable, less costly, easier to seal, and less vulnerable to corrosion and oxidation than prior art switches. Moreover, since according to the present invention, the current conducting switch is controlled in an intelligent manner by the same microchip which provides the man-machine-interface functioning, significant costs savings and reliability are achieved by the invention.
The present invention, according to one embodiment, also provides a microchip or circuit which may be embedded into a power source, for example, a battery, that supplies intelligence to the same. As a result, and according to the invention, functions such as delayed switching, dimming, delayed automatic shut off and an intermittent activation may be realized in less intelligent prior art electrical devices. According to certain embodiments of the present invention, the inventive microchips or circuits of the present invention can, inter alia, adjust the average electrical current through a current switch, provide an “on” and “off” sequence which, in the case of a flashlight, can be determined by an operator and may represent either a flash code sequence or a simple on-off oscillation, delayed shut off function, dimming function, provide indication of power strength, and provide gradual oscillating current flow to lengthen the life of the operating switch and the battery, etc.
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FIELD OF THE INVENTION
[0001] This invention relates generally to valves, and, more specifically to pin valves.
BACKGROUND OF THE INVENTION
[0002] Pin valves have been in existence for a quite some time and have been used for a multiplicity of purposes. Within the last 15 to 20 years pin valves have been adapted to be used in gas powered guns suitable for projecting paint balls. These type of guns have become popular for use in simulated combat games. Pin valves are an important component of these guns because they provide a removable connection between the gun and a high pressure gas source such as a CO 2 tank. The pin valve enables the CO 2 tank to be easily detached from the gun when the gun is not in use or when the CO 2 tank requires recharging.
[0003] As shown in FIG. 1, a prior art pin valve typically comprises a substantially cylindrical valve body having a first open end, a second open end, and an internal valve chamber in flow through connection with the first open end and the second open end. In a typical application, the first open end of the valve is connected to a paint ball gun, while the second open end is connected to a CO 2 tank. A valve stem assembly is disposed within the internal valve chamber. The valve stem assembly in a prior art pin valve may be accessed and removed only through an access opening in the second open end of the valve body. The valve stem protrudes through a valve stem opening in the first open end of the valve body. The valve stem moves between a retracted position where the valve is open and an extended position where the valve is closed. The valve stem is biased toward the extended position such that the valve stem protrudes through the valve stem opening in the valve body and a O-ring seal surrounding the valve stem is in sealing contact with a valve seat located on the inner surface of the internal valve chamber proximal to the first open end of the valve body. The pin valve is opened when the valve stem is depressed and moved to the retracted position such as by being connected to a paint ball gun at the first open end of the pin valve.
[0004] The first open end of the pin valve is typically disconnected from the paint ball gun when the gun is not in use. The valve stem is in the extended position and the valve is closed when the first open end is disconnected. Unfortunately, when the first open end of the pin valve is disconnected from the paint ball gun it becomes exposed and is easily dented or otherwise damaged. If the first open end of the valve is dented, for example by hitting a solid object such as a concrete curb or a truck bed wall, it can result in damage to the valve stem or the inability to form an air-tight seal at this perimeter of the valve. The result is a pin valve that leaks.
[0005] Also, valve stems sometimes leak because of a poor seal between the O-ring and the valve seat. This problem frequently arises because of the difficulty in forming a proper valve seat surface during the manufacture of prior art pin valves. In order to have a valve that does not leak, it is vital that the surface of the valve seat is machined properly so that the valve seat has a sufficiently smooth and contiguous surface. Unfortunately, the valve seat surface is difficult to access in a prior art pin valve because it is disposed within the internal valve chamber at the opposite end of the cylindrical valve body from the access opening. The result is that many valve seat surfaces are imprecisely machined and a undue number of new valves need to be discarded prematurely because they leak.
[0006] A problem with prior art valves is that they are not amenable to being repaired. In fact, the valves currently used in paint ball guns are one of the most commonly replaced parts of the paint ball gun because they are not easily repaired. A particular problem is that replacement of the valve stem is difficult and time consuming. As shown in the prior art valve in FIG. 1, the valve stem assembly must be removed and replaced from the access opening in the second open end of the valve body. This requires that the entire valve be disconnected from the CO 2 tank. Disconnecting the second open end of the valve is difficult because the threaded connection is typically fixed to the CO 2 tank by the application of a special sealant material. The sealant acts to physically secure the connection between the valve and the CO 2 tank and to prevent leaks at this junction. This sealant can be difficult to properly apply, and is even more difficult to remove when disconnecting the valve. Breaking this seal usually requires that the connection between the valve and the CO 2 tank be heated to loosen the previously applied sealant. When a valve is reconnected it is important that the sealant material be properly applied because the connection may otherwise leak or pose a safety hazard. However, the sealant material may not be readily available when the valve needs to be replaced. Moreover, application of the sealant material entails a requisite level of skill not possessed by many persons owning or servicing the gun. Improper application of the sealant material, or failure to use the sealant material, can result in a safety hazard because the back end of the valve may become unscrewed when disconnecting the first end of the valve.
[0007] A further problem with prior art valves is that damage to the face of the first end typically requires that the entire valve be replaced. As shown in the prior art valve illustrated in FIG. 1, the face of the first end where the valve stem protrudes is integral with the first end of the valve body. When this face is dented the valve must often be replaced in its entirety rather than being repaired because the face is integral with the valve body. Needless to say, replacement of the entire pin valve is this is not a cost effective approach to maintaining the valve in proper working condition.
[0008] There is therefore a need for a valve which is easier to manufacture, easier to repair, and allows the valve stem assembly to be replaced directly from the first open end of the valve body.
SUMMARY
[0009] The invention satisfies this need. The invention is an improved valve which is more easily repaired, and which is suitable for being used in a gas propelled paint ball gun for connecting the gun to a pressurized gas source.
[0010] The invention comprises:
[0011] (a) a valve body having first and second open ends;
[0012] (b) a valve body cover reversibly attached to the first end of the valve body, the valve body and the valve body cover cooperating to define an internal valve chamber, the valve body cover having an external face, an internal face and a valve stem opening, the internal face of the valve body cover comprising a valve seat; and
[0013] (c) a valve stem assembly disposed within the valve chamber, the valve stem assembly comprising a valve stem body, a valve stem attached to the valve stem body and a valve stem seal, the valve stem being movable between a retracted valve stem position and an extended valve stem position and being biased toward the extended valve stem position, the valve stem assembly being disposed within the valve chamber such that, (i) when the valve stem is in the extended valve stem position, the valve stem protrudes through the valve stem opening in the valve body cover and the valve stem seal is in sealing contact with the valve seat so as to seal closed the valve stem opening, and (ii) when the valve stem is in the retracted valve stem position, the valve stem seal is spaced apart from the valve seat sufficient so that the valve stem opening is not sealed closed.
[0014] The detachable valve body cover at the first open end of the valve body enables the valve stem assembly to be replaced directly from the first open end of the valve body, and thus virtually eliminates the need to disconnect the valve at the second open end. The valve seat surface is readily machined to form a smooth surface because it is disposed on the inner surface of the separately machined valve body cover. In a preferred embodiment, the removable valve body cover protects the first open end of the valve body and can be replaced independently if damaged. The removal of the valve body cover is simplified by designing the external face of the valve body cover such that it accommodates an allen wrench type tool.
DRAWINGS
[0015] These features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying figures where:
[0016] [0016]FIG. 1 is cross-sectional view of a prior art pin valve;
[0017] [0017]FIG. 2 is a cross-sectional view of a first embodiment having features of the invention; and
[0018] [0018]FIG. 3 is a cross-sectional view of a second embodiment having features of the invention.
DETAILED DESCRIPTION
[0019] The following discussion describes in detail two embodiments of the invention and several variations of those embodiments. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well. For example, the valves described herein are not limited to being used in gas propelled paint ball guns and may be used in connection with other equipment and devices.
[0020] The invention is a pin valve 10 comprising a valve body 12 , a valve body cover 14 , and a valve stem assembly 16 .
[0021] The valve body 12 is substantially cylindrical and comprises a first open end 18 which is in flow through contact with a second open end 20 . The valve body 12 and the valve body cover 14 cooperate to define an internal valve chamber 22 that is disposed within the valve body 12 . The internal valve chamber 22 is typically cylindrical. As illustrated in the embodiments in drawings, the valve body 12 preferably comprises external threads 24 proximal to the first open end 18 and proximal to the second open end 20 to enable the pin valve 10 to be connected to appropriate connectors at each end of the valve body 12 . In the embodiments illustrated in drawings, the valve body 12 further comprises a recessed lip 26 at the radial perimeter of the valve body 12 at the first open end 18 which accommodates a first open end O-ring 28 . The first open end O-ring 28 is sized and dimensioned such that it protrudes slightly from the radial perimeter of the valve body 12 and facilitates the formation of an air tight seal between the first open end 18 and an appropriate connector. In a typical embodiment, the diameter of the valve body 12 is between about ½ inches and about 1 inches and the length of the valve body 12 along it's longitudinal axis is between about 1 inches and about 3 inches.
[0022] The valve body cover 14 is attached to the first open end 18 of the valve body 12 and comprises an external face 30 , an internal face 32 , and a valve stem opening 34 . Preferably, the valve body cover 14 reversibly attaches to the valve body 12 , such as by a threaded connection. As illustrated in the embodiments in the drawings, the valve body cover 14 comprises external valve body cover threads 36 disposed between the external face 30 and the internal face 32 . In these embodiments, the internal valve chamber 22 further comprises chamber threads 38 that accommodate the valve body cover threads 36 .
[0023] The external face 30 of the valve body cover 14 typically comprises a valve body cover orifice 40 which is sized and dimensioned to accommodate an allen wrench type tool. As used herein, the form of an allen wrench type tool is meant to be interpreted broadly to include all tools which are suitable for applying torque to attach and detach the threaded valve body cover 14 , including, for example, screwdrivers. A typical allen wrench type tool is an L-shaped tool with at least one end terminating in a bit having the cross section shape of a hexagon, pentagon, octagon, or square.
[0024] In the embodiment illustrated in FIG. 2, the external face 30 of the valve body cover 14 comprises a flange 42 that substantially covers the first open end 18 of the valve body 12 . Typically, the flange 42 is circular and is sized and dimensioned to substantially cover the first open end 18 of the valve body 12 . Typically, the thickness of the flange 42 is between about 0.030 inches and about 0.070 inches. In the embodiment illustrated in FIG. 2, the first open end O-ring 28 is disposed between the flange 42 of the valve body cover 14 and the recessed lip 26 of the valve body 12 . The embodiment in FIG. 2 is distinguishable from the embodiment illustrated in FIG. 3, in which the external face 30 of the valve body cover 14 does not comprise a flange 42 .
[0025] The valve stem assembly 16 is disposed within the internal valve chamber 22 . The valve stem assembly 16 comprises a valve stem body 44 and a valve stem 46 that is attached to the valve stem body 44 . The valve stem 46 is capable of moving back and forth between a retracted valve stem position and an extended valve stem position. The valve stem 46 is biased toward the extended valve stem position. As illustrated in the embodiments in the drawings, the valve stem 46 is preferably fixedly attached to the valve stem body 44 . In these embodiments, there is a spring 48 disposed within the internal valve chamber 22 proximal to the second open end 20 of the valve body 12 . The spring 48 places a biasing force upon the valve stem body 44 and valve stem 46 directed toward the valve stem opening 34 . It is the force from this spring 48 which biases the valve stem 46 toward the extended valve stem position.
[0026] In an alternative embodiment, the valve stem assembly 16 comprises a stationary valve stem body 44 and a movable valve stem 46 that is attached to the valve stem body 44 . Again, the valve stem 46 is capable of moving back and forth between a retracted valve stem position and an extended valve stem position. In this embodiment this is accomplished by placement of a spring within the valve stem body 44 that interacts with the valve stem 46 and places a force directed toward the valve stem opening 34 upon the valve stem 46 . As the valve stem 46 is retracted, the portion of the valve stem 46 proximal to the stationary valve stem body 44 enters the valve stem body 44 .
[0027] The valve stem assembly 16 further comprises a valve stem seal 50 . As illustrated in the embodiments in the drawings, the valve stem seal 50 is preferably disposed radially about the valve stem 46 within the internal valve chamber 22 . The internal face 32 of the valve body cover 14 further comprises a valve seat 52 . The valve seat 52 is disposed within the internal valve chamber 22 on the internal face 32 of the valve body cover 14 . As illustrated in the embodiments in drawings, the valve seat 52 is preferably radially disposed around the valve stem opening 34 such that it encircles the valve stem opening. In these embodiments, the valve stem seal 50 is preferably an O-ring disposed radially about the valve stem 46 and the O-ring type valve stem seal 50 is sized and dimensioned to seat in sealing relationship with the valve seat 52 .
[0028] As illustrated in the embodiments in drawings, the valve stem assembly 16 is disposed within the internal valve chamber 22 such that, when the valve stem 46 is in the extended valve stem 46 position, the valve stem protrudes through the valve stem opening 34 in the valve body cover 14 and the valve stem seal 50 is in sealing contact with the valve seat 52 so as to seal closed the valve stem opening 34 . Conversely, when the valve stem 46 is in the retracted valve stem position, the valve stem seal 50 becomes sufficiently spaced apart from the valve seat 52 so that the valve stem opening 34 is not sealed closed. The valve stem 46 is normally in the retracted position when the first open end 18 of the valve body 12 is attached to an appropriate connector.
[0029] As illustrated in the embodiments in the drawings, there is typically a safety relief member 54 attached by a threaded connection to the valve body 12 between the first open end 18 and the second open end 20 . The safety relief member 54 connects with the internal valve chamber 22 to allow gas to escape when the pressure within the internal valve chamber 22 becomes too high.
[0030] The pin valve 10 described herein is distinguished from pin valves 110 of the prior art by the detachable valve body cover 14 attached to the first open end 18 . As illustrated in FIG. 1, prior art pin valves 110 do not have a valve body cover 14 at the first open end 118 . Instead, prior art pin valves 110 have an access opening 156 in the second open end 120 of the valve body 112 .
[0031] In operation, a user repairs a pin valve 10 with a damaged valve stem 46 entirely from the first open end 18 simply by removing the valve body cover 14 with an allen wrench and replacing the valve stem assembly 16 . Replacing the valve stem assembly 16 is much simpler with the pin valve 10 described herein in comparison to a prior art pin valve 110 . With reference to the prior art pin valve 110 illustrated in FIG. 1, the valve stem assembly 116 cannot be removed from the first open end 118 of the valve body 112 , but rather may be removed and replaced only through an access opening 156 in the second open end 120 of the valve body 112 . Replacement of a valve stem 146 in a prior art pin valve 110 necessitates that the second open end 120 normally fixedly attached to a CO 2 tank by a special sealant be removed.
[0032] If the first open end 18 of the pin valve 10 is dented, the user repairs the embodiment of the invention illustrated in FIG. 2 by adding a new valve body cover 14 rather than replacing the entire pin valve 10 . Again, the repair is performed from the first open end 18 of the pin valve 10 after the first open end 18 has been disconnected. The valve body cover 14 is easy to remove and reattach because it incorporates an opening for an allen wrench. A user wishing to remove the valve body cover 14 knows whether the pressurized gas source has been discharged prior to removing the valve body cover 14 because engagement of the allen wrench to detach the valve body cover 14 necessarily pushes the valve stem 46 to a retracted position and opens the pin valve 10 . This eliminates the danger of accidentally removing the valve body cover 14 from the pin valve 10 when the pressurized gas source has not been discharged.
[0033] Finally, a user wishing to repair a defective valve seat 52 simply replaces the valve body cover 14 . This repair is performed from the first open end 18 of the pin valve 10 , rather than replacing the entire pin valve 10 or attempting to re-machine the valve seat 52 from the access opening at the second open end 20 of the pin valve 10 . The user need not remove the fixedly attached second open end 20 of the pin valve 10 to perform this repair.
[0034] Having thus described the invention, it should be apparent that numerous structural modifications and adaptations may be resorted to without departing from the scope and fair meaning of the instant invention as set forth hereinabove and as described hereinbelow by the claims.
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The invention is a pin valve having a detachable valve body cover which makes the valve stem assembly accessible from the end of the valve in which the valve stem protrudes. The removable valve body cover can be replaced independently if this end of the valve is damaged. The valve body cover also has a valve seat which is more accessible and is more easily machined. The valve body cover is typically adapted to accommodate an allen wrench type tool to simplify removal and reattachment. The invention eliminates the need to disconnect the valve at the second open end when replacing the valve stem assembly.
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TECHNICAL FIELD OF THE INVENTION
This invention relates to graphics software and more particularly to a system and method for generating variable width lines by using pressure sensitive techniques or simulations thereof.
BACKGROUND OF THE INVENTION
In traditional artistic endeavors, an artist creates attractive visual effects by using a paintbrush to create lines, strokes or paths that have different widths along its length. The artist would traditionally accomplish this by varying the pressure, or the angle, of the moving brush. In computer graphics, variable line widths are not easy to achieve and when achieved are not easily changed.
For the most part existing graphics systems allow users to construct constant width paths by moving a pen (or mouse) over a pad. Such existing graphics software systems generally approximate varying width lines by forcing the user to create a path which describes the width boundaries of the desired stroke. The system then fills in between the boundaries to create the image of the variable width line.
Currently there are two major divisions between kinds of graphic software systems, one of which is generally referred to as raster or paint systems, and the other major division being vector based or outline based graphics software systems.
In the raster based systems, images are created by composing thousands of tiny dots. The advantage of this is that it allows for very free expression but it is very hard to edit discrete shapes once the initial line is drawn.
In raster systems, it is possible to approximate a traditional paintbrush effect by using a pressure sensitive pen which creates a range of dots across the screen. The problem is that when the user is finished drawing the line, it is very hard to go back and fine tune the shape because the image consists of a plurality of disconnected dots. Essentially, each created dot must be individually modified to create a different shape.
A vector based system describes shapes by a series of mathematical outlines. For example, a circle would be described as the mathematical outline of a circle along with an instruction that it should be filled. Using traditional vector graphics programs, a user would describe a variable width line but would have to think about what the boundary, i.e., the outline, of that final shape would be. These systems run counter to traditional artistic techniques and do not follow the normal mind flow of an artist.
Accordingly, one problem with the prior art graphics systems is that they are very difficult to use to obtain a traditional artist effect.
A further problem is that existing systems do not allow artists to create images in a manner which parallels their traditional training, i.e., by moving a paintbrush (stylus) over a pad.
Another problem with the prior art is that once a line has been created, it is very difficult to change that line and to create different graphic images of the width characteristics of the line.
A further problem exists when variable width lines are being created by a pressure stylus since at the end of the line the user would normally lift up on the stylus, thereby reducing the pressure. In a logical format then the line at the end would always become very thin because thin lines are a result of low pressure on the stylus. Thus, there is a need for a system which creates wide lines by heavy pressure on a stylus (pen) which allows a user to pick up on the pen at the end of the line and not create a very thin line.
SUMMARY OF THE INVENTION
These problems and others have been solved by graphics presentation software consisting of a system and method of generating variable width lines which in one embodiment, utilizes the force exerted on a surface to control the width of the line as the line is being generated. In this system the line is created in such a manner that it can be edited easily at any point to change the width. This editing function is controlled by traditional graphics editing techniques which rely upon the particular format followed by the initial line creation.
The system operates such that as the user moves a pen (or operates a key pad and mouse) a line image is created which contains direction and width information. The path shape information along with the variable width data (obtained by the pressure of the pen or by key pad data) is used to construct an actual boundary shape similar to one that the user desires. Thus, while in prior art systems, the outline must be created first, then filled in, this graphics system operates in the exact opposite manner such that the line width is created first, and then the outline formed from the line width. It is the creation of the outline then that allows for the easy editing of the image. Once the outline is created, there are a number of points created pertaining to the shape of the line and the width of the line at that point. Any one of these points then can be edited to change the line characteristics.
When the line is first created, the system operates to store the center line and the width at various points along the center line. It is from this stored data that points are created which form the outline for display to the user.
The system is designed to prevent the line from always becoming thin when pressure is removed as a user is releasing pressure at the natural end of a stroke. This system relies on a special filtering technique which compares the relative movement and pressure change of the stylus. Depending upon certain criteria, some information that is received from the stylus regarding pressure or location changes may be ignored. The system uses a look-back technique to see where the last several points were and what their thickness was to determine whether it looks like the user is really trying to make a thinner line or whether the user is, in fact, removing the pen from the pad.
Thus, one technical advantage of our system is that a user can move a stylus across a pad and by pressing harder, or softer, can create variable lines having variable widths.
Another technical advantage of our system is the creation of a graphics system which, depending upon line width information, creates an outline of the desired line in image format on a screen, such that the image contains points editable for controlling subsequent outlines of images.
A still further technical advantage is that our system allows a user to move a stylus across a pad to create an image of the line and to sense the pressure of the stylus at any point to create variable thickness lines.
A still further technical advantage of our system is to monitor the pressure and direction data from a stylus to create the proper width of the line at the end point of the line even though the user was in the process of reducing pressure on the stylus.
A still further technical advantage of our system is the ability to generate a font having variable width segments and to display the font on a video terminal or a printer.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows an overall system of the embodiment in which the invention could possibly reside;
FIG. 2 shows a variable width line created on a monitor screen;
FIG. 3 shows the outline form of the variable width line;
FIG. 4 shows the expansion of the variable width line at a point;
FIG. 5 shows the center line or spine of the variable width line;
FIG. 6 shows the center line or spine with various points and corresponding width information after filtering;
FIG. 7 shows the outline form of the variable width line in FIG. 6;
FIG. 8 is a flowchart of the variable-weight pen drawing process;
FIG. 9 is a flowchart detailing the process for capturing points and widths;
FIG. 10 shows the filling-in of the end-points of the variable width line;
FIG. 11 is a flowchart detailing end-point filtering; and
FIG. 12 is a flowchart for finding the minimum and maximum width values to be utilized within the curve fitter,
DETAILED DESCRIPTION OF THE INVENTION
In order to produce the variable width lines as described in the present invention, the reader is recommended to purchase the "FONTOGRAPHER" software from Altsys Corporation, 269 W. Rennet Road, Richardson, Tex. 75080, hereby incorporated by reference herein. With this software, a user may produce fonts for printing composed of the variable width lines.
Turning first to FIG. 1, there is shown a system 10 which has in it, in one example, a computer graphics display 11 and keypad 12. Also connected to the computer graphics display 11 is mouse 14 with its associated pad 13 and also connected to the computer graphics display 11 is pressure sensitive tablet 15 and its associated pen 16 and also connected to the computer graphics display 11 is a reservoir 18 containing a fluid 19 with its associated stylus 17. Displayed on the screen is an image 20 having a variable width from beginning to end. This image can be created in any number of different ways, either from the keypad and from a mouse or from a pressure sensitive tablet or from a stylus with a fluid-filled reservoir. In addition, there are many other methods in which such a image can be created using the principles of our invention.
If the image were to be created using pressure sensitive tablet 15 and pen 16, the user would grasp the pen 16 and proceed to move the pen 16 across the pressure sensitive tablet 15. The variable width of the line is described by using the pressure sensitive tablet 15 in two forms. The current position (or direction) of the line is represented by the user moving the pen 16 over the tablet 15 and is represented by the position of the pen 16 on the tablet 15. Simultaneously the user may vary the width of the line at any point by changing the pressure of the pen 16 on the tablet 15. This allows the user to simultaneously vary both the position and width of the line. This is one of the most fluid and simple techniques for the user to specify a variable width shape and follows the most natural inclination of an artist. One possible alternative method for the user to specify a variable width shape would be to use the mouse 14 and keypad 12 in conjunction with each other, the mouse 14 being used to vary the position, that is, describing the position and direction of the shape by moving the mouse 14 on its pad 13, and simultaneously varying the width by using various keys on the keypad 12 to either increase or decrease the width at a given point. Alternatively, the user could hold down a varying number of keys to represent a varying width at a given point. Another possible alternative method for the user to specify a variable width shape would be to move stylus 17 within the fluid 19 wherein the current position of the line is represented by the user moving the stylus 17 through the fluid 19 within the reservoir 18. Simultaneously, the user may vary the width of the line at any point by changing the depth of the stylus 17 within the fluid 19 causing the level of the fluid 19 to correspondingly change which is sensed by a sensing device within the reservoir 18.
In yet another alternative embodiment, the reservoir 18 containing the fluid 19 (or a pressurized gas) could be attached to the end of the stylus 17 in such a manner that the whole combination could be moved along any surface with the pressure exerted by the user on the stylus 17 measured by the displacement of the fluid 19 by the end of the stylus 17, or by the force from the stylus 17 exerted on a pressurized gas within the reservoir.
FIG. 2 depicts an example of a user-created variable width shape 20 beginning from point 201 and ending at point 202. Cursor 21 is the point used to describe the current position and width of the shape.
It will be recalled that this shape is created by the user moving a stylus 16 for example from point 201 to 202 and increasing the pressure on the stylus 16 as it is moving across the pad 15. The increasing pressure on the stylus 16 produces an increasingly wider shape as depicted in the present example. Also, as previously discussed, this could have been accomplished with a mouse 14 and a keypad 12, a stylus 17 and a fluid-filled reservoir 18 or any other number of ways of inputting data. Of course, shape 20 could be varied in dimensions such that it becomes wider or thinner as the line progresses; this shape has not been shown, but any number of widths and changes in widths can be accomplished using this system. Therefore, there can be an infinite number of shapes and widths utilizing the system of the present invention. In the embodiment shown line 20 is essentially a straight line, but it could certainly be a curved line or a circle or any other of an infinite number of shapes and sizes.
The illustration in FIG. 3 shows the results of the actual curve expansion after the user has finished specifying the shape that he wants. Shape 20 is still depicted here with beginning point 201 and ending point 202. However, rather than described as simply a shape 20, it is now described as the boundary outline of the shape 20 that was described in FIG. 2. Utilizing the system of the present invention, a user can determine which part of shape 20 requires editing. Points have been added along the shape 20 at the change points of the shape 20, where the boundary outline of the shape 20 changes direction significantly, so that the user can alter the shape 20 in the manner to be discussed. Therefore, it is important to note that the points that are added such as point 304 are added by the system at strategic points along the line such that the user can thereafter modify the line and create a new line in any economical fashion. It should also be noted that so long as pressure remains on the stylus 16 or so long as the line is continuing to be created, the entire form of the line is visible on the screen. When the user lets up or stops creating the line, the form is substituted for by the outline points. It is at this point that the points are added to the line for purposes of editing.
FIG. 4 shows the same form depicted in FIGS. 2 and 3 after the user has made a slight modification to the outline. This FIG. 4 is used to demonstrate that the boundary outline created by this technique is fully modifiable and easy to reshape in any manner that the user desires. For example, the cursor 21 which was used to create the line in shape 20 in FIG. 2 upon release from the creation line is then moved to, for example, point 304 along the shape 20 and captures point 304 in any one of the well known techniques and drags point 304 to a new point on the screen, thereby creating a different thickness of shape 20 in the center of line 201-202 as shown in FIG. 4. 0f course, the cursor 21 could then be moved to any other point along the outline of shape 20 and similarly move that point in any direction, again changing the thickness of the shape 20 at the newly selected point.
Referring next to FIG. 5 there is shown a representation of an internal structure used within the system to contain temporary information while the user is first constructing the shape 20 depicted in FIG. 2. Basically, 50 is the center line or spine and set of widths that are later used to construct shape 20. Object 50 is composed of two discrete sets of data, locations and widths. Locations are such as 501, 502, etc. Every location has associated with it a width 510, 511, 512, etc. A new sample is taken along the object 50 anytime the user specifies a change in location or width by moving the stylus 16 over the tablet 15 or by changing the pressure of the stylus 16 upon the tablet 15. The end result is a center line or spine used to describe the center of the desired shape 20 and a width at each point along that spine indicating the desired final width at that point.
FIG. 6 shows the information in object. 50 of FIG. 5 after a filtering process. The result is a filtering of the very large number of samples taken for each minute change the user specified into a small number of points to describe the center line of the desired shape 60. Each remaining point still contains a desired width. The number of samples has been filtered to the minimum number of points that can be used to most closely approximate the curve that the user has drawn. The actual choice of the placement and number of points on shape 60 is dependent not only upon the complexity of the curve but also on the variability of the widths. Normally, if the shape 60 was purely a straight line, it could be described with only two points. However, if the width varied considerably, more points would have to be inserted in order to describe the changes in widths. Thus, the required number of points does depend on two factors, both the accuracy with which the curve can be described and the accuracy with which the variability of width can be described without losing an unacceptable number of changes in the widths as inputted by the user. This system for describing a number of points will be detailed hereinafter with respect to FIG. 8.
In FIG. 7 there is superimposed shape 20 from FIG. 3 and shape 60 from FIG. 6 to show how shape 20 is actually derived from shape 60. Shape 60 describes the spine or center line of the desired form with a represented width at every point. A technique well known in the art is used to expand shape 60 into shape 20, that is, every point and width on shape 60 is going to be expanded out to become two points on the boundary for shape 20. The technique for doing so is a prior art technique known as centerline figure expansion which is available from Texas Instrument's CAD systems dating back to the late 1960's.
The flowchart of FIG. 8 illustrates how the system of the present invention implements variable-weight pen drawing.
The procedure begins at 801 and at 802 the points lying on the midpoint or spine of the variable-width stroke are captured from the drawing tablet along with the pressure at each of those points. Simple input filtering is also performed at this time. This is explained in more detail in FIG. 9.
Next at 803, filtering of the ends of the shape is required to remove random jitter at the end of the stroke. This process is explained in more detail in FIG. 11.
The variable-width drawing process moves to 804 where points with minimum and maximum width are marked for the curve fitter so that they are forced to be fit and cannot be removed during curve fitting. This is required to maintain width accuracy. This is further explained in FIG. 12.
At 805, the process of curve fitting reduces the large number of x-y points obtained by tracking an input device like a mouse or data tablet, or by contour-following a scanned image, to a much smaller number (typically 1% or less of the original point count) of line or curve segments that closely approximate the original data. Algorithms to do this with line segments or certain classes of curve segments are well known in the literature. In particular, a prior art algorithm to do interactive curve fitting for piecewise Bezier curves was first publicly demonstrated at the introduction of Aldus® FreeHand™ 1.0, in November 1987 (the program drew its name from this innovative capability of curve fitting freehand drawings). This algorithm calculates the average incoming and outgoing slope at each original input point, picks points of high curvature variation as important corner points, and fits the other original points as closely as possible using Bezier curves or straight lines between the identified corner points. The algorithm is modified in the following ways for variable width fitting: 1) During curve fitting the prior art algorithm had removed original input points unneeded for accurate fitting; the modified version does not remove minimum and maximum width points flagged in step 803. This preserves width variations along curves. 2) During clean-up after initial fitting, the prior art algorithm had removed colinear curve-fitted points (i.e. a point lying on a straight line connecting its previous and next curve-fit point neighbors); the modified version does not remove these colinear points if their width is significantly (5-10%) different from the adjacent points. This preserves width variations in straight lines. 3) During clean-up, the prior art algorithm had averaged nearby corner points together to reduce them to one point. The modified version also averages their widths if they are close to the same width, or maintains them as separate points if not.
Thereafter, at 806, during expansion, the expanded curve is offset from the spine by 1/2 the expansion width on each side of the spine, in a direction perpendicular to the slope of the curve at that point. Each curve-fit point along the spine of the variable-width line has an associated width collected at data input time, and possibly filtered during curve fitting. This works similarly to prior art first shown in Fontographer 3.0 in August 1990, but with a modification to allow a different width at each point being expanded. The end points of the expanded curve are fixed up as requested (with either blunt or round caps), and self-overlap is removed if it was inserted during expansion. This expansion process is not fully documented here, being prior art.
The important aspect of the present invention is that without the previously described curve fitting, or a process equivalent to such curve fitting, it is not possible to know the actual slope at each expansion point on the spine, and thus it is not possible to accurately know how to expand the curve in a direction perpendicular to the slope of the curve. Determining the true slope at a point requires knowing both the incoming slope and the outgoing slope. If this expansion was attempted during initial point capture, the outgoing slope of each point would not yet be known, so the expansion would not be accurately computable.
Two alternative methods of performing the entire variable-stroke pen drawing process are: 1) to use the graphical feedback provided during the initial drawing as a bitmap which could be curve fit by tracing its outer perimeter, or 2) to capture the spine and width, possibly performing simple filtering on the points and their widths, then draw the result into a temporary bitmap and curve fit to that bitmap. While initially considering both possibilities, the current invention improves upon them by allowing for curve fit and expansion as two separate steps. Thus, it is possible to maintain the original spine points together with width information at each of those points, and perform the expansion at a later time, possibly after editing either the coordinates of the points on the spine, their widths, or inserting or deleting other points and widths.
Referring now to FIG. 9, there is shown the flowchart detailing the capturing of points and widths 802 as previously shown in FIG. 8. This includes some simple filtering for handling the endpoint of the stroke. On a pressure sensitive data tablet, the pressure necessarily goes to zero at the end of each stroke as the stylus is lifted from the tablet surface, although this zero width is not desired if the stroke had high pressure just before the pen lift. Also during the lift up, it is very likely that the pen position will jitter slightly, giving inaccurate positional information which would distort the end of the stroke if not compensated for. This capture process eliminates most such problems, and the final filtering in detail drawing 802 completes the filtering process.
Initially at 901, the points lying on the midpoint or spine of the variable-width stroke are captured from the drawing tablet or other input device (such as a mouse) along with the pressure at each of those points, and stored in a memory array for later processing. This pressure can be interpreted as the width of the round or oval stroke at that point, as it is treated herein, or in a variety of other ways, such as intensity of color, color gradation, or pen angle and/or width for a calligraphic pen stroke. If the input device is not capable of reporting pressure, it can be simulated by pressing a variable number of keys on the keyboard during point input (more keys for more pressure), or by pressing one key to increase pressure and another key to decrease pressure. If pen angle is reported by the input device, this also can be stored in a similar fashion for directly controlling the angle of a calligraphic pen, or controlling another dimension of variation (for example the pressure could control the width of a stroke and the angle could control its shading or horizontal/vertical aspect ratio).
Next at 902, the process asks whether the pen is lifted up from the pad, or the mouse button is released. If yes, the capturing of the information is completed and the system proceeds to analyze it (see 803 in FIG. 8).
If the pen or mouse button is not up, the process proceeds to 903 where it decides if the location of the current point is relatively distant from the previous point (e.g., farther than 3 to 4 units). If it is distant, it is then stored in the point capture array 905.
If the current point is close to the previous point, then the process determines at 904 whether or not the pressure from the pen, for example, is decreasing. If yes, this new point is not stored. If this is part of the final pen lift, this step prevents spurious data from being stored. If this occurs during the middle of a stroke, the moving pen position will soon be farther away from the last stored point location, and that new point will be stored.
If the pressure is not decreasing, then at 905 the new point and its pressure (and angle, if that is captured) are stored in an array of points for later processing. The point array is expanded as necessary to hold as many points as are captured.
Next at 906, graphical feedback is given to the user. For a variable weight round or oval pen, a circle or oval is drawn at this new point and at the previous point, and a four-sided polygon is drawn to fill in between the circles as shown in FIG. 10. The circles 1001, 1002 are drawn with a radius corresponding to the stroke width at each point, and the polygon is drawn perpendicular to the line 1003 connecting the new point and the previous point, projecting out a distance equal to 1/2 the width at the corresponding point. Frequently this polygon is unnecessary, due to the points being very close together, but during fast drawing motions the point-to-point spacing may be large enough to leave gaps without this polygon.
The process then returns to 901 to repeat the steps for the next point drawn.
Referring next to FIG. 11 there is illustrated a flowchart for end-point filtering (see 803, FIG. 8). This process cleans up final hooks and jags caused by lifting up on the pen at the end of a stroke. It is very easy to wiggle the pen a bit at the end of a stroke, and if unfiltered, this wiggle would be curve fit, causing a nasty jag at best, or a self-intersecting figure at worst. This filtering attempts to determine the true end point, before the pen has lifted.
Beginning at 1101, the variable check -- radius is set to a large number, for example 32000. This is the radius within which widths are checked. The variable match -- point is also set to -1.
Next at 1102, the system scans backwards from the end point within a circle of radius check -- radius, which is the circular radius within which points must lie to be checked by the algorithm, finds the maximum width point and notes its point number in variable new -- max, which is the point number of the maximum-width point found so far in the width scanning process.
Thereafter at 1103, the system sets the check -- radius to 1.5 times the maximum width found in step 1102.
At 1104, the system asks if the variable new -- max found in 1102 is different than the previous point of maximum width called match -- point, which is the point number of the previously matched point. If yes, it sets match -- point to the value of new -- max and continues the loop another time at 1102. The radius checked is decreasing as the end becomes closer, which means the true desired radius is getting closer.
If the variable new max is not different from the previous point of maximum width, the system proceeds to 1105 and works backwards from the end point to the first point outside a circle of radius check -- radius centered on that end point. This point number is saved in match -- point and is the last known good point before the pen lift. The new -- max is set to this point also.
At 1106 the new -- max is set to its previous value plus one.
Then at 1107, the system asks whether the width at point new -- max is less than the width at point match -- point. If yes, lift up of the pen has started and the previous value of new -- max should return as the number of the end point.
If the width is not decreasing, the system proceeds to 1108 and asks whether the distance from new -- max to match -- point is less than the previous distance from new -- max to match -- point. If yes, the furthest point of a jag that doubles back on itself has just passed and should be thrown away. The end point becomes the previous value of new -- max. If the distance is not too far, the system returns to 1106 to advance to the next point.
Now referring to FIG. 12, there is shown a flow chart detailing the process for minimum/maximum width finding. This process picks out minimum and maximum width values (min -- width and max -- width) that should be retained by the curve fitter. It is insensitive to minor width variations which can be caused by jitter from the input device. It is likely that the input pressure, being an analog measurement digitized to fairly low accuracy, will vary slightly during a stroke. Such variations need to be filtered out or they will force an inordinate number of points to be generated by the curve fitter. However, if the variation is significant, it should be retained so the user can create a line that varies from thick to thin and back again which the curve fitter will properly fit.
Beginning with 1201, the min -- width and max -- width are initialized to initial values of 32000 and -32000 and a loop is begun for all points of the path. Next, at 1202, the system asks whether the width at this point is less than minimum. If yes, then at 1203 a new minimum is set at this point. If the width at this point is not less than the minimum, then at 1204 the system asks if the width at this point is greater than minimum, thus surpassing the minimum width point. If the width at the present point is equal to that of the previous point, then the system moves to 1208 to find the maximum width point. If the width is greater than minimum, then at 1205 the system will inquire whether the previous point is far enough away from the previous minima point (the exact distance being a parameter to this function), and if its width is sufficiently different from the last point.
If yes, then at 1206 the previous point is marked as a minima point.
The system proceeds to 1207 to reset the minimum width to this point's width.
Next at 1208 the system conducts a similar process and procedure as that of 1202-1207, except the procedural steps replace minimum with maximum, and replace greater-than with less-than, and less-than with greater-than. This process finds the maximum widths analogously to the process detailed above for minimum widths.
At 1209 the system asks if the end point of the variable width form has been reached. If no, the procedure is continued at 1202 for all points of the path. If the end point has been reached, the system ends at 1210. Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A video graphics system and method for creating variable width lines such that the lines may be easily edited. As a line image is created, a center point of that image along its length is temporarily established having width information at various points. This width information is used to create an outline of image of the desired shape, the outline having point data spaced at intervals. This point data can then be edited by a user to create different shapes. In situations where a pressure sensitive stylus is used to create the variable length line, a look-back technique is employed to insure that the line remains wide at the end point even though the user is reducing pressure as the system is removed from the pad.
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This application is a continuation-in-part of U.S patent application Ser. No. 08/687,776, filed Jul. 31, 1996 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to fluid line systems in which flexible hose is utilized to establish fluid connections between remote components or conduits, and more particularly, to a flexible hose which can be coupled to a system component or conduit without use of an external attachment or coupling device.
In automotive and other fields, flexible hose is utilized to provide fluid connections between remote components or conduits. Typically, external attachment or coupling devices are used to attach or couple the hose to the system components and provide reliable seals therebetween. Coupling devices which have been used for this purpose include metal or plastic clamps and quick connector fittings.
FIG. 1 depicts a typical prior art fluid line system 10 . A hose 12 is utilized to establish a fluid connection between fuel filter 14 and steel fuel line 16 . Fuel filter 14 includes a male member portion 18 having an enlarged upset 20 , and fuel line 16 includes a male member portion 22 having an enlarged upset 24 .
Quick connectors 26 and 28 are employed to couple hose ends 30 and 32 to, respectively, fuel line 16 and fuel filter 14 . Hose ends 30 and 32 are expanded over and retained on stem portions 34 and 36 of the connectors. Stem portions 34 and 36 may include barbs or bumps to enhance gripping of the hose. Housing portions 38 and 40 of the connectors receive the male member portions of fuel filter 16 and fuel line 14 . Housing portions 38 and 40 include retainers or other locking means which engage upsets 20 and 24 to secure the male member portions inside of the connectors. In this manner, a fluid connection is established between fuel filter 14 and fuel line 16 .
Use of external coupling devices, such as the quick connectors illustrated in FIG. 1, gives rise to various problems. External coupling devices add length to the fluid line and may conflict with geometrical constraints. Barbed-type fittings which engage the hose internal diameter may create undesirable internal line restriction. Additional potential leak paths are created through use of external coupling devices. Finally, production and installation of separate coupling devices leads to increased costs.
The present invention addresses these problems by providing a flexible hose having integral connector housings formed directly in its ends. These integral housings integrate the sealing and latching mechanisms necessary for coupling of the hose to a mating system component. The present invention is useful for low to medium pressure fluid applications and minimizes the problems noted in connection with use of external coupling devices.
SUMMARY OF THE INVENTION
A flexible hose for forming a fluid connection between components of a fluid line system includes an integral connector housing formed directly in at least one end. Male member portions of system components to be connected are insertable into the integral housing. The connector housing includes locking means for engaging upsets formed on the male member portions to prevent retraction of the male member from the hose. The locking means may be a radial wall defined in the integral housing. Alternatively, it may be a latch having locking beams extending through slots formed in the housing. Sealing means in the form of O-rings may be disposed inside of the hose or about the outer diameter of the male member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a typical prior art fluid line system which utilizes external coupling devices to couple a hose to system components;
FIG. 2 is a partial sectional view of a first embodiment of the present invention;
FIG. 3 is a partial sectional view of a second embodiment of the present invention;
FIG. 4 is a partial sectional view of a third embodiment of the present invention; and
FIG. 5 is a side view of a fluid line system utilizing a hose according to the present invention.
FIG. 6 is a side view of a fluid line system which utilizes end coupling devices of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the present invention is illustrated in FIG. 2 . One end of a tubular hose 50 is shown and is formed into an integral connector housing 52 . Connector housing 52 has an expanded diameter relative to the remainder of hose 50 . A radial shoulder 54 is defined inside of housing 52 . A seal package in the form of an O-ring seal 56 positioned between spacers 58 is press-fit into hose 50 against shoulder 54 . Notches or slots 60 formed through the sidewall of hose 50 define radial locking walls 62 .
Hose 50 may be formed from any material capable of being shaped at its ends into a functional and permanent connector body. Suitable materials include thermoplastics, elastomers, fluoropolymers, or combinations thereof which are capable of being formed into a housing. Nylon 6, 6/6, 11 or 12 (or combinations thereof) are preferred thermoplastics. Where appropriate, flexible metallic hose materials such as corrugated, fully annealed metallic/non-metallic braided hose composites or soft metal alloys could be utilized.
Processes capable of forming ends of a hose into geometrical shapes may be utilized to form integral connector housings 52 . Examples include vacuum forming, cold forming, heat forming and in-line extrusion techniques. Notches 60 are formed by simple notching, cutting or piercing processes which may be integral or non-integral with the forming process.
The hose 50 formed with integral connector housings 52 will be of a minimum length of 100 mm. This minimum length accommodates the hose length required for forming each hose end into integral connector housings 52 and allows sufficient hose length remaining between the integral connector housings 52 to allow for adequate bend flexibility.
The hose 50 will be used in situations where the installer would need to bend the hose 50 for installation with the mating male portion 64 . The need for manually bending the hose 50 is necessitated by the lack of precise tolerance of the location of the male portion 64 and the inability to have a consistent clearance area between the opposite male portions 64 due to variations of the packaging of other components. To allow the installer to install the hose, the degree of flexibility of the hose must be such that when the angular direction of the installation area differs from the angle of the hose form, the hose 50 can be flexed easily by hand to conform to the angle required to make the final installation of the flexible hose to the mating male member portion 64 . To allow the installer to bend the flexible hose easily by hand, the force required to bend the flexible hose should be 5 newtons or less.
Tubular male member portion 64 of a fluid line system component is received in integral connector housing 52 of hose 50 . Male member portion 64 includes a radially enlarged upset 66 which defines an abutment wall 68 formed substantially perpendicular to the outside surface of male member 64 , and a sloped wall 70 facing open end 72 . Sealing surface 74 extends between upset 66 and open end 72 .
Male member portion 64 is inserted into hose 50 until upset 66 is aligned with notches 60 and abutment wall 68 has passed radial wall 62 . Temporary expansion of hose 50 is necessary to move radially enlarged upset 66 into notch 60 . Expansion is facilitated by sloped surface 70 of upset 66 . Once upset 66 has moved beyond radial wall 62 , abutment wall 68 bears against radial wall 62 to prevent retraction of male member 64 from hose 50 . O-ring seal 56 contacts sealing surface 74 to establish a fluid seal between male member 64 and hose 50 .
A second embodiment of the invention is shown in FIG. 3 . Again, a flexible hose 80 is formed with an integral connector housing 82 . Notches 84 define radial locking walls 86 . Instead of including a seal package inside of hose 80 , as in FIG. 2, an O-ring seal 88 is disposed between upset 92 and open end 94 of male member 90 . A groove may be formed in the exterior surface of male member 90 to better secure O-ring 88 around male member 90 .
A third embodiment of the invention is depicted in FIG. 4 and FIG. 5 . Flexible hose 100 is formed with integral connector housing 102 . An O-ring 104 is held between spacers 106 which are press-fit into hose 100 against radial shoulder 108 . A latch 110 is attached to hose 100 . Latch 110 includes locking beams 112 (one shown) which extend through slots formed in hose 100 into the interior of hose 100 . Locking beams 112 define a radial locking wall 114 .
Tubular male member portion 116 of a fluid line system component is received in integral connector housing 102 of hose 100 . Male member portion 116 includes a radially enlarged upset 118 which defines an abutment wall 120 formed substantially perpendicular to the outside surface of male member 116 . Sealing surface 122 extends between upset 118 and open end 124 .
Male member portion 116 is inserted into hose 100 until upset 118 contacts locking beams 112 of latch 110 . Continued insertion of male member 116 causes beams 112 to spread to permit passage of upset 118 . Locking beams 112 may include sloped or canned surfaces to facilitate passage of upset 118 . Once upset 118 has moved beyond beams 112 , abutment wall 120 bears against radial wall 114 to prevent retraction of male member 116 from hose 100 . O-ring seal 104 contacts sealing surface 122 to establish a fluid seal between male member 116 and hose 100 .
FIG. 6 shows use of the present invention in a fluid line system. Hose 130 is formed with integral connector housings 132 at its ends. Latches 134 , as described with reference to FIG. 4, are attached to hose 130 . Seal packages (not shown) are disposed inside of hose 130 . It is noted that though the embodiment of FIG. 4 is illustrated, the embodiments of FIGS. 2 and 3 could also be utilized.
Integral connector housings 132 receive male member portions of remote system components. A fuel line 136 and fuel filter 138 are illustrated. Visual comparison of the arrangement of FIG. 5 to the prior art arrangement of FIG. 1 is indicative of the reduced complexity of the present invention. External connector housings or fittings are eliminated. This reduces the number of potential leak paths and the length of the fluid line. Installation is accomplished in one step: insertion of a male member into a hose; rather than in two steps: expansion of a hose around a connector body stem and insertion of a male member into a connector body housing.
The present invention is usefull in applications where low to medium pressure fluid is involved, that is, where significant pull-apart forces are not encountered.
Various features of this invention have been explained with reference to the embodiments shown and described. Modification may be made to the described embodiments without departing from the spirit and scope of the invention as represented by the following claims.
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A flexible hose for establishing a fluid connection between remote components of a fluid line system includes an integral housing formed directly in at least one end. Male member portions of the system components are received and retained in the integral housing. The hose housing includes a radial wall which engages an upset formed on the male member to prevent retraction of the male member from the hose. Sealing means in the form of O-rings may be disposed inside of the hose.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 61/775,505 filed on Mar. 9, 2013 by the present inventor which is incorporated by reference into this application.
FEDERALLY SPONSORED RESEARCH
[0002] None
SEQUENCE LISTING
[0003] None
FIELD OF THE INVENTION
[0004] This relates to a method and device which allow restart of an inter-carrier chat session hosted by a local chat server even if the session was originally started on another carrier's chat server.
BACKGROUND OF THE INVENTION
[0005] The RCS 5 as well as the OMA CPM telecommunication standards allow an inter-carrier group chat participant to restart a previously existing group chat session. This is known as a “long lived” chat session. This standard method uses a Join SIP protocol INVITE method to the original controlling function for the long lived chat session to restart the chat session. This can only be done with the “conference focus” IM Server that is maintaining the participant list. In an inter-carrier scenario, as per current standards, the conference focus that hosts the chat maintains the list at the beginning and throughout the session, as well as after the session is restarted.
[0006] For billing reasons as well as a desire to restrict initiation of use of network resources to only their own customers, in inter-carrier situations many carriers desire to have the restart of the chat session done within the same network as the client requesting the restart of the session. Under current standards, however, the restart of the long lived session is done by the original conference focus, regardless of the home carrier of the client requesting the restart of the session. This often results in server resources in one network being requested by a client of another network which many carriers find undesirable.
[0007] One known workaround is for every client to maintain a list of all participants in the chat and allowing each (nonstandard) client to restart the session themselves based upon information stored at the client. This method requires the cooperation of various providers of the clients, usually many different handset providers. This is also not desirable as storing extra information at the client requires extra network bandwidth passing participants lists needlessly between clients in order to allow each client to maintain a participant list locally. There also scenarios where the participant list can get out of sync with other clients. This client-based restart of the session can also cause other problems in the network, since, for a carrier that has multiple local IM servers, the Long Lived Chat Session may not be restarted at the same IM Server every time, leading to inefficiencies as multiple servers may have stored messages for the same subscriber related to the same Long Lived Chat Session.
[0008] What is needed is a way to restart the session local to the requesting client without the client being modified to maintain the chat participant list.
[0009] That is the problem solved by this inventor.
SUMMARY OF INVENTION
[0010] It is desirable to allow each telecommunication service carrier to restart a Long Lived Group Chat session in the local carriers network when a local subscriber attempts to restart or reestablish an inactive Long Lived Group Chat session. Currently it is required that the original focus in the foreign network be used to restart the session. This invention defines a method for the local IM Server to directly restart the session.
[0011] This uses the local IM Server (or participant function) to record the participant list on behalf of the local subscriber when the Long Lived Group Chat originated in another carrier's (a.k.a. “foreign”) network. The local IM Server in this case will act as a back to back UA (B2BUA) and look like the local subscribers to the session started in another carrier's server. The Local IM Server presents the session to the user as a session directly handled at the local server. Specifically the Contact address for the session is the local servers address (and Session ID). The local IM Server will link this to the Contact address and session ID received from the foreign server. This information is maintained after the active session ends to allow the local subscriber to restart the Long Live Group Chat session. During the session the local IM Server is reported at the controlling function for the session. So, in the preferred embodiment, the local subscriber uses the SIP protocol and sends the join INVITE request to restart the Long Lived Chat Session to the local IM Server (this can work with the IM Server handling both the controlling function and participating functions or treating these as separate entities in the network). The IM Server can then use the previously stored session information including the participant list to restart the session with the local IM Server acting as the controlling function for the session, thus replacing the other carrier's server as the host for the restarted chat session.
[0012] A method is also provided to link a locally restarted Long Lived Chat Session back to the original Controlling network for the session allowing any participant list changes in the new session to be reflected in the original controlling network.
DRAWINGS
List of Reference Numbers
[0000]
101 Shows a mobile client that is homed on a remote carrier
102 A second mobile client that is homed on a remote carrier
103 Mobile client that is homed on the local carrier.
110 IM Server that is remote carrier network.
120 IM Server that is in home carrier network.
190 Inter-carrier logical boundary
440 Second IM Server that is in home carrier network.
GLOSSARY
[0000]
B2BUA Back to Back User Agent
CLIENT Software that accesses a remote server
Conference Focus A specialized User Agent that processes chat invitations and maintains dialogs with each chat participant. Usually this is a dedicated server and in inter-carrier scenarios the conference focus can maintain dialogs across telecommunications carriers.
CPM Converged IP Messaging protocol for messaging
Foreign Not under control of the local telecommunications provider.
IETF Internet Engineering Task Force
IM Instant Message
IP Internet Protocol
OMA The Open Mobile Alliance is a standards body which develops open standards for the mobile phone industry.
RCS Rich Communications Suite
RFC IETF Request for Comments Document
SIP Session Initiation Protocol
UA User Agent. In RFC 3261 the term UA refers to both end points of a communications session
URI Uniform Resource Identifier—A string of characters used to identify a name or a web resource. Such identification enables interaction with representations of the web resource over a network using specific protocols.
BRIEF DESCRIPTION OF DRAWINGS
[0034] FIG. 1 shows the prior art where mobile 3 requests to restart a previous chat session with mobiles 1 and 2 which are on another network. When Mobile 3 , located on carrier B attempts to join the session that is no longer active, the request must be forwarded to server in Carrier A to restart the session.
[0035] FIG. 2 shows starting a session using the newly invented dynamic focus method. At session startup, the Carrier B IM Server records the Session Info. In the preferred embodiment this is from the SIP INVITE and also uses SUBSCRIBE/NOTIFY to get the correct participant list for the session, so that session can be restarted locally by carrier B's server. This information is readily available when acting as a back to back user agent (B2BUA) on behalf of the local subscriber.
[0036] FIG. 3 shows mobile 3 initiating a restart of the session with the newly invented dynamic focus method. When Mobile 3 attempts to join the session that is no longer active, the local IM Server uses the recorded session information to restart the session directly. Mobile 1 and Mobile 2 are still invited through the other carrier's IM Server, but Carrier B, not Carrier A is the controlling function for the restarted session.
[0037] FIG. 4 shows a restart of the session at the request of a client on the other carrier.
[0038] Long Lived sessions may also be restarted in the original home network (Carrier A). If Carrier B has multiple IM Servers that session may be restarted through a different IM Server. The figure shows the session information being replicated to another server in the Carrier B network so that all IM Servers in Carrier B network that may have previously handled this Long Lived Chat session is kept up to date with the latest session information for the session. This replication is useful in case the local subscriber later attempts to restart the session at a different server in Carrier B's network that previously processed an active session for this long lived chat session.
DETAILED DESCRIPTION
[0039] This uses the local IM Server (or participant function) to record the participant list on behalf of the local subscriber when the Long Lived Group Chat originated in another carrier's (a.k.a “foreign”) network. The local IM Server in this case will act as a back to back UA (B2BUA) and look like the local subscriber to the session started in another carriers server. The Local IM Server presents the session to the user as a session directly handled at the local server. In the preferred embodiment the Contact address for the session is the local servers address (and SESSION ID). In another embodiment, the contact address for the session is the address of the target CPM Group Session of CPM Long-live Group Session. In the preferred embodiment, the local IM Server will link this to the Contact address and session ID received from the foreign server. This information is maintained after the active session ends to allow the local subscriber to restart the Long Live Group Chat session. During the restarted session the local IM Server is reported as the controlling function for the session. Any requests from the local subscriber to restart this Long Lived Chat session the request will go to the local server, because when the original active session was setup to the subscriber, the local server was reported as the controlling functions for the session. In this case the local IM Server is the real controlling function for the restarted active session.
[0040] In the preferred embodiment, using the SIP protocol,
[0041] The local IM Server uses the participant list reported to the client in the NOTIFY messages to maintain the active participant list for the session. This information is maintained after the active session ends. The local subscriber will send the join INVITE request to restart the Long Lived Chat Session to the local IM Server (this can work with the IM Server handling both the controlling function and participating functions or treating these as separate entities in the network). The IM Server uses the previously stored session participant list to restart the session with the local IM Server acting as the controlling function for the session. If there are any changes to the session information (e.g. change to participant list) after the session is restarted by the local server, that session information is fed back to the original carrier's IM Server because the foreign network subscribers for the chat session are invited to the new active session using the Contact address of the Controlling Function in the foreign network that is the original controlling function for the session. The form of the SIP INVITE in this cases is not a join INVITE to restart the original session, but is the form of the INVITE for the controlling function to invite a single recipient to an chat session. The foreign network IM Server in this case is acting as the local IM Server for the foreign network recording and updating the session information and participant list for the long lived change session actively being controlled in the other network. In addition, if the local carrier has multiple IM servers, the session information should be shared with the other local servers so that local clients may restart the session on any local IM server (as shown in FIG. 4 ).
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This provides a method and message server device to allow restart of an inter-carrier chat session using a local chat server even if the same session was previously started on another carrier's conference focus server.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to the following U.S. patent applications, each of which is incorporated by reference herein:
U.S. patent application Ser. No. 10/903,283, filed Jul. 29, 2004, titled “SEARCH SYSTEMS AND METHODS USING IN-LINE CONTEXTUAL QUERIES;”
U.S. patent application Ser. No. 11/033,417, filed Jan. 10, 2005, titled “USER INTERFACES FOR SEARCH SYSTEMS USING IN-LINE CONTEXTUAL QUERIES;”
U.S. patent application Ser. No. 11/033,100, filed Jan. 10, 2005, titled “SEARCH SYSTEMS AND METHODS USING ENHANCED CONTEXTUAL QUERIES;”
U.S. patent application Ser. No. 11/033,101, filed Jan. 10, 2005, titled “USER INTERFACE TOOL FOR TEXT SELECTION;”
U.S. patent application Ser. No. 11/129,096, filed May 12, 2005, titled “SYSTEM AND METHOD FOR CONTEXTUAL TRANSACTION PROPOSALS;”
U.S. patent application Ser. No. 11/183,114, filed Jul. 14, 2005, titled “User ENTERTAINMENT AND ENGAGEMENT ENHANCEMENTS TO SEARCH SYSTEM;”
U.S. patent application Ser. No. 11/231,632, filed Sep. 20, 2005, titled “SYSTEMS AND METHODS FOR PRESENTING INFORMATION BASED ON PUBLISHER-SELECTED LABELS;”
U.S. patent application Ser. No. 11/232,270, filed Sep. 20, 2005, titled “SYSTEMS AND METHODS FOR PRESENTING ADVERTISING CONTENT BASED ON PUBLISHER-SELECTED LABELS;”
U.S. patent application Ser. No. 11/239,708, filed Sep. 29, 2005, titled “TAGGING OFFLINE CONTENT WITH CONTEXT-SENSITIVE SEARCH-ENABLING KEYWORDS;”
U.S. patent application Ser. No. 11/239,729, filed Sep. 29, 2005, titled “AUTOMATICALLY DETERMINING TOPICAL REGIONS IN A DOCUMENT;”
U.S. patent application Ser. No. 11/248,738, filed Oct. 11, 2005, titled “ENABLING CONTEXTUALLY PLACED ADS IN PRINT MEDIA;” and
U.S. patent application Ser. No. 11/270,917, filed Nov. 10, 2005, titled “WORD SENSE DISAMBIGUATION;”
U.S. patent application Ser. No. 11/584,403, filed Oct. 19, 2006, titled “CONTEXTUAL SYNDICATION PLATFORM”.
FIELD OF THE INVENTION
The present invention relates to automatic document modification. Specifically, the present invention relates to a client-side application automatically modifying a document subsequent to receiving the document from a server.
BACKGROUND
Generally, a client-side application receives a request from a user for a document and queries a server for the user-requested document. The server obtains or generates the document and provides the document to the client-side application. In some cases, the server, prior to sending the document to the client-side application, enhances each document based on metadata associated with the document. For example, one or more entities (e.g., text corresponding to person, event, etc.) within the document may be associated with metadata which is also stored at the server. Based on the metadata, the server may enhance an entity within the document by modifying the entity or adding content based on the metadata associated with the entity.
According to one such technique, when a web page is requested by a client, a server may add to the web page user interface elements (e.g., a search button) that, when activated, cause a search engine to provide search results that are directed to a particular topic to which the enhanced portion of the web page pertains. For example, a web page may mention the “Eiffel Tower”. When the web page is requested, the server may add a search button to the web page next to the mention of the Eiffel Tower. With this technique, a user can presume that, if he initiates a search using a user interface element (e.g., a search button) that is positioned in close proximity to a particular paragraph of text, then the search results obtained for the search will be constrained based on the topics to which the paragraph pertains.
Beneficially, the adaptation of the document by the server presents every user requesting that document with the enhanced content added by the server. Since the adaptation is made at the server and presented to every user, the resulting enhancement may be said to be server-executed and user-agnostic. Each user can locate the entity-related resources without redirecting his browser to a search engine portal page and, sometimes, without even formulating or typing any search query terms. Thus, the user-agnostic enhancement by the server can enable the delivery of entity information, by the server to a client-side application at the point of the user's inspiration or curiosity.
To date, such document enhancement is performed at the server side and accordingly, the documents are user-agnostically enhanced for every user and are transmitted to the client-side application for display to a user. As a result, the client-side application provides the functionality for requesting documents, receiving documents, and displaying documents.
The approaches described in this section are approaches that could be pursued, but not necessarily approaches that have been previously conceived or pursued. Therefore, unless otherwise indicated, it should not be assumed that any of the approaches described in this section qualify as prior art merely by virtue of their inclusion in this section.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 depicts an example of a system in accordance with one or more embodiments of the invention;
FIG. 2 illustrates an example of a flow diagram in accordance with one or more embodiments of the invention;
FIG. 3 illustrates an example in accordance with an embodiment of the invention; and
FIG. 4 depicts a block diagram of a computer system on which one or more embodiments of the invention may be implemented.
DETAILED DESCRIPTION
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the present invention.
Several features are described hereafter that can each be used independently of one another or with any combination of the other features. However, any individual feature might not address any of the problems discussed above or might only address one of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein. Although headings are provided, information related to a particular heading, but not found in the section having that heading, may also be found elsewhere in the specification.
Overview
As mentioned above, there are many circumstances in which documents (e.g., web pages, spreadsheets, text documents, slides, image files, etc.) that include one or more entities (e.g., text, images, symbols, etc.) are received for display at a client-side application from a server in response to a first query by the client-side application for a document or data. Techniques are provided here for allowing the client-side application to search the documents received to identify entities within the documents. The client-side application may further obtain entity information about the identified entities (e.g., with a second query from a local or external data repository). Based on the obtained entity information about the identified entities in the documents, the client-side application may modify the documents and present the modified documents to a user. Such client-side enhancement of the documents may be performed instead of or in addition to any server-side enhancements.
Embodiments of the invention may enable execution of successive queries by a client-side application based on a single request for a document from a user. The successive queries may be used to obtain the document and further obtain entity information associated with entities within the document. The document may be modified by the client-side application to include or link to entity information to obtain a modified document. The document modification may be selected based on the data available at the client system and accordingly, may be particularly relevant to a user or the client system. Thus, the client-side enhancement may be a user-customized enhancement, in contrast to the client-agnostic enhancement that may occur on the server-side. The modified document may be presented to the user instead of the document originally requested by the user.
System Architecture and Functionality
Although a specific computer architecture is described to perform the techniques described herein, embodiments of the invention are applicable to any architecture that can be used to modify search results based on user selections within the search results themselves.
FIG. 1 shows a system ( 100 ) in accordance with one or more embodiments of the invention. As shown in FIG. 1 , the system ( 100 ) includes a client machine ( 102 ), a web server ( 110 ), and a data repository ( 114 ).
In one or more embodiments of the invention, the data repository ( 114 ) corresponds to any data storage device (e.g., local memory on the client machine ( 102 ) itself, one or more servers connected over the internet, systems within a local area network, a memory on a mobile device, etc.) known in the art which may be searched for entities ( 116 ) to obtain entity information ( 118 ). In one or more embodiments of the invention, access to the data repository ( 114 ) may be restricted and/or secured. As such, access to the data repository ( 114 ) may require authentication using passwords, secret questions, personal identification numbers (PINs), biometrics, and/or any other suitable authentication mechanism. Those skilled in the art will appreciate that elements or various portions of data stored in the data repository ( 114 ) may be distributed and stored in multiple data repositories (e.g., servers across the world). In one or more embodiments of the invention, the data repository ( 114 ) includes flat, hierarchical, network based, relational, dimensional, object modeled, or data files structured otherwise. For example, data repository ( 114 ) may be maintained as a table of a SQL database. In addition, data in the data repository ( 114 ) may be verified against data stored in other repositories.
Entities ( 116 ) correspond to any document content that is associated with entity information ( 118 ). Examples of entities ( 116 ) include, but are not limited to, text, images, symbols, etc. corresponding to a person, place, event, thing, occupation, service, characteristic, verb, noun, etc. The entity information ( 118 ) may be any information related to the entity ( 116 ). Examples of entity information ( 118 ) may include, but are not limited to, definition of the entity, map of the entity, phone number associated with the entity, business type associated with the entity, history of the entity, children of the entity, availability of the entity, services provided by the entity, address of the entity, etc.
Examples of entity and entity information may include, but are not limited to:
Entity
Entity Information
Hotel
“Hotels in the area include: Night Inn, Hotel 5, etc.”
Rose
An image of a rose
Alberto's Restaurant
“333 E. Main St., San Jose, CA 95133,” and an
Image of a map
Bill Clinton
“President of the United States from 1992-2000.
Biography . . .”
Laptop
“Computer Store XYZ has laptop sales”
Picture of China
“Most populous country in the world. |China Tours
555-555-5555”
Anger
“Emotional State ranging from minor irritation to
intense rage . . . ”
Whale
“A whale is a mammal, different types of whales
include . . . ”
Terminator
“Terminator is a movie starring Arnold . . . ”
In one or more embodiments, the web server ( 110 ) corresponds to hardware and/or software that is used to manage (e.g., generate, modify, store, delete, etc.) documents ( 112 ). The web server ( 110 ) may be connected to one or more databases (not shown) which may be searched by the web server ( 110 ) to obtain the documents ( 112 ). The web server ( 110 ) may include functionality to accept document or data requests (e.g., HTTP requests) from the client machine ( 102 ). In response to the request, the web server ( 110 ) may provide one or more documents ( 112 ) to the client machine ( 102 ). In an embodiment, the documents ( 112 ) stored on the web server ( 110 ) may correspond to web pages, spreadsheets, text documents, slides, images, a combination thereof or any other suitable file type containing data requested by a user. Each document ( 112 ) may include one or more entities ( 116 ), described above.
In an embodiment, the client machine ( 102 ) corresponds to any system that includes functionality to obtain a document ( 112 ) from the web server ( 110 ), modify the document ( 112 ) with entity information ( 118 ) and present the modified document to a user. As shown in FIG. 1 , the client machine ( 102 ) includes a browser ( 104 ), an interface ( 106 ), and a web page modifier ( 108 ). The interface ( 106 ) corresponds to any sort of interface adapted for use to access the system and any services provided by the system in accordance with one or more embodiments of the invention. The interface ( 106 ) may be a web interface, graphical user interface (GUI), command line interface, or other interface accessible through a computer system. The interface ( 106 ) may include functionality to allow a user (or an automated equivalent) to enter a search criteria (including words, numbers, symbols, selections, or other suitable input) to request data, select a link on a web page, or otherwise request a document ( 112 ). The interface may further include functionality to display a modified document in response to receiving a document request from a user. In an embodiment, the interface ( 106 ) is displayed within a browser ( 104 ).
The browser ( 104 ) corresponds to a client-side application executing on the client machine ( 102 ) (such as personal computers (PCs), mobile phones, personal digital assistants (PDAs), and/or other digital computing devices of the users) or a client-side application executed remotely in conjunction with the client machine ( 102 ). The browser ( 104 ) may be a web browser application or an application for locally browsing the client machine ( 102 ) and/or local network. The browser ( 104 ) may be used for requesting and receiving a document ( 112 ) from the web server ( 110 ) that was requested by a user or includes data requested by a user. For example, based on a selection of a link from a user, the browser ( 104 ) may generate an HTTP request for a web page corresponding to the link and provide the HTTP request to the web server ( 110 ). In an embodiment, the browser ( 104 ) (or a component within the browser such as a toolbar) may include functionality to identify entities ( 116 ) within a document ( 112 ) received from the web server ( 110 ). For example, the browser ( 104 ) may include functionality to scan the document for text, images, symbols, or other objects within the document ( 112 ) and determine if the objects match a predetermined entity ( 116 ) stored in the data repository ( 114 ). The browser ( 104 ) may also include functionality to query the data repository ( 114 ) using an entire document ( 112 ) to determine if any text, image, graphic, symbol, etc. within the document ( 112 ) match an entity ( 116 ) associated with entity information ( 118 ) within the database.
In an embodiment, the browser ( 104 ) at the client-side may include functionality to perform successive searches initiated at the client machine ( 102 ) based on a single user request. For example, the browser ( 104 ) may include functionality to first perform a search to obtain the document ( 112 ) requested by the user, and thereafter the browser may perform additional searches for information related to content within the document ( 112 ). In an embodiment, the browser ( 104 ) may include functionality to perform any number of successive searches to obtain data related to the content within the document ( 112 ). For example, the browser ( 104 ) may first search for a web page associated with a movie “Old Yeller.” Upon receiving the web page, the browser ( 104 ) may query the data repository ( 114 ) resulting in identification of an entity “Dog” and receiving information associated with types of dogs including a golden retriever. Thereafter, the browser ( 104 ) may again query the data repository ( 114 ) for information related to a golden retriever. In an embodiment, the browser ( 104 ) may be configured for a minimum and/or maximum number of successive queries for each document ( 112 ) requested by a user.
In an embodiment, the document modifier ( 108 ) corresponds to software and/or hardware components for modifying documents ( 112 ) received from the web server ( 110 ) prior to presenting the documents ( 112 ) on the interface ( 106 ). The document modifier ( 108 ) may be a part of the browser ( 104 ) or may be a separate component, such as a plug-in or client-side proxy server.
In an embodiment, the web page modifier ( 108 ) includes functionality to modify documents ( 112 ) based on entity information ( 118 ) associated with entities ( 116 ) within a document ( 112 ). For example, the web page modifier ( 108 ) may include functionality to add links to entities within the document ( 112 ), add interface elements (e.g., buttons, input fields, text, images, etc.) to the document ( 112 ), or otherwise modify the document to directly include the entity information ( 118 ) or link to the entity information ( 118 ) associated with an entity ( 116 ) within the document ( 112 ).
Each of these components described above may be located on the same device or may be located on separate devices coupled by a network (e.g., Internet, Intranet, Extranet, Local Area Network (LAN), Wide Area Network (WAN), etc.), with wire and/or wireless segments. In one or more embodiments, the web server ( 110 ) and the client machine ( 102 ) are implemented using a client-server architecture. The web server ( 110 ) may be an enterprise application running on one or more servers, and in some embodiments could be a peer-to-peer system. In one or more embodiments of the invention, the client machine ( 102 ) is accessible over a network connection (not shown), such as the Internet, by one or more users. Information and/or services provided by the client machine ( 102 ) may also be stored and accessed over the network connection.
Document Modification at Client-Side Application
FIG. 2 shows a flowchart for document modification at a client-side application subsequent to receiving the document from a web server in accordance with one or more embodiments. In one or more embodiments, one or more of the steps described below may be omitted, repeated, and/or performed in a different order. Accordingly, the specific arrangement of steps shown in FIG. 2 should not be construed as limiting the scope of the invention.
Initially, a document request is received from a user at a client-side application in accordance with an embodiment of the invention (Step 202 ). The document request may be received by the user selecting a link, requesting a search by providing search terms, requesting a download of a particular document, or otherwise providing input requesting data.
In an embodiment, the client-side application makes a first request to a web server for the user-requested document (Step 204 ). The client-side application may identify the particular document in the request, may provide the search terms provided by the user to the web server, or may otherwise request data from the web server that is requested by a user. In response, the client-side application receives the requested document from the web server (Step 206 ). The document received from the web server may be associated with metadata identifying the entities within the document. In an embodiment, the requested document may comprise entities without any additional information related to the entities. The client-side application may execute code to identify the contents of the document and further may identify one or more entities within the document. For example, the client-side application may execute an optical character scan of an image to identify text within the image. The identified text, images, symbols, etc. or other content may be compared to locally stored dictionaries to determine whether the content corresponds to a predetermined entity. The client-side application may also query a data repository providing the document as input to identify entities within the document.
In an embodiment, a database is queried by the client-side application, using entities within the document as search terms, to request entity information (Step 208 ). The database may be queried by the client-side application with specific entities identified at the client-side application. The database may also be queried by the client-side application using, as input to the search, the entire document received from a web server. In an embodiment, the second query by the client-side application is successive to the query for the user requested-document because the contents of the user-requested document or the user-requested document itself, is input for the second query. Accordingly, the client-side application performs successive queries based on a single request from a user where the result of a first query by the client-side application is used as an input for a second query by the client-side application.
In response to the successive query for entity information associated with entities within the document, entity information is obtained from the data repository at the client-side application (Step 210 ). Entity information may be received in the form of metadata, may be embedded within the user-requested documents (e.g., when the documents themselves are used as query inputs), may be received in pairs with corresponding entities, may be received as links (e.g., pathways to the entity information rather than the entity information itself), or otherwise obtained. In an embodiment, executable code that results in the generation of entity information may be obtained. For example, entity information may correspond to code that incorporates entities as input for search engines which are activated upon selection of the entity information. In another example, an entity may correspond to the name of a business and entity information may correspond to executable code that provides the address of the business as an input to a mapping application that results in a map of the business upon selection of the entity information. The map of the business may also be generated prior to selection and simply provided to the client-side application for local storage or for direct incorporation into the document with the hotel.
Next, the user-requested document obtained from the web server is modified at the client-side application to include the entity information (or a link to the entity information) to obtain a modified document (Step 212 ) and displayed (Step 214 ), in accordance with one or more embodiments. The entities within the document may be modified to include the links corresponding to the respective entity information. For example, text or an image identified as an entity may be modified such as that the text or image links to another web page with information related to the text or image. In another embodiment, entity information may be embedded into a document such that hovering over the entity causes a display of the entity information. For example, a document comprising the name of a politician may be modified such that hovering over the politician's name displays a biography of the politician. In another embodiment, a paragraph related to a place may be identified as an entity and an interface element (e.g., button with “read more”) may be added to the end of the paragraph that links to more information with similar subject matter as the paragraph. In an embodiment, entities that are found within a web page that are modified to include embedded entity information or links to entity information are also modified with a visualization that indicates availability of the entity information. The visualization for the entity may include any visible addition to the entity that may be constantly displayed or activated by hovering over the entity. Visualizations may include highlighting, underlining, coloring, shading, blinking, or any other suitable indication of additional information.
Separate Listing of Entities
In an embodiment, a document with recognized entities and corresponding entity information may be modified to include a separate listing of recognized entities. For example, in a web page, all recognized entities from the web page may be listed in a separate frame or window within the web page. The separate listing of the entity within the web page may link to the location of the entity within the web page or may link to external documents (e.g., other web pages) with information related to the entity.
Selection of Entities for Including Entity Information
In an embodiment, modification of the document may involve inclusion of entity information for only particular entities. The client-side application may select which entities are to be associated with entity information based on information available on the local machine executing the client-side application or based on the user of the client-side application. For example, entities may be identified into classes or types and entities of a particular type may be selected for modification to include entity information. In an embodiment, the client-side application may be configured by a user to include entity information for certain entity types and/or not include entity information for entity types. For example, the user may configure the client-side application to modify the document to include a time and place for recognized events, however not modify the document for recognized persons. In another embodiment, the selection of the entity for entity information inclusion may depend on the geographic location of a system executing the client-side application. For example, the client-side application may include a map for all entities within a specified vicinity (e.g., a specified mile radius, a city, a town, etc.) associated with a client system executing the client-side application. The client-side application may also provide directions from the location of the client system or a default location set by a user to the entities when the entities are within the specified vicinity. The client-side application may also include entity information for recognized events based on time. For example, a user may select vacation dates that the user is available. Accordingly, the client-side application may filter event entities based on the vacation dates and only embed a document with event information if the event occurs during the vacation dates specified by the user. In another embodiment, the entity recognition may be based on a browsing history, files, or other data on a client system executing the client-side application. For example, the entities found within a document may be compared to data on the client system and entities that are found on the client system may further be queried by the client-side application to find and embed corresponding entity information. Accordingly, embodiments of the invention allow for selection of particular entities for inclusion of entity information based on the client system executing the client-side application or based on a user's preferences. In an embodiment, the client-side application modifying the documents may be a web application which saves the configuration of a user and allows a user to browse the internet after logging in using any system. A user's configuration and/or preferences for document modification may be stored on a server and provided to the client-side application executing on the machine the user is currently using. Accordingly, a user's configuration and/or preferences for document modification may be portable.
Selection of Entity Information
In an embodiment, the entity information embedded into the document may be selected out of all available entity information based on data available to the client-side application or based on user preferences obtained by the client-side application. Any of the selection methods used for selecting entities, described above, may also be used to select entity information to embed into a document. For example, user preferences, browsing history, local data, geographic location of system executing the client-side application etc. may be used in selection of entity information that is embedded into a document.
In an embodiment, entity information selection may be based on the source of the entity information. For example, one or more sources of entity information may be included and/or excluded for selection of entity information. The exclusion/inclusion of a source may be user configured or based on an algorithm. For example, a source may be used if a minimum amount of users use the source, such as a minimum level of network traffic on a website. In another example, a source ranked first by a search engine may be used as the source for the entity information. In an embodiment, a trusted source listing may be created by an independent third party or by a user which lists all sources to be used for entity information. The sources used for entity information may also be prioritized. For example, entity information may first be queried at a source with the highest priority. If entity information is not found, then the next highest priority source may be queried for the information. In an embodiment, the client-side application sets the priority of sources based on the number of times the user of the client-side application has used the source. For example, if a user frequently visits a web site the client-side application will be configured to query the trusted source for entity information. Conversely if a user has blocked a source or has received corrupted data, destructive data (e.g., a worm, a virus, etc.), etc. from a source, the source may not be queried by the client-side application for entity information. Accordingly, the source for entity information may be selected by the client-side application based on a user's history, preferences, etc. In an embodiment, a suitable source for entity information may be listed in metadata associated with a document. The metadata may be searched to determine the suitable source for information related to the entity and the source may be queried for entity information or links to the source may be added to the document.
EXAMPLE
FIG. 3 shows an example of document modification at a client-side application subsequent to receiving the document from a web server in accordance with one or more embodiments. The components and steps described in FIG. 3 are related to an example and should not be construed as limiting the scope of the invention in any manner.
Initially, the interface ( 306 ) within the browser ( 304 ) executing on the client machine ( 302 ) receives a request for a restaurant listings from a user. In Step 352 , the web browser ( 304 ) queries the restaurant directory web server ( 310 ) for a list of Mexican restaurants. In Step 354 , the restaurant directory web server ( 310 ) returns the restaurant listings web page with menus ( 312 ) to the browser ( 304 ). In Step 356 , the browser ( 304 ) queries a location record repository ( 314 ) with the restaurant listings web page with menus ( 312 ) to search for additional information. In Step 358 , the location record repository ( 314 ) matches the Mexican restaurants listed in the web page with the place records ( 316 ) and finds the associated location records ( 318 ) that include the addresses for the Mexican restaurants. In Step 360 , the Mexican restaurants and corresponding addresses are sent to the web browser ( 304 ). Next, in Step 362 , the web page modifier ( 308 ) modifies the restaurant listing web page with menus ( 312 ) to embed directions (e.g., pop up window activated by hovering) to each of the Mexican restaurants based on the address of the Mexican restaurants received from the location record repository ( 314 ) and the address of the user stored at the client machine ( 302 ). In Step 364 , the interface ( 306 ) displays the modified web page with the embedded directions instead of the original restaurant listings web page with menus ( 312 ) that was received from the restaurant directory web server ( 310 ).
Hardware Overview
FIG. 4 is a block diagram that illustrates a computer system 400 upon which an embodiment of the invention may be implemented. Computer system 400 includes a bus 402 or other communication mechanism for communicating information, and a processor 404 coupled with bus 402 for processing information. Computer system 400 also includes a main memory 406 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 402 for storing information and instructions to be executed by processor 404 . Main memory 406 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor 404 . Computer system 400 further includes a read only memory (ROM) 408 or other static storage device coupled to bus 402 for storing static information and instructions for processor 404 . A storage device 410 , such as a magnetic disk or optical disk, is provided and coupled to bus 402 for storing information and instructions.
Computer system 400 may be coupled via bus 402 to a display 412 , such as a cathode ray tube (CRT), for displaying information to a computer user. An input device 414 , including alphanumeric and other keys, is coupled to bus 402 for communicating information and command selections to processor 404 . Another type of user input device is cursor control 416 , such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor 404 and for controlling cursor movement on display 412 . This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.
The invention is related to the use of computer system 400 for implementing the techniques described herein. According to one embodiment of the invention, those techniques are performed by computer system 400 in response to processor 404 executing one or more sequences of one or more instructions contained in main memory 406 . Such instructions may be read into main memory 406 from another machine-readable medium, such as storage device 410 . Execution of the sequences of instructions contained in main memory 406 causes processor 404 to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.
The term “machine-readable medium” as used herein refers to any medium that participates in providing data that causes a machine to operate in a specific fashion. In an embodiment implemented using computer system 400 , various machine-readable media are involved, for example, in providing instructions to processor 404 for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device 410 . Volatile media includes dynamic memory, such as main memory 406 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise bus 402 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
Common forms of machine-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, punchcards, papertape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
Various forms of machine-readable media may be involved in carrying one or more sequences of one or more instructions to processor 404 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer system 400 can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on bus 402 . Bus 402 carries the data to main memory 406 , from which processor 404 retrieves and executes the instructions. The instructions received by main memory 406 may optionally be stored on storage device 410 either before or after execution by processor 404 .
Computer system 400 also includes a communication interface 418 coupled to bus 402 . Communication interface 418 provides a two-way data communication coupling to a network link 420 that is connected to a local network 422 . For example, communication interface 418 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 418 may be a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links may also be implemented. In any such implementation, communication interface 418 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
Network link 420 typically provides data communication through one or more networks to other data devices. For example, network link 420 may provide a connection through local network 422 to a host computer 424 or to data equipment operated by an Internet Service Provider (ISP) 426 . ISP 426 in turn provides data communication services through the world wide packet data communication network now commonly referred to as the “Internet” 428 . Local network 422 and Internet 428 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 420 and through communication interface 418 , which carry the digital data to and from computer system 400 , are exemplary forms of carrier waves transporting the information.
Computer system 400 can send messages and receive data, including program code, through the network(s), network link 420 and communication interface 418 . In the Internet example, a server 430 might transmit a requested code for an application program through Internet 428 , ISP 426 , local network 422 and communication interface 418 .
The received code may be executed by processor 404 as it is received, and/or stored in storage device 410 , or other non-volatile storage for later execution. In this manner, computer system 400 may obtain application code in the form of a carrier wave.
In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. Thus, the sole and exclusive indicator of what is the invention, and is intended by the applicants to be the invention, is the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. Any definitions expressly set forth herein for terms contained in such claims shall govern the meaning of such terms as used in the claims. Hence, no limitation, element, property, feature, advantage or attribute that is not expressly recited in a claim should limit the scope of such claim in any way. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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A method for modifying a document at a client-side application is disclosed. The method involves receiving a user-requested document at a client-side application from a server; querying a database by the client-side application with entities in the user-requested document, where at least one entity is associated with entity information stored in the database; in response to querying the database, receiving the entity information associated with the at least one entity at the client-side application; modifying the user-requested document at the client-side application to obtain a modified document, where modifying the document comprises adding the entity information or a link to the entity information associated with the at least one entity; and displaying the modified document with the client-side application.
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BACKGROUND OF THE INVENTION
The present invention relates to a quilting apparatus for quilting cloths in general.
As known, quilts, eiderdowns and cloths in general are quilted by laying the cloth on a frame which is moved along two orthogonal directions X and Y below a sewing machine.
Alternatively the cloth-holding frame is actuated in the X direction, whereas the sewing machine moves in the Y direction. In a different process, the frame is fixed and the sewing machine moves in both directions X and Y.
In any case, known apparatuses remain idle for all the time during which the quilted cloth must be replaced with a new one, so that in view of the high incidence of this deadtime there is a considerable reduction in the productivity of these apparatus.
SUMMARY OF THE INVENTION
The technical aim of the present invention is to provide an apparatus by means of which the above disadvantages are substantially eliminated.
Within the scope of this aim, an object of the present invention is to provide an apparatus which is structurally simple and thus constructively economical.
This aim and this object are achieved by an apparatus as defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become apparent from the following description of some embodiments, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a partially schematic side view of a first embodiment of the quilting apparatus according to the present invention; and
FIGS. 2, 3 and 4 are views of further embodiments of the quilting apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIG. 1, the illustrated apparatus comprises a framework, generally indicated by 1, which comprises four uprights 2 which are arranged along the vertices of a rectangle and are mutually connected by transverse members which extend along the sides of said rectangle; the longitudinal transverse members, indicated by 3, are visible in the drawing. Said members 3 are supported, in a median position, by a pair of posts 4 to prevent excessive deflection.
The members 3 constitute the guides for a carriage 5 on which one or more sewing heads are mounted.
Said carriage 5 comprises a pair of side walls 6 which are mutually connected by two beams 7, 8 perpendicular to the members 3 and are provided with rollers 9 for sliding on said members in the direction termed X by convention. The carriage 5 preferably has a structure similar to that of the carriage disclosed in U.S. Ser. No. 07/507,556 filed on Apr. 11, 1990, now U.S. Pat. No. 5,103,747 to which reference is made for better understanding of the details.
The beams 7, 8 slidingly support a sewing head 10, and a crochet device 11 which is operatively connected thereto, of the sewing machines, the movement whereof occurs in a transverse direction, i.e. in a direction which is termed Y by convention, by means such as mutually connected threaded rods which can be actuated in both rotational directions by an appropriate gearmotor unit.
Two further carriages 12, 13 are arranged on the members 3 on both sides of the first carriage 5; each comprises a grip element, for example a clamp 14, which is applied to an element 15 which can extend telescopingly in a vertical direction. The carriages 5, 12, 13 are provided with motorization units by means of which they can be moved along the members 3.
In particular, the carriage 5 can move along the entire length of the members 3 so that it can operate on cloths stretched on a pair of cloth-holding frames 16, 17.
Each frame is constituted by two longitudinal strips 18 which are provided, on their upper edge, with means (needles or hooks) 19 for engaging the longitudinal edges of the cloth to be quilted. Preferably, one strip of the frame is fixed, whereas the distance of the other one with respect to the first one can be adjusted so as to be able to adapt the dimensions of the frame to those of the cloth to be quilted. The frames 16, 17 are supported by fixed legs 20 at the end proximate to the uprights 2 of the frame and by pairs of jacks 21, 22 at the end proximate to the post 4. The height of the legs 20 and of the jacks 21, 22 is such that the frames 16, 17 extend at a level which is intermediate between the sewing heads 10 and the crochet devices 11.
Two tables 23, 24 are arranged below the frames 16, 17 and can be actuated between a raised position, in which they are substantially co-planar with the frames 16, 17, and a lowered position below the carriage 5.
The tables 23, 24 have the function of supporting the cloth during the step of application to the frames 16, 17, and are raised and lowered by means of respective pantograph systems 25 actuated by jacks 26.
The operation of the described apparatus is as follows.
Assume the apparatus is in the condition illustrated in FIG. 1, in which the carriage 5, on which the sewing machines are mounted, operates on the cloth stretched on the frame 16.
The previously quilted cloth is removed by means of the grip element 14 of the carriage 13, which grips it and, after lifting and separating it from the means 19 of the frame 17, moves it away by shifting toward the rightward end of the members 3.
While the carriage 5 completes the quilting of the cloth stretched on the frame 16, the table 24 is lowered, and a new cloth to be quilted is placed thereon; said cloth is raised, by the lifting of the table 24, to the level of the frame 17 and is manually applied thereto. The frame 24 is then lowered again to a level below the carriage 5. In this manner, when the quilting of the cloth stretched on the frame 16 is completed, the carriage 5 can pass onto the frame 17 to quilt the new cloth.
It should be noted that during the transfer of the carriage 5 onto the frame 17, in order to avoid interference between the jacks 21, 22 and the beam 8 which supports the crochet devices, said jacks 21, 22 are alternatively raised and lowered to allow the passage of the beam 8, while the frame remains constantly supported. For example, when the carriage 5 must move to the right, the jacks 21 are lowered and the jacks 22 are raised. When the beam 8 has passed beyond the jacks 21, said jacks 21 are raised and the jacks 22 are lowered to allow the approach of the carriage to the frame 17. The supporting jacks of said frame 17 are activated similarly to allow the advancement of the carriage onto the frame 17 and perform the quilting of the previously applied cloth.
As can be seen, the deadtimes of the apparatus are practically reduced to the times required for the transfer of the carriage 5 from one frame to the other, so as to provide a high increase in productivity.
In the embodiment of FIG. 2, the cloth-holding frames 27, 28 are mounted in a cantilever manner on the uprights 2 of the framework and are supported, at their adjacent ends, by individual jacks 29, 30. In this manner the passage of the carriage 5 from one frame to the other entails the alternation of the actuation (lifting and lowering) of the jacks 29, 30.
The apparatus can also be used on cloths which are unrolled to preset lengths from one or more reels 31 in a direction which is parallel to the sliding direction of the carriage 5, as illustrated in FIG. 3. Such an embodiment has two frames 32, 33 which are mounted in a cantilever manner, like the frames 27 and 28 of FIG. 2, and a cloth cutting device 34 which is structured so as to allow the passage of the carriage 5 from one frame to the other.
In another embodiment, illustrated in FIG. 4, it is possible to install two frames 35 which are mutually connected so as to form a single frame. In this case the application of the frame supporting jacks is no longer required. To avoid the forming of excessive deflection at the center of the frame, said frame is supported laterally, in a sliding manner, by means of rollers 36, by the carriage 5 itself.
The described apparatus can be advantageously provided with a remote control device capable of controlling the movement of the carriage and of the sewing heads along the X and Y directions. Said device can be programmed to automatically perform quilting according to a given pattern or can be guided by an operator.
In order to more clearly visualize the path of the needle in case of operator guiding, there is a TV camera which is aimed at the needle work area and is mounted rigidly with the sewing head; said camera is connected to a monitor so as to allow the operator to check the movements of the carriage and of the sewing heads by means of said control device.
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The quilting apparatus includes a framework upon which a carriage with sewing head and crochet device is slidingly supported in a first direction. The sewing head and crochet device are slidingly supported in a second direction perpendicular to the first direction on transverse beams of the carriage. The carriage is positionable on a selected one of at least two cloth holding frames carriages with cloth holding clamps, and cloth loading tables, working in synchronization with the sewing carriage to remove and load cloths at the cloth holding frame where quilting is not taking place.
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BACKGROUND OF THE INVENTION
This invention relates to a control circuit for initiating flow into a scrub sink and, in particular, to a circuit containing a photo sensitive component mounted on the scrub sink for contact with the torso of the user.
In preparation for performing a medical procedure, a doctor carefully washes his hands before placement of gloves thereon. It is necessary to complete the washing and operate the scrub sink without the use of hands so as to maintain a sterile condition. To enable the washing operation to be conducted without direct contact of the hands with the flow control mechanism or scrub sink, the combination of a light beam and photocell has been utilized. Interruption of the beam by the hands and arms of the doctor initiates flow from the spout. As long as the hands or arms continue to interrupt the beam, the flow continues. This type of device suffers from a significant disadvantage in that the doctor must continually maintain his hands in position to interrupt the beam. Since the beam width determines in part the sensitivity of the device, the use of a narrow beam is favored. Thus, the movement of the hands and/or arms during the scrubbing operation is unduly restricted else the flow of water becomes repeatedly interrupted.
Attempts to direct a beam of light to the torso of the user and monitor changes in reflected light have proven generally unsatisfactory. Changes in ambient conditions along with variations in the type of reflective surface cause the operation of the circuit to be unpredictable. Thus, the monitoring of changes in reflected light levels at or near scrub sinks has not proven satisfactory in these types of flow control devices.
Another approach has utilized an under the sink light beam and reflections sensor to detect the presence of the legs of the user. One such device is disclosed in U.S. Pat. No. 5,412,816 wherein a tubular extension is affixed under the sink for detection of the change in light level caused by the legs of the user being within a few inches of the sensor. The problems arising from changes in ambient conditions are countered by use of a short focus sensor. Thus, the doctor's movements are quite limited else the flow into the sink stops. Other under the sink approaches to providing remote actuation of flow to a scrub sink have relied on leg-actuated levers. These mechanical systems are characterized by the problems inherent in all mechanical devices subjected to repeated use. Furthermore, a doctor using this type of scrub sink actuating system is limited in movement during use since the same position is maintained to insure flow.
The present invention is directed to a dark-initiated flow control circuit which operates essentially independently of the sensitivity of a sensor and does not reply on reflected light levels for operation. The circuit utilizes a light-responsive resistive component mounted on the exterior of the edge adjacent the user. Contact by the torso or masking of the incident light causes the circuit to actuate a valve in the liquid flow line. The circuit permits adjustment for changes in ambient conditions to provide reliable operation. Further, the flow control circuit can be retrofitted on installed scrub sinks without requiring removal or alteration of the scrub sink or its tub.
SUMMARY OF THE INVENTION
In accordance with this invention, a scrub sink providing hands-free user control of the entering fluid includes an electrically-responsive valve located in the liquid flow line to control the flow of liquid through a spout in the tub of the sink.
A light-responsive component having light and dark impedance states is mounted on the exterior of the tub on the edge portion proximate to the user. The position of the cell enables the user to either rest directly against the cell or stand in close proximity thereto thereby permitting lateral movement while maintaining the cell in its dark impedance state.
The invention includes a control circuit containing a differential amplifier circuit. One input signal to the amplifier is derived through the light-responsive component, typically a photosensitive cell, with the other input signal being derived from the voltage across an adjustable resistor. The adjustment of the resistor enables the control circuit to operate under differing ambient conditions. When the user blocks incident light from the photosensitive cell, the differential amplifier provides an output which results in an actuating signal being supplied to the valve in the flow line.
The placement of the photosensitive cell and the use of the dark condition to actuate the valve enables the user to freely move the arms and hands during a scrub without experiencing interruption in flow. Further, the torso can be moved laterally without causing a cessation of flow since the photosensitive cell is considerably smaller than the torso of the user. Thus, the invention greatly enhances the mobility of the user during a scrub and facilitates the process of hands-free scrubbing.
Further features and advantages of the invention will become more readily apparent from the following detailed description of a specific embodiment of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in section showing a scrub sink utilizing one embodiment of the present invention.
FIG. 2 is an electrical schematic of a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a scrub sink is shown comprising tub 12 having a distal edge portion 15 with spout 18 extending upwardly therefrom. The proximal edge portion 16 is shown to be thicker in cross-section with a flat exterior surface. A bottom drain 14 is located in the base of the tub and coupled to the drain pipe by a conventional threaded coupler.
A light-responsive component 17 is attached to the exterior surface of proximal edge portion 16 with the translucent cover 19 facing outwardly toward the user. Attachment to the tub may be permanent by use of epoxy or removably adhered by another adhesive. The electrical connection to the control circuit housing 23 is made via cable 20 which is attached to the exterior of the tub by means of removable adhesive fasteners 22 . As shown, a grommet 24 is used to provide a watertight seal in housing 23 .
The housing 23 contains the electrically-responsive valve which is of conventional design and is normally a solenoid controlled valve. In the embodiment shown, the flow rate and temperature of the water flowing through flexible connector pipe 22 to spout 18 is preset. The mechanism and valving used are commercially available and are not part of the present invention. The housing 23 is inserted into the water supply circuit and the valve therein is normally closed. An electrical cable 25 extends between valve housing 23 and the electrical circuit housing 26 which is connected to the local power supply through a wall socket. The means of attachment of the scrub sink to the wall are not shown. However, it should be noted that the only modification to the scrub sink is the attachment of component 17 and the cable 20 to the exterior of the tub. The housing 23 is attached to the rigid vertical pipe 30 of the water supply and is normally supported thereby. Thus, the present invention is well-suited for use in connection with presently installed scrub sinks.
The electrical schematic diagram of the circuit is depicted in FIG. 2 with the photosensitive component 17 which is a commercially available cadmium sulfide photocell with light and dark resistance states of 100 and 500 k ohms respectively. The component 17 is coupled between the voltage regulator 41 and the second or minus input terminal of the differential amplifier 42 . Resistor 43 couples the second input terminal to ground. A potentiometer or tapped variable resistor 44 is used to apply the reference signal to the first or positive input of the differential amplifier. The resistance establishes the baseline for the operation of the amplifier and can be changed to compensate for changes in the ambient light level.
The output terminal of amplifier 42 is supplied to the drive transistor 46 . When the photosensitive component 17 enters the dark state, the output signal from amplifier 42 drives transistor 46 into conduction and a drive signal is supplied to relay 48 . Relay 48 is connected in series in the low voltage circuit of step down transformer 51 . The drive signal closes the normally open relay 48 to actuate the solenoid water valve 50 and permit flow through the spout into the scrub sink. A diode 49 is coupled across the relay for transient protection.
The low voltage side of transformer 51 is used to power the electrical control circuit. A bridge rectifier 53 is used to rectify the 24 volt stepped down voltage from the transformer. The rectified signal is supplied to a fixed positive 9 volt regulator 41 . A ceramic capacitor 57 rated at 0.1 μf 16 v. is provided at the regulator for transient protection. The regulated output signal is provided to amplifier 42 and drive transistor 46 as well as being applied across the potentiometer 44 and the combination of photocell 17 and resistor 43 . In addition, a flow indicating light-emitting-diode 56 can be utilized in the circuit. A second differential amplifier 55 is shown in FIG. 2 connected in parallel with the amplifier 42 . The output signal from amplifier 55 is supplied to diode 56 for a visual indication of the condition for flow.
The transformer 51 is connected to the facility power supply and may be housed individually or in combination with the electrical control circuit. The photocell 17 and the cable thereto can be removably affixed to the exterior surface of the scrub sink thereby enabling the invention to be placed in use with presently installed scrub sinks. While the embodiment shown and described is intended for use with the water flow line to a surgical scrub sink, it should be noted that the invention can be used in other cases where hands-free fluid flow control is used. It is recognized that modifications and variations may be made in the invention as described without departing from the scope of the invention as claimed.
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A control circuit for flow control of liquid into a scrub sink wherein a differential amplifier is provided with an adjustable input signal based on the ambient condition and an input signal from a photocell which is mounted on the exterior of the edge of the scrub sink. An electrically responsive valve is in the flow line. The torso of the user contacts the photocell to initiate flow into the scrub sink
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BACKGROUND OF INVENTION
[0001] This invention relates generally to refrigerators and, more particularly, to a method and apparatus for controlling refrigeration defrost cycles.
[0002] Known frost free refrigerators include a refrigeration defrost system to limit frost buildup on evaporator coils. Conventionally, an electromechanical timer is used to energize a defrost heater after a pre-determined run time of the refrigerator compressor to melt frost buildup on the evaporator coils. To prevent overheating of the freezer compartment during defrost operations when the heater is energized, in at least one type of defrost system the compartment is pre-chilled. After defrost, the compressor is typically run for a predetermined time to lower the evaporator temperature and prevent food spoilage in the refrigerator and/or fresh food compartments of a refrigeration appliance.
[0003] Such timer-based defrost systems, however are not as energy efficient as desired. For instance, they tend to operate regardless of whether ice or frost is initially present, and they often pre-chill the freezer compartment regardless of initial compartment temperature. In addition, the defrost heater is typically energized without temperature regulation in the freezer compartment, and the compressor typically runs after a defrost cycle regardless of the compartment temperature. Such open loop defrost control systems, and the accompanying inefficiencies are undesirable in light of increasing energy efficiency requirements.
[0004] Recognizing the limitations of such timer-based defrost systems, efforts have been made to provide adaptive defrost systems employing limited feedback, such as door openings and compressor and evaporator conditions, for improved energy efficiency of defrost cycles. As such, unnecessary defrost cycles are avoided and the defrost heater is cycled on and only as necessary, such as until the evaporator reaches a fixed termination temperature. See, for example, U.S. Pat. No. 4,528,821. However, achieving some defrost goals, such as melting all of the frost off of the evaporator and melting ice out of an icemaker fill tube, are detrimental to achieving other defrost goals, such as maintaining freezer compartment temperatures at sufficient levels during defrost operations to prevent freezer burn and moisture formation/ice buildup in the freezer compartment. Known defrost systems have not resolved these difficulties.
SUMMARY OF INVENTION
[0005] In one aspect, a method for defrosting an evaporator of a refrigeration system, the method utilizing a defrost heater and a controller operatively connected to the evaporator and a defrost heater, is provided. The method comprises initiating a defrost cycle to energize the defrost heater to defrost the evaporator, monitoring a temperature of the evaporator, terminating the defrost cycle by de-energizing the defrost heater when a low temperature termination point of the evaporator is reached when in a low temperature defrost cycle, and terminating the defrost cycle by de-energizing the defrost heater when a high temperature termination point of the evaporator is reached when in a high temperature defrost cycle.
[0006] In another aspect, a method for defrosting a refrigeration unit including an evaporator, a defrost heater, and a controller operatively connected to the evaporator and the defrost heater is provided. The controller includes a defrost counter, and the method comprises initiating a defrost cycle to energize the defrost heater to defrost the evaporator, selecting a low temperature defrost cycle when the defrost counter is less than a predetermined value, and selecting a high temperature defrost cycle when the defrost counter equals said predetermined value.
[0007] In still another aspect, a method for defrosting a refrigerator including a sealed system, an evaporator, a defrost heater, and a controller operatively connected to the evaporator and a defrost heater is provided. The controller includes a defrost counter and a defrost timer. The method comprises initiating a defrost cycle to energize the defrost heater to defrost the evaporator, selecting a low temperature defrost cycle when the defrost counter is less than a predetermined value, selecting a high temperature defrost cycle when the defrost counter equals the predetermined value, terminating the low temperature defrost cycle by de-energizing the defrost heater when a first temperature termination point of the evaporator is reached when the low temperature defrost cycle is selected, terminating the high temperature defrost cycle by de-energizing the defrost heater when a second temperature termination point of the evaporator is reached when the high temperature defrost cycle is selected, the second termination temperature higher than the first termination temperature, comparing an elapsed defrost time to a reference defrost time when either of the high temperature defrost and low temperature defrost are terminated, selecting a normal or abnormal defrost interval based upon the compared elapsed defrost time and reference defrost time, and operating the sealed system for the selected defrost interval.
[0008] In still another aspect, a refrigeration defrost unit for an evaporator is provided. The defrost unit comprises a defrost heater, a controller operatively coupled to said defrost heater, and a thermistor adapted for sensing a temperature of the evaporator. The controller is configured to operate said defrost heater in a low temperature defrost mode de-energizing said defrost heater at a first temperature in response to said thermistor, and to operate said defrost heater in a high temperature defrost mode de-energizing said defrost heater at a second temperature in response to said thermistor, said second temperature higher than said first temperature.
[0009] In another aspect a refrigeration unit is provided that comprises a compressor, an evaporator, a defrost heater, and a controller. The controller is operatively coupled to said compressor, said evaporator and said defrost heater, and the controller comprises a defrost timer and operates said compressor in a normal mode and an abnormal load in response to a value of the defrost timer. The controller further comprises a defrost counter and operates said defrost heater in a high temperature defrost mode and a low temperature defrost mode based upon a value of said counter.
[0010] In a further aspect a refrigerator is provided which comprises a cabinet defining at least one refrigeration compartment, a sealed system for cooling said at least one refrigeration compartment, a defrost heater, and a controller operatively coupled to said sealed system and to the defrost heater. The controller is configured to adaptively control said defrost heater and said sealed system in a high temperature defrost mode and a low temperature defrost mode between normal and abnormal defrost intervals.
BRIEF DESCRIPTION OF DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of a refrigerator.
[0012] [0012]FIG. 2 is a block diagram of a refrigerator controller in accordance with one embodiment of the present invention.
[0013] [0013]FIG. 3 is a block diagram of the main control board shown in FIG. 2.
[0014] [0014]FIG. 4 is a block diagram of the main control board shown in FIG. 2.
[0015] [0015]FIG. 5 is a defrost state diagram executable by a state machine of the controller shown in FIG. 2.
[0016] [0016]FIG. 6 is a method flow chart of an adaptive defrost algorithm executable by the controller shown in FIG. 2.
DETAILED DESCRIPTION
[0017] [0017]FIG. 1 illustrates a side-by-side refrigerator 100 in which the present invention may be practiced. It is recognized, however, that the benefits of the present invention apply to other types of refrigerators, freezers, and refrigeration appliances wherein frost free operation is desirable. Consequently, the description set forth herein is for illustrative purposes only and is not intended to limit the invention in any aspect.
[0018] Refrigerator 100 includes a fresh food storage compartment 102 and a freezer storage compartment 104 contained within an outer case 106 and inner liners 108 and 110 . A space between case 106 and liners 108 and 110 , and between liners 108 and 110 , is filled with foamed-in-place insulation. Outer case 106 normally is formed by folding a sheet of a suitable material, such as pre-painted steel, into an inverted shape to form top and side walls of case. A bottom wall of case 106 normally is formed separately and attached to the case side walls and to a bottom frame that provides support for refrigerator 100 . Inner liners 108 and 110 are molded from a suitable plastic material to form freezer compartment 104 and fresh food compartment 102 , respectively. Alternatively, liners 108 , 110 may be formed by bending and welding a sheet of a suitable metal, such as steel. The illustrative embodiment includes two separate liners 108 , 110 as it is a relatively large capacity unit and separate liners add strength and are easier to maintain within manufacturing tolerances. In smaller refrigerators, a single liner is formed and a mullion spans between opposite sides of the liner to divide it into a freezer compartment and a fresh food compartment.
[0019] A breaker strip 112 extends between a case front flange and outer front edges of liners. Breaker strip 112 is formed from a suitable resilient material, such as an extruded acrylo-butadiene-styrene based material (commonly referred to as ABS).
[0020] The insulation in the space between liners 108 , 110 is covered by another strip of suitable resilient material, which also commonly is referred to as a mullion 114 . Mullion 114 also preferably is formed of an extruded ABS material. Breaker strip 112 and mullion 114 form a front face, and extend completely around inner peripheral edges of case 106 and vertically between liners 108 , 110 . Mullion 114 , insulation between compartments, and a spaced wall of liners separating compartments, sometimes are collectively referred to herein as a center mullion wall 116 .
[0021] Shelves 118 and slide-out drawers 120 normally are provided in fresh food compartment 102 to support items being stored therein. A bottom drawer or pan 122 partly forms a quick chill and thaw system (not shown) and selectively controlled, together with other refrigerator features, by a microprocessor (not shown in FIG. 1) according to user preference via manipulation of a control interface 124 mounted in an upper region of fresh food storage compartment 102 and coupled to the microprocessor. A shelf 126 and wire baskets 128 are also provided in freezer compartment 104 . In addition, an ice maker 130 may be provided in freezer compartment 104 .
[0022] A freezer door 132 and a fresh food door 134 close access openings to fresh food and freezer compartments 102 , 104 , respectively. Each door 132 , 134 is mounted by a top hinge 136 and a bottom hinge (not shown) to rotate about its outer vertical edge between an open position, as shown in FIG. 1, and a closed position (not shown) closing the associated storage compartment. Freezer door 132 includes a plurality of storage shelves 138 and a sealing gasket 140 , and fresh food door 134 also includes a plurality of storage shelves 142 and a sealing gasket 144 .
[0023] In accordance with known refrigerators, refrigerator 100 also includes a machinery compartment (not shown) that at least partially contains components for executing a known vapor compression cycle for cooling air. The components include a compressor (not shown in FIG. 1), a condenser (not shown in FIG. 1), an expansion device (not shown in FIG. 1), and an evaporator (not shown in FIG. 1) connected in series and charged with a refrigerant. The evaporator is a type of heat exchanger which transfers heat from air passing over the evaporator to a refrigerant flowing through the evaporator, thereby causing the refrigerant to vaporize. The cooled air is used to refrigerate one or more refrigerator or freezer compartments via fans (not shown in FIG. 1). Collectively, the vapor compression cycle components in a refrigeration circuit, associated fans, and associated compartments are referred to herein as a sealed system. The construction of the sealed system is well known and therefore not described in detail herein, and the sealed system is operable to force cold air through the refrigerator subject to the following control scheme.
[0024] [0024]FIG. 2 illustrates a controller 160 in accordance with one embodiment of the present invention. Controller 160 can be used, for example, in refrigerators, freezers and combinations thereof, such as, for example side-by-side refrigerator 100 (shown in FIG. 1).
[0025] Controller 160 includes a diagnostic port 162 and a human machine interface (HMI) board 164 coupled to a main control board 166 by an asynchronous interprocessor communications bus 168 . An analog to digital converter (A/D converter) 170 is coupled to main control board 166 . A/D converter 170 converts analog signals from a plurality of sensors including one or more fresh food compartment temperature sensors 172 , a quick chill/thaw feature pan (i.e., pan 122 shown in FIG. 1) temperature sensors 174 (shown in FIG. 8), freezer temperature sensors 176 , external temperature sensors (not shown in FIG. 2), and evaporator temperature sensors 178 into digital signals for processing by main control board 166 .
[0026] In an alternative embodiment (not shown), A/D converter 170 digitizes other input functions (not shown), such as a power supply current and voltage, brownout detection, compressor cycle adjustment, analog time and delay inputs (both use based and sensor based) where the analog input is coupled to an auxiliary device (e.g., clock or finger pressure activated switch), analog pressure sensing of the compressor sealed system for diagnostics and power/energy optimization. Further input functions include external communication via IR detectors or sound detectors, HMI display dimming based on ambient light, adjustment of the refrigerator to react to food loading and changing the air flow/pressure accordingly to ensure food load cooling or heating as desired, and altitude adjustment to ensure even food load cooling and enhance pull-down rate of various altitudes by changing fan speed and varying air flow.
[0027] Digital input and relay outputs correspond to, but are not limited to, a condenser fan speed 180 , an evaporator fan speed 182 , a crusher solenoid 184 , an auger motor 186 , personality inputs 188 , a water dispenser valve 190 , encoders 192 for set points, a compressor control 194 , a defrost heater 196 , a door detector 198 , a mullion damper 200 , feature pan air handler dampers 202 , 204 , and a quick chill/thaw feature pan heater 206 . Main control board 166 also is coupled to a pulse width modulator 208 for controlling the operating speed of a condenser fan 210 , a fresh food compartment fan 212 , an evaporator fan 214 associated with an evaporator 215 (shown in phantom in FIG. 3), and a quick chill system feature pan fan 216 .
[0028] [0028]FIGS. 3 and 4 are more detailed block diagrams of main control board 166 . As shown in FIGS. 3 and 4, main control board 166 includes a processor 230 . Processor 230 performs temperature adjustments/dispenser communication, AC device control, signal conditioning, microprocessor hardware watchdog, and EEPROM read/write functions. In addition, processor 230 executes many control algorithms including sealed system control, evaporator fan control, defrost control, feature pan control, fresh food fan control, stepper motor damper control, water valve control, auger motor control, cube/crush solenoid control, timer control, and self-test operations.
[0029] Processor 230 is coupled to a power supply 232 which receives an AC power signal from a line conditioning unit 234 . Line conditioning unit 234 filters a line voltage which is, for example, a 90-265 Volt AC, 50/60 Hz signal. Processor 230 also is coupled to an EEPROM 236 and a clock circuit 238 .
[0030] A door switch input sensor 240 is coupled to fresh food and freezer door switches 242 , and senses a door switch state. A signal is supplied from door switch input sensor 240 to processor 230 , in digital form, indicative of the door switch state. Fresh food thermistors 244 , a freezer thermistor 246 , at least one evaporator thermistor 248 , a feature pan thermistor 250 , and an ambient thermistor 252 are coupled to processor 230 via a sensor signal conditioner 254 . Conditioner 254 receives a multiplex control signal from processor 230 and provides analog signals to processor 230 representative of the respective sensed temperatures. Processor 230 also is coupled to a dispenser board 256 and a temperature adjustment board 258 via a serial communications link 260 . Conditioner 254 also calibrates the above-described thermistors 244 , 246 , 248 , 250 , and 252 .
[0031] Processor 230 provides control outputs to a DC fan motor control 262 , a DC stepper motor control 264 , a DC motor control 266 , and a relay watchdog 268 . Watchdog 268 is coupled to an AC device controller 270 that provides power to AC loads, such as to water valve 190 , cube/crush solenoid 184 , a compressor 272 , auger motor 186 , a feature pan heater 206 , and defrost heater 196 . DC fan motor control 266 is coupled to evaporator fan 214 , condenser fan 210 , fresh food fan 212 , and feature pan fan 216 . DC stepper motor control 266 is coupled to mullion damper 200 , and DC motor control 266 is coupled to one of more sealed system dampers.
[0032] Processor logic uses many inputs to make control decisions pertaining to the present invention, including but not limited to Freezer Door State via light switch detection using optoisolators, Fresh Food Door State via light switch detection using optoisolators, Freezer Compartment Temperature via a thermistor, Evaporator Temperature via a thermistor, Compressor On Time, Time to Complete a Defrost, and User Desired Set Points via electronic keyboard and display or encoders.
[0033] The electronic controls activate many loads to control refrigerator functions and operation, many of which are beyond the scope of the present invention. Those loads having some effect on the defrost functions of the refrigerator include Multi-speed or variable speed (via PWM) fresh food fan, Multi-speed (via PWM) evaporator fan, Multi-speed (via PWM) condenser fan, Compressor Relay, Defrost Relay, and Drip pan heater Relay that activate the sealed system and defrost system components.
[0034] These and other functions of the above-described electronic control system are performed under the control of firmware implemented as small independent state machines. As is described in detail below, the electronic controls facilitate an effective defrost scheme that, unlike known defrost systems, employs more than one defrost interval (normal and abnormal) and more than one defrost cycle (high and low temperature defrost) dependent upon actual operating conditions for improved defrost performance. Low temperature defrost cycles having a reduced effect on freezer compartment temperature are typically executed, while high temperature defrost cycles having a greater effect on freezer compartment temperature are selectively executed only at predetermined intervals. Instances of freezer burn and moisture buildup in the freezer compartment are thereby substantially avoided while still achieving an energy efficient, effective defrost system.
[0035] [0035]FIG. 5 is a defrost state diagram 300 illustrating a state algorithm executable by a state machine of controller 160 (shown in FIGS. 2 - 4 ). As will be seen, controller 160 adaptively determines an optimal defrost state based upon effectiveness of defrost cycles as they occur.
[0036] In an exemplary embodiment, by monitoring evaporator temperature over time, it is determined whether defrost cycles are deemed normal or abnormal. More specifically, when it is time to defrost, i.e. after an applicable defrost interval (explained below) has expired, the refrigerator sealed system is shut off, defrost heater 196 is turned on (at state 2 ), and a defrost timer is started. As the evaporator coils defrost, the temperature of the evaporator increases. When evaporator temperature reaches a predetermined termination temperature (dependant upon the high or low temperature defrost cycle explained below), the defrost heater 196 is shut off and the elapsed time defrost heater 196 was on (Δt de ) is recorded in system memory. Also, if the termination temperature is not reached within a predetermined maximum time, defrost heater 196 is shut off and the elapsed time the defrost heater was on is recorded in system memory.
[0037] The elapsed defrost time Δt de is then compared with a predetermined defrost de reference time (Δt dr ) representative of, for example, an empirically determined or calculated elapsed defrost heater time to remove a selected amount of frost buildup on the evaporator coils that is typically encountered in the applicable refrigerator platform under predetermined usage conditions. If elapsed defrost time Δt de is greater than reference time Δt dr , thereby indicating excessive frost buildup, a first or abnormal defrost interval, or time until the next defrost cycle, is employed If elapsed defrost time Δt de is less than reference time Δt dr , a second or normal defrost interval, or time until the next defrost cycle is employed. The normal and abnormal defrost intervals, as defined below, are selectively employed, using Δt dr as a baseline, for more efficient defrost operation as refrigerator usage conditions change, thereby affecting frost buildup on the evaporator coils. In an exemplary embodiment, Δt dr is twenty minutes, although it is appreciated that Δt dr could be greater or lesser without departing from the scope of the present invention.
[0038] In one embodiment, the following control scheme automatically cycles between the first or abnormal defrost interval and the second or normal defrost interval on demand. When usage conditions are heavy and refrigerator doors 132 , 134 (shown in FIG. 1) are opened frequently, thereby introducing more humidity into the refrigeration compartment, the system tends to execute the first or abnormal defrost interval repeatedly. When usage conditions are light and the doors opened infrequently, thereby introducing less humidity into the refrigeration compartments, the system tends to execute the second or normal defrost interval repeatedly. In intermediate usage conditions the system alternates between one or more defrost cycles at the first or abnormal defrost interval and one or more defrost cycles at the second or normal defrost interval.
[0039] Upon power up, controller 160 reads freezer thermistor 246 (shown in FIG. 3) over a predetermined period of time and averages temperature data from freezer thermistor 146 to reduce noise in the data. If the freezer temperature is determined to be substantially at or below a set temperature, thereby indicating a brief power loss, a defrost interval is read from EEPROM memory 236 (shown in FIG. 3) of controller 160 , and defrost continues from the point of power failure without resetting defrost parameters. Periodically, controller 160 saves a current time till defrost value in system memory in the event of power loss. Controller 160 therefore recovers from brief power loses and associated defrost cycles due to resetting of the system from momentary power failures are therefore avoided.
[0040] If freezer temperature data indicates that freezer compartment 104 (shown in FIG. 1) is warm, i.e., at a temperature outside a normal operating range of freezer compartment, humid air is likely to be contained in freezer compartment 104 , either because of a sustained power outage or opened doors during a power outage. Because of the humid air, a defrost timer is initially set to the first or abnormal defrost interval. In one embodiment the first or abnormal defrost interval is set to, for example, eight hours of compressor run time. For each second of compressor run time, the first defrost interval is decremented by a predetermined amount, such as one second, and the first defrost interval is generally unaffected by any other event, such as opening and closing of fresh food and freezer compartment doors 134 , 132 . In alternative embodiments, a first or abnormal defrost interval of greater or lesser than eight hours is employed, and decrement values of greater or lesser than one second are employed for optimal performance of a particular compressor system in a particular refrigerator platform.
[0041] When the first defrost interval has expired, controller 160 runs compressor 272 (see FIG. 3) for a designated pre-chill period or until a designated pre-chill temperature is reached (at state 1 ). Defrost heater 196 (shown in FIGS. 2 - 4 ) is energized (at state 2 ) to defrost the evaporator coils. Defrost heater 196 is turned on to defrost the evaporator coils either until a predetermined evaporator temperature has been reached or until a predetermined maximum defrost time has expired, and then a dwell state is entered (at state 3 ) wherein operation is suspended for a predetermined time period, which as described further below is dependent upon whether a high temperature or low temperature defrost cycle is executed.
[0042] Upon completion of an abnormal defrost cycle after the first or abnormal defrost interval has expired, controller 160 (at state 0 ) sets the time till defrost to the second or normal pre-selected defrost interval that is different from the first or abnormal time to defrost. Therefore, using the second defrost interval, a normal defrost cycle is executed. For example, in one embodiment, the second defrost interval is set to about 60 hours of compressor run time. In alternative embodiments, a second defrost interval of greater or lesser than 60 hours is employed to accommodate different refrigerator platforms, e.g., top-mount versus side-by-side refrigerators or refrigerators of varying cabinet size.
[0043] In one embodiment, the second defrost interval, unlike the first defrost interval, is decremented (at state 5 ) upon the occurrence of any one of several decrement events. For example, the second defrost interval is decremented (at state 5 ) by, for example, one second for each second of compressor run time. In addition, the second defrost interval is decremented by a predetermined amount, e.g., 143 seconds, for every second freezer door 132 (shown in FIG. 1) is open as determined by a freezer door switch or sensor 242 (shown in FIG. 3). Finally, the second defrost interval is decremented by a predetermined amount, such as 143 seconds in an exemplary embodiment, for every second fresh food door 134 (shown in FIG. 1) is open. In an alternative embodiment, greater or lesser decrement amounts are employed in place of the above-described one second decrement for each second of compressor run time and 143 second decrement per second of door opening. In a further alternative embodiment, the decrement values per unit time of opening of doors 132 , 134 are unequal for respective door open events. In further alternative embodiments, greater or fewer than three decrement events are employed to accommodate refrigerators and refrigerator appliances having greater or fewer numbers of doors and to accommodate various compressor systems and speeds.
[0044] When the second or normal defrost interval has expired, controller 160 runs compressor 272 for a designated pre-chill period or until a designated pre-chill temperature is reached (at state 1 ). Defrost heater 196 is energized (at state 2 ) to defrost the evaporator coils. Defrost heater 196 is turned on to defrost the evaporator coils either until a predetermined evaporator temperature has been reached or until a predetermined maximum defrost time has expired. Defrost heater 196 is then shut off and the elapsed time defrost heater 196 was on (Δt de ) is recorded in system memory. A dwell state is then entered (at state 3 ) wherein sealed system operation is suspended for a predetermined time period. As will be seen further below, the duration of the dwell state is dependent upon the particular defrost cycle executed.
[0045] The elapsed defrost time Δt de is then compared with a predetermined defrost de reference time Δt dr . If elapsed defrost time Δt de is greater than reference time Δt dr , thereby indicating excessive frost buildup, the first or abnormal defrost interval is employed for the next defrost cycle If elapsed defrost time Δt de is less than reference time Δt dr , the second or normal defrost interval is employed for the next defrost cycle. The applicable defrost interval is applied and a defrost cycle is executed when the defrost interval expires. The elapsed defrost time Δt de of the cycle is recorded and compared to reference time Δt dr to determine the applicable defrost interval for the next cycle, and the process continues. Normal and abnormal defrost intervals are therefore selectively employed on demand in response to changing refrigerator conditions.
[0046] It is recognized that that other known reference data may be employed in lieu of elapsed defrost time as indicative of evaporator frost buildup to distinguish between normal and abnormal defrost cycles. For example, compressor and evaporator loads may be monitored to determine effectiveness of the sealed system due frost buildup on the evaporator coils, and pressure and temperature sensors may be employed on the evaporator and/or compressor to sense performance parameters and changes over time that are indicative of defrost effectiveness. In addition, other reference values, such as elapsed time to cool a refrigeration compartment to a given temperature, or total elapsed door-open time may be employed to evaluate and demarcate a need for a normal or abnormal defrost cycle.
[0047] [0047]FIG. 6 is a method flow chart of an adaptive defrost method 350 executable by controller 160 (shown in FIG. 2) for energy efficient effective defrost while minimizing the effect of freezer compartment temperature during defrost operations.
[0048] As refrigerator controller 160 powers up 352 , controller 160 sets 354 a time till defrost interval X i to a first or minimum length X min , which in an exemplary embodiment corresponds to the abnormal cycle described above, namely eight hours of compressor run time undecremented by door openings or external factors. In alternative embodiments, however, it is recognized that X min may be greater or lesser than eight hours of compressor run time and further may be based or otherwise determined by other factors in lieu of or in addition to compressor run time.
[0049] Additionally upon power up, a defrost counter N D is set 356 to zero and controller 160 operates 358 the refrigerator sealed system to obtain set point temperatures in freezer compartment 104 and/or fresh food compartment 102 (shown in FIG. 1). Thus condenser fan speed 180 , evaporator fan speed 182 , compressor control 194 , mullion damper 200 , and pulse width modulator 208 for controlling the operating speed of condenser fan 210 , fresh food compartment fan 212 , and evaporator fan 214 (all shown in FIG. 2) are activated and regulated by controller 160 to cycle the appropriate components on and off to maintain refrigeration compartments 102 , 104 at specified temperatures. As will be seen defrost counter N D is employed to determine whether a high temperature or low temperature defrost cycle will be activated.
[0050] As controller 160 operates the refrigerator sealed system, an elapsed sealed system time t ss is compared 360 to defrost interval X i set 354 by controller 160 upon power up. If elapsed sealed system time is less than the abnormal defrost time, i.e., if t ss <X i , then controller 160 continues to operate 358 the sealed system. If elapsed sealed system time is equal to or exceeds the abnormal defrost time, i.e., if t ss ≧X i , then controller 160 initiates 362 defrost operations by pre-chilling freezer compartment 104 and turning off sealed system components to prepare for defrost. While pre-chilling of freezer compartment 104 is desirable in an illustrative embodiment, it is recognized that the low temperature defrost may partially, if not wholly, obviate the desirability of pre-chilling functions in alternative embodiments.
[0051] When defrost is initiated 362 , controller 160 checks or compares 364 defrost counter N D to a predetermined value N H that corresponds to a high temperature defrost cycle. As will be seen further below, N D is incremented with each low temperature defrost cycle executed and reset to zero at the completion of a high temperature defrost cycle. Thus, low temperature defrost cycles will be successively executed for a predetermined number of times before a high temperature defrost cycle is executed. In an illustrative embodiment, N D equals five so that every fifth defrost is a high temperature defrost cycle. It is understood, however, that other values of N D may be employed in alternative embodiments without departing from the scope of the present invention.
[0052] If N D does not equal N H then a low temperature defrost is initiated and defrost heater 196 (shown in FIGS. 2 - 4 ) is energized 366 to heat the evaporator coils. Evaporator temperature is sensed or monitored and evaporator temperature (T e ) is compared 368 to a low defrost cycle termination temperature (T l ). In an illustrative embodiment T l is set to a temperature (about 55° F. in a particular embodiment) sufficient to melt frost off of the evaporator but not necessarily to defrost other components, such as an icemaker fill tube. Further, T l is selected to prevent freezer burn and moisture formation and ice buildup in freezer compartment 104 during the low temperature defrost cycle. In alternative embodiments it is appreciated that greater or lesser values for T l may be employed in lieu of about 55° F.
[0053] If actual evaporator temperature T e is less than T l , controller 160 continues to energize 366 defrost heater 196 . If actual evaporator temperature T e is not less than T l , controller 160 de-energizes 370 defrost heater 196 , sets 372 sealed system dwell time to a value corresponding to the low temperature defrost cycle, and also sets 374 a sealed system delay time to a value corresponding to the low temperature defrost cycle. As used herein, dwell refers to a period of time after defrost termination temperature is reached when the sealed system and evaporator fan are both off, and delay refers to time after the dwell period wherein the evaporator fan is off but the sealed system is on. The system will therefore remain in a dwell state for a certain time period and then in a delay state for another period of time. In the illustrative embodiment, the low temperature dwell time is set 372 to five minutes and the low temperature delay is set to zero (i.e., no delay). It is recognized that the foregoing low temperature dwell time and delay values are for illustrative purposes only and that other values may be employed in alternative embodiments.
[0054] Once defrost heater 196 is de-energized and low temperature dwell and delay values are set 372 , 374 , defrost counter ND is incremented 376 to its current value plus one for further use by controller 160 .
[0055] When defrost operations are initiated 378 , if N D does equal N H when N D and N H are compared 364 , then a high temperature defrost is initiated and defrost heater 196 (shown in FIGS. 2 - 4 ) is energized 378 to heat the evaporator coils. Evaporator temperature is sensed or monitored and evaporator temperature (T e ) is compared 380 to a high defrost cycle termination temperature (T h ) that is different from low defrost cycle termination temperature T l . In an illustrative embodiment T h is set to a temperature (about 65° F. in a particular embodiment) sufficient to melt frost off of the evaporator and to defrost other components, such as an icemaker fill tube, but without causing unacceptable temperature rises in freezer compartment 104 . It is appreciated, however, that greater or lesser values for T h may be employed in lieu of about 65° F. in alternative embodiments.
[0056] If actual evaporator temperature T e is less than T h , controller 160 continues to energize 378 defrost heater 196 . If actual evaporator temperature T e is not less than T h controller 160 de-energizes 382 defrost heater 196 , sets 384 sealed system dwell time to a value corresponding to the high temperature defrost cycle, and also sets 386 a sealed system delay time to a value corresponding to the high temperature defrost cycle. In the illustrative embodiment, the high temperature dwell time is set 384 to twenty minutes and the high temperature delay is set to 10 minutes. It is recognized, however, that the foregoing high temperature dwell time and delay values are for illustrative purposes only and that other values may be employed in alternative embodiments.
[0057] Once defrost heater 196 is de-energized 382 and high temperature dwell and delay values are set 384 , 386 , defrost counter ND is reset 388 to zero for further use by controller 160 .
[0058] After defrost counter N D is reset 376 , 388 upon completion of low temperature and high temperature defrosts, respectively, controller compares 390 elapsed defrost time Δt de (explained above in relation to FIG. 5) to defrost reference time Δt dr (also explained above in relation to FIG. 5). If elapsed defrost time Δt de is greater than the reference defrost time Δt dr , defrost interval X i is set 392 to the first or minimum length X min corresponding to the abnormal defrost interval. Thus, in an illustrative embodiment defrost interval X min is about eight hours of compressor run time unaffected by door open events. As noted previously, however, it is understood that other measures besides compressor run time may be utilized in alternative embodiments to define X min .
[0059] If elapsed defrost time Δt de is not greater than the reference defrost time Δt dr , defrost interval X i is set 394 to the second or maximum length X max corresponding to the normal defrost interval. Thus, in an illustrative embodiment defrost interval X max is about sixty hours of compressor run time decremented by door open events as described above in relation to FIG. 5. It is understood, however, that other measures besides decremented compressor run time may be utilized in alternative embodiments to define X max .
[0060] Once defrost counter has been incremented or reset 376 , 378 and X i has been determined as X min or X max 392 , 394 as described above, controller 160 returns to operate 358 the sealed system with the current values of defrost counter ND and defrost interval X i . The sealed system is operated and controller 160 compares 360 the sealed system time t ss with defrost interval X i until another defrost is initiated and the method repeats.
[0061] It is believed that the above-described methodology could be programmed and implemented in control logic by those in the art without further explanation.
[0062] A defrost system and method is therefore provided that utilizes a high termination temperature defrost at defined intervals in conjunction with a plurality of low temperature termination defrosts, and also employs normal and abnormal defrost intervals responsive to refrigerator usage through door open events. By using a low termination temperature defrost frequently and a high termination temperature defrost infrequently, freezer burn and moisture/ice buildup is substantially avoided and energy efficiency improved while providing satisfactory defrost performance.
[0063] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A method and apparatus for defrosting an evaporator of a refrigeration system including a defrost heater and a controller operatively connected to the evaporator and a defrost heater is provided. The method comprises initiating a defrost cycle to energize the defrost heater to defrost the evaporator, monitoring a temperature of the evaporator, terminating the defrost cycle by de-energizing the defrost heater when a low temperature termination point of the evaporator is reached when in a low temperature defrost cycle, and terminating the defrost cycle by de-energizing the defrost heater when a high temperature termination point of the evaporator is reached when in a high temperature defrost cycle.
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This application is a divisional application of my copending application Ser. No. 802,675 filed Nov. 29, 1985 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the field of water heating and distilling apparatus and in particular to such apparatus wherein the condenser of the distilling apparatus is incorporated with a water heating apparatus to effect energy conservation.
Distilling apparatus and water heating apparatus is, of course, well known. In many geographic localities, water is not potable and consequently it must be distilled or otherwise treated prior to being consumed by humans or animals or in many well known processes. Moreover, water heating equipment is often utilized in buildings in which equipment is installed to distill or otherwise treat water.
Typically,, when water distillation equipment has been installed adjacent water heating equipment, latent heat available from the condensing of steam in the distillation process has been merely wasted. In some cases, such heat is considered a nuisance because it must be transferred to the exterior of a building to keep the temperature of an equipment room with acceptable levels.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a device for distilling and heating water which utilizes, for heating water, latent heat given off by water condensing during a distillation process.
It is a further object of the present invention to provide an apparatus for distilling water and heating water concurrently which obviates and mitigates from the difficulties and disadvantages of the prior art.
According to an aspect of the present invention there is provided a water heater and distiller apparatus adapted for utilizing latent heat of water condensing in a distilling process for heating water, said water heater and distiller apparatus comprising, a boiler chamber means for containing water to be boiled to steam, said boiler chamber means having an inlet for receiving water from a water supply and an outlet disposed for delivery of steam thereout said boiler chamber being closed except for said inlet and said outlet, heating means for boiling water in said boiler chamber means. A water heating tank means for containing water to be heated, said water heating tank means having an inlet for receiving water from a water supply and an outlet for passage of heated water thereout. A condenser means disposed for being cooled by water in said water heating tank means, said condenser means having an inlet for receiving steam, an outlet for delivery of condensate thereout and means for collection of condensate from said outlet and arranged such that said condensate is removed for use separate from said boiler chamber means, duct means communicating with said outlet of said boiler chamber means and said inlet of said condenser means for delivery of steam from said boiler chamber means to said condenser means, a reservoir disposed laterally of said boiler chamber means, said reservoir being open to air pressure, flow control means for controlling the flow of water from said reservoir for maintaining the level of water in said boiler chamber means below a predetermined maximum and above a predetermined minimum, said flow control means comprising a float valve controlled by a float, said float valve being adapted for closing upon said level of water moving to said predetermined maximum and adapted for opening upon moving of said water level to said predetermined minimum, conduit means communicating water from said reservoir to said boiler chamber means, at least a portion of the length of said conduit means being disposed entirely downwardly of said predetermined minimum so as to form a gas trap for impeding venting of steam from said boiler chamber means through said conduit, and heating means separate from said condenser means for heating said water to be heated.
DESCRIPTION OF THE DRAWINGS
The invention and the advantages thereof will be more fully explained by reference to preferred embodiments described in relation to the drawings in which:
FIG. 1 illustrates a schematic of a preferred embodiment of a water heater and distillar apparatus adapted for use in preheating water for introduction into a conventional water heating tank, and
FIG. 2 illustrates a schematic of a domestic water system including a preferred embodiment of a water heater and distiller apparatus.
FIG. 3 illustrates a schematic of yet another preferred embodiment wherein a water heater and distiller apparatus is incorporated in a natural gas domestic water heater.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to a preferred embodiment, a water heater and distiller apparatus is illustrated in FIG. 1.
A boiler 11 is provided in which an electrical heater 12, is provided for boiling water to steam. A duct 13 is provided in communication with an outlet 14 of boiler 11 for conveying steam from the boiler 11 to an inlet 15 of a condenser means, such as tube 16. Tube 16 passes through a water heating tank 17. Steam generated in boiler 11 passes through outlet 14, duct 13, inlet 15 and into tube 16. Tank 17 has an inlet 18 for receiving water from a water supply 19 typically but not necessarily the domestic water supply of a building. Tank 17 also has an outlet 20 for passage of heated water out of tank 17.
Steam entering tube 16 condenses on the interior of tube 16 and gives up the latent heat available on a change of state of water from a gas to a liquid. Condensation occurs, of course, due to the fact that the interior of tube 16 is cooled by water passing through tank 17. Condensate forming in tube 16 drains by gravity through outlet 21 of tube 16 and is received by a container 22.
The condenser means could, of course, be provided by a condenser having a plurality of passages in acting in parallel to receive steam and pass condensate to container 22. Furthermore, tube 16 may advantageously be provided integral with a wall of tank 17. Further, it may be advantageous to provide, in place of container 22, a further conduit communicating with the outlet 21 of tube 16 for conveying distilled water to a point of utilization. However, in the event that container 22 is utilized a float control switch 23 may be used for turning off heater 12 when the level of distilled water in container 22 goes above a predetermined level. Valve 24 can be utilized for draining distilled water from container 22. Safety switch 25 may also preferrably be provided for turning off heater 12 in the event of a loss of feed water to boiler 11.
A float valve 26, actuated by float 27, is provided for maintaining the level of water in a reservoir 28 within a predetermined range. A conduit 29 is provided in communication with an inlet 30 of boiler 11 and an outlet 31 of reservoir 28 for conveying of liquid between reservoir 28 and boiler 11. Float valve 26 controls flow from a pipe 32 supplied from water supply 19, typically, but not necessarily, the domestic water system of a building. Float valve 26 is adapted so that it will open should the level of water in reservoir 28 drop below a predetermined range and so that it will close should the level of water rise above said predetermined range. It is apparent that, the lower limit of the predetermined range should be above heater 12. Futhermore the lower limit of said predetermined range can preferrably be above at least a portion of the length of conduit 29 so that a gas trap is formed for inhibiting venting of steam from boiler 11 through conduit 29 upon the level of water in boiler 11 rising above the lower limit of the predetermined range. A suitable lower limit of the predetermined range could conceivably be as indicated by numeral 33. A gas trap so provided will allow sufficient pressure to build in boiler 11 to cause steam to flow through duct 13. However, the gas trap so provided will vent gases prior to damaging pressures being developed as a result of unintentional blocking of duct 13 or tube 16. The outlet 14 must remain at all times higher than the upper level of the predetermined range within which the level of water may fluctuate. A suitable upper limit of the predetermined range could conceivably be as indicated by numeral 34.
Conduit 29 may advantageously be of a length sufficient for allowing boiler 11 to be insulated and reservoir 28 may advantageously be disposed sufficiently laterally from boiler 11 so that water in reservoir 28 remains relatively cool in relation to water in boiler 11. By maintaining water in reservoir 28 relatively cool, less heat will be lost through evaporation from the surface of water in reservoir 28 and through conduction of heat through the walls of reservoir 28. Furthermore, if water in reservoir 28 is maintained relatively cool, it is believed that mineral build up on float valve 26 will occur more slowly than if the water in reservoir 28 was at a higher temperature. A valve 35 may be provided for draining reservoir 28 and boiler 11 from time to time. A sealable cover 36 may be provided on boiler 11 for providing access for cleaning.
FIG. 2 illustrates a water heater and distiller apparatus 37 installed in a domestic water system of a building. The water heater and distiller apparatus 37 is connected to a water supply 19 under pressure suitable for a domestic water system in a building. A water pipe 38 receives water heated in water heater and distiller 37. Distilled water is available upon opening a valve 24.
The operational cycle of the water heater and distiller apparatus will now be described in relation to FIG. 1. Water flows from water supply 19 through float valve 26 until reservoir 28 and boiler 11 are filled to upper limit 34 of a predetermined range. Initially container 22 is empty. Float control switch 23 thus indicates a low level in container 22 and closes to provide electrical power to electrical heater 12. Electrical heater 12 boils water in boiler 11 to produce steam. The steam exits through outlet 14 passes through duct 13 to tube 16. The volume within tank 17 surrounding tube 16 is filled with water which has entered tank 17 through inlet 18 from water supply 19. Water in tank 17 cools the tube 16 to cause steam within tube 16 to condense and drain by gravity through outlet 21 of tube 16 into container 22.
Normal operation of float valve 26 maintains the level of water in reservoir 28 and boiler 11 above lower level 33 of a predetermined range. In this preferred embodiment lower level 33 is above at least a portion of the length of conduit 29 and thus a gas trap is formed for assuring that steam generated in boiler 11 normally exits through duct 13. However should duct 13 or tube 16 become blocked the gas trap will vent steam through conduit 29 to prevent damage to boiler 11. When a demand for heated water arises water is drawn from tank 17 through outlet 20 of tank 17. Water drawn from tank 17 is replaced by water from water supply 19.
Assuming a constant temperature of water from water supply 19, the temperature of water leaving outlet 20 of tank 17 will depend upon the rate of flow of water through tank 17 and the rate at which water is condensing in tube 16 neither of which is necessarily constant. It may therefore be advantageous to use the water distiller and heater apparatus as a preheater for a conventional water heater as illustrated in FIG. 2. In such an arrangement, whenever heated water is allowed to flow through valve 41, water supply 19 causes water to flow through tank 17 and water pipe 38 into conventional water heater 39.
Turning to FIG. 3, there is illustrated schematically another preferred embodiment wherein a water heater and distiller apparatus is incorporated in a natural gas domestic water heater.
As illustrated in FIG. 3, there is provided in this embodiment a float valve 45, a float 46 and a reservoir 47 such as float valve 26, float 27 and reservoir 28 illustrated in FIG. 1. Moreover as illustrated in FIG. 3 there is also provided in this embodiment an inlet 48 to a boiler 49 communicating through a conduit 50 with an outlet 51 of reservoir 47 in a like manner to the embodiment of FIG. 1. Water can be introduced to reservoir 47 through a conduit 52 and a manual control valve 53 from a water source 54.
In the preferred embodiment illustrated in FIG. 3, there is a water heating tank 63 having a vertical combustion gas flue 65 passing vertically therethrough from a combustion chamber 64 to a heat exchanger 66. Flue 65 contains a baffle 67 for causing turbulence in combustion gases rising through flue 65 to enhance the conduction of heat from the combustion gases to water in water heating tank 63. Baffle 67 advantageously can be of heat conducting material contacting flue 65 to further facilitate heat conduction to the water in tank 63. Heat exchanger 66 is an air-to-water heat exchanger in which heat obtained from combustion gases rising from flue 65 into heat exchanger 66 is conducted through the walls of pipe 68 to water contained in pipe 68. Combustion gases exit heat exchanger 66 at outlet 61 which typically connects with a known chimney flue. Water heating tank 63 is supplied with water from water source 54 by means of control valve 69, conduit 70, pipe 68 of heat exchanger 66, and conduit 71. It can be noted that conduit 71 introduces cold water to the bottom 62 of tank 63. Heated water is permitted to exit water heating tank 63 through conduit 75 when heated water is required.
In the preferred embodiment illustrated in FIG. 3, there is a boiler chamber 49 having an inlet 48 and an outlet 76. A condenser coil 73 is provided within water heating tank 63 and a conduit 72 is provided for passage of steam from outlet 76 into conduit 73. Steam condensing in conduit 73 will pass by gravity through distilled water outlet 74 to a collection tank 741.
In the preferred embodiment illustrated in FIG. 3, there is a water heating tank burner 55 disposed above boiler 49 and adjacent the bottom side 62 of water heating tank 63. There is also provided a boiler burner 56 disposed adjacent the bottom side 77 of boiler 49. The flammable gas which is used to fuel boiler burner 56 is controlled by a solonoid valve 57 and a known pilot light apparatus (not shown). Likewise, the flammable gas which is used to fuel water heating tank burner 55 is controlled by a solonoid valve 58 and a known pilot light apparatus (not shown). Both burners 55 and 56 receive their air supply from an air inlet 59 and their flammable gas from a gas supply 60. The burners 55 and 56 are disposed with boiler 49 in combustion chamber 64.
It may be advantageous to route conduit 72 other than as illustrated in FIG. 3. In particular, conduit 72 may be disposed so as to pass laterally through the wall of combustion chamber 64, rise vertically along the outside of the water heating tank 63 and enter water heating tank 63 opposite the highest point of condenser coil 73. If conduit 72 is disposed and insulated in such a position, there will be a minimum of condensation occurring in vertical tube 72 during operation. It is desirable to minimize condensation occurring in conduit 72 because gravity will cause such condensation to flow to boiler 49 rather than distilled water outlet 74 with a resultant reduction in output of the distilling apparatus.
The operation of the preferred embodiment illustrated in FIG. 3 will now be explained. When valve 53 is opened water passes to reservoir 47 and float valve 45 acts to maintain water in boiler 49 at or about a desired level 78 in the manner described in relation to the embodiment illustrated in FIG. 1. Valve 69 is open and water passes through conduit 70, heat exchanger 66, conduit 71 and into water heating tank 63. When water heating tank 63 has been filled gas solonoid valve 57 is opened to fuel boiler burner 56. Burner 56 is of course ignited by the action of the pilot light (not shown). Water in boiler 49 is boiled to steam and the steam passes through outlet 76 into conduit 72 and into condenser coil 73 where it condenses to form distilled water. The distilled water drains down the condenser coil 73 by gravity and exits at distilled water outlet 74. The steam in condenser coil 73 of course condenses due to the fact it gives up its latent heat to the water in water heating tank 63. The products of combustion produced by the operation of burner 56 pass upwards in the combustion chamber and provide heat to the bottom 62 of water heating tank 63 prior to passing upwardly through flue 65. Thus while burner 56 provides heat to boiler 49 and tank 63 it tends to provide higher temperature heat to boiler 49 due to the close proximity of burner 56 and boiler 49. Thus in this mode of operation the condensing of steam in coil 73 is believed to provide the prime means of heating the water in water heating tank 63. Also, for this mode of operation it can be noted that the products of combustion of burner 56 are sequentially cooled by boiler 49, water tank 63 and heat exchanger 66. From a cold start up burner 55 could be operated simultaneously with burner 56. However, once a sufficient stock of distilled water has been obtained through the operation of the illustrated apparatus, burner 56 can be shut down and burner 55 can be operated alone to provide heat for water heating tank 63. In this mode of operation products of combustion of burner 55 give up their heat to water heating tank 63 and heat exchanger 66.
While only certain embodiments of the present invention have been described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as claimed.
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A water heater and distiller apparatus is provided in which condensing steam is the distilling portion of the apparatus giving up its latent heat to water which is being heated in the water heating portion of the apparatus. In a preferred embodiment, products of combustion which are used to boil water in the distiller boiler, are later passed in heat exchange relation with the water heating tank in the water heating portion of apparatus. It is believed that the present apparatus is both energy efficient and uncomplicated as compared to the prior art.
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FIELD OF THE INVENTION
The present invention relates to medication delivery devices which are implanted within the body of a patient and methods of construction of the devices. More particularly, the invention relates to a medication delivery device having a uniquely compact size due to the lateral placement of the fluid medication reservoir and the reservoir refill assembly and methods of its construction.
BACKGROUND OF THE INVENTION
The use of implantable fluid medication dispensers is well known. These devices typically include a medication reservoir within a generally cylindrically shaped housing. Some form of fluid flow control is also provided to control or regulate the flow of fluid medication from the reservoir to the outlet of the device for delivery of the medication to the desired location, usually through a catheter. The flow control may be provided by a pumping or metering device such as disclosed in U.S. Pat. No. 4,692,147 issued to Duggan. Other forms of flow control are disclosed in U.S. Pat. Nos. 3,951,147 and 4,360,019.
All implantable fluid medication dispensers must also include some means to replenish the fluid medication in the medication reservoir. The previously mentioned U.S. Pat. Nos. 4,692,147 to Duggan and 3,951,147 to Tucker et al. disclose typical reservoir refill assemblies. Both include an opening or port through which a resealable septum may be accessed. To refill the reservoir a hypodermic needle is inserted through the septum and into a chamber between the septum and a needle stop, which may be a plug or filter. The medication is injected under pressure into the chamber and flows into the Reservoir.
A disadvantage of these reservoir refill assemblies is that they have been stacked on top of the reservoirs. Thus, the external housing of the device must be sized not only to accommodate the depth of the reservoir but, additionally, the depth of the refill assembly including the septum, the chamber and the needle stop. This adds considerably to the total depth of the drug dispensing device which is undesirable, especially in view of technological advances being made in the miniaturization of other components of the device. Since the device is implanted in the body it is advantageous to make the device as small as possible. A smaller (thinner) device can be implanted in smaller people and in children and allows all patients to be more active.
SUMMARY OF THE INVENTION
The present invention is a medication delivery device having a particularly compact size. Specifically, a very thin profile is achieved by arranging the components of the device so that the medication reservoir is radially or laterally spaced from the reservoir refill assembly rather than being axially spaced or in a stacked relationship. The invention includes the method of making the device.
In one embodiment the invention is a medication delivery device comprising a housing, a reservoir within the housing, and a reservoir refill port or assembly in fluid communication with the reservoir. The refill assembly is substantially surrounded by the reservoir and is radially spaced from the reservoir in a lateral arrangement. The device includes an outlet port, and means connected between the reservoir and the outlet port for dispensing medication from the reservoir through the outlet port. The dispensing means may be a flow regulator or a flow restrictor. The reservoir may include an aperture through which the refill assembly is positioned. The aperture may be approximately concentric with a longitudinal axis of the housing.
In another embodiment the invention is a medication delivery device comprising a housing within which is a reservoir having an aperture approximately concentric with a longitudinal axis of the housing. A reservoir refill assembly is positioned within the aperture of the reservoir in fluid communication with the reservoir. A flow regulator is connected between the reservoir and an outlet port.
In a further embodiment the invention is a medication delivery device having a cover and a bulkhead connected to the cover. The bulkhead includes a base portion and a reservoir refill assembly which extends through the cover. The device further includes a reservoir having a top portion, a side portion, and a bottom portion. An aperture extends through the reservoir between the top and bottom portions. The bottom portion of the reservoir is connected to the base portion of the bulkhead such that the refill assembly extends through the aperture and is radially spaced from the reservoir in a lateral arrangement. A manifold is connected to the base portion of the bulkhead. The device further includes means for providing fluid flow from the refill assembly to the reservoir, a flow regulator in fluid communication with the reservoir, and an outlet port connected to the flow regulator. The refill assembly may include a hollow neck portion having first and second open ends, a resealable septum within the hollow neck portion near the first end thereof, a filter within the hollow neck portion near the second end thereof, and a refill chamber lying between the septum and the filter. Additionally, the manifold may include an inlet portion for receiving medication passing through the filter, and one or more fluid channels for carrying fluid from the inlet portion. The bulkhead may include one or more fluid flow paths for providing a fluid path from the one or more fluid channels of the manifold to the reservoir. The inlet portion and the one or more fluid channels of the manifold together with the one or more fluid flow paths of the bulkhead may comprise the means for providing fluid flow.
In another aspect, the invention is a method of making a medication delivery device. The method comprises providing a housing and mounting a reservoir within the housing. A reservoir refill port or assembly is mounted at least partially within the housing such that it is substantially surrounded by the reservoir and is radially spaced from the reservoir in a laterally positioned arrangement. The method further includes providing a fluid path between the reservoir refill assembly and the reservoir, providing an outlet port, and connecting between the reservoir and the outlet port a means for dispensing medication from the reservoir to the outlet port. The dispensing means may comprise a flow regulator. Further, the reservoir may include an aperture through which is positioned the reservoir refill assembly. In that aspect, the aperture may be approximately concentric with a longitudinal axis of the housing.
In a further embodiment the method of making the medication delivery device includes providing a housing and mounting a reservoir within the housing. The reservoir may have an aperture approximately concentric with a longitudinal axis of the housing. The method further includes mounting a reservoir refill assembly within the aperture of the reservoir so that the refill assembly is radially spaced from the reservoir in a laterally positioned arrangement and is in fluid communication with the reservoir. The method includes connecting a flow regulator to the reservoir, and connecting an outlet port to the flow regulator.
In another embodiment the invention is a method of making a medication delivery device comprising providing a cover and connecting a bulkhead to the cover. The bulkhead may include a base portion and a reservoir refill assembly extending at least partially through the cover. The method includes mounting a reservoir between the cover and the bulkhead, the reservoir having a top portion, a side portion, an aperture and a bottom portion. The bottom portion of the reservoir is connected to the base portion of the bulkhead such that the refill assembly is radially spaced from the reservoir in a lateral arrangement. The method further includes connecting a manifold to the base portion of the bulkhead, connecting between the reservoir and the refill assembly a means for providing fluid flow from the refill assembly to the reservoir, connecting a flow regulator in fluid communication with the reservoir, and connecting an outlet port to the flow regulator. The refill assembly may include a hollow neck portion having first and second open ends, a resealable septum within the hollow neck portion near the first end thereof, a filter within the hollow neck portion near the second end thereof, and a refill chamber lying between the septum and the filter. The manifold may include an inlet portion for receiving medication passing through the filter, and one or more fluid channels for carrying fluid from the inlet portion. The bulkhead may include one or more fluid flow paths for providing a fluid path from the one or more fluid channels of the manifold to the reservoir. Further, the inlet portion and the one or more fluid channels of the manifold together with the one or more fluid flow paths of the bulkhead may comprise the means for providing fluid flow.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an exploded perspective view of one embodiment of the medication delivery device 10 of the present invention; and
FIG. 2 is a cross-sectional view thereof, taken generally along line 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-2, a medication delivery device 10, for delivering a fluid medication 12, is illustrated. The term "medication" is used in its broad sense, and may be any fluid, whether or not the fluid is medicinal in nature. The term "fluid" is also used in its broad sense, and includes both liquids and gasses.
Turning again to FIGS. 1-2, the medication delivery device 10 may comprise five main components, namely, a manifold 13, a donut-shaped bellows reservoir 14, a bulkhead 15, a cover 16, and a flow regulator 30. Optionally, flow regulator 30 may be any type of flow restriction device such as capillary tubing. Additionally, it should be understood that although the embodiment of the invention disclosed in FIGS. 1 and 2 has a dispensing means consisting of a flow regulator, the invention is equally applicable to devices utilizing other means of dispensing medication such as programmable or nonprogrammable pumping means as will be familiar to those of skill in the art. The manifold 13, the reservoir 14, the cover 16, and the flow regulator 30 may all be bonded or assembled to the bulkhead 15 in any suitable way, as will be described in more detail below. The cover 16, manifold 13 and bulkhead 15 together form an external housing of the medication delivery device.
The bulkhead 15 may have a hollow neck 17, a base 18, a number of through holes 19, a flow regulator mounting cavity 20; an outlet housing 21, an outlet conduit 22, and an outlet port 23. Although ten through holes 19 are illustrated in FIG. 1, there may be fewer, or more, through holes 19.
Although the bulkhead 15's neck 17, base 18 and outlet housing 21 are illustrated as being made as one integral component, they may be manufactured as separate components, and then bonded or assembled together in any suitable way. Similarly, although the outlet port 23 is illustrated as being made as a separate component, which is then bonded or assembled to the outlet housing 21, the outlet port 23 and the outlet housing 21 may be made as one integral component.
Although not illustrated, for clarity, the medication delivery device 10 may be equipped with any suitable means for preventing back flow of any fluid into the outlet port 23, such as a check valve. The means for preventing back flow of any fluid into the medication delivery device 10's outlet port 23 may be mounted in any suitable location, either internally or externally of the device 10, such as in its outlet conduit 22 or adjacent to its outlet port 23.
Although also not illustrated, for clarity, the medication delivery device 10 may be equipped with any suitable means for permitting or preventing flow of the medication 12 out of the outlet port 23, such as an on-off valve. The means for permitting or preventing flow of the medication 12 out of the outlet port 23 may be mounted in any suitable location, either internally or externally of the device 10, such as in its outlet conduit 22 or adjacent to its outlet port 23.
The bulkhead 15's hollow neck 17 may have an inlet 28. Housed within the neck 17 may be a septum 29, which may be held in place by any suitable means, such as by a threaded hollow plug 31 or by an interference (press) fit between the neck 17 and the plug 31, or by welding the neck 17 to the plug 31. The septum 29 may be made from any suitable resilient, self-sealing material which may be pierced by a needle, such as silicone rubber. Neck 17, inlet 28 and septum 29 together comprise a refill port which enables reservoir 14 to be filled and refilled with medication in a manner described more fully hereafter.
Also housed within the neck 17 may be any suitable filter 33, which may be bonded or assembled within the neck 17 in any suitable way. For example, as seen in FIG. 2, the filter 33 may be held within the neck 17 by being sandwiched between the neck 17's shoulder 63 and the manifold 13's ribs 27.
The filter 33 may be selected to filter particles from the medication 12 of a size which might clog, or otherwise harm, any of the device 10's components which are located downstream from the filter 33; or which might clog, or otherwise harm, whatever is receiving the medication 12 from the device 10. For example, if the device 10 is to be used for medical or veterinary purposes, the filter 33 may be selected to filter out particles as small as bacteria, or even as small as viruses, to help protect the patient or animal from the possibility of infection. By way of further example, if the filter 33 is located upstream from the fluid flow regulator 30, then the filter 33 may serve the dual functions of filtering out harmful bacterial or viruses from the medication 12, and of filtering out any particles from the medication 12 which might clog, or otherwise harm, the fluid flow regulator 30 and/or flow restrictor and keep it from operating properly.
Although the filter 33 is illustrated as being located within the bulkhead 15's neck 17, it could be placed in any other suitable location within the medication delivery device 10 which is upstream from where the outlet port 23 exits the device 10, such as in the reservoir 14, the through holes 19, the manifold 13's inlet recess 25, the manifold 13's outlet channels 26, the flow regulator mounting cavity 20, the outlet conduit 22, or the outlet port 23. Alternatively, the filter 33 may be placed externally of the medication delivery device 10 in any suitable location, such as upstream from the neck 17's inlet port 28, or downstream from the device 10's outlet port 23. In such an event, the neck 17's shoulder 63 may be eliminated, since it would no longer be needed to hold the filter 33 in place within the neck 17.
The flow regulator 30 may be bonded or assembled to the bulkhead 15's regulator mounting cavity 20, over the outlet conduit 22, in any suitable way. Alternatively, the flow regulator 30 may be placed within the device 10 in any other suitable location which is downstream from the reservoir 14, the outlet conduit 22, or the outlet port 23.
Alternatively, the flow regulator 30 may be placed externally of the medication delivery device 10 in any suitable location, such as downstream of the outlet port 23. In such an event, the flow regulator mounting cavity 20 may be eliminated.
The flow regulator 30 may be any suitable fluid flow regulator which is selected to have the particular fluid flow characteristics which are desired for the particular intended use of the medication delivery device 10. For example, in order to help prevent an overdose of medication from being delivered to a patient by the device 10, the flow regulator 30 may be selected to provide a predetermined maximum flow rate of the medication 12, despite an overpressure of the medication 12 within the reservoir 14 which exceeds the normal operating parameters of the device 10. Such an overpressure might occur if, for example, the reservoir 14 was overfilled with the medication 12.
The manifold 13 may be bonded or assembled to the periphery of the bottom of the bulkhead 15's base 18 in any suitable way, and may form the bottom of the medication delivery device 10. The manifold 13 may have a cutout 24, an inlet recess 25, a number of outlet channels 26, and a number of ribs 27. The cutout 24 may be sized to accommodate the bulkhead 15's outlet housing 21. The ribs 27 may separate the outlet channels 26 from each other, and may help to hold the filter 33 within the bulkhead 15's neck 17. One end of each of the outlet channels 26 may be in fluid communication with the inlet recess 25, while the other end of each of the outlet channels 26 may be in fluid communication with a respective through hole 19 in the bulkhead 15.
Although ten outlet channels 26 and nine ribs 27 are illustrated, there may be fewer, or more, outlet channels 26 and ribs 27. Although the manifold 13's inlet recess 25 and outlet channels 26 are illustrated as being separate components, the outlet channels 26 may be eliminated and replaced by an enlarged inlet recess 25 which fluidly communicates with the bulkhead 15's through holes 19; and the inlet recess 25 may be eliminated and replaced by enlarged outlet channels 26 which are in fluid communication with the bulkhead 15's hollow neck 17.
The reservoir 14 may have a central hole 35, pleated inner and outer sides 37, 39, and an open bottom having inner and outer mounting flanges 41, 43. The reservoir 14 may be bonded or assembled to the bulkhead 15 in any suitable way; such as by bonding or assembling its inner mounting flange 41 to the outside of the base of the neck 17, and by bonding or assembling its outer mounting flange 43 to the inside of the bulkhead 15's peripheral lip 45. As a result, the bulkhead 15's base 18 forms the bottom of the reservoir 14, and the medication 12 may enter the reservoir 14 through the holes 19 in the base 18.
The use of a donut-shaped reservoir 14, with the bulkhead 15's neck 17 extending through the reservoir 14's central hole 35, may be preferred. This is because such a construction results in an unusually compact medication delivery device 10 while retaining sufficient medication storage capacity. This arrangement provides a compact radially adjacent or side-by-side positioning of the reservoir and the refill port which does not add to the thickness of the medical delivery device in the direction of the longitudinal axis of the housing. Such compactness may be particularly desirable for the device 10 in certain circumstances, such as if it is designed to be implanted within a patient's body. Although the reservoir 14 and its central hole 35 are illustrated as having circular shapes, they could have any other suitable rounded or angular shape, such as oval, square or rectangular. Additionally, instead of being positioned concentrically with the longitudinal axis of the housing at the center of reservoir 14 as illustrated, hole 35 could be offset to any desired nonconcentric location.
The reservoir 14's pleated inner and outer sides 37, 39 permit the volume of the reservoir 14 to be varied. For example, as seen in FIG. 2, when the reservoir 14 is full, then its pleated inner and outer sides 37, 39 unfold a maximum amount, thereby permitting the reservoir 14's top 61 to be located a maximum distance from the bulkhead 15's base 18, which forms the bottom of the reservoir 14.
On the other hand, when the reservoir 14 is empty or evacuated, its pleated inner and outer sides 37, 39 fold up a maximum amount, thereby permitting the reservoir 14's top 61 to be located a minimum distance from the bulkhead 15's base 18.
Although the reservoir 14 is illustrated as having pleated inner and outer sides 37, 39, the reservoir 14 may be any other suitable adjustable volume device. For example, the reservoir 14 may be a simple balloon or bladder, having unpleated sides, which is made from any suitable flexible or elastic material, such as rubber or plastic.
The cover 16 may have a central hole 47 for the bulkhead 15's neck 17; and inner and outer mounting flanges 49, 51. The cover 16 may be bonded or assembled to the bulkhead 15 in any suitable way, such as by bonding or assembling its inner mounting flange 49 to the outside of the top of the neck 17, and by bonding or assembling its outer mounting flange 51 to the outside of the bulkhead 15's peripheral lip 45.
A positive pressure may be imparted to the medication 12 within the reservoir 14 in any suitable way. For example, the space 53 between the reservoir 14 and the cover 16 may be pressurized in any suitable way, such as by locating in the space 53 a quantity of any suitable, volatile substance which has a relatively high vapor pressure at the intended operating temperature range of the medication delivery device 10. The suitable, volatile substance may, for example, be Freon 87, which has a gas liquid-gas vapor pressure of 3.9 PSIG at 37° C. or R-11 which has a vapor pressure of 8.4 PSIG at 37° C. Alternatively, the space 53 may be pressurized by filling it with a compressed gas.
Alternatively, a positive pressure may be imparted to the medication 12 within the reservoir 14 by making the reservoir 14 to be self-collapsing, such as by fabricating the reservoir 14 from an elastic material which is stretched when the reservoir 14 is filled with the medication 12.
Alternatively, a positive pressure may be imparted to the medication 12 within the reservoir 14 by using an external mechanical force to collapse the reservoir 14, such as by locating a spring between the reservoir 14's top 61 and the inside of the cover 16.
The medication delivery device 10 may be initially filled with the medication 12 in any suitable way, such as by first inserting a hollow needle 55 through the neck 17's septum 29, and into the space 57 which is located between the septum 29 and the filter 33. Any undesired perforation of the filter 33 by the needle 55 may be prevented in any suitable way, such as by providing a space 57 between the septum 29 and the filter 33. In addition, the needle 55 may be selected to be of the type which has a relatively blunt end, with an outlet hole 59 on its side. Further, although not illustrated for clarity, a perforated needle stop may be located in the neck 17 between the septum 29 and the filter 33. The size of the perforations in the needle stop may be selected to be small enough to prevent the passage of the needle 55 therethrough; but large enough to permit the free passage of the medication 12 therethrough.
A vacuum may then applied to the needle 55 until all of the air in the space 57, the filter 33, the inlet recess 25, the outlet channels 26, the through holes 19, the reservoir 14, the flow regulator 30, the outlet conduit 22, and the outlet port 23 has been evacuated. The check valve, which was mentioned above, may be used to prevent air from flowing into the medication delivery device 10 through its outlet port 23 during the evacuation process. The needle 55 may then be withdrawn, and the septum 29 will automatically reseal itself, thereby not admitting any air into the device 10.
A new needle 55, connected to a source of medication 12, may then be inserted through the septum 29 into the space 57. The source of the medication 12 for the needle 55 may be pressurized. The medication 12 will then be drawn into and/or forced into the medication delivery device 10 through the needle 55, and fill the space 57, the filter 33, the inlet recess 25, the outlet channels 27, the through holes 19, the reservoir 14, the flow regulator 30, the outlet conduit 22, and the outlet port 23. After the medication delivery device 10 has been filled with the desired amount of the medication 12, the on-off valve, which was mentioned above, may be used to prevent the medication 12 from leaking out of the outlet port 23. The needle 55 may then be withdrawn, and the septum 29 will automatically reseal itself, to prevent any medication 12 from leaking out of, and any air from leaking into, the space 57.
Once the desired amount of the medication 12 has been inserted into the medication delivery device 10, any suitable delivery means, such as a catheter, may then be attached in any suitable way to the medication delivery device 10's outlet port 23, for conveying the medication 12 from the outlet port 23 to the location where the medication 12 is to be delivered. The on-off valve, which was mentioned above, may be turned on long enough to permit the medication 12 to flow out of the outlet port 23 until any undesired air in the outlet port 23 and the delivery means has been purged; at which time the on-off valve may then be turned off.
The medication delivery device 10 may then be secured in any suitable way in its location of intended use, such as by inserting it within a patient's body. The free end of the delivery means, such as the free end of the catheter, may then secured in any suitable way at the location where the medication 12 is to be delivered.
Once the device 10 and the free end of the delivery means have been secured in their desired location, the on-off valve may be turned on. That will permit the pressurized medication 12 in the reservoir 14 to flow out of the reservoir 14 and through the flow regulator 30, the outlet conduit 22, the outlet port 23, the delivery means. The rate of flow of the medication 12 from the reservoir 14 is governed by the flow regulator 30.
After a period of use, the reservoir 14 may be refilled with medication 12 in any suitable way, such as by the use of a needle 55 in a manner similar to that described above. Since the medication delivery device 10 may be installed within a patient's or animal's body, the needle 55 may be used to fill the reservoir 14 without removing the device 10 from the patient or animal, by simply inserting the needle 55 into the septum 29, through the patient's or animal's skin.
Within the scope of the present invention, the medication delivery device 10, as well as its various components, may have many alternative shapes, arrangements and variations. For example, instead of the device 10 having an overall circular or cylindrical shape, it could have any other suitable rounded or angular shape, such as oval, square or rectangular. In addition, instead of the device 10 having a concentric arrangement in which the bulkhead 15's neck 17 is located within the reservoir 14's hole 35, the reservoir 14 may not have a hole 35, and the neck 17 may be located along side of and substantially surrounded by the reservoir 14.
All of the medication delivery device 10's components may be made from, and bonded or assembled with, any suitable, durable, stable, corrosion-resistant substances which are compatible with the medication 12; which are compatible with the intended environment in which the device 10 is intended to be used; and which are compatible with the person, animal or thing with which the 10 is intended to be used.
The manifold 13; the cover 14; and the bulkhead 15's neck 17, base 18, outlet housing 21, outlet port 23 and plug 31 may be made from any suitable material which is also relatively rigid, such as plastic, ceramic, or metal. A suitable metal may be commercially pure titanium or Ti-6Al-4V.
The reservoir 14 may be made from any suitable material which is also relatively flexible (for proper operation of its pleated inner and outer sides 37, 39), such as plastic, or metal. A suitable metal may be commercially pure titanium or Ti-6Al-4V.
In addition, if the medication delivery device 10 is to be used in a medical or veterinary context, all of the device 10's components may be made from, and bonded or assembled with, substances which are compatible with at least one suitable sterilization process, such as heat sterilization (e.g., steam autoclaving), gas sterilization (e.g., ethylene oxide), liquid sterilization (e.g., hydrogen peroxide); or radiation sterilization (e.g., gamma radiation).
Any of the medication delivery device 10's components may be assembled together in any suitable leak-proof way, with or without gaskets, such as by using any suitable mechanical fastening means. For example, the plug 31 may be connected to the neck 17 with threads, in which case the septum 29 may act as a gasket for the plug 31. Further, the flow regulator 30 may be secured within the flow regulator mounting cavity 20 by the use of an 0-ring gasket and any suitable mechanical clamping mechanism.
In addition, any of the medication delivery device 10's components may also be bonded together in any suitable leak-proof way, such as by using any suitable welding process, such as laser welding. For example, the outer edge of the manifold 13 may be welded to the bottom of the periphery of the bulkhead 15's base 18; the outlet port 23 may be welded to the bulkhead 15's outlet housing 21; the reservoir 14's inner and outer mounting flanges 41, 43 may be welded to the bulkhead 15's neck 17 and lip 45, respectively; and the cover 16's inner and outer mounting flanges 49, 51 may be welded to the bulkhead 15's neck 17 and lip 45, respectively.
Alternatively, any of the medication delivery device 10's components may also be bonded together in a leak-proof way, with or without gaskets, by using any suitable bonding materials, such as adhesives, glues and epoxies.
Alternatively, any of the medication delivery device 10's components may be bonded together in a leak-proof way with any suitable anodic bonding process. For example, the flow regulator 30 may be anodically bonded to the regulator mounting cavity 20 if the flow regulator 30's base 11 and the regulator mounting cavity 20's bottom 60 are made from, or have applied thereto in any suitable way, any suitable respective materials which may be anodically bonded together, such as silicon or titanium and 7740 Pyrex® glass made by the Corning Company of Corning, N.Y.
Alternatively, if the regulator's base 11 and the cavity's bottom 60 are not made from, or coated with, materials which may be anodically bonded directly together, then a layer of any suitable, compatible material which is anodically bondable with the regulator's base 11 and the cavity's bottom 60 may be inserted between the regulator's base 11 and the cavity's bottom 60 in any suitable way, before starting the anodic bonding process. For example, if both the regulator's base 11 and the cavity's bottom 60 were made from, or were coated with, 7740 Pyrex® glass (which will not anodically bond to itself), then the layer of suitable, compatible, anodic bonding material may be selected to be made from silicon.
It is understood that the foregoing forms of the present invention were described and/or illustrated strictly by way of non-limiting example.
In view of all of the disclosures herein, these and further modifications, adaptations and variations of the present invention will now be apparent to those skilled in the art to which it pertains, within the scope of the following claims.
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A medication delivery device having a particularly compact size. The compact size is achieved by arranging the components of the device so that the reservoir refill port is positioned laterally adjacent a bellows medication reservoir. Preferably, the medication reservoir is doughnut shaped and the refill port is positioned in a centrally located aperture.
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This is Continuation-in-part of Ser. No. 10/263,208, filed Oct. 2, 2002.
BACKGROUND OF THE INVENTION
This invention relates generally to the field of human support apparatus such as beds or chairs. More particularly, a combined position support and chair are presented which facilitate sexual intercourse.
A number of devices have been produced which are designed specifically to facilitate the act of sexual intercourse. Among these are beds, chairs, and other supports which enable the participants to engage in sexual intercourse in various positions while supporting the bodies of the participants. One such device is found in the 1999 U.S. Patent issued to Fuhrman (U.S. Pat. No. 5,875,779). Fuhrman disclosed an arcuately reciprocating human sexual fitness machine. Fuhrman has a seat for the male and a reciprocating and pivoting seat for the female which is placed about a horizontal axis to pivot toward and away from the male seat. The female seat is counterbalanced to provide a levitating effect as the seat pivots forward. Fuhrman discloses a device for facilitating sexual intercourse by moving the female's position forward towards the seated male position.
Other devices in the field have dealt with the general proposition that sexual intercourse may be facilitated by use of a support other than a conventional bed. For example, folding chairs, rim chairs, reclining platforms and other types of devices have been disclosed in the prior art. However, none of the prior art discloses a device for practicing sexual intercourse using varied positions and methods. It is an object of this invention to provide an apparatus for performing sexual intercourse using different methods and positions.
Most of the other art devices disclosed do not provide support for the female and the male both. In some positions, it is important for both the male and female to be supported during sexual intercourse. It is another object of this invention to provide a support for both the male and female during acts of sexual intercourse.
While there are many positions available for practicing sexual intercourse, the apparatus or supports for such activity are quite limited. For example, when utilizing the standard flat bed, certain positions may become uncomfortable or tiring. It would be of benefit to this particular field if a device were disclosed which can be utilized when practicing varying methods for performing the sex act. It is a still further object of this invention to provide an apparatus which may be utilized during sex while employing varying methods and positions.
It has been found that a platform upon which the non-dominant partner may rest is preferable to a simple rail and footrest system. Such a platform provides stability to the apparatus as well as the availabilty of broader support for both partners. It is a still further object of this invention to provide a platform chair for sexual intercourse which not only includes a padded section, but which also includes a platform for positioning and support of the participants' feet.
Other and further objects of this invention will become apparent upon reading the below described Specification.
BRIEF SUMMARY OF THE INVENTION
A platform chair for sexual intercourse apparatus includes front and rear legs which are attached to each other by means of cross supports and a platform. The flat platform supports the left and right sides of the chair as well as a flat, horizontal padded surface. One participant may lay in a supine position on the padded surface. The padded surface is connected to the platform support by a number of springs, usually five. Also included is a seat for the other partner as well as upper handlebars to support the dominant partner during sexual intercourse. The location of the handle bars, flat padded platform, seat and the flat horizontal supporting platform are compatable with performing acts of sexual intercourse or in participating in various forms of sexual activity while maintaining support and positioning for the participants.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of the apparatus.
FIG. 2 is a left side view of the apparatus shown in FIG. 1 .
FIG. 3 is a top plan view of the apparatus shown in FIG. 1 .
FIG. 4 is a perspective view of the platform embodiment of the sexual intercourse chair.
FIG. 5 is a side view of the platform embodiment shown in FIG. 4 .
FIG. 6 is a top view of the platform embodiment shown in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus for sexual intercourse is made of essentially tubular material and a padded platform and seat attached to the tubular frame. The apparatus, to be marketed commercially as the “DO-ME Chair”™, is shown generally in FIG. 1 .
The apparatus 1 has left 2 and right 2 ′ tubular, arcuate inverted U-shaped supporting legs, which form the frame. The left 2 and right 2 ′ arcuate legs are connected near the apex or center of the arc by a center bracket shown generally at 3 . This center bracket 3 is made up of vertical bracket leg sections 4 connected at their ends to a horizontal leg bracket section 5 . The upper portions of the vertical leg brackets 4 are connected to the arcuate supporting legs 2 and 2 ′ as shown. The frame has a head end 20 and a seat end 21 , as shown on FIG. 1 .
A non-dominant, padded, essentially horizontal support 6 is supported by the center bracket apparatus 3 . The non-dominant flat support 6 has a hip end 17 and a head end 18 , as best shown on FIG. 3 . The hip end 17 is adapted to receive the pelvic and hip area of the non-dominant sexual intercourse partner, while the head end 18 is adapted to receive the head of the non-dominant partner. This padded support 6 comprises a firm base, and is made of approximately two inches of foam rubber and a decorative cover.
The head end 18 of the non-dominant flat support 6 is also supported by a non-dominant padded support brace 7 . The opposite ends of brace 7 are connected to left 2 and right 2 ′ arcuate supporting legs near the head end 20 as best shown in FIGS. 1 and 3. The head part 18 of the non-dominant flat support 6 is connected to and supported by the non-dominant support brace 7 .
While the non-dominant flat support 6 is designed to support the non-dominant partner during sexual acts, provision is also made for the dominant sexual partner to be seated on a dominant padded seat 8 . This dominant padded seat 8 is shown in Drawing FIGS. 1 through 3. The seat 8 is padded in the preferred embodiment.
In order to facilitate the act of sexual intercourse, and other sex acts, two pairs of footrests are provided on the apparatus. Supine position foot rests 9 are located near the dominant padded seat 8 and are connected to left 2 and right 2 ′ arcuate legs, respectively, near the seat end of the device. Each footrest 9 is located such that the non-dominant sexual intercourse partner can rest her feet and part of her body weight on the footrests.
In certain other methods of sexual conduct, it is desirable to have footrests located near the center of the non-dominant flat support 6 . A pair of upright position footrests 10 are connected to the left and right supporting legs, respectively, and are located near the center of the non-dominant flat support 6 . Each of these footrests is connected, respectively, to left 2 and right 2 ′ arcuate legs as best shown in FIGS. 1 and 3.
In order to facilitate various acts of sexual conduct, an upper handrail support 11 is attached to the top of the arcuate legs 2 and 2 ′ near the center bracket 3 . This handrail support 11 is arcuate in shape. The lower ends 19 of the handrail 11 are connected to the arcuate legs 2 and 2 ′ near the center bracket 3 . The arcuate handrail 11 is connected at an oblique angle as best shown in FIG. 2 . The handrail 11 slopes upwardly from the hip part 17 of the flat support 6 towards the head part 18 of the flat support 6 .
In order to enhance the motion of the non-dominant partner on the non-dominant, flat, padded support 6 , springs 12 are provided. A plurality of springs connect the head part 18 and the hip part 17 of the flat padded support 6 to the center bracket 3 and non-dominant support brace 7 , respectively. Hip portion springs 12 and head portion springs 12 ′ connect the flat padded support 6 to the center bracket 3 and the non-dominant brace 7 , respectively, as best shown in FIGS. 1 and 2. In the preferred embodiment, a pair of springs support the head portion and a pair of springs support the hip portion, at the approximate corners of the support 6 . These vertically mounted compression springs facilitate both horizontal and vertical movement.
Each end of the left 2 and right 2 ′ arcuate-shaped legs have end caps 13 . These end caps provide better stability for the apparatus and also close off the tubular cross section of the arcuate-shaped legs.
Non-dominant flat padded support brace 7 , as best shown in FIG. 1, is connected to the left 2 and right 2 ′ arcuate legs. The non-dominant flat padded support 6 is connected to the non-dominant padded support brace 7 by a plurality of head springs 12 ′ as best shown in FIGS. 1 and 2. Since the non-dominant flat padded support 6 is now connected to the arcuate legs 2 and 2 ′ , and hence the apparatus frame only through springs, the flat support 6 can move in a variety of directions. For example, the flat support 6 can rock from head to hip, can move in the direction of the head, or in the direction of the hip, or can move from left to right as one is facing the flat support 6 . The padded support 6 may incline upwardly from hip end to head end in one embodiment.
The dominant padded seat 8 is connected to the apparatus frame. The seat 8 is connected to a vertical seat support 16 . The vertical seat support 16 is connected to the horizontal leg 5 of the center bracket 3 by an oblique seat support 15 . The dominant partner padded seat 8 is thus connected to the apparatus frame in a stationary position, whereas the non-dominant flat padded support 6 is connected to the apparatus frame by a plurality of springs. The vertical seat support 16 has the seat end cap 14 at its lower end.
The apparatus described herein is composed essentially of bent steel tubing, the compression springs, the padded support 6 and the padded seat 8 . The tubing is designed for strength, beauty and functionality and should support the weight of two adults, generally in the area of 400-500 pounds. The curved design of the device, as well as the location of the seats and footrests, provides both an esthetically pleasing apparatus as well as a functional device.
In actual use, it has been found that the use of the steel tubing and footrests is cumbersome and distracting. During the act of sexual intercourse, with only tubing and footrests, the participants must be careful not to fall from the chair and to keep their feet and legs correctly positioned on the steel tubing. This requires, at times, a high degree of concentration and physical skill; In order to enhance the enjoyment of the sexual intercourse chair, a platform 25 is added in another embodiment.
In the platform embodiment of this invention, shown particularly in FIGS. 4, 5 and 6 , the lower frame of the chair is modified. In the platform embodiment, the lower frame includes front legs 22 that have a vertical 35 and oblique 36 component as shown best in Drawing FIGS. 4 and 5. These front legs 22 are connected to rear legs 23 at point 31 . The front legs 22 may terminate at point 31 , or may form one continuous piece including the footrest brace 32 . The footrest brace 32 terminates with the supine position footrest 9 , as best shown on FIGS. 4 and 5. The front legs 22 may comprise one continuous piece, including the footrest brace 32 .
The rear legs 23 have a vertical 37 and oblique 38 section as shown in Drawing FIGS. 4 and 5. The rear legs 23 join the front legs 22 at connection point 31 . The rear legs 33 may include the upper handrail support 11 as shown. The rear legs 23 may be one continuous piece, or may comprise both the section between the floor and the connection point 31 and the handrail support extension 11 . Both the handrail support 11 and the footrest brace 32 include supporting struts 34 .
The front 22 and rear 23 legs are also connected by left 24 and right 24 ′ cross leg braces. These cross leg braces form the supporting structure for the stabilizing platform 25 .
The stabilizing platform 25 allows either the dominant or non-dominant partner a stable and broad area upon which to place feet or knees, or upon which to stand. The stabilizing platform 25 is connected to the cross leg braces 24 and 24 ′ by means of bolts 27 . Any number of bolts may be used, however four bolts for each platform-brace edge is preferred. The stabilizing platform 25 may have a number of holes 26 cut out from the body of the platform to reduce the weight of the device.
The stabilizing platform 25 may be made of lighweight metal, plywood, plastic or any other suitable material. However, the platform must be strong enough to hold 500 to 600 pounds.
The non-dominant, flat padded support 6 is attached to the stabilizing platform 25 by means of a plurality of springs 12 . Preferably, there are two springs located at the hip part 17 of the platform and padded support and two springs located near the head part 18 of the platform and padded support (see FIG. 6 ). Another spring may be located near the center of the padded support 6 .
Due to the presence of the stabilizing platform 25 , the dominant padded seat 8 may be connected to the apparatus by means of a platform seat vertical brace 28 and a platform seat horizontal brace 30 , as best shown in FIG. 5 . The vertical brace 28 is connected to the stabilizing platform 25 by means of platform-seat vertical brace bolts 29 , as best shown in FIG. 4 .
It has been found that the addition of this stabilizing platform greatly enhances the sturdiness of the apparatus. In addition, this stabilizing platform adds the dimension of mobility to the apparatus since either participant is no longer bound to stay in contact with slender rails or footrests. In the rail embodiment described initially herein, either participant could necessarily be called upon to balance precariously on a rail or footrest while still engaging in sexual intercourse. Since the physical activity may create a distraction, the addition of the stabilizing platform greatly enhances the safety and usefulness of the device.
The non-dominant flat padded support 6 is adapted to support a non-dominant partner in either a prone, sideline or side position. The footrests and platform are designed to support the feet and legs in varying positions depending on the location of the non-dominant partner's head, torso, and hips.
The springs enhance the movement efforts of the participants and are designed to support a weight of 500 pounds. The dominant partner seat provides a comfortable option for a variety of sexual positions. The handrail support 11 allows each participant to achieve a handgrip to assist in whatever motion is produced by the sexual activity and the springs in the flat padded support.
In the manufacture of the rail embodiment of this device, the left 2 and right 2 ′ arcuate legs are spaced apart a distance of approximately four feet near the hip part of the padded support 6 and approximately two feet near the head part of the padded support. Each arcuate leg rises approximately 3 feet 4 inches from the floor. The platform embodiment has similar dimensions.
The non-dominant padded support 6 slants slightly upwardly from the hip part to the head part, with a slope of approximately 2 inches.
The padded support 6 and padded seat 8 are fabricated from foam rubber material and may be sprayed with a rubberized outer coating for comfort and durability. Supine position footrests 9 function as footrests when the non-dominant partner is laying in a supine position on the flat, padded support 6 . The upright position footrests 10 function as footrests when the non-dominant partner assumes a more upright sitting position on the flat padded support 6 . Alternatley, the platform 25 provides support for either participant in variou positions.
The tubular members are fabricated, in the preferred embodiment, from 1¼ inches, 11 gauge metal tubing. The tubular members may be attached in any efficient and convenient manner, such as welds, bolts, or other attaching means.
Even individuals with limited strength or mobility will benefit from the use of the instant invention. For example, the chair of the instant invention does not require that the non-dominant partner in the supine position bear the full weight of the dominant partner in the seated position. The compression spring-mounted flat padded support 6 insures that movement is achieved with minimal input of energy from either of the participants.
It is to be understood that one of the important features of the invention is to provide both a flat padded support for the non-dominant partner and a padded seat for the dominant partner. Another important feature of the invention includes the compression springs which connect the flat padded support 6 to the center bracket 3 and the non-dominant brace 7 or to the platform. Another important feature of this invention includes the spatial orientation of the flat padded support 6 , the padded seat 8 , the handrail support 11 and the footrests or platform.
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A platform chair for sexual intercourse includes front and rear legs connected to each other by cross braces. A horizontal flat supporting platform connects the legs and cross braces. The platform supports a cushioned surface. The cushioned surface is connected to the horizontal platform by a number of springs, usually five. The cushioned surface slopes from the upper head to the lower hip sections. In front and below the hip section of the cushion is a padded seat. The seat is used by the dominant partner and is located between the legs. A handrail is also located above the flat padded support such that it is within easy reach of either participant. Supine footrests are located in front of the hip portion of the cushion and above the seat for use when the non-dominant partner is in a supine position. A flat solid platform is located beneath the cushion such that either the dominant or non-dominant participant can support themselves, their feet, or other parts of their body for use in other sexual intercourse positions. The flat cushioned support is connected to the platform by the springs such that the participants, with minimal efforts, can achieve a rocking, lateral or forward motion.
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[0001] This Nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 10-2005-0014759 filed in Korea on Mar. 2, 2005, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a refrigerator, and more particularly, to a bottom freezer type refrigerator and container moving system, in which a container of a freezing chamber can be automatically moving along a horizontal or vertical direction.
[0004] 2. Description of the Related Art
[0005] Refrigerators can be classified into several types depending on the locations of a freezing chamber and a chilling chamber. For example, a top mount refrigerator includes a freezing chamber and a chilling chamber that are partitioned up and down, a side-by-side refrigerator includes a freezing chamber and a chilling chamber that are partitioned left and right, and a bottom freezer refrigerator includes a freezing chamber and a chilling chamber that are partitioned down and up.
[0006] Although the bottom freezer refrigerator is illustrated to describe the present invention, the present invention is not limited to this particular type of refrigerator.
[0007] The bottom freezer refrigerator includes a chilling chamber door and a freezing chamber door. Although the chilling chamber door is a hinged door like other types of refrigerators, the freezing chamber door is a drawer type door because the freezing chamber is relatively small and located at a lower portion of the refrigerator.
[0008] Therefore, what is needed is a simple, easy, and convenient way to stow and remove food in the freezing chamber.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention is directed to a refrigerator and refrigerator container moving system that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0010] An object of the present invention is to provide a refrigerator and refrigerator container moving system that gives a more convenient way of putting food in the refrigerator and taking food out of the refrigerator.
[0011] Another object of the present invention is to provide a refrigerator and refrigerator container moving system that has a simple and effective power supply unit for moving a container along a horizontal or vertical direction.
[0012] A further another object of the present invention is to provide a refrigerator and refrigerator container moving system that gives a convenient way of handling a container installed in a drawer type door.
[0013] 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.
[0014] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided a refrigerator including: a main body including at least one chamber; a container disposed in the chamber, the container being movable along a first direction and along a second direction; a door located on the main body, the container being moveable along the first direction by moving the door along the first direction; a motor, the container being movable along the second direction by the motor; and a battery electrically connected to the motor to supply power to the motor.
[0015] In another aspect of the present invention, there is provided a refrigerator including: a main body including a chamber; a door for opening and closing the chamber; a container supporter located on a side of the door facing the chamber; a rotary arm connected to the container supporter, the container supporter being movable along a first direction by rotating the rotary arm; a motor for driving the rotary arm; and a power supply unit to supply power to the motor when the door is open.
[0016] In a further another aspect of the present invention, there is provided a container moving system for a refrigerator with a door, the system including: a container supporter located on a side of the door; a container seated on the container supporter; a power supply unit, the power supply unit being chargeable when the door is closed; and a motor located on the side of the door to move the container supporter along a first direction.
[0017] According to the present invention, food can be more conveniently put in and taken out of the refrigerator.
[0018] Further, the power requiring for moving the container can be supplied in a simple, reliable, and convenient way. Therefore, the refrigerator can have an improved outer appearance and it can be conveniently used.
[0019] 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
[0020] 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:
[0021] FIG. 1 is a perspective view of a refrigerator equipped with a container moving system according to an embodiment of the present invention;
[0022] FIG. 2 is a sectional view taken along line I-I′ in FIG. 1 ;
[0023] FIG. 3 shows a container that is lifted from a position depicted in FIG. 2 ;
[0024] FIG. 4 is a rear perspective view of a door according to an embodiment of the present invention;
[0025] FIG. 5 is a rear view of a door according to an embodiment of the present invention; and
[0026] FIG. 6 is a block diagram of a container moving system for a refrigerator according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. FIG. 1 is a perspective view of a refrigerator equipped with a container moving system according to an embodiment of the present invention. Referring to FIG. 1 , a refrigerator 1 is a bottom freezer type refrigerator that includes a freezing chamber at a lower portion and a freezing chamber door capable of sliding along a horizontal direction, e.g., the forward and backward directions.
[0028] In detail, the refrigerator 1 includes a main body 2 , first doors 5 , a second door 6 , a slider 10 , a first chamber (refer to the reference numeral 3 in FIG. 2 ), a second chamber (refer to the reference numeral 4 in FIG. 2 ), drawers 8 , a container supporter 55 , and a power supply terminal 32 . The first doors 5 are hinged on a front upper portion of the main body 2 to open and close the first chamber 3 . The second door 6 is slidably installed at a front lower portion of the main body 2 to open and close the second chamber 4 . The slider 10 is connected between the main body 2 and the second door 6 to enable the sliding of the second door 6 in forward and backward directions. The drawers 8 are formed under the first chamber 3 to store food. The power terminal 32 is formed above or between the drawers 8 to supply power to a container moving system (as will be described later) for lifting the container supporter 55 .
[0029] Further, the refrigerator 1 includes a control panel such as control switch buttons 7 at a front side of the second door 6 and a container 62 behind the second door 6 . The control switch buttons 7 are formed at a front side of the second door 6 for controlling the operation of the second door 6 . The container 62 is supported by the container supporter 55 to store food. The container 62 can be vertically lifted by lifting the container supporter 55 . That is, the container 62 may be lifted up for an easy access to food in the container 62 , and it may be lowered down to open and close the second door 6 .
[0030] The lifting and lowering of the container 62 will now be described with reference to accompanying drawings. FIG. 2 is a sectional view taken along line I-I′ in FIG. 1 , and FIG. 3 shows a container that is lifted from a position depicted in FIG. 2 . Referring to FIGS. 2 and 3 , a container moving system in the illustrate embodiment includes an actuating unit 40 , a vertical guide unit 20 , and a power supply unit 30 . The actuating unit 40 lifts up and lowers down the container supporter 55 along a rear wall of the second door 6 . The vertical guide unit 20 guides the lifting and lowering of the container supporter 55 . The power supply unit 30 supplies power to the actuating unit 40 . It should be noted that in the illustrated embodiment the container moving system moves the container supporter 55 along the vertical direction. However, the present invention can also be applied to move the container supporter along the horizontal or other directions.
[0031] The refrigerator 1 further includes a compartment wall 61 between the first chamber 3 and the second chamber 4 . The drawers 8 are placed under the compartment wall 61 to provide storages at a constant temperature. That is, food and other substances requiring a constant temperature condition can be kept in the drawers 8 .
[0032] When the second door 6 is extended outward, the slider 10 stably guides the second door 6 . After the second door is fully extended, the actuating unit 40 operates to lift up the container supporter 55 . Accordingly, the lifting of the container supporter 55 is stably guided by the vertical guide unit 20 . The power supply unit 30 controls power supply to the actuating unit 40 .
[0033] The slider 10 includes a pair of horizontal rails 11 . An inner rail is mounted on an inner side of the main body 2 and an outer rail is mounted on an outer side of the second door 6 . The inner rail and the outer rail are slidably engaged with each other such that the outer rail can be slid in and out when the second door 6 is closed and open.
[0034] The vertical guide unit 20 is provided to guide the container supporter 55 when the container supporter 55 is lifted up and lowered down. The vertical guide unit 20 includes a vertical rail 21 fixed to the rear surface of the second door 6 . The vertical rail 21 defines a groove (refer to the reference numeral 22 in FIG. 4 ) running its length to receive a protrusion formed on a corresponding side of the container supporter 55 , such that the lifting and lowering of the container supporter 55 can be exactly guided by the vertical rail 21 .
[0035] To lift the container supporter 55 , the actuating unit 40 includes an arm support 57 fixed to the rear surface of the second door 6 , an rotary arm 47 hinged on the arm support 57 and extended toward the inside of the refrigerator 1 , a free end 56 of the rotary arm 47 , and a roller 48 rotatably fixed to the free end 56 to make contact with the container supporter 55 at a bottom of the container supporter 55 . The actuating unit 40 further includes a motor (refer to the reference numeral 41 in FIG. 4 ) to rotate the rotary arm. The actuating unit 40 will be further described later.
[0036] The power supply unit 30 includes a battery 33 connected to the motor 41 to supply power to the motor 41 . The battery can be located at any place, e.g., within the door 6 as shown in FIG. 3 , on the rear side of the door 6 as shown in FIG. 4 , or on/within the main body 2 with a wiring connection to the motor 41 . The charging terminal 31 is connected to the batter 33 via a wire connection, and the charging terminal 31 comes into contact with the power terminal 32 formed on the main body 2 when the second door 6 is closed.
[0037] The lifting of the container 62 will now be described more fully. First, when a user presses a lift-up button of the control switch buttons 7 after the second door 6 is fully open, the battery 33 supplies power to the motor 41 . The battery can be recharged when the second door 6 is closed and the charging terminal 31 and the power terminal 32 are connected.
[0038] When the power is on, the motor 41 rotates the rotary arm 47 about the arm support 57 in an upward direction. Thus, the roller 48 as it turns pushes the container supporter 55 upward to lift up the container 62 .
[0039] The relationship between the rotary arm 47 and the container supporter 55 can be clearly understood with reference to FIGS. 2 and 3 , which respectively show the container 62 before and after the lifting.
[0040] The power supply unit 30 is provided with the battery 33 . When the second door 6 is closed, the battery 33 is charged by receiving power from the main body 2 through the power terminal 32 and the charging terminal 31 . Therefore, the battery 33 can supply power to the motor 41 when the two terminals 32 and 31 are disconnected because of the opening of the second door 6 .
[0041] That is, since the power supply unit 30 is provided with the rechargeable battery 33 , in this illustrated embodiment, an additional wire connection is not required between the main body 2 and the second door 6 to supply power to the motor 41 when the second door 6 is open. Therefore, the container moving system can be simply constructed and conveniently used.
[0042] FIG. 4 is a rear perspective view of the second door 6 according to an embodiment of the present invention, and FIG. 5 is a rear view of the second door 6 according to an embodiment of the present invention. An operation of the refrigerator with the container moving system will now be more fully described with reference to FIGS. 4 and 5 .
[0043] The actuating unit 40 includes the motor 41 installed on the rear surface of the second door 6 , a motor shaft 42 coupled with a rotor of the motor 41 , a driving gear 43 connected to the motor shaft 42 , a driven gear 44 engaged with the driving gear 43 , an arm shaft 46 coupled to a center of the driven gear 44 , and the rotary arm 47 fixed to an end of the arm shaft 46 . A gear support 45 is fixed to the rear surface of the second door 6 to support the driving gear 43 and the driven gear 44 .
[0044] In the illustrate embodiment, there are two rotary arm 47 that are respectively coupled to both ends of the arm shaft 46 . Therefore, the container supporter 55 can be supported at both sides by the rotary arms 47 and thus it can be stably lifted.
[0045] The gear support 45 includes an arm stopping structure such as a first arm stopper 49 and a second arm stopper 50 that are projected from a surface of the gear support 45 to restrict the rotation of the rotary arm 47 to a predetermined angle range. That is, the container supporter 55 can be limited between the non-lifted and lifted positions. For example, even when the motor 41 is not properly controlled, the arm stoppers 49 and 50 can prevent the rotary arm from over-rotation.
[0046] Another stopping structure can be formed on the vertical rail 21 to stop the container supporter 55 . That is, the upper and lower stoppers 51 and 52 may be formed on the upper and lower ends of the vertical rail 21 in order to further limit the container supporter 55 between the non-lifted and lifted positions. Therefore, the container moving system can be more reliably operated.
[0047] A sensing unit is provided to detect the up and down motions of the container supporter 55 . For example, the upper and lower sensors 53 and 54 are respectively installed on the upper and lower ends of the vertical rail 21 to detect the lifting and lowering of the container supporter 55 . Both of the contact type sensor and the optical type sensor can be used for the upper and lower sensors 53 and 54 . Based on the detection of the upper and lower sensors 53 and 54 , the power supply to the motor 41 may be controlled.
[0048] Operational steps of the container moving system will now be described in detail. When the second door 6 is closed, the power terminal 32 and the charging terminal 31 come into contact with each other so that the battery 33 can be charged. When a user presses a lift-up button of the control switch buttons 7 after the second door 6 is open, the battery 33 supplies power to the motor 41 to drive it. Driving force is transmitted from the motor shaft 42 to the rotary arm 47 through the driving gear 43 , the driven gear 44 , and the arm shaft 46 . Upon the rotation of the rotary arm 47 , the roller 48 on the free end 56 of the rotary arm 47 pushes up the container supporter 55 .
[0049] When the container supporter 55 is completely lifted up, the upper sensor 53 detects the container supporter 55 . In response to the detection of the container supporter 55 by the upper sensor 53 , the motor 41 is powered off to stop rotating the rotary arm 47 and lifting the container supporter 55 . Further, when the container supporter 55 is completely lifted up, the container supporter 55 is prevented from being further lifted up by the physical structure of the upper stopper 51 and/or the first arm stopper 49 . Therefore, even if the upper sensor 53 failed to detect the completely lifted container supporter 55 , the container supporter 55 would be prevented from being over-lifted. This increases the reliability of the actuating unit 40 .
[0050] The container supporter 55 is lowered down in the same way as it is lifted up. Merely, the motor is rotated in the reverse direction.
[0051] FIG. 6 is a block diagram of a container moving system for a refrigerator according to an embodiment of the present invention. Referring to FIG. 6 , a container moving system of the illustrated embodiment includes: a lift-up sensing unit 71 to detect the container 62 when it is completely lifted up; a lowered-down sensing unit 72 to detect the container 62 when it is completely lowered down; a control panel 73 to receive inputs from a user; a controlling unit 70 to output control signals according to signals from the lift-up sensing unit 71 , the lowered-down sensing unit 72 , and the control panel 73 ; an arm driving motor 74 capable of operating under the control of the controlling unit 70 ; and a power source 75 to supply power to the arm driving motor 74 .
[0052] The control panel may be the control switch buttons 7 that are formed on the front surface of the second door 6 . The lift-up sensing unit 71 and the lowered-down sensing unit 72 may be respectively the upper sensor 53 and the lower sensor 54 that are installed on the upper and lower ends of the vertical rail 21 . The power source 75 may include the battery 33 to supply power to the arm driving motor 74 .
[0053] The lift-up operation of the container moving system is as follows: a lift-up button of the control panel 73 is pressed; the arm driving motor 74 is operated to lift up the container supporter 55 ; the lift-up sensing unit 71 detects the container supporter unit 55 when the container supporter 55 is completely lifted up; and the arm driving motor 74 stops. The lowered-down operation of the container moving system is carried out in a similar way.
[0054] As described above, the container is automatically lifted up and lowered down by the container moving system such that users can use the container more easily and conveniently.
[0055] Further, the power source (e.g., the battery) is charged when the door is closed and it supplies power to the motor when the door is open, such that an additional power supply unit or a lead wire is not required to supply power to the motor.
[0056] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. 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 refrigerator and a container moving system for a refrigerator are provided. The refrigerator includes a main body including at least one chamber; a container disposed in the chamber, the container being movable along a first direction and along a second direction; a door located on the main body, the container being moveable along the first direction by moving the door along the first direction; a motor, the container being movable along the second direction by the motor; and a battery electrically connected to the motor to supply power to the motor.
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BACKGROUND OF THE INVENTION
Various forms of building blocks heretofore have been provided with interlocking projections and recesses. However, most of these previously known forms of building blocks include mating projections and recesses which may be used to interlock only adjacent staggered courses of blocks and which are not operative to interlock stacked tiers of blocks while a quantity thereof are being stored or shipped in a compact state.
Examples of various different forms of building blocks including some of the general structural and operational features of this instant invention are disclosed in U.S. Pat. Nos. 86,961, 253,416, 779,613, 1,833,875, 2,062,851, 2,474,186 and 3,382,632.
BRIEF DESCRIPTION OF THE INVENTION
The building block of the instant invention includes projections and recesses which enable longitudinally staggered adjacent courses of blocks to be interlockingly engaged with each other and yet which further allow vertical tiers of stacked blocks to be interlocking engaged relative to each other for compact storage and shipment.
The building block additionally is constructed in a manner including internal reinforcing whereby vertical loads may be transferred directly through the vertical reinforcing in a wall of stacked staggered courses of blocks and the reinforcing may also be tubular whereby heating and cooling fluids may be circulated through a wall constructed of the blocks. Further, some forms of block reinforcing may also be utilized to reinforce cementitious filler material poured into the block cavities and the interfitting projections and recesses of the blocks may be dimensioned to provide a desired thickness layer mortar between adjacent block surfaces.
The main object of this invention is to provide a universally usable building block which may be compactly stored and shipped with vertically adjacent blocks interlockingly engaged with each other and yet which may be erected in a wall of longitudinally staggered adjacent courses of blocks in a manner such that the blocks of adjacent courses are interlocked with each other.
Another object of this invention is to provide an improved building block construction including internal reinforcing.
A further object of this invention, in accordance with the immediately preceding object, is to provide a building block including internal reinforcing which may function to transfer vertical loads placed upon a wall of the blocks directly therethrough by the internal block reinforcing.
Still another object of this invention is to provide a building block including internal reinforcing which may be used to define heating or cooling fluent passages formed in a wall constructed of the blocks.
A further important object of this invention is to provide a building block and a companion header block constructed in a manner whereby the header block and building block may be interfittingly engaged with each other.
A still further object of this invention is to provide a building block whose coacting projections and recesses may be dimensioned to define mortar joints between opposing surfaces of adjacent blocks to be of a predetermined thickness.
A final object of this invention to be specifically enumerated herein is to provide an improved building block in accordance with the preceding objects and which will conform to conventional forms of manufacture, be of simple construction and easy to use so as to provide a device that will be economically feasible, long lasting and relatively trouble free in operation.
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 a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a wall construction utilizing interfittingly engageable blocks constructed in accordance with the present invention;
FIG. 2 is a fragmentary enlarged elevational view of the wall illustrated in FIG. 1 with portions of two of the blocks of the wall being broken away and illustrated in vertical section;
FIG. 3 is a fragmentary vertical sectional view taken substantially upon the plane indicated by the section line 3--3 of FIG. 2;
FIG. 4 is an enlarged top plan view of a block constructed in accordance with the present invention;
FIG. 5 is a fragmentary elevational view illustrating the manner in which tiers of vertically spaced blocks constructed in accordance with the present invention may be interlockingly engaged with each other;
FIGS. 6, 7 and 8 comprise fragmentary vertical sectional views of blocks including projections of slightly different configurations;
FIGS. 9 and 10 are fragmentary vertical sectional view illustrating different forms of upper bearing plate equipped vertical reinforcing rods which may be used in the block;
FIG. 11 is a top plan view of a modified form of building block including cavity seals for sealing cavities between adjacent courses of blocks and wherein the internal reinforcing of the block may comprising tubular members;
FIG. 12 is an elevational view of the block illustrated in FIG. 11 with portions thereof being broken away and illustrated in vertical section;
FIG. 13 is a fragmentary enlarged vertical sectional view illustrating the mann in which blocks inclusive of the structure illustrated in FIGS. 10 and 12 may be interfitted relative to each other;
FIG. 14 is an enlarged vertical sectional view taken substantially upon the plane indicated by the section line 14--14 of FIG. 13;
FIG. 15 is a fragmentary top plan view of the corner portion of the lower block illustrated in FIG. 14 and with the face seal illustrated in FIGS. 11 and 12 removed;
FIG. 16 is a top plan view of a modified form of building block including internal reinforcing which may also serve to reinforce cementitious filler placed in the block cavities and further including block end openings through which cementitious filler in end adjacent blocks may bridge between the interiors of the attendant adjacent blocks;
FIG. 17 is a right side elevational view of the block illustrated in FIG. 16;
FIG. 18 is a respective view of a header or lintel block which may be used in conjunction with the blocks illustrated in FIGS. 1-17;
FIG. 19 is an enlarged transverse vertical sectional view taken substantially upon the plane indicated by the section line 19--19 in FIG. 18; and
FIG. 20 is a fragmentary enlarged top plan view of the lintel block illustrated in FIGS. 18 and 19.
DETAILED DESCRIPTION OF THE INVENTION
Referring now more specifically to FIGS. 1-5 of the drawings, there may be seen a building block referred to in general by the reference numeral 10. The building block 10 may be formed as a cinder block or as a concrete block, or the block 10 may be constructed of other materials including glass and plastic. The block 10 includes top and bottom faces 12 and 14, front and rear surfaces 16 and 18 and opposite end surfaces 20 and 22. The top and bottom faces are generally parallel as are the front and rear surfaces 16 and 18 and the opposite end surfaces 20 and 22. The central portion of the rear marginal edge of the top face 12 includes an upwardly opening recess 24 formed therein which also opens rearwardly through the rear surface 18 and the opposite ends of the front marginal edge of the top face 12 includes a pair of corner recesses 26 formed therein which also open horizontally outwardly of the front face 16 and the opposite end surfaces 20 and 22.
It will also be noted that the forward marginal portion of the bottom face 14 includes opposite end downward corner projections 28 and that the central portion of the rear surface 18 includes a downward central section 30.
When a plurality of blocks 10 are stacked in vertically registered positions with the front surfaces 16 thereof facing in the same direction, the downward corner and central projections 28 and 30 of each upper block 10 are received in the recesses 26 and 14, respectively, of the next lower block 10. In this manner, vertically stacked blocks 10 are keyed together for compact storage and shipment in the manner illustrated in FIG. 5 of the drawings. However, when the blocks 10 are to be used in the construction of a wall such as the wall referred to in general by the reference numeral 34 in FIG. 1, the blocks 10 in adjacent horizontal courses of blocks 10 are reversed front to rear relative to each other.
At this point, it is pointed out that the recesses 24 are of substantially twice the plan area of the recesses 26 and, accordingly, while the corner projections 28 and projections 30 are received in the recesses 26 and 24 when the blocks 10 are vertically stacked in full registered positions, when the blocks 10 of vertically adjacent courses of blocks are reversed front to rear relative to each other and relatively staggered in the manner illustrated in FIG. 1 of the drawings, each corner projection 28 of an upper block is received in one-half of the recesses 24 of adjacent blocks disposed therebelow and each projection 30 is received in the pair of corner recesses 26 disposed therebelow. In this manner, the blocks 10 of vertically adjacent courses of blocks may also be interfitted relative to each other when the blocks of vertically adjacent courses of longitudinally staggered blocks are reversed relative to each other in front to rear relation.
With attention again invited to FIGS. 1-5 and more particularly to FIGS. 2, 3 and 4, each front corner portion of each block 10 includes a vertically extending reinforcing member 36 embedded therein and extending vertically therethrough with the upper end of each reinforcing member 36 being generally centered in the corresponding recess 26 and terminating upwardly flush with the bottom of the corresponding recess 26. The lower ends of the reinforcing members 36 may extend, for example, approximately 1/16 of an inch below the lower extremity of the corresponding corner projection 28 so that a small mortar space of substantially 1/16 of an inch will be defined between the top face 12 of a lower block 10 and the bottom face 14 of an upper block 10. Also, the extent of the projections 28 lengthwise of the blocks 10 is slightly less than one-half the extent of the recesses 24 longitudinally of the blocks 10, whereby the spacing between end opposing blocks 10 will also be approximately 1/16 of an inch. In this manner, a very thin mortar joint may be used.
If it is desired, however, the lower ends of the reinforcing members 36 may terminate flush with the lower ends of the corner projections 28.
The vertical midportions of the reinforcing members 36 are joined by a forward mid-heihgt reinforcing member 38 extending and secured therebetween and the rear longitudinal midportion of the block 10 includes a pair of slightly laterally spaced apart reinforcing members 40. The reinforcing members 40 terminate upwardly flush with the lower extremities of the recesses 24 and the lower ends of the reinforcing members 40 may project downwardly below the lower ends of the projections 30 by approximately 1/16 of an inch. Accordingly, the 1/16 inch mortar joint between all opposing surfaces of adjacent blocks is maintained.
Blocks 10 may have a pair of vertically extending openings or voids 42 formed therein and if it is desired, vertically adjacent blocks 10 may be separated by thin mortar joints 44 which do not include portions thereof disposed between the lower ends of the projections 28 and 30 and the lower extremities of the recesses 24 and 26, see FIG. 6. In addition, the projections 28 as well as th projections 30 may be bevelled in the manner indicated as at 28' in FIG. 8 or otherwise bevelled in the manner indicated by the reference numeral 28" in FIG. 8. Still further, FIG. 8 also illustrates the manner in which the recesses 26 and 24 may be bevelled as indicated at 26" in FIG. 8.
The reinforcing members 40 of the block 10 are connected to the central portion of the reinforcing member 38 by front to rear extending reinforcing members 46 extending and secured between the reinforcing members 40 and the reinforcing member 38 and in this manner the central web 50 of the block 10 as well as the front wall thereof is adequately reinforced.
As may be seen from FIG. 9, the upper ends of each vertical reinforcing member 36 may be provided with a plate 52 secured thereto in any convenient manner such as welding and recessed within that portion of block 10 defining the lower extremity of the corresponding recess 26. In addition, the upper ends of the reinforcing rods 40 may be equipped with similar plates.
A further modification of the block 10 is illustrated in FIG. 10 of the drawings in which the lower end of the reinforcing member 36 projects downwardly below the bottom face 14 and is not embedded within a projection such as the projection 28. Rather, the lower terminal end 36' of the reinforcing member 36 which projects below the bottom face 14 may be weakened by any suitable means at the plane of the bottom face 14 in order that the lower terminal end 36' may be laterally deflected and broken from the remaining upper portion of the reinforcing member 36, if desired.
With attention now invited more specifically to FIGS. 11 through 15 of the drawings, a modified form of building block is referred to in general by the reference numeral 10'. The block 10' is substantially identical to the block 10, except that the vertical openings or voids 42' formed therein are of a slightly different shape and the top face 12' of the block 10' includes open frame resilient seals 56 supported therefrom whereby the upper and lower ends of the openings or voids 42 of adjacent blocks may be sealed relative to each other. In addition, instead of utilizing solid reinforcing members which is the reinforcing members 36, 38, 40 and 46, the block 10' includes tubular reinforcing members 36', 38', 40' and 46' which are communicated with each other. The upper ends of the tubular reinforcing members 36' include bell ends 49 which open upwardly into the corresponding recess 26' corresponding to the recesses 26 and the lower ends of the tubular reinforcing members 36' define spigot ends 37 which are downwardly receivable in a fluid tight manner within the bell ends, see FIG. 4 wherein it may be seen that the bell ends are provided with sealing washers 41 for engagement with the opposing spigot ends and the bell ends 39 further include mid-height circumferentially extending ribs 43 for tightly frictionally engaging the corresponding spigot ends 37. The bell ends 39 may open upwardly through plates 52' corresponding to the plates 52 and the spigot ends 38 may open downwardly through plates 53 carried thereby and abutted against the lower ends of the projections 28' corresponding to the projections 28. Of course, the upper and lower ends of the tubular reinforcing members 40' are formed in the same manner.
With attention invited more speifically to FIGS. 16 and 17 of the drawings, there will be seen a third form of building block referred to in general by the reference numeral 10". The building block 10" includes projections and recesses corresponding to the projections 28, 30 and recesses 24, 26 and reinforcing members 38" and 46" corresponding to the reinforcing members 38 and 46. However, the reinforcing members 38" include front to rear extending cross pieces 60 projecting forwardly through the front surface 16" in the form of upwardly opening hooks and projecting horizontally rearwardly through the front wall of the block 10" and terminating rearwardly adjacent the centers of the corresponding vertically extending block openings or cavities. In this manner, the openings or cavities may be filled with cementitious material or the like and such cementitious material may be reinforced by the rearwardly projecting portions of the cross pieces 60. In addition, the reinforcing members 46" include a cross piece 62 extending longitudinally of the block 10" and which project into the vertically extending openings or cavities of the block 10' and whose opposite ends may also be embedded in cementitious material used to fill the openings or voids. Further, the end walls 64 of the block 10" may have mid-height openings 66 formed therethrough whose inner ends open into the corresponding vertical openings or cavities and which thereby enable a cylindrical rod of cementitious material to connect cementitious filler portions disposed in the vertical openings or cavities in adjacent block ends.
With attention now invited more specifically to FIGS. 18, 19 and 20, an upper lintel block or header is referred to in general by the reference numeral 70. The header 70 is in the form of an upwardly opening U-shaped channel member and opposite longitudinal sides of the undersurface of the lintel block 70 include longitudinally staggered downward projections 71 which are receivable in the recesses 24 and 26 of blocks disposed immediately therebeneath. The lintel block 70 includes central longitudinally extending reinforcing members 72 which may be embedded in cementitious material used to fill the interiors of the channel-shaped lintel blocks 70 and the latter additionally include opposite side longitudinally extending reinforcing members 74 extending between adjacent upright reinforcing members 76 which project upwardly through the projections 71 and have lateral integral arm portions 78 from which the corresponding reinforcing members 72 are supported. Accordingly, it may be seen that the lintel block 70 may be supported atop the uppermost course of blocks 10. Also, it is to be noted that the lower ends of the reinforcing members 76 may project slightly below the lower ends of the corresponding projections 71.
When the tubular reinforcing members illustrated in FIGS. 10-15 are used, heating or cooling liquids may be circulated through these tubular reinforcing members, as desired, to heat or cool the associated wall. It is also to be noted that the various vertical reinforcing members act to transfer a vertical loading on the upper portion of the wall 34 directly downwardly therethrough to the footing of the wall. In this manner, the wall 34 includes considerably greater load bearing capacity than a similar wall constructed without the utilization of vertically extending reinforcing members embedded in the individual blocks of the wall.
The amount the vertical reinforcing members project downwardly from corresponding projections determines the vertical thickness of the mortar joints between adjacent horizontal courses of blocks 10. In addition, the longitudinal extent of the projections 28 longitudinally of the blocks 10 determines the mortar joint spacing between adjacent block ends.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A building block, of generally the same overall shape as a concrete or cinder block, is provided and includes upper and lower recesses and projections which interlock the blocks in tiers of blocks for compact storage and shipment and which enable the blocks of adjacent courses of blocks to be interlocked with each other during construction of a wall. In addition, the blocks include reinforcing members embedded therein for transferring vertical loads through vertically stacked courses of blocks and some forms of reinforcing enable cementitious material poured into the cavities of the block to be reinforced. One form of reinforcing is tubular and includes bell and spigot ends which may be sealingly engaged with each other and used to allow heating or cooling fluids to flow through the blocks.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/798,012 filed Mar. 15, 2013, which application is incorporated by reference.
TECHNICAL FIELD
The present invention relates generally to chain control devices for roller shades, curtains or blinds or the like, and more specifically to a chain control device that minimizes jamming and chain disengagement and also prompts a user to move the chain in a direction to effect a desired movement of shades or curtains and within a desired chain tension range.
BACKGROUND OF THE INVENTION
Chain operating systems for window blinds are known in the art. They generally include a sprocket or drive wheel for driving a driven blind member such as a drive shaft, a ball chain operatively engaging the sprocket wheel, a cover on the sprocket wheel and a chain stopper on the ball chain. In these systems, the sprocket wheel is drivingly connected to a driven member of a blind. For example, the blind may be a roller blind or a vertical venetian blind. A sprocket wheel can also drive other blinds, such as a horizontal venetian blind or a roman shade. The driven member can be a conventional drive shaft of a roller blind, a central control shaft of a roman shade, a lift or tilt shaft of a horizontal venetian blind or a traverse or tilt shaft of a vertical venetian blind, or the like.
The ball chain, in such systems, comprises a plurality of spaced apart balls. The ball chain is looped over the sprocket wheel to operatively engage it, so that first and second depending portions of the ball chain are on either side of the sprocket wheel. By pulling one of the depending portions of the ball chain, the sprocket wheel is rotated in either a clockwise or counter-clockwise direction, and the driven shaft also is rotated. This results in a roller blind being rolled up or unrolled, a venetian blind being tilted or lifted or lowered, a vertical venetian blind being traversed or tilted or a roman shade being lifted or towered.
The sprocket wheel, in such systems, is typically hidden with a cover. The cover generally is over at least the part of the sprocket wheel where the ball chain is looped over it, but open top covers are also known (e.g., U.S. Pat. No. 2,577,046). The cover is open at the bottom for passage of the opposite depending portions of the ball chain. The cover acts as a guiding means to guide the ball chain into engagement with the sprocket wheel and prevent the ball chain from disengaging from the sprocket wheel.
In such systems, ball chains have been provided with one or more separate members which act as chain stoppers. The stoppers are adapted to block movement of the ball chains into the mechanism, thus stopping the rotation of the sprocket wheels and operating movement of the blinds. They have also been used to prevent ball chain from being pulled further than necessary for performing desired operating movements of the blinds, for example, for preventing farther than a maximum tilt of a venetian blind or preventing a roller blind from being rolled-up too far whereby its bottom would collide against its roller or its housing.
The chain stoppers are often larger than the cross-section of the balls or entrance into the clutch covers. These stoppers thus block the ball chains at the bottom of the sprocket covers and prevent the ball chains from being further pulled over their sprocket wheels.
Beaded (ball) chains or cords are thus utilized in roller shades, curtains and blinds for opening or closing the roller shades, curtains or blinds in a horizontal or vertical direction. Existing beaded chains utilize a continuous headed chain in which all of the beads are of uniform size except one or two stopper beads which are of larger size. Such beaded chains introduce a purely “by chance” event when rotating the chains as there is no way for an operator to know which chain direction is going to produce the desired result. In some situations, a person desiring to open the roller shade, curtains or blinds will pull on a side of a chain/cord only to jam or disengage from the clutch mechanism. For example, excessive forces applied to the ball chain can cause the larger chain stopper to crash into the clutch housing and disengage the ball chain or cause other damage to components of the clutch.
In addition to frustrating the operator, pulling the beaded chain in the undesired direction introduces unnecessary wear and tear on the mechanisms of the roller shades, curtain or blinds. For example, if a roller shade is fully opened, a hard tug on the chain stresses the chain because the roller shade does not move in response to the downward pulling force. A strong tug on the chain when the roller shade is at full extension, either opened or closed, has the potential of snapping the chain, damaging the housing or clutch, or worse, pulling an entire assembly off of a wall. Similarly, a tug on the incorrect side of the beaded chain, will cause the beaded chain or the gearing to slip which, over an extended time, will degrade the rotational mechanisms of the blinds.
A beaded chain of the prior art does not provide an operator with the opportunity to learn which chain side to pull because the beaded chain tends to hang in such a manner that the sides of the chain are indistinguishable. For example, the chain sides often are touching or are wound around each other, and may not be in predictable locations, e.g. to the front or to the back, due to interference with the blinds, furniture, or the window sill. Further, the typical operator does not have the patience to scrutinize the chain and sprocket (not shown) to determine which side to pull.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages and shortcomings of the prior art by providing a control device which limits chain stopper collisions with the clutch housing or cover. The present invention provides a device which limits the transfer of forces to the clutch housing, such as resulting from excessive pulling of the chain. Instead, the device redirects forces applied through the chain, particularly through the chain stopper, to a location remote from the housing and clutch assembly.
A device of the present invention provides a user with an indication of desired chain movement wherein chain movement is limited in one direction upon stopper contact with the device. A chain control device enables a user to manipulate roller shades in a desired manner while limiting threes applied by the chain to the clutch mechanism.
It is another advantage to provide a chain control device that prevents wear and tear on the clutch or drive mechanisms by tactilely prompting a user to pull the correct side of the chain or cord to effect a desired movement of the shade. The chain control device of the exemplary embodiment utilizes a spring sized to provide a tactile differentiation as the spring is compressed.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a perspective view of a roller shade and control device of the present invention.
FIG. 2 is a perspective view of a vertical blind and control device of the present invention.
FIG. 3 is a perspective view of the shade control device of FIG. 1 .
FIG. 4 is a view of the beaded chain and stopper engaging the spring and spring caps of the control device of FIG. 1 .
FIG. 5 is another perspective view of the shade control device of FIG. 1
FIG. 6 is a cross-sectional view of the shade control device of FIG. 1 .
FIG. 7 is a perspective view of the retainer of the shade control device of FIG. 1 .
FIG. 8 is a perspective view of another embodiment of a shade control device of the present invention.
FIGS. 9 and 10 are perspective views of a third embodiment of a shade control device of the present invention.
FIG. 10 is a perspective view of the spring clip of the connector of FIG. 9 .
FIG. 11 is a perspective view of a forth embodiment of a shade control device of the present invention.
FIG. 12 is a top view of the control device of FIG. 11
FIG. 13 is a cross-sectional view of the control device of FIG. 12 taken along lines 13 - 13 .
FIG. 14 is an exploded perspective view of the control device of FIG. 11
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a roller shade 2 is supported by a pair of brackets including a end plug bracket 4 and a clutch bracket 6 . A clutch 8 is provided at an end of shade 2 and is supported upon clutch bracket 6 . Clutch 8 is engaged to rotate the roller shade into a desired position by a pulling manipulation of chain 12 . A control device 10 of the present invention engages chain 12 at a location remote from the clutch 8 . Preferably control device 10 is secured to a window frame or molding or nearby wall surface.
Control device 10 includes a body adapted to receive portion of chain, such as ball chain 12 . Other chains, such rope or segmented metal chains may also be used. Ball chain 12 is utilized as described above to control movement of a roller shade 2 . Ball chain 12 is provided with stoppers 14 , which in this embodiment, are larger ball elements. Ball chain 12 may include multiple ball stoppers to control movement of the roller shade. For example, one ball stopper 14 may be used to delimit the upper or open position of the shade and another ball stopper 14 may be used to delimit the lower or closed position of the shade. Examples of chain drive systems for window shades include U.S. Pat. No. 4,424,852, Bead-Chain Drive System for Window Shade, and U.S. Pat. No. 5,137,073, Chain Pulling Device, each patent being incorporated by reference.
FIG. 2 illustrates another embodiment of a shade system include a plurality of vertical blinds 20 supported by a housing 22 and positioned by a bead chain-driven clutch 24 . Control device 10 of the present invention is positioned away from housing 22 , preferably secured to a window frame or nearby wall. Ball chain 12 and stoppers 14 are utilized to control the position of vertical blinds 20 .
FIG. 3 through FIG. 7 illustrate a first embodiment of the invention. Control device 10 includes a body 30 and a pair of springs 32 held within body 30 . Spring caps 34 are inserted into ends of springs 32 . Spring caps 34 include an opening 36 through which ball chain 12 passes, but openings 36 prevent ball stoppers 14 from passing. Springs 32 and spring caps 34 are thus held within body 30 , but are free to react to forces applied by ball chain 12 and ball stoppers 14 .
During operation of the control device 10 , ball stopper 14 engages and compresses spring 32 held within the body 30 . Ball stopper 14 may assume other designs or configurations functioning to provide some structural differentiation to the other elements of the ball chain 12 . For simplicity of explanation, only a portion of the ball chain 12 is shown in FIG. 3 and a second portion of ball chain 12 (not shown) would pass through other spring 32 .
FIG. 4 shows the spring 32 , spring caps 34 , chain 12 and stopper 14 . Ball stopper 14 engages spring 32 via lower spring cap 34 . Spring caps 34 have a first end sized to be received into the spring 32 and a second, wider end sized to engage stopper 14 .
Referring to FIGS. 5 and 6 , the springs 32 and spring caps 34 are held within the body 30 by a retaining 37 . Retaining 37 is secured to the body 13 via a threaded fastener 38 . A pair of alignment pins 40 are utilized to align the retainer 37 upon body 30 , such as during assembly. The ball stoppers 14 are sized to pass through openings in retainer 37 so as to engage with springs 32 and spring caps 34 . The control device 10 is adapted to be secured to a wall or window structure with threaded fasteners passing through a pair of apertures 39 in body 30 .
Referring to FIG. 7 , retaining 37 has a pair of apertures 54 through which the ball chain 12 and ball stoppers 14 can pass. The apertures 54 are sized to prevent the spring retainers caps 34 from escape out of body 30 .
Body 30 is adapted to be secured to a wall or other surface via threaded fasteners (not shown) passing through apertures 39 . Body 30 is secured against internal and external surfaces of the window frame or other opening. The body 30 is preferably secured at a location away from the roller shade housing.
In operation, the user applies tension to the chain 12 causing movement of the roller shade. The tension force being transferred to the clutch/drive assembly is effectively limited when the ball stopper 14 engages the control device 10 of the present invention. As the ball stopper 14 engages the spring cap 34 , the spring 32 is compressed within body 30 . If the user applied tension on the chain is sufficient, spring 32 is fully collapsed and the ball stopper 14 is stopped by contact with inner surfaces of the housing 30 or contact between spring retainers 34 . The device thus redirects destructive forces applied to the ball chain 12 away from the clutch housing/drive assembly to a remote location (wall, window casing, etc.)
Springs 32 may be held within body 30 without the use of retainer 36 . For example, the springs 32 could be inserted through an opening (not shown) at the back face of body the surface held against wall or window frame). The springs 32 could simply be compressed and inserted into an elongated cavity. The cavity could be cylindrical in form with ends tending to engage and secure the spring 32 within the body 30 . A variety of spring retention structures could be used to maintain the spring 32 within the body 30 .
The spring caps 34 could be eliminated by using a different spring, for example, a coil spring having reduced diameter ends. A variety of different springs could be utilized in alternative embodiments. For example, a resilient polymer spring may be utilized in place of coiled spring 32 . Or, a foam or fluid-filled shock absorbing element could be utilized in place of spring 32 .
The ball chains 12 could be shaped by balls formed on a chain or cord. The balls could be spherical or non-spherical. For example, a rectangular (cylindrical) stopper may be utilized.
FIG. 8 illustrates another embodiment of the invention which a single control device 80 is utilized with a pair of shades (not shown). The control device 80 is positioned between the pair of shades and four segments of hall chains 12 are received into the control device 80 . For simplicity of explanation, only a single ball chain 12 is shown in FIG. 8 . The springs 32 and spring retainers 34 of control device 80 may be placed into the body 82 through openings accessible at the rear side 84 of body 82 . The chain stoppers 14 engage the springs 32 through lower openings in body 82 .
FIG. 9 illustrates yet another embodiment of the invention 90 where the body includes a mounting plate 92 which is generally perpendicular to a plane containing the springs 32 . The mounting plate 92 would allow the control device 90 to be mounted, for example, within a window frame interior or window moldings, depending on the application.
FIG. 10 is another view of the control device 90 of FIG. 9 showing a rear access 100 through which the spring 32 and spring retainers 34 are inserted, such as during manufacture.
FIG. 11 is a perspective view of another embodiment of the present invention. A control device 102 include a body 113 , a pair of springs 132 , spring caps 134 , and cap retainers 135 . Cap retainers 135 secure the springs and caps 134 within body 113 . Cap retainer 135 includes a latch structure to prevent it from being dislodged. Body 113 is shown mounted to bracket 136 . Body 113 can also be directly mounted to a window frame or wall surface without the use of bracket 136 . Body 113 can be mounted to intermediate bracket 136 which is mounted to a window frame or wall surface. Bracket 136 can be used to mount the control device 102 within certain window interiors.
FIG. 12 is a top view of control device 102 showing body 113 secured to bracket 136 via fastener 138 . FIG. 13 is a cross-sectional view of control device 102 taken along lines 13 - 13 in FIG. 12 . FIG. 14 is an exploded view of the control device 102 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A chain control device for inhibiting movement of chains used in window blinds, shades and the like for moving the blinds between operative positions. The chain control device is secured at a location remote from the shades' clutch/drive housing. The chain control device is characterized by redirecting tension forces applied by the user of the blinds away from the shade drive.
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This application is a continuation of application Ser. No. 07/996,888 filed Dec. 23, 1992, now abandoned, which is a continuation of application Ser. No. 07/478,496 filed Feb. 12, 1990, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data processing apparatus and, more particularly, to an input/output integrated type data processing apparatus for performing display control on the basis of, e.g., a coordinate input.
2. Related Background Art
In an apparatus of this type, for example, a map is displayed, and data such as a time in a designated city is displayed thereon. In another apparatus, a name list of all the cities to be processed is displayed, and when a target city is designated on the list, data of the designated city is displayed.
However, in the former conventional apparatus, when the number of cities is large, an area corresponding to one city becomes small, and it is difficult to correctly designate a target city.
In the latter conventional apparatus, when the number of cities is large, many city names must be displayed on one frame, or city names must be separately displayed on many frames. Therefore, a cumbersome operation is required until a target city is found.
SUMMARY OF THE INVENTION
It is an object of the present invention to a provide a data processing apparatus, with which when desired one of data displayed on a display apparatus is designated, data associated with the designated data can be quickly and accurately displayed.
It is another object of the present invention to provide data processing apparatus, with which when a desired area of data displayed on a display apparatus is designated, data included in the designated display area can be quickly and accurately displayed.
It is still another object of the present invention to provide a data processing apparatus which causes a display apparatus to display a world map, and, when a desired position on the world map is designated, can quickly and accurately display place name data, e.g., a name of a city near the designated position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an arrangement of a data processing apparatus according to the first embodiment of the present invention;
FIG. 2 is a block diagram for explaining a processing system of the first embodiment;
FIG. 3 shows an example of a data storage format of a display buffer 7a;
FIG. 4 is a flow chart for explaining an operation of a CPU 5 of the first embodiment;
FIGS. 5(a), 5(b), 5(c), and 5(d) are views for explaining operations of the first embodiment; and
FIG. 6 is a flow chart for explaining an operation of a CPU (not shown) of the second embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Preferred embodiments of the present invention will be described in detail hereinafter with reference to the accompanying drawings. Note that the present invention exemplifies an input/output integrated type data processing apparatus.
First Embodiment
The first embodiment will be described below.
FIG. 1 is a block diagram showing an arrangement of a data processing apparatus according to the first embodiment of the present invention. In FIG. 1, an operation unit 1 performs a coordinate input and an output display by integrating a coordinate input device 3 and a display 2. The display 2 displays a map, a window for displaying a time in a city, and a list of city names near a designated city, as will be described later. The coordinate input device, i.e., the input device 3 detects a position depressed by a finger or a pen as coordinates by horizontal and vertical transparent electrodes on the display 2. Although not shown, the operation unit 1 comprises a window moving key for selecting a mode of moving a window on the display screen of the display 2. A display controller 4 performs display control of the display 2.
A CPU 5 controls the entire apparatus on the basis of various programs stored in a ROM 6. The ROM 6 stores a control program, an error processing program, a program for operating the CPU 5 in accordance with the flow chart of FIG. 3, display data of the display 2, and the like. A RAM 7 serves as work areas for various programs in the ROM 6, a temporary saving area in error processing, and the like. The ROM 6 stores the following tables as display data. A map forming table 6a stores data for displaying a world map on the entire display screen of the display 2. A list forming table 6b stores data for displaying a list of city names on the entire screen of the display 2. In the list forming table 6b, each city name is stored in correspondence with a plurality of city names adjacent thereto. The list forming table 6b is used when coordinates in the window on the display screen of the display 2 are designated by a user. Upon designation by the user, a city name displayed on the window is searched from the list forming table 6b, and a plurality of city names corresponding to the city name are displayed on the entire display screen of the display 2. The list is displayed to include the city name in the window. A window forming table 6c is used to display a city name and local time (month, day, day of the week, and time) designated in a partial area on the display screen when a certain city on the world map displayed by the map forming table 6a is designated. A time conversion table 6d stores local time conversion data in units of cities in correspondence with areas. An area-city table 6e stores area numbers and corresponding city names in correspondence with a list display mode and a map display mode (including a window). The RAM 7 includes a display buffer 7a for, when a user makes a designation on the display screen, storing position data of a window for determining the designated area, area identification data indicating a list display or a map display, data indicating a window moving mode, and the like, and a work area 7b for various programs stored in the ROM 6. The area identification data can be set to be determined by a flag.
A timer 8 measures time using, e.g., Greenwich time as the reference time. A bus line 9 is used for transferring address signals, data, control signals, and the like in the apparatus.
A processing system of the first embodiment will be described below.
FIG. 2 is a block diagram for explaining the processing system of the first embodiment. In FIG. 2, a coordinate input device 51 corresponds to the input device 3, and a display 61 corresponds to the display 2. A coordinate calculator 71 receives a signal corresponding to an input position from the coordinate input device 51 and calculates X- and Y-coordinate values. An area discriminator 72 discriminates an area on the basis of the content of the display buffer 7a in accordance with whether an area indicated by coordinate values from the coordinate calculator 71 corresponds to area designation in the list, area designation in a map, or designation of a window area. A city selector 73 determines a city corresponding to the area discriminated by the area discriminator 72 on the basis of the area-city table 6e.
When the current display mode is a list display mode, a list generator 74 supplies area division data in the list forming table 6b to the area discriminator 72, and outputs list forming data to a display controller 78 (to be described later) on the basis of an instruction from the city selector 73. When the current display mode is a world map display mode, a map generator 75 supplies area division data in the map forming table 6a to the area discriminator 72, and outputs map forming data to the display controller 78 on the basis of an instruction from the city selector 73. When the current display mode is the world map display mode, a window generator 76 supplies position and size data of a window to the area discriminator 72, and outputs window forming data to the display controller 78 on the basis of an instruction from the city selector 73.
A time calculator 77 calculates a time in a city determined by the city selector 73 on the basis of time data of the timer 8 with reference to the time conversion table 6d, and outputs the calculation result to the window generator 76. The display controller 78 corresponds to the display controller 4, and performs display control of the display 61 on the basis of display data from the list generator 74, the map generator 75, and the window generator 76. A window mover 79 selects the window moving mode in response to the window moving key on the operation unit 1. Data from the window mover 79 is supplied to the window generator 76 and the area discriminator 72, and a window is moved to a coordinate position detected in the window display mode. The list generator 74, the map generator 75, the window generator 76, the time calculator 77, and the window mover 79 are used as screen updating means.
A method of storing display data will be described below.
FIG. 3 is a view for explaining a storage format of data in the display buffer 7a. For example, when a list or a map (including a window) is formed on the display screen of the display 2, the display buffer 7a stores position data and area numbers of rectangular areas each having the position of a principal city as the center in units of principal cities to be displayed, which can be discriminated in correspondence with the list, the map, and the window. FIG. 3 exemplifies a case wherein the world map and the window are displayed, and the display buffer 7a stores display data in which start coordinates of each rectangular area are represented by X 1 and Y 1 , end coordinates thereof are represented by X 2 and Y 2 , and an area number in the display screen is represented by n (natural number).
The operation of the first embodiment will be described below.
FIG. 4 is a flow chart for explaining the operation of the CPU 5 of the first embodiment, and FIGS. 5(a), 5(b), 5(c), and 5(d) are views for explaining operating states of the first embodiment. In FIGS. 5(a), 5(b), 5(c), and 5(d), a world map is designated by reference numeral 100, a window is designated by 200, and a list is designated by 300.
An operation sequence for obtaining a time in Paris will be exemplified below. After the apparatus of this embodiment is initialized, the world map is displayed on the entire display screen of the display 2. In this case, the display buffer 7a stores positions and area numbers of rectangular areas of principal cities (step S1). Then, the window is formed. In this case, as an initial display, the window 200 which shows a local time in Los Angeles is displayed on a predetermined display area, as shown in FIG. 5(a). Therefore, the window area display data is additionally stored to be able to be discriminated from the display data stored in step S1 (step S2). After an initial frame is formed in this manner, the CPU 5 waits for a coordinate input or an input of the window moving key (step S3 or S4). For example, if an input of the window moving key is detected, the CPU 5 waits for an input of a destination coordinate position (step S5). If the coordinate input indicates a position within the window 200, the CPU 5 does not execute a window movement procedure; otherwise, the CPU 5 calculates a window moving position on the basis of the input coordinate position, and the flow advances to step S3 to wait for the next coordinate input (step S6).
If coordinates (x,y) of an area on the upper left position of the screen are input in step S3, as shown in FIG. 5(a), an area discrimination procedure is started. In this case, the CPU 5 discriminates on the basis of data in units of areas in the display buffer 7a which area defined by the start coordinates (X 1 ,Y 1 ) and the end coordinates (X 2 ,Y 2 ) includes the input coordinates (x,y). More specifically, if certain coordinate values satisfy X 1 ≦x≦X 2 and Y 1 <y<Y 2 , it is discriminated that these coordinate values are present within an area which is in comparison. When one area is discriminated in this manner, the area number n serves as data of a city selection procedure. The city selection procedure is executed by using area identification data for identifying whether the discriminated area corresponds to a city area on the map, a window area, or a city name area on the list, as well as the area number n.
If it is identified based on the area identification data that the area number n corresponds to the city area on the map, the flow advances to step S9; if it is identified to be the window area, the flow advances to step S10; and if it is identified to be the city name area on the list, the flow advances to step S11. For example, if the coordinates (x,y) of an upper left area of the screen are input, as shown in FIG. 5(a), it is discriminated that the input area is a city area on the map, and the window 200 displaying a time in Los Angeles at present is updated to that including London as a designated city, as shown in FIG. 5(b). In this case, the city selector 73 selects the designated city on the basis of the area number n and the area identification data of the displayed map. The selected city name is displayed by the window generator 76 within the window 200 together with a time calculation result by the time calculator 77. For example, when the content of the window 200 is updated from Los Angeles to London, if a wrong city is displayed although it is near a designated city, a user can update the content of the window 200 which displays a time in London at present. In this case, the user designates the window 200 to display a list of names of cities near London (including London). After a display of London is made on the window 200, a coordinate input is detected (step S3), and if it is discriminated that the coordinate input designates the area of the window 200 which displays a time in London (steps S7 and S8), the flow advances to step S10 to form a list. As shown in FIG. 5(c), a display procedure of the list 300 of European cities including London is executed (step S10). In this procedure, data of nearby cities corresponding to the city name "London" stored in the list forming table 6b are read out. Thus, the content of the display buffer 7a is rewritten with data based on the list display area division, and the list is displayed on the display 2.
Thereafter, when the user finds a target city name "Paris" from the list 300 and designates the position at the coordinate input device 3, as shown in FIG. 5(c), area discrimination from the input coordinate position is executed, as described above (steps S3, S7, and S8). In this case, the area number n in the area discrimination result is processed as a city name in the list 300 on the basis of the area identification data, and the city name "Paris" is selected from the area-city table 6e. The map is formed in the same manner as in the map forming procedure in step S1 (step S11). Furthermore, a time in Paris as the designated city is calculated, and a display frame in which the window 200 is superimposed on the map 100, as shown in FIG. 5(d), is formed (step S12). With the above operations, principal cities can be selected by one-touch by only designating the positions of cities on the map, and a desired one of cities which cannot be displayed by one-touch can be reliably selected by displaying city names near the principal cities using the list. Since the list presents a plurality of city names near the desired city, the target city can be quickly and accurately searched.
As described above, according to the first embodiment, the data of a target city can be quickly and accurately obtained.
Second Embodiment
The second embodiment will be described below.
The second embodiment exemplifies a data processing apparatus which has a summer time display function in addition to the display functions of the first embodiment. Since the arrangement of the second embodiment is the same as that of the first embodiment except that a summer time display means is added, a description of the overall arrangement will be omitted. The summer time display means serves as a time calculator for causing the window generator to display a time in a city by advancing it in correspondence with the duration of the daytime during a predetermined period of the summer.
The operation of the second embodiment will be described below.
FIG. 6 is a flow chart for explaining the operation of a CPU (not shown) of the second embodiment.
The procedures in steps S21 to S28 are the same as those in steps S1 to S8 in FIG. 3 described in the first embodiment, and a detailed description thereof will be omitted. Note that a display buffer (not shown) stores summer time identification data for identifying whether a time displayed in a window at present is a summer time or standard time. A designated area on the display screen is discriminated in steps S27 and S28, and the following procedures are executed on the basis of the discrimination results. The second embodiment includes four types of display procedures. More specifically, in the first embodiment, even if a city designated on the map is the same city displayed on the window, the display screen is never updated. However, in the second embodiment, if the same city is designated twice on the map, the list of names of cities near the designated city is formed (step S30). When a city name on the list is designated in area discrimination after the coordinate input in step S23, the map and the window of the designated city are formed in the same manner as in the first embodiment (steps S34 and S35). Furthermore, if a window area is designated in area discrimination after the coordinate input in step S23, a summer time and standard time in the city in the designated window are alternately switched on the basis of the summer time identification data (steps S31 to S33). If a city which is not displayed in the window is designated on the map, the window of the designated city is formed in the same manner as in the first embodiment (step S29).
As described above, according to the second embodiment, since a list can be easily displayed by designating the same area on the map twice, a quick display is allowed in a list display mode as well as the same effects as in the first embodiment. A summer time can be displayed, and a variety of needs of users can be satisfactorily met.
In the first and second embodiments, the entire display screen is used when the list is formed. For example, the map and list may be simultaneously displayed. Alternatively, a plurality of windows may be formed so that they can be compared with each other.
In the first and second embodiments, a time in a selected city on the world map is displayed. However, the present invention is not limited to this. For example, the present invention may be applied to a map of a certain city, so that the name of a family of a house selected on the map of the certain city may be displayed. That is, various other changes and modifications may be made within the spirit and scope of the invention.
In the first and second embodiments, movement of the window is allowed so that a time in an area covered by the window is obtained. However, the present invention is not limited to this. If no problem is posed although a time in an area covered by the window cannot be extracted, the window movement procedure function can be omitted. In this case, all the operations can be designated on only the display screen.
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A data processing apparatus includes a memory for storing image data and data corresponding to a display area of the image data, a display for displaying the image data stored in the memory, an input device for designating a position of the image data displayed by the display, a discriminator for discriminating a display area to which the position designated by the input device belongs, and a controller for reading out data corresponding to the display area discriminated by the discriminator and displaying the readout data on the display.
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TECHNICAL FIELD
The present invention relates to a network router and a method of configuring network routing information in a network router.
BACKGROUND
Existing Internet Protocol (IP) routers operate based on a hop-by-hop forwarding principle. The base function of this is realised in a table containing destinations or destination prefixes and corresponding next hops, i.e. outgoing interfaces. This way, each node receiving a packet data unit (PDU) is capable of searching the next-hop to which it should forward the packet. In the forwarding engine hardware, this table is often referred to as a forwarding table.
The internet is currently organised in a hierarchical manner, meaning that an intra-domain routing protocol or Interior Gateway Protocol (IGP)—typically Open Shortest Path First (OSPF), or Intermediate System to Intermediate System IS-IS—calculates the shortest paths inside a local domain, and a separate protocol takes care of inter-domain routing. This Exterior Gateway Protocol (EGP) in IP networks is typically implemented as Border Gateway Protocol (BGP). In practice, BGP identifies and returns the edge-router (i.e. the inter-domain next-hop) that should be used to reach the destination prefix. Subsequently recursive lookup is used in the router in order to find the local next-hop (i.e. the outgoing interface) leading towards this particular edge router.
IP router implementations often contain a separate forwarding table for each incoming interface, although in practice the tables are often filled with the same values. However, some recent proposals already utilise the possibility that these tables may be filled with different values (Zifei Zhong, et al.: “Failure Inferencing based Fast Rerouting for Handling Transient Link and Node Failure”, Infocom 2005.)
If a link or node goes down in the network, the appropriate routing protocols propagate this information and the router calculates a new route to the destinations. During this so-called routing re-convergence, i.e. as long as not all routers have installed the new routes (i.e. new next-hops), the network may experience transient routing loops and lost packets.
Normally, forwarding tables are recalculated in each router by a control element (the routing engine). However, in some other concepts, like in the distributed router system described in “Performance Evaluation of Control Plane Modularization and Decentralisation for BGP”, Markus Hidell et al., Usenix 2006, the forwarding tables are calculated on distributed control elements and are downloaded to the physically separate forwarding elements over the regular IP network.
Some solutions for IP-based fast re-route (IP-FRR) are based on putting alternative “virtual” IP addresses per node (also known as “not-via addresses”) into each router's forwarding table. These virtual addresses are then allocated a different next-hop than the normal IP address of the destination. This way, in case of a failure, a detour path can be used leading to the same destination.
Existing forwarding tables are nowadays very long. It has been observed by M. Hidell et al. (supra) that the number of entries can be higher than 100,000. Currently the forwarding table of a router is set up in such a way that it contains an entry for each destination or each destination prefix the router is aware of.
Using not-via addresses further increases the entries in forwarding tables. Aiming at the repair of single node or link failures, the increase is a number of additional entries equal to the number of links in the network. With double failure protection the increase is a square function of links.
The growth of forwarding tables slows down the forwarding, because the lookup from a large database takes longer than from a small one.
Calculating the routes for external prefixes takes more time than required due to the lookup of irrelevant prefixes in recursive lookup.
A major part of re-convergence time of link state routing protocols is spent with the download of the next-hops into the forwarding engines of line cards.
In the distributed router concept, a high number of destination prefixes also increases the signalling bandwidth overhead required to download the forwarding tables to the forwarding elements.
SUMMARY
It is an object of the present invention to obviate at least some of the above disadvantages and provide an improved network router and an improved method of configuring a network router.
According to a first aspect of the present invention there is provided a method of configuring a network router. The network router comprises a plurality of ingress interfaces, and an interface forwarding table assigned to each ingress interface. The method comprises the step of determining if the ingress interface may be used as part of a route from any source node to any destination node in the network. The forwarding table entries that are not used are removed from at least one of the interface forwarding tables.
According to a second aspect of the present invention there is provided a method of configuring a network router. The network router comprises a node forwarding table for the node itself. The method comprises the step of determining if the node may be used as part of a route from any source node to any destination node in the network. The forwarding table entries that are not used are removed from the node forwarding table.
In a first configuration of the second aspect the network router may further comprise a plurality of ingress interfaces, and an interface forwarding table assigned to each ingress interface. The method may further comprise removing the forwarding table entries that are not used from at least one of the interface forwarding tables.
In a configuration of the first or second aspect, the routing tables of all nodes and interfaces in the network may be known. The step of removing the forwarding table entries which are not used may comprise for all destination entries in the forwarding table, checking for all source nodes in the network whether the route from the source node to the destination node comprises a link directed towards the network router. The entry for a destination may be removed from the forwarding table, if for no source node the route to the destination node comprises a link directed towards the network router.
In another configuration of the first or second aspect the topology of the network and the link weights of the network may be known. The step of removing the forwarding table entries which are not used may comprise for all destination entries in the forwarding table, comparing for all source nodes in the network (a) the length of the shortest path from a node directly linked to the network router to a destination with (b) the sum of the length of the direct link and the length of the shortest path from the network router to the destination. The entry for a destination may be removed from the forwarding table, if the lengths of the paths are not equal.
In a further configuration of the first and second aspect at least some of the destinations may be inter-domain addresses. The method may further comprise the step of removing the inter-domain destinations from the forwarding table, if the edge node through which the inter-domain destination is reachable has been removed from the forwarding table.
In yet another configuration of the first and second aspect an entry from the node forwarding table is not removed if it is part of a static route.
According to a third aspect of the present invention a network router comprises a plurality of ingress interfaces, and an interface forwarding table assigned to each ingress interface. At least one of the interface forwarding tables comprises only forwarding table entries that are used.
According to a fourth aspect of the present invention a network router comprises a node forwarding table assigned to the router itself. The forwarding table comprises only forwarding table entries that are used.
According to a first configuration of the fourth aspect, the network router may further comprise a plurality of ingress interfaces, and an interface forwarding table assigned to each ingress interface. At least one of the interface forwarding tables is a copy of the reduced node forwarding table.
According to a configuration of the third or fourth aspect the forwarding table of at least one of its interfaces may comprise an entry for a destination, if for at least one source node the route to the destination node goes through the corresponding interface.
According to another configuration of the third or fourth aspect the forwarding table of the node or at least one of its interfaces may comprise an entry for a destination, if for at least one source node the route to the destination node comprises a link directed towards the network router.
According to a fifth aspect of the present invention a network router comprises a node forwarding table assigned to the router itself, a plurality of ingress interfaces, an interface forwarding table assigned to each ingress interface, and means for removing the forwarding table entries that are not used from at least one of the interface forwarding tables.
According to a sixth aspect of the present invention a network router comprises a node forwarding table assigned to the router itself and means for removing the forwarding table entries which are not used.
In a first configuration of the sixth aspect the network router may further comprise a plurality of ingress interfaces, an interface forwarding table assigned to each ingress interface, and means for copying the reduced node forwarding table to at least one of the interface forwarding tables.
In a configuration of the fifth or sixth aspect the network router may further comprise means for reducing a forwarding table in accordance with the method of the first or second aspect.
According to a seventh aspect of the present invention a computer program product comprises data processing device program code means adapted to perform the method of the first or second aspect when said program is run on a data processing device.
According to an eighth aspect of the present invention a computer-readable medium comprises computer-executable instructions to reduce any forwarding table of a network router in accordance with the first or second aspect.
The smaller size of the forwarding tables obtained by the present invention may significantly improve the performance of a router. The lookup of the next-hop may take less time. Fewer recursive lookups may allow the processing capacity requirement of the routing engine to be reduced. The smaller size of the forwarding tables may also reduce traffic by the control messages. Moreover, routing convergence time may be reduced. Furthermore, the present invention may be applied to each node individually without influencing the behaviour of the rest of the network.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates schematically the logical view of the forwarding tables in a router.
FIG. 2 is a schematic of a network illustrating per-interface forwarding table reduction according to the present invention.
FIG. 3 illustrates a method of reducing an interface forwarding table according to the present invention.
FIG. 4 is a schematic of a network illustrating a method of node forwarding table reduction according to the present invention.
FIG. 5 illustrates a method of reducing a node forwarding table according to the present invention.
DETAILED DESCRIPTION
A router has a forwarding table assigned to each ingress interface, referred to as interface forwarding table. Another table is assigned to the router itself, referred to as node forwarding table. The interface forwarding tables may be identical copies of the node forwarding table. This would serve the purpose of decreasing the forwarding delay. Packets arriving at the router at an ingress interface are routed according to the corresponding interface forwarding table, while packets originating from the router itself (e.g., ping commands from the command line interface, or higher level protocol messages) are routed based on the node forwarding table.
Many of the forwarding entries are actually never used during the routing. In a certain routing configuration, packets headed to a certain destination may never go through some nodes, or—more frequently—may never go through some links. These destinations are superfluous in the forwarding tables since they are never used.
However, as with normal destinations, most of the “not-via” destinations are also not used since the detour paths corresponding to a failure do not pass through a lot of links and nodes. These nodes do not need to have these not-via addresses in their forwarding tables.
A lot of the recursive lookups are not required because their results are never used during forwarding, but they place a processing burden on the routing engine. It makes no sense to stretch re-convergence time by the download of a lot of unneeded entries into the forwarding engine. Knowing that a lot of the entries are never used, this is a waste of bandwidth and processing capacity.
In a particular routing configuration, routes headed to a certain destination usually never go through some nodes, or—more frequently—may never go through some links. In these cases such destinations may safely be removed from the forwarding table of the corresponding node or interface, respectively.
With reference to FIG. 1 , a logical view of the forwarding tables in a router is shown in a schematic manner. A router 1 has a number of line cards for the ingress interfaces 2 and 3 as well as egress interfaces 4 and 5 . For reasons of simplicity, however, only two interfaces of each kind are depicted in FIG. 1 . Moreover, the router has a forwarding table assigned to each ingress interface, referred to as interface forwarding tables 6 , 7 , 8 , 9 . The router also has another forwarding table assigned to the router itself, referred to as node forwarding table 11 . The interface forwarding tables 6 , 7 , 8 , 9 may be identical copies of the node forwarding table 11 . This would serve the purpose of reducing the forwarding delay. Packets arriving at the router at one of the ingress interfaces 2 or 3 are routed according to the corresponding interface forwarding table 6 or 7 , while the packets originating from the router 1 itself, e.g. ping commands from the command line interface (CLI) 10 , or higher level messages, are routed based on the node forwarding table 11 .
In a first scenario, the actual routing in the network is known, i.e. the routing tables of all nodes and interfaces are known. This is a realistic assumption if
the routing tables are computed in a centralised way, or each node runs the same routing algorithm and the output of it is deterministic and predictable by the other nodes, i.e. deterministic tie-breaking rules are used if multiple equivalent paths are used.
An exemplary network that fulfils these conditions may consist of the same kind of routers.
In a second scenario, the routing is on shortest paths. While the nodes know the topology and the actual link weight, it cannot be predicted which shortest path was actually chosen by the intermediate routers. The most prominent example for this is OSPF or IS-IS, where the tie-breaking rules are vendor dependent, so that a router cannot always guess which alternative paths are used. In fact, in the case of Equal-Cost Multi-Path (ECMP) routing all of the shortest paths are in use.
In some cases, the administrator may also statically configure explicit forwarding table entries having precedence over the OSPF based routes. These will be referred to as explicit paths.
FIG. 2 is a schematic of a network illustrating per-interface forwarding table reduction according to the present invention. S 1 and S 2 are source nodes, A and B are nodes in the network linked by link L, and D is a destination node. The forwarding tables at the incoming interfaces signed with a cross do not need to contain an entry to destination D, because arriving traffic will not be directed towards destination D. Utilising the fact that in an advanced router, the forwarding tables of each interface can be set individually, it is possible that one interface of node A must list destination D, while two other interface of node A do not need this destination.
According to the present invention, the unused destination addresses are removed from the ingress interface forwarding table of node B at link L, where L is the link between node A and node B. Further, link L is considered a directed link going from node A to node B, and carrying traffic only in this direction. In order to determine whether a destination D may be removed from this forwarding table, it needs to be checked if link L may be used by any traffic arriving at the ingress interface of link L at node B heading towards destination D. If link L is not used by any possible traffic, it may safely be removed from the forwarding table at node B.
In the first scenario described above the exact routes are known. As shown in FIG. 3 it is determined in step 310 whether the route from a certain source S to D contains the link L. This is repeated for each possible source node S within the autonomous system or routing area and the unused destinations are removed from the forwarding table in step 320 . After reducing the table, the forwarding table of the ingress interface of L at node A comprises an entry for destination node D if and only if there exists a source node S for which the traffic from S to D may go through link L.
With respect to the second scenario, let w(L) denote the administrative weight (length) of the link L and let d(X,Y) be the length of the shortest path from node X to node Y, i.e.
d ( X , Y ) := min { ∑ L ∈ P w ( L ) }
where P is a path from X to Y. If node A generates or forwards traffic towards destination D, then this traffic may use link L if and only if
d ( A,D )= w ( L )− d ( B,D ).
However, if explicit paths are given, it also needs to be checked whether there is an explicit table entry in node A suppressing the default shortest path behaviour. This can be done in many ways:
1. If static routes are distributed with OSPF or IS-IS, the information is present.
2. Otherwise, it may be assumed that the node forwarding tables are always filled with all potential destination prefixes, since the user may wish to send traffic to any destination. If an interface receives a packet headed towards a destination that is not listed in the respective interface forwarding table, it may divert this packet to the node forwarding table to obtain a valid outgoing (egress) interface.
3. Alternatively, the FIB of node A must be queried, e.g. via SNMP. This, however, requires a new function in the routers and is a slower process that could cause longer transient times with packet losses during updates of the static routing tables.
Finally, in order to determine the necessary routing table entries, the set of interfaces which may forward traffic to D needs to be identified. Let this set be denoted by FD. The result can be found by dynamic programming:
The edge nodes must be in set FD. If a node A is in FD, and A can forward the traffic to node B, then B (i.e. the ingress interface coming from A) must also be in FD.
Also note that the prefix or prefixes of the directly connected interfaces are never removed from the forwarding tables.
Assuming that the router itself does not generate packets to arbitrary destinations and that there are no explicit paths configured into the network that are not learnt by any of the means (1. to 3.) listed above, an alternative to the interface forwarding table reduction would be to remove the unnecessary destination addresses from the node forwarding table of any node. If one wishes to reduce the node forwarding table of a node N, the functionality of making an identical copy of the node forwarding table for the interface remains unchanged, thus reducing the required new functionality and processing.
FIG. 4 is a schematic of a network illustrating a node forwarding table reduction according to the present invention. S represents a source node, N A , N B and N C are network nodes, and D is a destination node. This example shows that the upper node N A does not need to contain an entry towards destination D as normally traffic from source S will not pass through this node, i.e., the shortest path between source S and destination D does not pass the upper node N A through any interface.
With reference to FIG. 5 , in step 510 it is determined whether a node N may be used by the traffic from any source S toward D. If node N is not used, destination D may be removed from the node forwarding table in step 520 .
In the first scenario described above the actual routing in the network, and thus the exact routes, are known. It is therefore trivial to check whether the route from S to D contains node N.
In the second scenario mentioned above routing is on shortest paths. Hence, the dynamic programming procedure described in the previous section may be used.
It is well known that the majority of the forwarding table entries come from external prefixes (i.e. inter-domain routes). These are generally propagated by BGP. However, BGP only determines the edge router to use in order to reach a given prefix. The intra-domain route is left for the IGP protocol; hence the actual egress (outgoing) interface towards an external prefix is learnt by recursive lookup.
However, if an interface or node B is not along the IGP route towards an edge node D from any other node S, then this edge node D is not listed as a destination in the corresponding interface forwarding table or node forwarding table at node B. This also means that the forwarding table of B does not need to contain any external prefixes which would use edge node D. Therefore, the number of external prefixes may also be greatly reduced, and the routing engine does not even need to perform a recursive lookup on these prefixes.
The smaller size of the forwarding tables obtained by the present invention may significantly improve the performance of a router: when a packet is to be forwarded, the lookup of the next-hop takes less time because the number of entries in the forwarding table is smaller.
Such a reduction is particularly important when the network nodes propagate several virtual addresses for failure protection or other purposes. According to the present invention, a lot of these virtual addresses do not need to be stored in each router and can be removed.
Furthermore, by needing less recursive lookups the processing capacity requirement of the routing engine may be reduced.
Using centralised router configuration, the smaller size of the forwarding tables also means that less traffic is generated by the control messages and reduces the management complexity.
According to the present invention, routing convergence time may be reduced with OSPF or IS-IS, since the major part of the re-routing time with fast IGPs is the time needed to download and install the forwarding table to the linecard.
The method according to the present invention may be applied to each node individually without influencing the behaviour of the rest of the network.
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Disclosed is a method of configuring routing information in a network router linked into a network. The network router has a forwarding table. The method comprises removing the forwarding table entries which are not used. A network router configured in accordance with the method has a forwarding table comprising only forwarding table entries that are used.
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BACKGROUND OF THE INVENTION
The present invention relates to an information recording medium which can record digital information in real time such as an analog video or audio signal which is FM-modulated, data of an electronic computer, a facsimile signal, and a digital audio signal by a recording energy beam such as a laser beam or an electron beam.
There are various systems of recording data on a thin film by an energy beam such as a laser beam or an electron beam. In a recording system using a phase change (may be called a phase transition) between the crystalline structure and the amorphous structure of a recording layer material itself or between one crystallized structure and another crystallized structure, diffusion of atoms between layers of constituted thin films, and changing of the optical constants due to changing of the atomic arrangement such as photodarkening, the structured thin film is little deformed. Therefore, the recording system has an advantage that it is possible to produce a single disk whose surface is just covered with a protective coating material for protection of scratch and a double sided disk comprising two disks which are directly bonded. A number of developments relating to this kind of recording have been applied and a number of thin films including the Te--Ge system, As--Te--Ge system, and the Te--O system are described in Japanese Patent Publication 47-26897 which is the earliest one. In Japanese Patent Application Laid-Open 57-24039, thin films such as Sb 25 Te 12 .5 Se 62 .5, Cd 14 Te 14 Se 72 , Bi 2 Se 3 , Sb 2 Se 3 , In 20 Te 20 Se 60 , Bi 25 Te 12 .5 Se 62 .5, CuSe, and Te 33 Se 67 are described.
A dedicated reproduction type optical information storage medium such as a compact disc (CD), CD-ROM, Video-CD, or laser disc has a structure so as to be suitable for mass production that concave or convex prepits having information beforehand are formed on a polycarbonate substrate or an acrylic substrate by a transfer art such as an injection method or a photopolymerization method, and a metallic reflection layer having a high reflectivity of 70% or more to a reproduction energy beam such as Al or Au is formed directly on them, and furthermore an organic protective layer is formed on it for scratch protection. As a result, the reflection ratio to a reproduction energy beam in the flat portion of the aforementioned dedicated reproduction type optical information storage medium is as high considerably as 70% or more. Therefore, to allow a recordable information recording medium using a recording energy beam to preserve complete compatibility with the aforementioned dedicated reproduction type optical information storage medium, it is necessary that the reflection ratio in the unrecorded portion or the recorded portion is as high as 70% or more. An information recording medium of a type that data is recorded (or erased) by a change in the optical constants due to a change in the atomic arrangement of the material of a recording layer as the aforementioned information recording medium is described in Japanese Patent Application Laid-Open 4-228126, Japanese Patent Application Laid-Open 4-254925, and Japanese Patent Application Laid-Open 6-44606.
In the aforementioned information recording medium of the prior art, the composition of recording layer and film structure are not optimized, so that when such a medium is used as an information recording medium which can write data once or can rewrite data, there are problems imposed that the reproduced signal strength is not sufficiently high, and the reproduced waveform is distorted extremely, and a large unerased portion remains, and the recording sensitivity is bad, and the reversibility is small.
An object of the present invention is to provide an information recording medium which has satisfactory recording and reproduction characteristics, a high recording sensitivity, and a satisfactory rewriting performance.
SUMMARY OF THE INVENTION
To accomplish the object of the present invention, an information recording medium comprises at least a substrate, a recording layer which is formed directly on the substrate or via a protective layer comprising at least one of an inorganic substance and an organic substance and in which the atomic arrangement is changed without the shape thereof being changed when a recording energy beam is irradiated and the optical constants are changed, and a reflection layer reflecting the recording energy beam and the information recording medium comprises a material in which the mean composition of the recording layer is expressed by a general expression of A w Ge x Te y Se z (where symbols w, x, y, and z indicate atomic percent, and their values are within the ranges of 1≦w≦20, 30≦x≦70, 1≦y≦34, and 1≦z≦29 respectively, and A indicates at least one element selected from the group consisting of Sb, Bi, Al, Ga, In, Si, Sn, Pb, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, La, Hf, Ta, W, Re, Os, Ir, Pt, Au, Ag, and Cu). According to the present invention, the mean composition of the recording layer or the reflection layer means the mean composition in the direction of film thickness.
In the recording layer of the information recording medium of the present invention, the shape thereof is not changed even if an energy beam such as a laser beam or an electron beam is irradiated, and a phase change (phase change between the crystal and amorphous substance of the material of recording layer itself) is caused as an atomic arrangement change, and the optical constants are changed. Information is reproduced by a power reproduction energy beam for the irradiation time during which the recording layer is not changed.
Information is recorded or erased by a power energy beam (for example, a semiconductor laser beam) for the irradiation time during which the aforementioned atomic arrangement change can be caused and the recording layer is not deformed greatly and information is reproduced by a power energy beam for the irradiation time during which no atomic arrangement change is caused.
The Role of each element among the elements expressed by A of the recording layer of the information recording medium of the present invention is as follows: The alloy system including Ge, Te, and Se can execute crystallization for recording at high speed with the stability of the amorphous status kept. Moreover, the difference in the optical constant between the crystallized structure and the amorphous structure of the recording layer is large, so that the reproduced signal strength also can be increased. Furthermore, by coexistence of elements expressed by A such as Sb, the stability of the amorphous status can be increased more and the rewriting performance and the life of recording points can be improved more.
The elements Sb and Bi of the Vb group among the typical elements in the elements expressed by A are desirable in respect of improving the rewriting performance. The elements Si, Sn, and Pb of the IVb group are desirable in respect of improving the stability of the amorphous status and the elements Al, Ga, and In of the IIIb group are desirable in respect of increasing the reproduced signal strength.
The elements Au, Ag, and Cu of the Ib group among the transition metallic elements in the elements expressed by A are desirable in respect of increasing the crystallization speed for recording. The other transition metallic elements such as Cr, Co, and Pd are desirable in respect of decreasing the distortion of reproduced waveform for rewriting many times.
A desirable element among the elements of the Vb group among the typical elements of the elements expressed by A is Sb, and a desirable element among the elements of the IVb group is Sn, and a desirable element among the IIIb group is Bi. A desirable element among the elements of the Ib group among the transition metallic elements of the elements expressed by A is Ag and desirable elements among the elements of other than the Ib group are Cr and Co.
A change in the content of each element in the recording layer in the direction of film thickness is small, though an optional pattern change may exist. Particularly when the content of Se in the neighborhood of one of the interfaces of the recording layer (it may be an interface with another layer) is larger than that on the inner side, the oxidation resistance improves.
It is desirable to change the optical property by any change in the atomic arrangement by irradiating a recording energy beam without the shape of the recording layer being little changed in addition to phase change, diffusion of atoms, and photodarkening. For example, it may be a change in the diameter of crystal grains or the crystal form or a change between the crystallized structure and the metastable status (π, γ, etc.) or between metastable statuses. Even when a change is caused between the amorphous status and the crystallized status, it is possible that the amorphous status is not completely amorphous but a crystallized portion coexists. It is possible that data is recorded by transferring (due to chemical reaction or others) a part of the atoms constituting the recording layer or the protective layer to the protective layer or the recording layer or by both phase change and atom transfer.
When the content of Sb is changed with the relative ratio to the other elements kept almost constant in a recording layer of the Ge--Te--Se--Sb system and the rewritable count and the carrier to noise ratio when a repetitive signal of 11T and a repetitive signal of 3T are overwritten at a linear speed of 5.6 m/s are measured, the rewritable count when the Sb content is 0 atomic percent is as very small as 50 times and when the Sb content is 25%, the read out signal modulation degree is small. Therefore, the carrier to noise ratio is lower than the lowest level 45 dB at which a signal can be reproduced as a digital signal free of an error such as 43 dB. When the Sb content is within a range from 1 atomic percent to 20 atomic percent, both the rewritable count and the carrier to noise ratio show satisfactory characteristics. When the Sb content is within a range from 2 atomic percent to 10 atomic percent, both the rewritable count and the carrier to noise ratio show particularly satisfactory characteristics.
Next, when the Sb content is fixed to 4 atomic percent, and the ratio of the Te content to the Se content is fixed to 2:1, and the ratio of the Ge content to the total of the contents of Ge, Te, and Se {x/(x+y+z)} is changed in a recording layer of a composition of Ge 48 Te 32 Se 16 Sb 4 , the crystallization time of the recording layer itself (the shortest irradiation time necessary for erasing) and the rewritable count when a repetitive signal of 11T and a repetitive signal of 3T are overwritten at a linear speed of 1.4 m/s are measured. As a result, when the ratio of the Ge content to the total of the contents of Ge, Te, and Se {x/(x+y+z)} is 0.25 or 0.75, the crystallization time of the recording layer is long such as 5 μs and overwriting cannot be executed at a linear speed of 1.4 m/s. When 0.3<{x/(x+y+z)}<0.7, the crystallization time is short such as 1 μs and overwriting can be executed at a linear speed of 1.4 m/s. When 0.4<{x/(x+y+z)}<0.65, both the crystallization time and overwriting show satisfactory characteristics. When 0.45<{x/(x+y+z)}<0.6, both the crystallization time and overwriting show particularly satisfactory characteristics.
Next, when the Sb content is fixed to 4 atomic percent, and the Ge content is fixed to 48 atomic percent, and the content of Te and Se the ratio of the Te content to the total of the contents of Te and Se {y/(y+z)}! is changed in a recording layer of a composition of Ge 48 Te 32 Se 16 Sb 4 , the crystallization time of the recording layer itself (the shortest irradiation time necessary for erasing) and the holding life of the recording point until the carrier to noise ratio when a disk is left under the condition of 60° C. and 95% RH is reduced to 3 dB are measured. As a result, when the content of Te is large such as 38 atomic percent, the holding life of the recording point is short and the disk is not suited to an information recording medium. When the content of Se is large such as 32 atomic percent, the crystallization time is as long as 3 μs and overwriting cannot be executed. When the content of Te is 34 atomic percent or less and the content of Se is 29 atomic percent or less, both the crystallization time and the holding life of the recording point show satisfactory characteristics. When the ratio of the Te content to the total of the contents of Te and Se {y/(y+z)} is 0.45 or more, the crystallization time shows a particularly satisfactory characteristic such as 0.5 μs.
From the aforementioned experiment results, the ranges within which the ratios w, x, y, and z of the constituent elements of the recording layer show satisfactory characteristics are as shown below.
1≦w≦20, 0.3≦x/(x+y+z)≦0.7, 1≦y≦34, and 1≦z≦29.
More desirable ranges of w, x, y, and z are as shown below.
1≦w≦20 and 0.4≦x/(x+y+z)≦0.65.
Still more desirable ranges of w, x, y, and z are as shown below.
1≦w≦15 and 0.45≦x/(x+y+z)≦0.6.
Particularly desirable ranges of w, x, y, and z are as shown below.
2≦w≦10, 0.45≦x/(x+y+z)≦0.6, and 0.45≦y/(y+z).
Therefore, it is desirable that the additional amount of an element expressed by A is within a range from 1 atomic percent to 20 atomic percent and when the additional amount is beyond the range, the recording and reproducing characteristics are degraded. It is more desirable that the additional amount of an element expressed by A is within a range from 1 atomic percent to 15 atomic percent and it is still more desirable that the additional amount is within a range from 2 atomic percent to 10 atomic percent.
In the recording layer and the reflection layer of the present invention, when the mean composition in the direction of film thickness is within the aforementioned ranges, it is possible that the composition is changed in the direction of film thickness. It is desirable that the composition does not change discontinuously.
Even if a part or the whole of Sb is replaced by at least one element selected from among Bi, Al, Ga, In, Si, Sn, Pb, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, La, Hf, Ta, W, Re, Os, Ir, Pt, Au, Ag, and Cu in a recording layer of the Ge--Te--Se--Sb system, when data is recorded, reproduced, and erased as a reversible type, characteristics which are very similar to each other are obtained. Elements among the aforementioned elements expressed by A in the general expression which have particularly satisfactory recording, reproducing, and erasing characteristics are Sb in the Vb group, Sn in the IVb group, In in the IIIb group, Ag in the Ib group, and Cr and Co in the transition metallic elements of other than the Ib group.
In the reflection layer of the information recording medium of the present invention, at least one element of Al, Au, Ag, and Cu is a main component. When the Co content is changed in a reflection layer of a composition of Au 97 Co 3 in atomic percent, the reflection factor of the reflection layer, the electric resistivity and thermal conductivity at 298K, and the recording power when a repetitive signal of 11T at EFM is overwritten at a linear speed of 1.4 m/s are measured. As a result, when the Co content is less than 0.5 atomic percent, the electric resistivity at 298K is less than 7 μΩ·cm, so that the thermal conductivity at 298K is more than 105 W/m·K and no data can be recorded at 45 mW on the surface of the disk. When the Co content is more than 15 atomic percent, the reflection factor is less than 85% and it is difficult that the disk reflection factor becomes 65% or more. When the Co content is within a range from 1 atomic percent to 8 atomic percent, the reflection factor of the reflection layer is high such as 91% or more, so that the disk reflection factor can be increased more. When the Co content is within a range from 2 atomic percent to 5 atomic percent, the disk reflection factor is high and the electric resistivity is high such as 14 μΩ·cm or more, so that the thermal conductivity is as low as 53 W/m·K or less and the recording sensitivity and the erasing sensitivity are satisfactory. Even if a part or the whole of Co is replaced by at least one element among Al, Si, Sc, Ti, V, Cr, Mn, Fe, Ni, Zn, Ga, Ge, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, In, Sn, Sb, Te, La, Hf, Ta, W, Re, Os, Ir, Pt, Tl, Pb, and Bi, the same result is obtained. When Co among the aforementioned additional elements is added, the recording sensitivity and the erasing sensitivity are satisfactory compared with the other elements. When Pd is added, the oxidation resistance of the reflection layer is satisfactory. When Ti is added, the diameter of crystal grains of the reflection layer is small and the noise is low. When Mo is added, the adherence of the reflection layer is satisfactory and the erasing ratio of the rewritable type is large. On the other hand, when Ni is added, the adhesive strength of the reflection layer is lower than that of the other additional element and the rewriting count of the rewritable type is limited. When Cr is added, the unevenness of the surface of the reflection layer is slightly larger than that of the other additional elements and the disk noise is slightly higher.
In a recording layer of a composition of Au 97 Co 3 , even if a recording layer of a composition of Au 50 Ag 50 is used in place of Au 97 Co 3 , the same result is obtained.
When the Ag content is changed in the aforementioned recording layer of a composition of Au 50 Ag 50 , the reflection factor of the reflection layer itself for a reproduction light beam, the disk reflection factor when a repetitive signal of 11T at EFM is overwritten at a linear speed of 1.4 m/s, the electric resistivity and thermal conductivity at 298K, and the recording power are measured. As a result, when the Ag content is less than 10 atomic percent or more than 90 atomic percent, the electric resistivity at 298K is less than 7 μΩ·cm, so that the thermal conductivity at 298K is more than 105 W/m·K and a high recording power is necessary such as 35 mW or more on the surface of the disk though the disk reflection factor is low such as 34%. When the Ag content is within a range from 30 atomic percent to 70 atomic percent, the electric resistivity is high such as 14 μΩ·cm or more, so that the thermal conductivity is as low as 53 W/m·K or less and the recording sensitivity and the erasing sensitivity are satisfactory. Furthermore, even if a reflection layer of the Au--Cu system is used in place of the aforementioned reflection layer of the Au--Ag system, the same result is obtained.
From the above results, when the mean composition of a reflection layer in the direction of film thickness is expressed by a general expression (Au) 100-x (A) x (where a symbol x indicates atomic percent and has a value of 0.5≦x≦15 and A indicates at least one element of Al, Si, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Ga, Ge, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, In, Sn, Sb, Te, La, Hf, Ta, W, Re, Os, Ir, Pt, Tl, Pb, and Bi) or a general expression (Au) 100-y (D) y (where a symbol y indicates atomic percent and has a value of 15≦y≦85 and D indicates at least one element of Ag and Cu), the reflection factor of the reflection layer itself for a reproduction light beam is as high as 85% or more and the electric resistivity at 298K is 7 μΩ·cm or more, so that the thermal conductivity is as low as 105 W/m·K or less. In this case, the reflection factor of the medium for the reproduction light beam from the substrate side of the information recording medium is 65% or more in the unrecorded portion and 45% or less in the recorded portion or 45% or less in the unrecorded portion and 65% or more in the recorded portion and the recording sensitivity and the erasing sensitivity improve greatly. Furthermore, when the initial reflection factor in the unrecorded portion of the mirror portion is 70% or more and the reflection factor in the recorded portion is 28% or less, the medium can conform perfectly to the red book of the CD standard, the orange book Part II of the CD-R (write-once type CD) standard, so that it can be read satisfactorily in an apparatus of a dedicated reproduction CD or a laser disk.
When the reflection layer is installed on the opposite side of the substrate of the recording layer in the information recording medium of the present invention, a high read out signal modulation degree can be obtained. In this case, it is desirable that the film thickness of the reflection layer is within a range from 30 nm to 200 nm and the information recording medium has a constitution that a substrate 1, a lower protection layer 2, a recording layer 3, an upper protection layer 4, and a reflection layer 5 are formed in this order from the substrate side (FIG. 1).
When reflection layers are installed on both sides of the recording layer, the high reflection factor and the high read out signal modulation degree can be compatible with each other. In this case, it is desirable that the film thickness of the lower reflection layer on the substrate side is within a range from 5 nm to 30 nm and the film thickness of the upper reflection layer on the opposite side of the substrate is within a range from 30 nm to 200 nm.
Furthermore, the film thickness of a recording layer which is within a range from 10 nm to 250 nm is particularly desirable because a change in the reflection factor due to recording becomes larger by the effect of light interference. When the film thickness is within a range from 10 nm to 100 nm, it is more desirable because the recording sensitivity is also high. In this case, the information recording medium has a constitution that a substrate 7, a lower reflection layer 8, a lower protection layer 9, a recording layer 10, an upper protection layer 11, and an upper reflection layer 12 are formed in this order from the substrate side (FIG. 2).
In a part of the information recording medium of the present invention, dedicated reproduction data is formed in a shape of concave or convex prepits on the substrate beforehand and coexists with other rewritable data. In the portion of a repetitive signal of 11T at EFM at a linear speed of 1.4 m/s in the dedicated reproduction data portion, the reflection factor in the flat portion is 71% and a reproduction signal output of a carrier to noise ratio of 63 dB is obtained at a read out signal modulation degree of 82% and a measurement band of 10 kHz. In the portion of a repetitive signal of 3T at EFM, a reproduction signal output at a read out signal modulation degree of 58% and a carrier to noise ratio of 60 dB is obtained.
As explained above, according to the present invention, as an information recording medium which has at least a recording layer and a reflection layer and records data by irradiating a recording energy beam, an information recording medium on which the recording, erasing, and reproducing characteristics are satisfactory, and the recording and erasing sensitivities are high, and the stability is kept superior for a long period of time can be obtained. Furthermore, an information recording medium on which a recording light beam of an inexpensive low-output type can be used because the recording and erasing sensitivities are high even if the reflection factor of a medium for a reproduction light beam from the substrate side is as high as 65% or more, and the recording, erasing, and reproducing characteristics are superior, and the holding life of recorded data is long, and the environment resistance is superior can be obtained. Information recorded in the aforementioned information recording medium having a reflection factor of 65% or more can be read by an inexpensive dedicated reproduction apparatus for a compact disk (CD) or a laser disk which is now widespread.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view showing the structure of an information recording medium of a disk I in this embodiment; and
FIG. 2 is a cross sectional view showing the structure of an information recording medium of a disk II in this embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EMBODIMENT 1
FIG. 1 shows a disk I which is an embodiment of the present invention. On a replica substrate 1 in which a spiral groove with a pitch of 1.6 μm for tracking is formed on the surface of a disk-shaped polycarbonate plate with a diameter of 120 mm and a thickness of 1.2 mm by the injection method, a lower protection layer 2 of a composition of (ZnS) 80 (SiO 2 ) 20 of atomic percent is formed with a film thickness of 130 nm first by using a radio frequency magnetron sputtering apparatus. Then, a recording layer 3 of a composition of Ge 48 Te 32 Sel 16 Sb 4 of atomic percent is formed with a film thickness of 25 nm in the same sputtering apparatus. Then, an upper protection layer 4 of a composition of (ZnS) 80 (SiO 2 ) 20 of atomic percent is formed with a film thickness of 25 nm in the same sputtering apparatus. Then, a reflection layer 5 of a composition of Al 97 Ti 3 of atomic percent is formed with a film thickness of 70 nm in the same sputtering apparatus. Furthermore, an organic layer 6 with a thickness of 50 μm is formed by curing ultraviolet curing resin which is spin-coated on the reflection layer 5.
Using the disk I which is prepared as mentioned above as a reversible type, recording, erasing, and reproduction are evaluated by an optical disk drive (semiconductor laser wave length 780 nm, maximum power 50 mW on the disk surface) as shown below. The disk reflection factor immediately after the disk I is prepared is as low as 8%, so that when the disk is initialized overall by a laser beam equivalent to a power of 18 mW on the disk surface at a linear speed of 5.6 m/s, the reflection factor increases from 8% to 34%. Next, by rotating the disk at a fixed linear speed, keeping continuous light from the semiconductor laser at a low level at which no data is recorded in an optional radius position, focusing it by an object lens of a numerical aperture of 0.55 in the optical head, and irradiating it to the recording layer 3 via the substrate 1, and detecting the reflected light, the head is driven so that the center of the light spot always coincides with each middle between tracking grooves. By using each middle between grooves as a recording track, the effect of noise generated from grooves can be avoided. By executing tracking like this and furthermore automatic focusing so that the focal point is set on the recording layer, recording and erasing are executed at the same time by overwriting by one beam. When data is recorded on a track (middle between tracking grooves) by crystallization, the range of laser power which is suited to crystallization is a range such that it is high enough for generation of crystallization and it is lower than that for generation of amorphization. When data is erased by amorphization, the range of laser power which is suited to amorphization is a range such that it is higher than that for crystallization and lower than that for strong deformation or boring. Overwriting by one beam is executed by changing the laser power between the intermediate power level for generating crystallization and the high power level for generating amorphization. It is particularly desirable that the power ratio between the high power level for amorphization and the intermediate power level for crystallization is within a range from 1:04 to 1:0.8. When the recording portion passes, the laser power is lowered to the reproduction light level at which nothing is changed and the tracking and automatic focusing are continued. The tracking and automatic focusing are continued even during recording. By doing this, even if information is recorded in a portion where information is already recorded, the recorded information is rewritten to the newly recorded information. However, if continuous light of a power close to the higher power of the aforementioned laser power modulation is irradiated so as to erase a record by the first rotation or a plurality of rotations for rewriting the record and a laser beam which is modulated between the high power level and the intermediate power level according to an information signal is irradiated so as to record information by the next one rotation, the unerased portion of the information which is previously written is little and a high carrier to noise ratio is obtained. In this case, when the power of continuous light which is irradiated first is within a range from 0.8 to 1.1 assuming the aforementioned high power level as 1, satisfactory rewriting can be executed.
The linear speed of the disk I is set to 5.6 m/s, and the reproduction light level is set to 1.0 mW, and the laser power is changed between the intermediate power level (on the disk surface) due to crystallization and the high power level (on the disk surface) due to amorphization so as to record information. Continuous light of 1.0 mW on the disk surface at the reproduction light level at which no recording and erasing are executed is irradiated by executing tracking and automatic focusing on the track which is recorded in this way and the information is reproduced by detecting the intensity of the reflected light. In this case, a repetitive signal (0.79 MHz, duty 50%) of 11T at 8 to 14 modulation (EFM) and a repetitive signal (2.88 MHz, duty 50%) of 3T are divided into multi-pulses of 8.64 MHz and a duty of 50% and the recording laser beam is modulated between the high power level 30 mW and the intermediate power level 18 mW so as to execute overwriting. In this case, from the medium reflectivity (Ro) in the unrecorded portion and the medium reflectivity (Rw) in the information recorded portion, the read out signal modulation amplitude (Mod) in the information recorded portion is defined as indicated by the following Formula 1:
Mod(%)=100×|Ro-Rw|/Ro Formula 1!
When the repetitive signal of 11T at EFM is recorded first, the reflectivity in the recording laser beam irradiation portion changes from 34% to 12% and a reproduction signal output of a carrier to noise ratio of 60 dB is obtained at a read out signal modulation amplitude of 65% with a resolution band width of 10 kHz. If the repetitive signal of 3T at EFM is overwritten furthermore, a reproduction signal output of a carrier to noise ratio of 58 dB and of an erasing ratio of 30 dB of the previous signal (repetitive signal of 11T) is obtained at a read out signal modulation amplitude of 61% with a measurement band width of 10 kHz. In this case, the rewritable cycles is 100000 times or more.
The oxidation resistance of the aforementioned disk I is extremely superior and even if the disk I is left under the condition of 60° C. and 95% RH for 3000 hours, the medium reflectivity or transmissivity for a laser beam is not changed. Even if the disk I on which a repetitive signal of 3T at EFM is overwritten at a linear speed of 5.6 m/s beforehand is left under the condition of 60° C. and 95% RH for 3000 hours, the read out signal modulation amplitude and the carrier to noise ratio of a reproduction signal output are not changed.
In the recording layer 3 of the Ge--Te--Se--Sb system of the disk I, when the relative ratio of the other elements is kept almost constant and the Sb content is changed, the rewritable cycles and the carrier to noise ratio when a repetitive signal of 11T and a repetitive signal of 3T are overwritten at a linear speed of 5.6 m/s are changed as shown in Table 1.
TABLE 1______________________________________Composition of recording Carrier tolayer (atomic percent) Cyclability noise ratio______________________________________Ge.sub.50 Te.sub.33.3 Se.sub.16.7.7 Sb.sub.0 50 times 58 dBGe.sub.49.5 Te.sub.33 Se.sub.16.5 Sb.sub.1 10000 times 58 dBGe.sub.49 Te.sub.32.7 Se.sub.16.3 Sb.sub.2 50000 times 59 dBGe.sub.48 Te.sub.32 Se.sub.16 Sb.sub.4 100000 times 60 dBGe.sub.46 Te.sub.30.7 Se.sub.15.3 Sb.sub.8 100000 times 59 dBGe.sub.45 Te.sub.30 Se.sub.15 Sb.sub.10 100000 times 58 dBGe.sub.42.5 Te.sub.28.3 Se.sub.14.2 Sb.sub.15 100000 times 55 dBGe.sub.40 Te.sub.26.6 Se.sub.13.3 Sb.sub.20 50000 times 50 dBGe.sub.37.5 Te.sub.25 Se.sub.12.5 Sb.sub.25 10000 times 43 dB______________________________________
When the Sb content is 0 atomic percent, the rewritable count is very small such as 50 times and when the Sb content is 25 atomic percent, the carrier to noise ratio is 43 dB which is lower than the lowest level 45 dB at which a signal can be reproduced as a digital signal free of an error because the read out signal modulation amplitude is small. When the Sb content is within a range from 1 atomic percent to 20 atomic percent, the rewritable count and the carrier to noise ratio show satisfactory characteristics. When the Sb content is within a range from 2 atomic percent to 10 atomic percent, both the rewritable count and the carrier to noise ratio show particularly satisfactory characteristics.
When the Sb content is fixed to 4 atomic percent, and the ratio of the Te content to the Se content is fixed to 2:1, and the ratio of the Ge content to the total of the contents of Ge, Te, and Se {x/(x+y+z)} is changed in the recording layer 3 of a composition of Ge 48 Te 32 Se 16 Sb 4 , the crystallization time of the recording layer itself (the shortest irradiation time necessary for erasing) and the rewritable cycles when a repetitive signal of 11T and a repetitive signal of 3T are overwritten at a linear speed of 1.4 m/s are changed as shown in Table 2.
TABLE 2______________________________________{x/(x + y + z)} Crystallization time Cyclability______________________________________0.25 10 μs Overwriting disabled0.3 1 μs 10000 times0.35 0.8 μs 10000 times0.4 0.5 μs 50000 times0.45 0.3 μs 100000 times0.5 0.15 μs 100000 times0.55 0.2 μs 100000 times0.6 0.3 μs 100000 times0.65 0.5 μs 50000 times0.7 0.8 μs 10000 times0.75 5 μs Overwriting disabled______________________________________
In this case, when the ratio of the Ge content to the total of the contents of Ge, Te, and Se {x/(x+y+z)} is 0.25 or 0.75, the crystallization time of the recording layer is as long as 5 μs or more and overwriting cannot be executed at a linear speed of 1.4 m/s. When 0.3<{x/(x+y+z)}<0.7, the crystallization time is as short as 1 μs and overwriting can be executed at a linear speed of 1.4 m/s. When 0.4<{x/(x+y+z)}<0.65, both the crystallization time and overwriting show satisfactory characteristics. When 0.45<{x/(x+y+z)}<0.6, both the crystallization time and overwriting show particularly satisfactory characteristics.
When the Sb content is fixed to 4 atomic percent, and the Ge content is fixed to 48 atomic percent, and the content of Te and Se the ratio of the Te content to the total of the contents of Te and Se {y/(y+z)} is changed in the recording layer 3 of a composition of Ge 48 Te 32 Se 16 Sb 4 of the disk I, the crystallization time of the recording layer itself (the shortest irradiation time necessary for erasing) and the retention life of the recording marks until the carrier to noise ratio when the disk is left under the condition of 60° C. and 95% RH is reduced by 3 dB are changed as shown in Table 3.
TABLE 3______________________________________Composition ofrecording layer Crystalli- Retention life of(atomic percent) {y/(y + z)} zation time recording marks______________________________________Ge.sub.48 Te.sub.38 Se.sub.10 Sb.sub.4 0.792 0.1 μs 1000 hoursGe.sub.48 Te.sub.34 Se.sub.14 Sb.sub.4 0.708 0.12 μs 3000 hours or moreGe.sub.48 Te.sub.32 Se.sub.16 Sb.sub.4 0.667 0.15 μs 3000 hours or moreGe.sub.48 Te.sub.28 Se.sub.20 Sb.sub.4 0.583 0.25 μs 3000 hours or moreGe.sub.48 Te.sub.24 Se.sub.24 Sb.sub.4 0.5 0.3 μs 3000 hours or moreGe.sub.48 Te.sub.22 Se.sub.26 Sb.sub.4 0.458 0.5 μs 3000 hours or moreGe.sub.48 Te.sub.19 Se.sub.29 Sb.sub.4 0.396 0.8 μs 3000 hours or moreGe.sub.48 Te.sub.16 Se.sub.32 Sb.sub.4 0.333 3.0 μs 3000 hours or more______________________________________
In this case, when the content of Te is as large as 38 atomic percent, the retention life of the recording marks is short and the disk is not suited to an information recording medium. When the content of Se is as large as 32 atomic percent, the crystallization time is as long as 3 μs and overwriting cannot be executed. When the content of Te is 34 atomic percent or less and the content of Se is 32 atomic percent or less, both the crystallization time and the retention life of the recording marks show satisfactory characteristics. When the ratio of the Te content to the total of the contents of Te and Se {y/(y+z)} is 0.45 or more, the crystallization time shows a particularly satisfactory characteristic such as 0.5 μs.
From the aforementioned experiment results, the ranges within which the ratios w, x, y, and z of the constituent elements of the recording layer show satisfactory characteristics are as shown below.
1≦w≦20, 0.3≦x/(x+y+z)≦0.7, 1≦y≦34, and 1≦z≦29.
More desirable ranges of w, x, y, and z are as shown below.
1≦w≦20 and 0.4≦x/(x+y+z)≦0.65.
Still more desirable ranges of w, x, y, and z are as shown below.
1≦w≦15 and 0.45≦x/(x+y+z)≦0.6.
Particularly desirable ranges of w, x, y, and z are as shown below.
2≦w≦10, 0.45≦x/(x+y+z)≦0.6, and 0.45≦y/(y+Z)
Therefore, it is desirable that the incorporated amount of an element expressed by A is within a range from 1 atomic percent to 20 atomic percent and when the incorporated amount is beyond the range, the recording and reproducing characteristics are degraded. It is more desirable that the incorporated amount of an element expressed by A is within a range from 1 atomic percent to 15 atomic percent and it is still more desirable that the incorporated amount is within a range from 2 atomic percent to 10 atomic percent.
In the recording layer and the reflection layer of the present invention, when the mean composition in the direction of film thickness is within the aforementioned ranges, it is possible that the composition is changed in the direction of film thickness. It is desirable that the composition does not change discontinuously.
A rare gas element such as Ar or Xe may get mixed in a recording layer depending on conditions for forming the recording layer such as sputtering and no particularly remarkable effect is produced in the recording and reproduction characteristics by addition of a rare gas element as mentioned above. When the incorporated amount is as small as less than 5 atomic percent, no great adverse effect is produced. However, when 5 atomic percent or more is mixed in, it is necessary to take care because the reproduction waveform is greatly distorted when data is rewritten many times.
Even if a part or the whole of Sb is replaced by at least one element selected from among Bi, Al, Ga, In, Si, Sn, Pb, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, La, Hf, Ta, W, Re, Os, Ir, Pt, Au, Ag, and Cu in the recording layer 3 of the Ge--Te--Se--Sb system of the disk I, when data is recorded, reproduced, and erased as a reversible type, characteristics which are very similar to each other are obtained. Elements among the aforementioned elements expressed by A in the general expression which have particularly satisfactory recording, reproducing, and erasing characteristics are Sb in the Vb group, Sn in the IVb group, In in the IIIb group, Ag in the Ib group, and Cr and Co in the transition metallic elements of other than the Ib group.
In place of the reflection layer 5 of a composition of Al 97 Ti 3 of the disk I, even if a reflection layer composed of one of the other Al alloy, Au alloy, Ag alloy, and Cu alloy is used, the same result is obtained.
When the film thickness of the recording layer 3 in the disk I is within a range from 5 nm to 500 nm, data can be recorded by a semiconductor laser. In respect of that a change in the reflection factor due to recording becomes larger by the effect of light interference, it is desirable that the film thickness is within a range from 10 nm to 250 nm. When the film thickness is within a range from 10 nm to 100 nm, it is more desirable because the recording sensitivity is also high.
When the film thickness of the reflection layer 5 in the disk I is within a range from 20 nm to 500 nm, the disk reflectivity is 30% or more and data can be recorded by a semiconductor laser. In respect of that the read out signal modulation degree can be increased more and the recording sensitivity is also high, it is more desirable that the film thickness is within a range from 30 nm to 200 nm.
Even if a semiconductor laser with a wave length of 830 nm is used in place of a semiconductor laser with a wave length of 780 nm in the optical disk drive, by slightly adjusting the film thickness of each layer in the disk I except the reflection layer 5, the same results of recording, erasing, and reproducing characteristics are obtained. When data which is recorded and erased by an optical disk drive having a semiconductor laser with a wave length of 780 nm is reproduced by an optical disk drive having a semiconductor laser with a wave length of 680 nm or 630 nm, by slightly adjusting the film thickness of each layer in the disk I except the reflection layer 5 according to the respective wave length, the same result of reproducing characteristic is obtained.
Two disks I are bonded to each other with the surfaces on the opposite side of the substrate located inside by using hot melt type adhesive. In the bonded disks, the recording, erasing, and reproducing characteristics which are quite equal to the aforementioned case of this embodiment are obtained on both surfaces and the capacity per each disk can be doubled.
EMBODIMENT 2
FIG. 2 shows a disk II which is another embodiment of the present invention. On a replica substrate 7 in which a spiral groove with a pitch of 1.2 μm for tracking is formed on the surface of a disk-shaped polycarbonate plate with a diameter of 120 mm and a thickness of 1.2 mm by the injection method, a lower reflection layer 8 of a composition of Au 97 Co 3 represented by atomic percent is formed with a film thickness of 13 nm first by using a high frequency magnetron sputtering apparatus. Then, a lower protection layer 9 of a composition of (ZnS) 80 (SiO 2 ) 20 represented by atomic percent is formed with a film thickness of 25 nm in the same sputtering apparatus. Then, a recording layer 10 of a composition of Ge 48 Te 32 Se 16 Sb 4 represented by atomic percent is formed with a film thickness of 20 nm in the same sputtering apparatus. Then, an upper protection layer 11 of a composition of (ZnS) 80 (SiO 2 ) 20 represented by atomic percent is formed with a film thickness of 40 nm in the same sputtering apparatus. Then, an upper reflection layer 12 of a composition of Au 97 Co 3 represented by atomic percent is formed with a film thickness of 35 nm in the same sputtering apparatus. Furthermore, an organic layer 13 with a thickness of 50 μm is formed by curing ultraviolet curing resin which is spin-coated on the upper reflection layer 12. FIG. 2 shows a cross sectional structure diagram of the disk II which is prepared as mentioned above.
Using the disk II which is prepared as mentioned above as a reversible type, recording, erasing, and reproduction are evaluated by an optical disk drive (recording, erasing, and reproducing apparatus) by rotating the disk at a fixed linear speed in the same was as with Embodiment 1. The disk reflectivity immediately after the disk II is prepared is low such as 14%, so that when the disk is initialized overall by a laser beam equivalent to a power of 18 mW on the disk surface at a linear speed of 1.4 m/s, the reflectivity increases from 14% to 71%. The linear speed of the disk II is set to 1.4 m/s, and the reproduction light power level is set to 1.0 mW, and the laser power is changed between the intermediate power level (on the disk surface) due to crystallization and the high power level (on the disk surface) due to amorphization so as to record information. A repetitive signal (0.2 MHz, duty 50%) of 11T at EFM and a repetitive signal (0.72 MHz, duty 50%) of 3T are divided into multi-pulses of 2.16 MHz and a duty of 33% and overwriting is executed by using recording laser beams of a high power level of 31.5 mW and an intermediate power level of 17 mW alternately. When the repetitive signal of 11T at EFM is recorded first, the reflection factor in the recording laser beam irradiation portion changes from 71% to 24% and a reproduction signal output of a carrier to noise ratio of 61 dB is obtained at a read out signal modulation amplitude of 66% and a measurement band width of 10 kHz. If the repetitive signal of 3T at EFM is overwritten furthermore, a reproduction signal output of a carrier to noise ratio of 58 dB and of an erasing ratio of 30 dB of the previous signal (repetitive signal of 11T) is obtained at a read out signal modulation amplitude of 49% and a measurement band width of 10 kHz. In this case, the rewritable count is 10000 times or more. The oxidation resistance of the aforementioned disk II is extremely superior and even if the disk II is left under the condition of 60° C. and 95% RH for 3000 hours, the medium reflectivity or transmissivity for a laser beam is not changed. Even if the disk II on which a repetitive signal of 3T at EFM is overwritten at a linear speed of 1.4 m/s beforehand is left under the condition of 60° C. and 95% RH for 3000 hours, the read out signal modulation amplitude and the carrier to noise ratio of a reproduction signal output are not changed.
When the Co content is changed in the lower reflection layer 8 and the upper reflection layer 12 of a composition of Au 97 Co 3 in the disk II, the reflectivity of the upper reflection layer 12, the electric resistivity and thermal conductivity at 298 K, and the recording power (high power level) when a repetitive signal of 11T at EFM is overwritten at a linear speed of 1.4 m/s are changed as shown in Table 4.
TABLE 4______________________________________ Reflecti- Electric ThermalCo content vity resistivity conductivity Recording power(Atomic %) (%) (μΩ cm) (W/m · K) (mW)______________________________________0 98 3 245 Unrecordable at 50 mW0.5 97.5 7 105 451 97 9 82 382 96 14 53 333 95 19 39 304 94 26 28 275 93 32 23 258 91 33 22 24.510 89 33 22 2415 85 33 22 2320 80 33 22 22______________________________________
In this case, when the Co content is less than 0.5 atomic percent, the electric resistivity at 298K becomes less than 7 μΩ·cm, so that the thermal conductivity at 298K becomes more than 105 W/m·K and no data can be recorded at 45 mW on the disk surface. When the Co content is more than 15 atomic percent, the reflectivity becomes less than 85% and it is difficult that the disk reflectivity becomes 65% or more. When the Co content is within a range from 1 atomic percent to 8 atomic percent, the reflectivity of the reflection layer is as high as 91% or more, so that the disk reflection factor can be increased more. When the Co content is within a range from 2 atomic percent to 5 atomic percent, the disk reflectivity is high and the electric resistivity is as high as 14 μΩ·cm or more, so that the thermal conductivity is as low as 53 W/m·K or less and the recording sensitivity and the erasing sensitivity are satisfactory. Even if a part or the whole of Co is replaced by at least one element selected from among Al, Si, Sc, Ti, V, Cr, Mn, Fe, Ni, Zn, Ga, Ge, Y, Zr, Nb, Mo, Ru, Rh, Pd, Cd, In, Sn, Sb, Te, La, Hf, Ta, W, Re, Os, Ir, Pt, Tl, Pb, and Bi, the same result is obtained. When Co is added among the aforementioned additional elements, the recording sensitivity and the erasing sensitivity are satisfactory compared with the other elements. When Pd is added, the oxidation resistance of the reflection layers 8 and 12 is satisfactory. When Ti is added, the crystal grain diameter of the reflection layers 8 and 12 is small and the noise is low. When Mo is added, the adhesion of the reflection layers 8 and 12 is satisfactory and the erasing ratio of the rewritable type is high. On the other hand, when Ni is added, the adhesive strength of the reflection layers 8 and 12 is lower than that of the other additional elements and the rewriting count of the rewritable type is limited. When Cr is added, the roughness of each surface of the reflection layers 8 and 12 is slightly larger than that of the other additional elements and the disk noise is slightly higher.
In the lower reflection layer 8 and the upper reflection layer 12 of a composition of Au 97 Co 3 in the disk II, even if a reflection layer of a composition of Au 50 Ag 50 is used in place of Au 97 Co 3 , the same result is obtained.
When the Ag content is changed in the aforementioned lower reflection layer 8 and upper reflection layer 12 of a composition of Au 50 Ag 50 , the reflection factor of the reflection layers themselves for a reproduction light beam, the disk reflection factor when a repetitive signal of 11T at EFM is overwritten at a linear speed of 1.4 m/s, the electric resistivity at 298K, the thermal conductivity at 298 K, and the recording power (high power level) are changed as shown in Table 5.
TABLE 5______________________________________ Reflecti- Electric Thermal RecordingComposition vity resistivity conductivity power(Atomic %) (%) (μΩ cm) (W/m · K) (mW)______________________________________Au.sub.90 Ag.sub.10 97 5 147 Unrecordable at 50 mWAu.sub.85 Ag.sub.15 97 7 105 48Au.sub.80 Ag.sub.20 96.5 9 82 40Au.sub.70 Ag.sub.30 96.5 14 53 34Au.sub.60 Ag.sub.40 96 15.5 47 32Au.sub.50 Ag.sub.50 96 16 46 30Au.sub.40 Ag.sub.60 96 15.5 47 32Au.sub.30 Ag.sub.70 96.5 14 53 34Au.sub.20 Ag.sub.80 96.5 9.5 77 38Au.sub.15 Ag.sub.85 97 7 105 48Au.sub.10 Ag.sub.90 97 4.5 163 Unrecordable at 50 mW______________________________________
In this case, when the Ag content is less than 10 atomic percent or more than 90 atomic percent, the electric resistivity at 298K is less than 7 μΩ·cm, so that the thermal conductivity at 298K is more than 105 W/m·K and such a high recording power as 35 mW or more is necessary on the surface of the disk though the disk reflectivity is as low as 34%. When the Ag content is within a range from 30 atomic percent to 70 atomic percent, the electric resistivity is as high as 14 μΩ·cm or more, so that the thermal conductivity is as low as 53 W/m·K or less and the recording sensitivity and the erasing sensitivity are satisfactory. Furthermore, even if a reflection layer of the Au--Cu system is used in place of the aforementioned reflection layer of the Au--Ag system, the same result is obtained.
When the film thickness of the upper reflection layer 12 in the disk II is within a range from 20 nm to 500 nm, the disk reflection factor is 65% or more and data can be recorded by a semiconductor laser. In respect of that the reflectivity can be increased more and the recording sensitivity is also high, it is more desirable that the film thickness is within a range from 30 nm to 200 nm. When the film thickness of the lower reflection layer 8 is within a range from 2 nm to 40 nm, the disk reflection factor is 65% or more and data can be recorded by a semiconductor laser. In respect of that the reflection factor can be increased more and the recording sensitivity is also high, it is more desirable that the film thickness is within a range from 5 nm to 30 nm. When the film thicknesses of the lower reflection layer 8 and the upper reflection layer 12 are within the aforementioned ranges even if the reflection layers are different in the composition, the same result is obtained.
Even if a semiconductor laser with a wave length of 830 nm is used in place of a semiconductor laser with a wave length of 780 nm in the optical disk drive, by slightly adjusting the film thickness of each layer in the disk II except the upper reflection layer 12, the same results of recording, erasing, and reproducing characteristics are obtained. When data which is recorded and erased by an optical disk drive having a semiconductor laser with a wave length of 780 nm is reproduced by an optical disk drive having a semiconductor laser with a wave length of 680 nm or 630 nm, by slightly adjusting the film thickness of each layer in the disk II except the upper reflection layer 12 according to the respective wave length, the same result of reproducing characteristic is obtained.
When at least one surface of the recording layer of the information recording medium of the present invention is adhered and protected by a protection layer formed by a different material (FIG. 1), the environment resistance of the information recording medium is improved and when both sides thereof are protected as shown in FIG. 2, the environment resistance of the information recording medium is improved more and the rewriting performance when it is used as a reversible type is improved.
These protection layers may be formed from inorganic substances containing, for example, an oxide, fluoride, nitride, sulfide, carbide, boride, boron, carbon, or metal as a main component. Or, the protection layers may be formed from an organic substance such as, for example, acrylic resin, polycarbonate, polyolefine, epoxy resin, polyimide, polyamide, polystyrene, polyethylene, polyethylene terephthalate, fluorine-contained resin (poly-4-fluorinated ethylene), or ultraviolet curing resin. Furthermore, the protection layers may be formed from a composite material thereof.
An example of an inorganic protection layer comprises as a main component an oxide of at least one element selected from the group consisting of Ce, La, Si, In, Al, Ge, Pb, Sn, Bi, Te, Ta, Sc, Y, Ti, Zr, V, Nb, Cr, and W, a sulfide of at least one element selected from the group consisting of Cd, Zn, Ga, In, Sb, Ge, Sn, Pb, and Bi, a fluoride of Mg, Ce, Ca or the like, a nitride of Si, Al, Ta, B or the like, a carbide of B, Si or the like, a boride of Ti or the like, boron, and carbon and for example, the main component thereof has a composition close to one of SiO 2 , SiO, CeO 2 , La 2 O 3 , In 2 O 3 , Al 2 O 3 , GeO, GeO 2 , PbO, SnO, SnO 2 , Bi 2 O 3 , TeO 2 , Ta 2 O 5 , Sc 2 O 3 , Y 2 O 3 , TiO 2 , ZrO 2 , V 2 O 5 , Nb 2 O 5 , Cr 2 O 3 , WO 2 , WO 3 , ZnS, CdS, In 2 S 3 , Sb 2 S 3 , Ga 2 S 3 , GeS, SnS, SnS 2 , PbS, Bi 2 S 3 , MgF 2 , CeF 3 , CaF 2 , TaN, Si 3 N 4 , AlN, BN, Si, TiB 2 , B 4 C, SiC, B, and C or a mixture thereof. Among these inorganic protection layers, a sulfide which is close to ZnS is desirable in respect of that the refractive index is suitably high and the layer is stable, and a nitride which has a composition close to TaN, Si 3 N 4 , or AlN (aluminum nitride) is desirable, in respect of that the surface reflection factor is not so high and the layer is stable and strong. A desirable oxide is a one having a composition of SiO 2 , SiO, Y 2 O 3 , Sc 2 O 3 , CeO 2 , TiO 2 , ZrO 2 , Ta 2 O 5 , In 2 O 3 , Al 2 O 3 , or SnO 2 or close to one of them. An amorphous Si containing hydrogen is also desirable. Among mixtures, a mixture of ZnS and SiO 2 is desirable in respect of that the recording sensitivity is satisfactory.
In inorganic and organic protection layers, it is desirable for heat resistance that a recording layer is adhered closely to an inorganic protection layer. However, when an inorganic layer is thick, at least one of occurrence of cracks, reduction in the transmissivity, and reduction in the sensitivity is caused easily, so that it is desirable that the above inorganic layer is made thin and a thick organic layer is adhered to the side of the inorganic layer opposite to the recording layer so as to increase the mechanical strength. By doing this, deformation is hard to occur. A material used for an organic layer is, for example, polystyrene. poly-4-fluorinated ethylene, polyimide, acrylic resin, polyolefine, polyethylene terephthalate, polycarbonate, epoxy resin, ethylene-vinyl acetate copolymer which is known as a hot melt adhesive, pressure sensitive adhesive, or ultraviolet curing resin.
A protective layer composed of inorganic substances may be formed by electron beam deposition or sputtering as it is. However, it can be produced easily by forming a layer composed of at least one element of metal, metalloid, and semiconductor by reactive sputtering and then allowing it to react with at least one of oxygen, sulfur, and nitrogen.
Use of multi protection layers increases the protection effect more. For example, when a thin film with a thickness between 10 nm and 300 nm having a composition close to SiO 2 is formed on the far side from the recording layer and a thin film with a thickness between 10 nm and 300 nm having a composition close to ZnS is formed on the near side to the recording layer, the environment resistance and the recording and erasing characteristics improve greatly and the rewriting performance can be improved substantially. When the aforementioned protection layer is formed on the substrate side (light entering side), it can serve as a reflection prevention layer for increasing the reproduction signal strength.
When the film thickness of each layer is within the ranges indicated below, satisfactory recording, erasing, and reproduction are possible.
Film thickness of recording layer: From 5 nm to 500 nm
Film thickness of reflection layer: From 5 nm to 500 nm
Film thickness of inorganic protection layer: From 5 nm to 500 nm
Film thickness of organic protection layer: From 500 nm to 5 mm
When the film thickness of each layer is within the ranges indicated below, more satisfactory recording and reproduction are possible.
Film thickness of recording layer: From 10 nm to 300 nm
Film thickness of reflection layer: From 5 nm to 200 nm
Film thickness of inorganic protection layer: From 10 nm to 300 nm
Film thickness of organic protection layer: From 2 μm to 0.5 mm
Even if ZnS, SiO 2 , SiO, CeO 2 , Al 2 O 3 , Ta 2 O 5 , Y 2 O 3 , ZrO 2 , V 2 O 5 , TaN, Si 3 N 4 , or AlN or a mixture thereof in which the extinction coefficient which is the imaginary part of the complex refractive index for a laser beam is 0.2 or less is used in the same way in place of the (ZnS)--(SiO 2 ) system which is used for the protection layers in the disks I and II, by controlling each film thickness according to the respective optical constants, the same recording and erasing characteristics as those of the disk II are obtained.
In a disk comprising two disks II which are bonded to each other with the surfaces on the opposite side of the substrate located inside by using two-part mixture reactive adhesive, the recording, erasing, and reproducing characteristics which are quite equal to the aforementioned case of this embodiment are obtained on both surfaces and the capacity per each disk can be doubled.
Even if a replica in which an ultraviolet curing resin layer having a tracking groove is formed on the surface of a chemically reinforced glass plate, a polycarbonate plate, a polyolefine plate, an epoxy plate, or an acrylic resin plate by the photopolymerization method is used in addition to a polycarbonate substrate or a polyolefine substrate prepared by the injection method as a substrate of the information recording medium of the present invention, the same results of recording, erasing, and reproducing characteristics are obtained.
As a method of forming the aforementioned substrates and layers, a suitable one is selected from the methods of injection, photopolymerization (2P method), casting, vacuum deposition, in-gas deposition, sputtering, ion beam deposition, ion plating, electron beam deposition, spin coating, and plasma polymerization. It is desirable to form a reflection layer, an inorganic recording layer, and an inorganic protection layer by sputtering because the composition and film thickness can be managed easily and the production cost is low.
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An information recording medium comprises at least a substrate, a recording layer which is installed on the substrate via a protection layer and in which the atomic arrangement is changed without the shape thereof being changed when a recording energy beam is irradiated and the optical constants are changed, and a reflection layer reflecting the recording energy beam and by making the information recording medium comprise a material such that the mean composition of the recording layer is expressed by a general expression of A w Ge x Te y Se z (where symbols w, x, y, and z indicate atomic percent and have the predetermined values and A indicates at least one of the predetermined elements Sb, Cr, Co, In, and Ag, etc.), an information recording medium in which the recording, erasing, and reproducing characteristics are satisfactory and the stability is kept superior for a long period of time can be obtained.
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TECHNICAL FIELD
[0001] The present invention relates to a medical implant and method, and, more particularly, to an improved surgical implant and method for expanding the spinal canal to eliminate pressure on the spinal cord caused by an impinging vertebral bone.
BACKGROUND OF THE INVENTION
[0002] Various medical conditions may result in a reduction of the area within the vertebrae available for the spinal cord. Spinal stenosis is one such condition involving the narrowing of the canal in the center of the spine through which the spinal cord and nerve roots run. Spinal stenosis may result when the ligaments of the spine thicken and calcify (harden from deposits of calcium salts), or when bones and joints enlarge, and osteophytes (bone spurs) form. A herniated (bulging) disk may also place pressure on the spinal cord or nerve root. Furthermore, diseased bone or tumors may result in an ingrowth into the spinal cord area. This decreases the space (neural foramen) available for nerve roots leaving the spinal cord.
[0003] Two surgical methods currently exist to create additional room in the spinal canal. The first is called a laminectomy, and involves removal of the lamina (roof) of one or more vertebrae. A limitation of the laminectomy procedure is that it involves removal of the supporting structures at the back of the vertebrae which align the spinal column. The result may be that a patient suffers some postural deformity. To prevent such postural problems, a graft may be installed between the ends of the removed bone to span the void and reinstate the necessary support. The second procedure is called a laminoplasty, in which the targeted vertebra is cut, spread apart and a graft is inserted to permanently enlarge the space. Unlike the laminectomy, typically no bone material is excised during the laminoplasty procedure. Two different laminoplasty procedures are currently used. The first is called the unilateral or “open door” laminoplasty in which one side (lamina) of the vertebra is cut all the way through, while the other side is cut only half way to create a hinge. The vertebral element is then rotated about the hinge, and the graft is inserted into the opening, increasing the opening of the spinal canal. The second procedure is called the bilateral or “French door” laminoplasty in which the midline of the vertebra (spinous process) is cut all the way through, and the lamina are cut half way through, creating two hinges. The vertebral element is then opened at the bisected spinous process, and a graft inserted into the opening, again increasing the opening of the spinal canal.
[0004] Various materials may be used for the grafts installed during laminoplasty procedures. U.S. Pat. No. 6,080,157 to Cathro et al. and U.S. Pat. No. 5,980,572 to Kim et al. disclose the use of titanium, ceramic and nylon inserts. Further, using allografts taken from long bones such as the femur, humerus, tibia and fibula, for spinal fusion procedures is known, as disclosed by U.S. Pat. No. 5,728,159 to Stroever et al. Allografts, as such bone grafts are called, are removed from a donor and processed using known techniques to preserve the allograft until implantation. Allografts have mechanical properties which are similar to the mechanical properties of vertebrae even after processing. The benefit of such property matching is that it prevents stress shielding that occurs with metallic implants. Allografts, unlike magnetic metals, are also compatible with magnetic resonance imaging (MRI) procedures, allowing more accurate ascertainment of fusion. Furthermore, allografts are naturally osteogenic providing excellent long term fusion with the patient's own bone.
[0005] Several different spacer designs have been used in laminoplasty procedures to the present. For example, the Cathro patent discloses a metal, nylon or teflon spacer for use in a unilateral laminoplasty procedure. The Cathro spacer is a rectangular plate having shouldered edges which engage the ends of the cut lamina, and is held in place by a spring mechanism. The difficulty with the Cathro spacer is that its operation relies on the continued satisfactory operation of the installed spring. Further, the Cathro device provides little available area for the packing of fusion enhancing (i.e. osteogenic) material. The Kim patent discloses a spacer for use in a bilateral laminoplasty procedure. The Kim spacer consists of inner and outer trapezoidal segments joined together by a rectangular segment. The tapered surface of the inner trapezoidal segment is designed to conform to the inner surface of the split spinous process halves, while the taper of the outer segment is designed to assume the shape of the removed spinous process tip. The Kim spacer seats on the resulting flat surface of bone. Like the Cathro device, the Kim device provides little area in which to pack osteogenic material to facilitate bone-implant fusion. Neither the Cathro nor Kim device use allograft as a spacer material, which may result in reduced propensity for fusion and the possibility for stress shielding.
[0006] Accordingly, there is a need in the art to provide implants and methods for both laminectomy and unilateral and bilateral laminoplasty procedures, which provide excellent dimensional, strength and retention capability, which enhance fusion with the patient's own bone, which are easy to select, fit and install and which provide excellent compatability with post-operative imaging (MRI).
SUMMARY OF THE INVENTION
[0007] The implants of present invention are provided for use in the spinal column. In one embodiment, the implants comprise an allograft fabricated from cancellous bone material and a member formed of non-allograft material having first and second bone engaging portions and an allograft engaging portion. The graft engaging portion may be configured to retain the allograft when the allograft contacts the graft engaging portion.
[0008] The graft engaging portion may comprise at least one raised tab. Further, the implant member may have a central region between the first and second bone engaging portions and the at least one raised tab angled inward toward the central region of the member. The allograft may have first and second ends, each comprising bone engaging portions, where at least one of the bone engaging portions is comprised of partially, substantially, or fully demineralized bone. At least one of the implant member bone engaging portions may comprise a suture attachment portion configured to allow a surgeon to secure the member bone connecting portions to the first and second bone segments.
[0009] In a different embodiment, an implant is provided for use in maintaining a desired distance between a first spinal bone cut end and a second spinal bone cut end, in which the implant comprises an allograft having a body and first and second ends, and a plate formed of a non-allograft material having an intermediate portion and first and second ends, where the intermediate portion has an allograft engaging portion configured to retain the allograft, and where the first and second ends of the plate have bone engaging portions which themselves have fastener receiving portions. The allograft engaging portion is configured to engage the allograft body and the bone engaging portions are configured to engage respective outer surfaces of first and second spinal bone cut ends. The allograft first and second ends are configured to contact the first and second cut bone ends. In a specific embodiment, the allograft engaging portion may comprise deformable fingers configured to engage the graft. In another specific embodiment, the allograft engaging portion may comprise a hollow portion, where the allograft has a shape complementary to the hollow portion, and where the hollow portion is configured to at least partially receive the allograft. In a further embodiment, the allograft first and second ends comprise bone engaging portions, at least one of which may comprise partially, substantially, or fully demineralized bone.
[0010] A method for providing a desired distance between first and second cut bone ends of the spine is also provided. This method comprising the steps of: cutting a vertebra to produce first and second cut bone ends; separating the bone ends to define a space therebetween; providing an allograft having a body and first and second ends; providing a plate formed of a non-allograft material having an intermediate portion and first and second ends, where the intermediate portion has an allograft engaging portion configured to retain the allograft, the first and second plate ends have bone engaging portions with fastener receiving portion, and where the allograft engaging portion is configured to engage the allograft body, the bone engaging portions are adapted to engage the first and second bone outer surfaces, and the allograft first and second ends are configured to contact the first and second cut bone ends, then engaging the allograft engaging portions of the plate with the allograft; engaging the bone engaging portions with respective cut bone ends; providing at least two bone fasteners; inserting at least one fastener into the fastener receiving portion of each bone engaging portion; and engaging the at least one bone fasteners with said cut bone end. In a further embodiment, the step of cutting a vertebra may comprise cutting all the way through one lamina. In a further embodiment, the adjacent lamina further may be cut half way through.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The features and advantages of the implant and method of use will become more readily apparent from the following detailed description of the invention in which like elements are labeled similarly and in which:
[0012] [0012]FIGS. 1A, 1B and 1 C are perspective, end and top views of the first embodiment of the implant, for use in a unilateral laminoplasty procedure;
[0013] [0013]FIGS. 2A and 2B are side and top views of the implant of FIG. 1 installed between the cut lamina segments of a vertebra during a unilateral laminoplasty procedure;
[0014] [0014]FIGS. 3A and 3B are a perspective view of a retaining plate of the present invention, and a side view of two such retaining plates installed over the implants of FIGS. 2A and 2B;
[0015] [0015]FIGS. 4A and 4B are perspective and side views of a second embodiment of the implant, a unilateral implant incorporating demineralized bone flaps;
[0016] [0016]FIGS. 5A, 5B and 5 C are perspective, side and end views of a third embodiment of the implant, for use in a bilateral laminoplasty procedure;
[0017] [0017]FIGS. 6A and 6B are side and section views of the implant of FIG. 5 showing the incorporation of a channel to accept the corresponding arms of a set of distractor pliers used to install the implant;
[0018] [0018]FIG. 7 is a detail view of the end of the implant of FIG. 5B showing a preferred embodiment of the surface projections used to facilitate retention of the implant between cut spinous process segments.
[0019] [0019]FIGS. 8A, 8B and 8 C are perspective, end and side views of a fourth embodiment of the implant, for use in a bilateral laminoplasty procedure;
[0020] [0020]FIGS. 9A and 9B are front and top views of the implants of FIGS. 7 and 8 installed between the cut spinous process segments of a vertebra during a bilateral laminoplasty procedure;
[0021] [0021]FIGS. 10A, 10B and 10 C are perspective, end and top views of a fifth embodiment of the implant, for use in a unilateral laminoplasty procedure;
[0022] [0022]FIGS. 11A, 11B and 11 C are top, side and end views of a sixth embodiment of the implant, for use in a unilateral laminoplasty procedure; and
[0023] [0023]FIGS. 12A and 12B are perspective views of seventh and eighth embodiments of the implant, for use in unilateral laminoplasty procedures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Preferred embodiments, features and aspects of an implant adapted to be used in unilateral and bilateral laminoplasty procedures are described, in which a portion of a targeted vertebra is cut, the space available for the spinal cord and associated nerves is expanded, and an implant is installed between the cut segments of bone.
[0025] Referring more particularly to the drawings, FIGS. 1A, 1B and 1 C show an implant for use in a unilateral or “open door” laminoplasty. The implant 1 has a longitudinal axis “CL,” a length “L,” a wall 5 defining an outside surface 3 and an inside surface 4 , and first and second ends 6 A, 6 B. Inside surface 4 communicates with first and second ends 6 A, 6 B to define a hollow central region 7 of the implant. Outside surface 3 has an outer side region 3 A and an inner side region 3 B such that when the implant is installed between cut segments of lamina, outer side region 3 A faces outward away from the spinal canal, while inner side region 3 B faces inward toward the spinal canal. The implant 1 further has a depth “D” which is the distance between outer side region 3 A and inner side region 3 B. Implant 1 also has a width “W” which is the distance between opposing outer surfaces 3 measured along a drawn line perpendicular to a line defining the depth “D.” Length “L” preferably should be between about 11.5 millimeters (mm) to about 15.5 mm; depth “D” preferably should be between about 5.5 mm to about 6.5 mm; and width “W” preferably should be between about 8.0 mm to about 9.5 mm.
[0026] The shape and size of outside surface 3 is not critical and, therefore, any implant configuration can be used preferably so long as the first and second ends 6 A, 6 B provide sufficient contact area with the lamina ends, and the implant 1 does not interfere with other anatomy, and does not intrude on the spinal cord space. In a preferred embodiment, however, the outside surface 3 is configured such that the shape of the implant, when viewed from the end, displays the form of a substantially geometric shape (e.g. ellipse, oval, circle, etc.). In this embodiment the exterior dimensions of the implant also approximate those of the outside surface of the cut lamina segments between which the implant is installed. Although implants having cross sections of greater or lesser proportion than the lamina to which they attach will function properly, for aesthetic purposes and in an attempt to minimize the amount of material introduced into a patient's body, the outer surface of the implant should preferably not extend beyond the outer surface of the adjoining bone.
[0027] In a further embodiment, the inside surface 4 of the implant 1 may be machined so that the hollow central region 7 approximates the configuration and geometry of the implant exterior (i.e. form an ellipse or oval shape). The hollow central region may be designed to be packed with osteogenic material such as bone chips, etc. to facilitate fusion of the implant with the patient's lamina. Preferably, the central region may be as large as possible to enhance fusion of the implant to the patient's lamina. The thickness of wall 45 preferably should be between about 1.00 to about 1.50 mm; more preferably about 1.25 mm. Preferably the thickness of wall 5 should not be less than about 1.0 mm to ensure the implant retains sufficient strength to withstand the stresses imparted on the spine.
[0028] The implant 1 may be fabricated from a biocompatable metal (e.g. stainless steel, or titanium, etc.) or polymer, or from allograft material preferably taken from a long bone (e.g. femur, tibia, fibula, humerus). Where the implant is an allograft, the inside surface 4 and hollow central region 7 may be defined by the intermedullary canal of the donor bone. The hollow center may be left as such, or the inner surface 4 may be machined, as with other implant materials, to maximize the space available for packing with osteogenic material. Again, the thickness of the implant wall 5 , preferably is not reduced to less than about 1.00 mm.
[0029] During the unilateral laminoplasty procedure, the targeted lamina is cut in half and the segment attached to the spinous process is rotated or swung out to increase the area available for the spinal cord and associated nerves. Subsequent to this rotation, the lamina segments no longer reside along the same axis, but instead the ends are disposed at an angle with respect to each other. Implant 1 is substantially straight along its length, and so to accommodate this angular displacement of the lamina, first and second ends 6 A, 6 B incorporate arcuate cutouts 8 A, 8 B to grasp and retain the cut lamina segments. Viewed from the top of the implant (FIG. 1C), these arcuate cutouts 8 A, 8 B are generally concave and may be circular in shape, or they may consist of a cutout spanning an obtuse angle and converging to a small radius at the crotch of the first and second ends 6 A, 6 B. Arcuate cutouts 8 A, 8 B have a centerline 1 a which runs parallel to the longitudinal axis of the implant 1 . The centerline 1 a of the arcuate cutouts may be coexistent with the longitudinal axis of the implant 1 , or it may be offset with respect to that axis to further improve retention of the cut and displaced lamina ends. In a further embodiment, the centerlines 1 a of the arcuate cutouts may each be offset on an opposite side of the implant centerline to facilitate retention of the implant in cases where the angle between the cut and spread lamina is more severe, such as when the surgeon spreads the lamina segments as wide as possible to provide maximum additional space for the spinal cord and associated nerves.
[0030] In the preferred embodiment, shown in FIG. 1C, each arcuate cutout 8 A, 8 B comprises first angled faces 88 A, 89 A and second angled faces 88 B, 89 B, respectively, which meet at crotch “C” to form a face angle “A.” Preferably, face angle A is about 100 degrees. Crotch radius “R,” comprises the transition between the first and second angled faces. Crotch radius “R” is preferably about 2 mm. Each arcuate cutout further comprises first and second face depths “F1” and “F2.” The first and second face depths are a measure of the depth of the crotch relative to the inner side region 3 B and outer side region 3 A of the implant, and will be different lengths whenever the centerline 1 a of the arcuate cutout is offset from the centerline “CL” of the implant 1 . Preferably first face depth “F1” is about 1.25 mm, and second face depth “F2” is about 1.5 mm. Each arcuate cutout 8 A, 8 B also has a centerline offset “d,” which is the degree to which the arcuate cutout 8 A, 8 B is shifted from the centerline “CL” of the implant 1 . Preferably, the centerline offset “d” is from about 0 to 2.5 mm toward the inner side region 3 B of implant 1 . The face depth “F1” of the first and 6 A of the implant 1 may be the same or different than the face depth “F1” of the second end 6 B. Likewise, the face depth “F2” of the first end 6 A may be the same or different than the face depth “F1” of the second end 6 A.
[0031] In a further embodiment of the implant comprising allograft material, first and second ends 8 A, 8 B may comprise regions of partially, substantially, or fully demineralized cortical bone to further facilitate fusion of the implant to the lamina. Preferably the demineralized bone portion comprises the entire surface of each first and second end 6 A, 6 B of the implant 1 . Preferably, the depth of the demineralized portion will be up to about 2 mm.
[0032] The implants further may incorporate at least one suture hole 9 in the implant wall 5 to allow the surgeon the option of suturing the implant to the cut lamina ends. These suture holes 9 may vary in number and size, with the only limitation being that they should not be so large or numerous as to compromise the strength or integrity of the implant.
[0033] [0033]FIGS. 2A and 2B are side and top views of the implant of FIG. 1 installed in a patient between the cut lamina ends in a unilateral laminoplasty procedure. In FIG. 2A two different sized implants 1 are installed on the cut lamina segments 10 of adjacent vertebrae, to illustrate application of the implant design to bones of different size. FIG. 2B shows the interaction between the implant and the cut vertebra segments 10 .
[0034] The design of the bone engaging ends 6 A, 6 B of the implants 1 are sufficient to ensure retention of the implants 1 between the cut ends of lamina 10 . Some surgeons, however, desire an additional measure of assurance that the implants 1 will not loosen or otherwise be expelled from between the lamina ends 10 . The implant, therefore, provides for the optional installation of a plate 12 to be secured over an installed implant in a unilateral laminoplasty procedure. FIG. 3A is a perspective view of a plate 12 which may be installed to secure the implant 1 of FIGS. 1 & 2, to ensure the implant 1 is not expelled from the cut lamina ends 10 . Plate 12 has a length 13 , a thickness 14 and a body portion 15 with first and second ends 16 A, 16 B comprising bone engaging portions 17 and implant engaging portions 18 . As shown in FIG. 3A the bone engaging portions 17 and implant engaging portions 18 may consist of the holes adapted for receiving bone screws 19 or hooks 20 (not shown) capable of grasping bone screws installed in the lamina and/or implant. Each side of plate 12 may have one or more bone engaging portions 19 and one or more implant engaging portions 18 . In a further embodiment the plate 12 may be flexible to allow the surgeon to form it to the individual contour of the patient's spine, thereby achieving a tight fit between components. The plates may be fabricated from a biocompatable metal or other material known in the art that would be suitable for long term retention of an implant 1 .
[0035] Instead of a single plate 12 , smaller plates without connecting body portion 15 may be utilized, each plate comprising at least one bone engaging portion 17 and one implant engaging portion 18 .
[0036] [0036]FIG. 3B is a side view of the implants 1 installed in FIG. 2A, further showing the installation of optional plates 12 of FIG. 3A. Bone screws 19 are installed to secure the plates 12 to both the respective opposing lamina segment 10 , and the implant. In this embodiment, bone screws are also installed in the screw holes 18 of the implant engaging portion, to secure the plates to the implants 1 . Also in this embodiment, the plates are flexible and are bent to assume the varying contour of the lamina segments and the implant. More than one optional plate may be used to secure the implant to the lamina.
[0037] [0037]FIGS. 4A and 4B show perspective and side views of an allograft implant 30 which incorporates the design features of the implants of FIG. 1, but which further includes a pair of bone flaps 31 A, 31 B disposed at first and second ends 32 A, 32 B of the implant 30 . These bone flaps are used to secure the implant 30 to the respective cut ends of lamina in a unilateral laminoplasty procedure. At least a portion of each flap comprises demineralized bone. Demineralization of the flaps, but not the implant, provides the implant with flexible attachment points which may be contoured to conform to the shape of the adjacent lamina. Bone flaps 31 A, 31 B comprise thin, flat, rectangular segments of allograft having an outer surface 34 and a bone engaging surface 35 . The outer surfaces 34 of the flaps preferably are the same width as, are contiguous with, and extend axially like wings from the outer surface 36 of the implant 30 . In a preferred embodiment, bone flaps 31 A, 31 B are machined from the same segment of donor bone as implant 30 . At least a portion of flaps 31 A, 31 B may be demineralized using any commercially acceptable process (e.g. hydrochloric acid bath, etc.) that will render the resulting flaps flexible. Flaps 31 A, B are provided with holes 36 A, 36 B suitable for receiving bone screws 37 A, 37 B which are used to secure the bone flaps 31 A, 31 B and implant 30 to the adjacent cut lamina ends.
[0038] In another embodiment, these bone flaps may not be demineralized, but instead each bone flap may comprise a notch 131 A, 131 B in the respective region where the bone flaps 31 A, 31 B connect to the implant 30 . Notches 131 A, 131 B may be any type of notch or reduction in the thickness of the bone flap appropriate to provide flexibility for placing the flaps on the adjacent laminae surfaces, while retaining the requisite strength to ensure the bone flaps will not separate from the implant during installation.
[0039] [0039]FIGS. 5A, 5B and 5 C show an embodiment of an implant for use in a bilateral or “french door” laminoplasty procedure, in which the spinous process of a targeted vertebra is bisected along the sagittal plane and the segments separated to enlarge the spinal canal. The implant 40 has a wall 45 having an inside surface 47 and an outside surface 48 , and first and second ends 46 A, 46 B. The outside surface 48 has an outer side region 41 having an outer side length 42 and an inner side region 43 having an inner side length 44 . Inside surface 47 communicates with first and second ends 46 A & 46 B to define a hollow central region 49 of the implant. The implant 40 has a generally trapezoidal shape when viewed from the side (FIG. 5B), and inner side region forms angle “TA” with respect to the first and second ends 46 A, 46 B. This trapezoidal configuration allows the implant first and second ends 46 A, 46 B to conform to the cut, angled surfaces of the spinous process segments to which the implant will eventually fuse. Inner side length 44 preferably is from between about 6.0 mm to about 10 mm, and angle “TA” preferably is from between about 50 to about 70 degrees.
[0040] The shape and size of outside surface 48 is not critical and, therefore, any implant external configuration can be used preferably so long as first and second ends 46 A, 46 B provide sufficient contact area with the cut spinous process segments, does not project out from between the bone segments so far as to interfere with other anatomy, and does not intrude on the spinal cord space For aesthetic purposes and in an attempt to minimize the amount of new material introduced into a patient, however, the outside surface 41 of the implant 40 should preferably not extend beyond the outside surface of the cut spinous process segments. In a preferred embodiment the outside surface 41 of the implant 40 is configured such that the outside surface 41 , when viewed from the end, displays the form of a substantially geometric shape (e.g. ellipse, oval, circle, etc.) (FIG. 5C).
[0041] In a further embodiment, the inside surface 43 of the implant 40 may be machined so that the hollow central region 49 approximates the configuration and geometry of the implant outside surface 41 (i.e. an ellipse or oval). The hollow central area is designed to be packed with osteogenic material such as bone chips, etc. to facilitate fusion of the implant with the patient's cut spinous process segments. Preferably, this center area may be made as large as possible to facilitate the fusion process.
[0042] The thickness of wall 45 preferably should be from between about 1.00 to about 1.50 mm; more preferably about 1.25 mm. Preferably the thickness of wall 45 should not be less than about 1.0 mm to ensure the implant retains sufficient strength to withstand the stresses imparted on the spine associated with daily living.
[0043] The implant 40 may be fabricated from a biocompatable metal (e.g. stainless steel, or titanium, etc.) or polymer, or from allograft material preferably taken from a long bone (e.g. femur, tibia, fibula, humerus). Where the implant is fabricated from metal or polymer, it may be provided in a solid form. Preferably, however, the implant should incorporate a hollow region, and the inside surface 44 , should be formed to maximize the space available for packing with osteogenic material while maintaining adequate wall thickness. Where the implant is an allograft, the inside surface 44 and hollow center 49 may be defined by the intermedullary canal of the donor bone. The allograft may be left in this state, and the hollow central region 49 packed with osteogenic material. Preferably, however, the inside surface 44 of the allograft will be machined and the hollow central region 49 enlarged to maximize the space available for packing with osteogenic material.
[0044] [0044]FIGS. 6A and 6B show first and second ends 46 A, 46 B of implant 40 each incorporating a channel 50 to accept the corresponding arms of a set of distractor pliers (not shown) which may be used to separate the bisected spinous process segments during the bilateral laminoplasty procedure. Each channel 50 has two sidewalls 51 each having a depth “CD”, a bottom surface 52 having a width “CW” and a centerline 54 which is formed by a line extending along the implant 40 from inner side surface 43 to outer side surface 41 . Preferably, each channel 50 may incorporate a radiused transition 55 between the sidewalls 51 and the bottom surface 52 . In a further preferred embodiment, the channel runs from the inner side surface 43 to the outer side surface 41 of each end 46 A, 46 B of the implant. The specific dimensions of the channels is not critical, but should be configured to accept the distractor arms used during the distraction and insertion portion of the procedure. Preferably, the channel bottom surface width “CW” is about 4 mm, and the sidewall depth “CD” is about 1 mm.
[0045] [0045]FIG. 7 shows a further embodiment of bilateral laminoplasty implant 40 , in which first and second ends 46 A, 46 B comprise surface projections to improve pre-fusion retention of the implant 40 between respective cut spinous process segments. In a preferred embodiment, a plurality of saw-tooth serrations 56 having a height 58 and a tooth angle 59 are provided. Preferably the serrations are oriented to run vertically when the implant 40 is installed in the patient. Height 58 and tooth angle 59 are defined with respect to the respective planes formed by implant first and second ends 46 A, 46 B. Height 58 is measured from the trough 60 of each serration, while tooth angle is measured from the plane formed by the implant first and second ends 46 A, 46 B. Preferably, height 58 is about 0.5 mm, tooth angle 59 is about 45 degrees, and the distance between troughs 60 is about 1.2 mm. While these dimensions and profile are preferred, other suitable surface profiles (e.g. pyramidal teeth, etc.) may be used to ensure implant retention.
[0046] In a further embodiment of the implant 40 comprising allograft material, first and second ends 46 A, 46 B may comprise regions of partially, substantially, or fully demineralized cortical bone to further facilitate fusion of the implant to the lamina. Preferably the partially, substantially, or fully demineralized bone portion may comprise the entire surface of each first and second ends 46 A, 46 B of the implant 40 . Preferably the depth of the demineralized portion of will be up to about 2 mm.
[0047] The implant 40 may also incorporate a plurality of sutures holes 61 (see FIG. 5C) formed through the implant wall 45 to allow the surgeon to secure the implant to the cut spinous process segments. These suture holes 61 may vary in number, size and position, with the only limitation being that their size, position and number preferably should not compromise the strength and integrity of the implant.
[0048] [0048]FIGS. 8A, 8B and 8 C show a further embodiment of an implant for use in a bilateral laminoplasty procedure. Implant 62 has a first and second ends 63 A, 63 B, an inner side region 68 , an outer side region 65 , and sides 66 and 67 . The implant 62 , like the implant of FIG. 5, has a generally trapezoidal shape when viewed from the side (FIG. 8C). Again, this trapezoidal configuration allows the implant first and second ends 63 A, 63 B to conform to the cut, angled surfaces of the spinous process segments to which the implant will eventually fuse. As such, inner side 68 forms angle “IA” with respect to the first and second ends 63 A, 63 B. In this embodiment, the implant 62 is an allograft, comprising “tri-cortical” bone taken from the crest of the ilium region of the pelvis. Harvesting bone from this segment of the pelvis provides an implant which naturally comprises a thin region 64 of cortical bone on outer side 65 , and sides 66 & 67 . The inner side 68 of the implant, as well as the implant body portion 69 comprise cancellous bone. This combination of bone types allows the surgeon to exploit both the good strength characteristics of cortical bone, and the good osteogenic characteristics of cancellous bone in a single implant. In a further embodiment, the implant 62 comprises a cavity 70 which communicates with implant first and second ends 63 A & 63 B, and which may be used for packing osteogenic material to promote fusion between the implant and the cut spinous process segments.
[0049] In a preferred embodiment of the implant 62 of FIG. 8, the implant first and second ends 63 A, 63 B comprise surface projections to improve pre-fusion retention of the implant 62 between respective cut spinous process segments. Saw-tooth serrations, similar to those illustrated and described with regard to the implant of FIG. 5, may be provided. Again, other suitable surface profiles (e.g. pyramidal teeth, etc.) may also be provided to ensure implant retention.
[0050] In a further embodiment of the implant 62 comprising allograft material, first and second ends 63 A, 63 B may comprise regions of partially, substantially, or fully demineralized cortical bone to further facilitate fusion of the implant to the lamina. Preferably the demineralized bone portion may comprise the entire surface of each first and second ends 63 A, 63 B of the implant 62 . Preferably, the depth of the demineralized portion of will be up to about 2 mm.
[0051] In another embodiment, the implant 62 may incorporate a plurality of sutures holes (not shown) similar to those shown in FIG. 5C, to allow the surgeon to secure the implant to the cut spinous process segments. These suture holes may vary in number, size and position, with the only limitation being that their number, size and position should not compromise the strength and integrity of the implant.
[0052] [0052]FIGS. 9A and 9B are front and top views of either trapezoidal implants 40 , 62 of FIGS. 5, 8 installed in a patient. First and second ends 46 A, 46 B, 63 A, 63 B of implant 40 , 62 contact cut spinous process segments 72 and 71 respectively. Hinge cuts 73 and 74 in lamina 75 , 76 enable the spinous process segments to be “swung out” by the surgeon to facilitate insertion of the implant 40 , 62 therebetween.
[0053] [0053]FIGS. 10A, 10B and 10 C show a further embodiment of an implant adapted for use in a unilateral laminoplasty procedure. Implant 77 comprises first and second plate portions 78 A, 78 B for connecting to the opposing segments of cut lamina produced during a unilateral laminoplasty procedure. First and second plate portions 78 A, 78 B are connected by an intermediate portion 80 . The plate portions further comprise respective first and second bone engaging portions 79 A, 79 B which are configured to engage the opposing cut lamina segments. In a preferred embodiment, first and second bone engaging portions 79 A, 79 B comprise arcuate surfaces for engaging and cradling the respective cut lamina ends. Arcuate surfaces are particularly suited for this purpose because their concave shape can engage and retain lamina segments residing along different axes, a phenomenon which occurs during the unilateral laminoplasty procedure when a single lamina is cut and the resulting segments are swung out to enlarge the area available for the spinal cord. The swinging out process results in an angle being formed between the segments, and it is this misalignment which the arcuate surfaces of the bone engaging portions 79 A & 79 B accommodate.
[0054] In a further embodiment, the thickness of the intermediate portion 80 may be smaller than the height of the first and second plate portions 78 A, 78 B.
[0055] Implant 77 may be fabricated from any biocompatable metal (e.g. titanium, stainless steel, etc.) or polymer, or the implant may be formed of allograft material. If allograft is used, the implant 77 preferably should be fabricated from cortical bone.
[0056] In a further embodiment of the implant 77 comprising allograft material, first and second bone engaging portions 79 A, 79 B may comprise regions of partially, substantially, or fully demineralized cortical bone to further facilitate fusion of the implant to the lamina segments. Preferably the demineralized bone portion may comprise the entire surface of each first and second bone engaging portions 79 A, 79 B. Preferably, the depth of the demineralized portion will be up to about 2 mm.
[0057] In another embodiment, the implant 77 may incorporate suture hole 80 to allow the surgeon to secure the implant to the cut spinous process segments. Additional suture holes (not shown) may be provided, and may vary in number, size and position, with the only limitation being that their size, position and number preferably should not compromise the strength and integrity of the implant 77 .
[0058] [0058]FIGS. 11A, 11B and 11 C show a further embodiment of an implant adapted for use in a unilateral laminoplasty procedure. Implant 84 comprises a plate portion 85 having bone engaging portions 86 A, 86 B, a graft engaging portion 87 , and an allograft 91 . Bone engaging portions 86 A, 86 B further comprise a plurality of suture holes 88 configured to allow the surgeon to secure the cut lamina segments to bone engaging portions 86 A, 86 B Graft engaging portion 87 comprises a graft seating surface 89 and a graft retaining portion 90 configured to retain a correspondingly shaped allograft 91 for engaging the opposing cut lamina segment. In a preferred embodiment, graft retaining portion 90 comprises two raised tabs 92 A, 92 B, each residing along at least a portion of opposing ends of graft seating surface 89 . In a preferred embodiment, raised tabs 92 A, 92 B are angled slightly toward the center of graft seating surface 89 so as to facilitate retention of allograft 91 . Preferably the angle “A” between raised tabs 92 A, 92 B and graft seating surface 89 will be from about 70 to about 80 degrees; more preferably this angle will be about 75 degrees. Plate portion 85 further comprises a bottom surface 855 . When installed, graft 91 comprises the inner side surface of the implant (i.e. the surface which is closest to the spinal canal), while plate bottom surface 855 comprises the outer side surface of the implant (i.e. the surface which faces away from the spinal canal). In a preferred embodiment, bottom surface 855 comprises a convex shape which assumes the rounded contour of the lamina segments. Preferably, this convex surface has a radius of about 18 mm.
[0059] Plate portion 85 may be fabricated from any biocompatable metal (e.g. titanium, stainless steel, etc.) or polymer, or it may be made of allograft material. If allograft is used, the plate portion 85 may be fabricated from cortical bone. Graft 91 preferably may be comprised of a cancellous type bone material to facilitate fusion of the implant to the patient's lamina.
[0060] [0060]FIGS. 12A and 12B show implant embodiments comprising plates configured to attach directly to the opposing cut segments of lamina produced during a unilateral laminoplasty. These plates are further configured to capture segments of allograft and to engage these segments with the opposing cut segments of lamina to facilitate fusion between the implant and the patient's bone. Plate 93 comprises a body portion 94 having a longitudinal axis and first and second ends 95 A, 95 B, and a graft retaining portion 96 , midway between the ends 95 A, 95 B, preferably approximately midway between ends 95 A, 95 B. First and second ends 95 A, 95 B each comprise a bone engaging portion 97 . In a preferred embodiment the bone engaging portion at each first and second end comprises at least one hole suitable for receiving a bone screw 98 (not shown). The bone screws are then used to secure the plate 93 to each opposing segment of lamina. In a further embodiment the bone engaging portions may be hooks capable of grasping bone screws that are installed in the lamina segments.
[0061] In the embodiment shown in FIG. 12A, the graft retaining portion 96 comprises a plurality of deformable fingers 99 which are initially arrayed flat along an axis perpendicular to the longitudinal axis of the plate 93 . These fingers 99 are capable of being deformed to cradle an allograft 100 , preferably cylindrical in shape. Allograft 100 preferably has a length sufficient to engage the cut ends of lamina upon installation, and a diameter of size sufficient to be captured by the deformed fingers 99 of the plate 93 .
[0062] In the embodiment of FIG. 12B, plate 93 has a graft retaining portion 96 which comprises a hollow region 101 , preferably rectangular in shape. A correspondingly configured allograft of cancellous bone is provided having a body 102 capable of being received within the hollow region 101 , and further having shoulders 103 which extends beyond the hollow region to contact seating surface 104 . In a preferred embodiment, shoulders 103 of allograft 100 are secured to plate 93 using a bone screw 98 placed through bone engaging portion 97 .
[0063] In a preferred embodiment the plate 93 may be flexible to allow the surgeon to form the body 94 to the individual contour of the patient's spine, thereby achieving a tight fit between components. The plate 93 may be fabricated from a biocompatable metal or other material known in the art that would be suitable for long term retention of an implant and graft.
[0064] The current invention also provides a method of using an allograft implant according to any of the embodiments shown in FIGS. 1A, 5A, 8 A, 10 A or 11 A which further has partially, substantially, or fully demineralized end segments to promote fusion between opposing segments of lamina or spinous process produced during a unilateral or bilateral laminoplasty procedure. This method comprises the steps of cutting a targeted lamina or spinous process as required for either a unilateral or bilateral laminoplasty procedure, separating the resulting segments of bone a sufficient distance to allow for insertion of an appropriately sized allograft implant, providing an allograft implant having bone engaging surfaces which comprise partially, substantially, or fully demineralized cortical bone to a depth of up to about 2 mm, and contacting the allograft implant bone engaging surfaces with respective cut segments of lamina or spinous process. This method may be augmented, in the case of a unilateral laminoplasty, to include the additional step of installing a plate over the allograft implant to further assist retention of the implant between the bone segments. Where such a plate is provided, the additional steps of providing bone screws or other fasteners to attach the plate to the opposing segments of bone and/or to attach the plate to the implant, may further be included.
[0065] A further embodiment of the above method comprises providing an allograft implant according to the above method, which implant further has partially, substantially, or fully demineralized bone flaps capable of receiving bone screws. Providing such an implant allows the surgeon to affirmatively secure the implant to the cut lamina segments, preferably without the need for a separate plate.
[0066] A method of installing a tri-cortical allograft implant as part of a bilateral laminoplasty procedure is also provided. This method comprises the steps of bisecting a targeted spinous process, providing hinge cuts on both adjacent lamina sufficient to allow the spinous process segments to be spread apart, separating the spinous process segments to allow for insertion of an appropriately sized allograft implant, providing an allograft implant having first and second angled bone engaging surfaces which approximate the angle between the bisected and spread spinous process segment cut surfaces, the allograft implant comprising cancellous bone material having a thin outer layer of cortical bone surrounding the cancellous bone, and which cortical bone layer is in communication with the first and second engaging surfaces so as to support the compressive stresses imparted by the cut spinous process segments.
[0067] A method of using only a screwed plate to maintain the distance between bone ends produced during a unilateral or bilateral laminoplasty procedure is also provided and described. This method comprises the steps of cutting a targeted lamina or spinous process as required for the respective laminoplasty procedure, separating the cut bone segments to increase the space available for the spinal canal and associated nerves, providing an appropriately sized plate having first and second ends, wherein each end is configured to allow engagement with the surface of the lamina opposite the surface of the spinal canal and adjacent the cut bone end, and securing first and second ends of the plate to the adjacent bone segments.
[0068] In a preferred embodiment of the method, each first and second end of the plate will have at least one recess suitable for receiving a bone screw, wherein the plate is secured to the adjacent cut bone ends using bone screws. In a further embodiment, two plates may be provided to attach to the adjacent cut bone ends.
[0069] Accordingly, it should be understood that the embodiments disclosed herein are merely illustrative of the principles of the invention. Various other modifications may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and the scope thereof.
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Implants for use in the spinal column are disclosed. The implants comprise a bone allograft coupled with a non-allogenic plate. The plate has ends that fasten to opposing spine segments, and an intermediate portion that engages the allograft using deformable fingers, or with a hollow portion sized to receive and hold part of the allograft, or with fixed tabs. Methods of using the implants are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a document reader, and more particularly to a document reader which, when any region of a given manuscript is desired to be exclusively read out or copied, enables designation of the aforementioned region for reading or copying to be easily effected while the manuscript is left standing on a platen glass or kept inserted in a manuscript slot of the document reader.
2. Description of the Prior Art
The conventional electrophotographic copying machine is based on the principle that a copy of a given manuscript is obtained by illuminating the manuscript with a light from a light source and causing the light reflected on the surface of the manuscript to impinge directly on the surface of a photosensitive body thereby generating an electrostatic latent image on the photosensitive body.
In accordance with this method, the process for formation of the electrostatic latent image on the photosensitive body is wholly carried out under mechanical control. When the ratio of magnification used in copying the manuscript in an enlarged or reduced size is to be set at any desired value, therefore, mechanisms such as for adjustment of the lens position and for control of scanner speed greatly gain in complexity so much as to boost the cost of production of the electrophotographic copying machine. Besides, the desire to copy the manuscript exactly at a desired ratio of magnification proves difficult.
In consequence of the advance of various office automation machines, the conventional process of reading a given manuscript in a predetermined paper size such as A3 or A4 and producing the output on recording papers is no longer able to meet all the needs of the day. There have arisen needs which make it necessary to have only a pertinent region of a given manuscript exclusively read out and copied, or even to have only the pertinent region of the manuscript copied as enlarged or reduced at a desired ratio of magnification and/or rotated at a desired angle in a desired position on a recording paper (hereinafter the processing described above will be collectively referred to as "editing").
By the aforementioned method for formation of an electrostatic latent image under mechanical control, however, it is totally infeasible to confer the aforementioned editing function upon the electrophotographic copying machine.
In the circumstance, efforts are being devoted to the development of an electrophotographic copying machine which produces a copy of a given manuscript by illuminating the manuscript with a light from a light source, causing the light reflected on the surface of the manuscript to be read and converted into digital signals by a photoelectric element such as CCD, subjecting the digital signals to a proper processing, and thereafter forming an electrostatic latent image on the surface of a photosensitive body by the use of a light emitting element such as LED (hereinafter referred to as a digital copying machine).
One version of the aforementioned digital copying machine is disclosed in the specification of Japanese Patent Laid-open SHO No. 59(1984)-63,868. This specific digital copying machine is depicted in the specification as comprising a document reading device (reader) and a digital document reproducing device (printer).
When only a pertinent region of a given manuscript is to be read out by the document reading device disclosed in the aforementioned specification, the following operation must be carried out.
The operator, before placing the manuscript on a platen glass, is required to cover the manuscript with a transparent sheet having checkers printed thereon for reading coordinates in such a manner that the reference line on the manuscript will coincide with that on the checkers, read the coordinates of the pertinent region of the manuscript (or the masking region of the manuscript), and then feed in the numerical values of the coordinates through a ten-key arranged on the operation panel for the document reading device.
FIG. 2 is a schematic diagram for illustrating the correspondence between the face of the manuscript and the regions on the document recording memory. FIG. 2(a) represents the face of the manuscript and FIG. 2(b) the document recording memory.
When only a region indicated by hatch lines in the entire face of the manuscript shown in FIG. 2(a) is desired to be read or to be masked, the transparent sheet having checkers printed thereon is placed as described above to cover the manuscript.
Then, the distances x O and x O +Δx in the direction of main scanning (the direction indicated by the arrow x) from the reference line L y and the distances y O and y O +Δy in the direction of sub-scanning (the direction indicated by the arrow y) from the reference line Lx are read out. The numerical values of these distances are fed in through the ten-key.
Between the numerical values fed in through the ten-key as described above and a region of the document data memory (defined by the coordinates of the directions indicated by the arrows X and Y) illustrated in FIG. 2 (b), the following known functional relations exist, for example.
f(x)=X
f(y)=Y
The region indicated by hatch lines in FIG. 2(b), therefore, can be set on the document data memory by allowing the numerical values, x O , x O +Δx, y O , and y O +Δy, fed in by the operation of the ten-key to be processed as by a micro-computer. In other words, the numerical values of X O , X O +ΔX, Y O , and Y O +ΔY can be set and, as the result, only the pertinent region of the manuscript can be read out.
In FIG. 2, the pertinent region of the manuscript desired to be read out is depicted as a rectangle having four sides parallel to the direction of main scanning or sub-scanning. Optionally, the pertinent region may be a polygon so long as all the sides of the polygon run parallelly to the direction of main scanning or the direction of sub-scanning.
In the foregoing description, the document data are presumed to be tentatively stored in the memory. Instead of elaborately assigning the memory to the tentative storage of the data, the signals representing the information in the pertinent region of the face of the manuscript can be fed out on the real-time basis (optionally after being subjected to a proper processing).
In accordance with the conventional method described above, when only a pertinent portion of a given manuscript is desired to be read out, the operator is required, before placing the manuscript on a platen glass, to cover the manuscript with a transparent sheet having checkers printed thereon for reading coordinates, read out the numerical values of the coordinates of the pertinent region of the manuscript with reference to the checkers on the transparent sheet, and feed in the numerical values through the ten-key arranged on the operation panel for the document reading device as already described above. Thus, the conventional method has entailed the following disadvantages.
(1) If the numerical values of the coordinates of the pertinent region of the manuscript are read out erroneously or they are fed in erroneously through the ten-key, the portion of the manuscript actually read out or the copy of the manuscript formed on the recording paper may deviate from the region desired to be copied. Thus, the produced copy is found to be rejected.
(2) Even if the numerical values of the coordinates of the pertinent region of the manuscript are correctly read out and then are fed in correctly through the ten-key, there is still the possibility that a reference line of the manuscript will deviate from a reference line of the checkers printed on the transparent sheet or the manuscript will not be correctly placed at the prescribed position on the platen glass. This incorrect location of the manuscript results in production of a rejectable copy.
(3) When a pertinent region is selected in the manuscript, the manuscript is placed so that the face of the manuscript will fall on the upper side. When the manuscript is exposed to light for copying, the manuscript is placed on the platen glass in such a manner that the face of the manuscript will fall on the lower side. Thus, the handling of the manuscript during the copying work takes up twice as much time and labor as the handling involved in the case of the ordinary electrophotographic copying machine. The operator tending the document reading deivce, therefore, is burdened with a highly troublesome job.
(4) The setting of the pertinent region of the manuscript has no alternative but to rely on the procedure of actually measuring the pertinent region and subsequently feeding in the numerical outcomes of the measurement through the ten-key. This particular procedure proves to be a toublesome job for the operator.
BRIEF SUMMARY OF THE INVENTION
An object of this invention, therefore, is to provide a document reader which is incapable of generating any positional deviation in the copy produced on a recording paper.
Another object of this invention is to provide a document reader which enables the setting of a pertinent region of a given manuscript to be effected without requiring the region to be actually measured or the numerical data defining the region to be fed in through the ten-key.
Yet another object of this invention is to provide a document reader which enables the setting of a pertinent region on a given manuscript to be effected without necessitating reference to checkers or requiring the manuscript to be turned upside down on a platen glass.
To accomplish the objects described above, this invention furnishes a document reader with a document display window for focussing the light reflected from the surface of a given manuscript thereon, a scale formed on the document display window and provided with a cursor capable of being moved in the direction of main scanning, means for freely controlling the shift of a reading line on the manuscript in the direction of the sub-scanning, and means for automatically sensing the position of the cursor and the position of the reading line on the manuscript and admitting the numerical values indicative of the two positions for designating the pertinent region of the manuscript to be read out, whereby the operator is enabled to set the pertinent region of the face of the manuscript very easily and accurately while keeping visual observation of the image displayed in the document display window, with the manuscript left standing on the platen glass or kept inserted in the manuscript slot of the document reader.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of an embodiment of the present invention.
FIGS. 2 a+b are schematic diagrams illustrating the correspondence between the face of a manuscript or a platen glass and the region of a document recording memory.
FIG. 3 is a schematic perspective view of a digital copying machine utilizing an embodiment of the present invention.
FIG. 4 is a schematic cross section for illustrating an optical system in the document reader suitable for the present invention.
FIG. 5 is a schematic plan view of a document display window.
FIG. 6 is a plan view of region setting keys.
FIG. 7 is a schematic cross section illustrating a first modification of the optical system suitable for the present invention.
FIG. 8 is a schematic cross section illustrating a second modification of the optical system suitable for the present invention.
FIG. 9 is a schematic cross section illustrating a third modification of the optical system suitable for the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention can be applied to the fixed platen type, moving platen type, or manuscript feeding type document reader.
Now, the present invention will be described in detail below with reference to the accompanying drawings.
FIG. 1 is a schematic block diagram of an embodiment of this invention.
As illustrated in the diagram, a digital copying machine comprises a document reading device 1 and a digital image reproducing device 2. This document reading device 1 is assumed to be of the fixed platen type.
A microcomputer 100, as widely known, is composed of CPU 101, RAM 102, ROM 103, and an input/output interface 104. The aforementioned CPU 101, RAM 102, ROM 103, and input/output interface 104 are interconnected with a common bus 105.
The aforementioned RAM 102 serves to store the image data read out by an image sensor 13 and/or a pertinent region of a manuscript desired to be read out or masked as described afterward. Thus, it possesses the same function as the memory illustrated in FIG. 2(b).
The casing of the document reading device 1 is provided with a document display window 3 as described afterward with reference to FIG. 3 and FIG. 4. As described afterward with reference to FIG. 4 or to FIG. 7 through FIG. 9, a part of light reflected on the manuscript reaches the document display window 3.
In the document display window 3, a liquid crystal scale 19 of the bar graph type is formed. The number of bars 20 (FIG. 5) or the height of the column of bars displayed in the liquid crystal scale 19 can be increased or decreased, by a cursor operating button 23 connected to the input/output interface, in the direction parallel to the direction of main scanning in the manuscript display window 3. Optionally, only the top of the column of bars may be shifted instead of changing the number of bars 20.
FIG. 2(a) has been described as representing the face of a manuscript. In the following description, it will be assumed as representing the face of a platen glass or the maximum document reading region which corresponds to the face of the platen glass. The number of bars 20 displayed in the liquid crystal scale 19 can be increased or decreased in the direction of the arrow x in FIG. 2(a) and in FIG. 5 by the cursor operating button 23 in substantially the same manner as in the cursor position control effected in a conventional microcomputer.
A cursor position sensing device 20A is connected to the liquid crystal scale 19 (or a drive device therefor) and is enabled to detect the number of bars 20 displayed in the liquid crystal scale 19, i.e. the position of the uppermost of the bars 20 (hereinafter referred to as "cursor").
The detection can be carried out by any of the known methods using the magnitude of voltage or amperage or the count displayed in a counter, for example. The output from the cursor position sensing device 20A is connected to the input/output interface 104.
A scanner 50 is connected to the input/output interface 104 and is enabled to effect automatic scanning for the reading of a manuscript in response to the output from the interface 104.
In addition to the automatic scanning mentioned above, the scanner 50 is enabled to effect manual scanning by the use of a scanner operating button 22 connected to the input/output interface 104. By the manual scanning, the scanner 50 can be stopped at any position in the document reading device 1 which is freely elected by the operator.
A scanner position sensing device 50D is connected to the scanner 50 and enabled to detect the position of the scanner 50. The position of the scanner can be detected in terms of the magnitude of resistance or that of voltage by fastening a slider of a variable resistor to the scanner 50.
The detection of the position of the scanner can otherwise be effected by providing a rotary shaft of a scanner drive motor (not shown) with a rotary encoder or by using a pulse motor for the driving of the scanner.
The output from the scanner position sensing device 50D is connected to the input/output interface 104, similarly to the output from the cursor position sensing device 20A.
To the input/output interface 104 are further connected a read start button 6D to set the document reading device 1 reading the manuscript (automatic scanning), a position input button 24 to feed to the input/output interface 104 the position of the cursor and the position of the scanner 50 detected respectively by the cursor position sensing device 20A and the scanner position sensing device 50D, and a image sensor 13 to read the document.
Further to the input/output interface 104 can be connected the digital reproducing device 2 serving to convert the image signals processed within the microcomputer 100 into a visible image, as illustrated in FIG. 1.
FIG. 3 is a schematic perspective view illustrating the outward appearance of a digital copying machine utilizing an embodiment of this invention.
As illustrated in this diagram, the digital copying machine comprises a document reading device 1 and a digital image reproducing device 2. The document reading device 1 is mounted on the digital image reproducing device 2.
A platen glass 16 (FIG. 4) is disposed on the upper side of the document reading device 1 and a manuscript cover 5 is disposed to cover the platen glass.
On an operation panel for the document reading device 1, a power source switch 6A, a region setting key 6B which will be described afterward with reference to FIG. 6, a read start button 6D, a ten-key 6C for setting the number of copies chosen to be produced, etc. are arranged.
The manuscript display window 3 is disposed in the casing of the document reading device 1 in such a manner as to be easily observed. The optical system including the scanner 50 is configurated so that a part of light reflected on the manuscript will reach the manuscript display window 3 and form an image thereon as described afterward with reference to FIG. 4.
FIG. 4 is a schematic cross section illustrating the optical system used in the embodiment of this invention. In this diagram, the same numerical symbols as found in FIG. 3 denote identical or equivalent components.
A reading line to be read out or a selected region of the manuscript 4 laid on the platen glass 16 is illuminated by the light from an exposure lamp 8. The light reflected from the manuscript 4 (image light) is reflected by a first mirror 9 and a second mirror 10 and allowed to reach a third mirror 11.
Since the third mirror 11 is translucent, a part of image light is reflected by the third mirror 11, passes through a focussing lens 12, and is brought to the image sensor 13.
The remaining image light which passes through the third mirror 11 is reflected by a fourth mirror 14 and a fifth mirror 15 and allowed to reach a Fresnel lens 7. In the document display window 3, therefore, an image of the selected region of the manuscript 4 is focussed.
At this point, the scanner 50 can be moved to any desired position in the direction of the arrow y [the direction of sub-scanning in FIG. 2(a)] by using the scanner operating button 22 as described afterward with reference to FIG. 6. The operator, therefore, is enabled to observe a desired portion of the manuscript through the medium of the manuscript display window 3 by manual scanning of the scanner 50.
The speed of movement of the exposure lamp 8 and the first mirror 9 is twice that of the second mirror 10, the third mirror 11, and the fourth mirror 14 as widely known.
FIG. 5 is a schematic plan view of the manuscript display window 3. As illustrated in the diagram, a liquid crystal scale 19 and a sub-scanning direction region setting line 21 are formed in the document display window 3.
The liquid crystal scale 19 is of the bar graph type. By using the cursor operating button 23 as described afterward with reference to FIG. 6, this liquid crystal scale 19 is enabled to increase or decrease the number of bars 20 displayed as arranged parallelly in the direction of the arrow x. In other words, the position of the cursor of the liquid scale 19 can be moved in the direction of the arrow x.
FIG. 6 is a plan view of the region setting key 6B shown in FIG. 3. In this diagram, the same numerical symbols as found in FIG. 1 denote identical or equivalent components.
As illustrated in FIG. 6, the region setting key 6B is composed of a pair of scanner operating buttons 22, a pair of cursor operating buttons 23, and a position input button 24.
The scanner operating buttons 22 are a pair of switches for moving the scanner 50 to a desired position (manual scanning). By the scanner operating buttons 22, the scanner 50 can be moved in the direction of the arrow inscribed on the surface thereof--namely, in the direction of the arrow y (FIG. 2(a), FIG. 4) or the opposite direction.
The cursor operation buttons 23 are a pair of switches for moving the cursor of the liquid crystal scale 19 to a desired position. By the cursor operating buttons 23, the cursor of the liquid crystal scale 19 can be moved in the direction of the arrow inscribed on the surface thereof --namely, in the direction of the arrow X (FIG. 2(a), FIG. 5) or in the opposite direction.
The position input button 24 is used for reading into the microcomputer 100 the position of the scanner 50 and the position of the cursor of the liquid crystal scale 19.
Now, the method for setting the pertinent region of a manuscript in the embodiment of this invention will be explained below.
First, the exposure lamp 8 is turned on to illuminate the manuscript 4 on the platen glass 16 and cause the light reflected on the surface of the manuscript to be directed toward the manuscript display window 3.
Then, the scanner operating button 22 is depressed to move the scanner 50 in the direction of the arrow y. When an image of the pertinent region of the manuscript appears in the manuscript display window 3 in consequence of the movement of the scanner 50, the boundaries between the pertinent region and the rest of the region--namely y O and (y O +Δy) (FIG. 2(a))--are sequentially aligned with the sub-scanning direction region setting line 21 formed in the manuscript display window 3.
Then by the operation of the position input button 24, the numerical values of y O and (y O +Δy) are written in the RAM 102 to set the region in the direction of the arrow Y indicated in FIG. 2(b).
Then by the depression of the cursor operating button 23, the cursor of the liquid crystal scale 19 is moved in the direction of the arrow x. When the cursor is aligned severally with the boundaries between the pertinent region and the rest of the region--namely x O and (x O +Δx) (Fig. 2(a)), the position input button 24 is depressed each time the alignment is made.
By the operation just mentioned, the numerical values of x O and (x O +Δx) are written in the RAM 102. In this manner, the region in the direction of the arrow x indicated in FIG. 2(b)--namely X O and (X O +ΔX) are set.
In consequence of the operation described above, the pertinent region in the RAM 102 is set so as to correspond to the pertinent region of the manuscript. Thereafter, the scanner 50 is returned to its predetermined home position and automatic scanning with the scanner 50 is started by depression of the read start button 6D (FIG. 1). Consequently, the image sensor 13 read out the image of the manuscript.
Of the output from the image sensor 13, the portion which corresponds to the region indicated by hatch lines in FIG. 2(b) and designated as described above is written in the RAM 102. Otherwise, the data covering all area of the manuscript may be tentatively stored in the RAM 102 and only the data corresponding to the aforementioned designated region may be read out of the RAM 102.
In the foregoing description, the pertinent region of the manuscript has been depicted as a rectangle whose four sides are parallel to the direction of main scanning or the direction of sub-scanning. Optionally, the pertinent region may be a polygon containing a projection or depression on condition that all the sides of the polygon are parallel to the direction of main scanning or the direction of subscanning.
Even when this invention is configurated so as to lack the document memory illustrated in FIG. 2(b), only image signals of the pertinent region of the manuscript can be fed out in their unmodified form or after being subjected to a proper processing on the real-time basis.
Now, a modification of the optical system shown in FIG. 4 will be described.
FIG. 7 is a schematic cross section for illustrating a first modification of the optical system suitable for the present invention. In this diagram, the same numerical symbols as found in FIG. 4 denote identical or equivalent components.
A third mirror 11A furnished for a scanner 50A of a document reading device 1A illustrated in FIG. 7 is a reflecting mirror as compared with the third mirror 11 in the document reading device 1 of FIG. 4 which is a translucent mirror.
The aforementioned third mirror 11A is so adapted that it will thrust itself into the path of the image light reflected from the second mirror 10 or retract from the path as occasion demands.
To be specific, during the setting of the pertinent region of the manuscript, the third mirror 11A is retracted from the aforementioned light path as indicated by the dotted line to enable the image light to be wholly directed toward the Fresnel lens 7. After the setting of the pertinent region and during the subsequent automatic scanning with the scanner 50A, the third mirror 11A is thrust into the aforementioned light path as indicated by the solid line to permit the image light to be wholly directed toward the image sensor 13.
As the result, either during the setting of the pertinent region of the manuscript or during automatic scanning with the scanner 50A, the image light, namely the light reflected from the manuscript 4 can be wholly directed toward the Fresnel lens 7 or the image sensor 13.
In the document reading device 1 illustrated in FIG. 4, the image light reflected from the second mirror 10 can be directed by means of the third mirror (translucent mirror) 11 simultaneously toward the Fresnel lens 7 and the image sensor 13. Thus, the intensity of the image light reaching the Fresnel lens 7 and the image sensor 13 is roughly one-half of that of the image light impinging upon the third mirror 11. Thus, the exposure lamp 8 is required to have about twice intensity of light.
As is plain from the foregoing description, the exposure lamp 8 used in the modification of FIG. 7 has only about half intensity of light required for the exposure lamp 8 of the aforementioned embodiment. The modification, therefore, permits a cut in the electric power consumed by the document reading device and a cut in the cost of maintenance.
FIG. 8 is a schematic cross section for illustrating a second modification of the optical system suitable for the present invention. In this diagram, the same numerical symbols as found in FIG. 4 denote identical or equivalent components.
The document reading device 1B illustrated in FIG. 8, as clearly noted from comparison with the counterpart in FIG. 4, has a lens 17 interposed between the fourth mirror 14 and the fifth mirror 15 in the place of the Fresnel lens 7. The manuscript display window 3A is formed of a translucent material such as ground glass or a light diffusing plate.
FIG. 9 is a schematic cross section for illustrating a third modification of the optical system suitable for the present invention. In the diagram, the same numerical symbols as found in FIG. 4 denote identical or equivalent components.
In FIG. 9, the manuscript 4 placed on the platen glass 16 of the document reading device 1C is illuminated by the light from the exposure lamp 8.
The light (image light) reflected from the manuscript 4 is reflected by the first mirror 9 and allowed to reach the second mirror 10A. Since the second mirror 10A is a translucent mirror, a part of image light is reflected by the second mirror 10A and the third mirror 11B, passes through the focussing lens 12, and reaches to the image sensor 13. The remaining part of the image light passing through the second mirror 10A is reflected by the fourth mirror 18 and allowed to reach the manuscript diaplay window 3B.
The scanner 50B is capable of scanning in the direction of the arrow y. In this case, the speed of movement of the exposure lamp 8 and the first mirror 9 is twice that of the second mirror 10A and the third mirror 11B.
In the optical system illustrated in FIG. 9, when the scanner 50B is scanning, the length of the light path from the surface of the manuscript to the manuscript display window 3B is varied while that of the light path from the surface of the manuscript to the image sensor 13 remains unchanged. As the result, the size of the image of the manuscript appearing in the display window is varied.
The setting of the pertinent region in the direction of main scanning with reference to the image appearing in the manuscript display window 3B, therefore, must be carried out at the estimated position of the scanner 50B. At the same time, the operator has to keep his eye within a plane which includes the image of the boundary of the pertinent region of the manuscript in the main scanning direction formed in the display window 3B and is perpendicular to the surface of the display window. The operator is also required to control the number of bars 20 or the position of the cursor while keeping his eye in the position described above.
In accordance with the arrangement illustrated in FIG. 9, the number of reflecting mirrors can be decreased and the construction of the document reading device 1C can be simplified despite the inconvenience suffered during the setting of the region. Particularly since the number of reflecting mirrors arranged in the direction of height is decreased, the overall dimensions of the document reader can be reduced in the direction of height to permit compaction of equipment.
The present invention described above may be embodied as modified as follows.
(1) The manuscript display window has been depicted as having a liquid crystal scale formed therein. In place of the liquid crystal scale, some other scale such as a LED array may be formed in the display window on condition that the substitute scale is provided with a cursor capable of being moved in a direction parallel to the sub-scanning direction region setting line.
(2) In the foregoing description, the image sensor 13 has been depicted to be an image sensor of the kind of CCD which forms the image in a reduced size. In place of this size-reducing image sensor, an image sensor of the intimate-contact type capable of reading the manuscript in an equal size, i.e. at a rate of 1:1, can be used. In this case, it proves convenient to use Selfok(self-focussing) lenses as a lens for focussing the reflected light from the manuscript on the image sensor.
When the image sensor of the intimate-contact type is adopted, the length of the light path from the manuscript to the image sensor must be decreased as much as possible. Even in this case, a part of reflected light from the manuscript can be directed toward the manuscript display window 3 as by interposing a translucent mirror between the platen glass and the Selfok lenses.
(3) The foregoing description has portrayed application of the present invention to the fixed platen type document reading device. This invention can be applied similarly effectively to the moving platen type or manuscript feed and read type document reader as already pointed out.
When this invention is applied to the moving platen type document reader, for example the scanner 50 illustrated in FIG. 1 is required to be substituted with means for moving the platen glass, the scanner position sensing device 50D to be substituted with a platen glass position sensing device, and the scanner operating button 22 to be substituted with a platen glass moving button respectively.
When this invention is applied to the manuscript feed and read type document reader, the scanner 50 in FIG. 1 is required to be substituted with means for conveying the manuscript, the scanner position sensing device 50D to be substituted with a device for detecting the position of the manuscript or the amount of conveyance of the manuscript, and the scanner operating button 22 to be substituted with a manuscript transfer control button respectively.
(4) The present invention has been portrayed as possessing means for setting the pertinent region in the direction of main scanning and in the direction of sub-scanning. Instead of the means just described, the present invention is only required to be provided with means capable of setting the pertinent region at least in the direction of main scanning or the direction of subscanning.
As is clear from the foregoing description, the present invention enables the required setting of the pertinent region of the manuscript to be carried out by moving the portion of the manuscript to be read out and the cursor of the liquid crystal scale formed in the manuscript display window while keeping the manuscript placed on the platen glass or inserted in the manuscript slot of the document reader, with the face of the manuscript kept under the visual observation of the operator. Thus, this invention permits the setting of the pertinent region of the manuscript to be effected very simply and accurately.
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A document reader contains a document display window for focussing the light reflected from the surface of a given manuscript thereon, a scale formed on the document display window and provided with a cursor capable of being moved in the direction of main scanning, means for freely controlling the shift of a reading line on the manuscript in the direction of sub-scanning, and means for automatically sensing the position of the cursor and the position of the reading line on the manuscript and admitting the numerical values indicative of the two positions for designating the pertinent region of the manuscript to be read out, whereby the operator is enabled to set the pertinent region of the face of the manuscript very easily and accurately while keeping visual observation of the image displayed in the document display window, with the manuscript left standing on the platen glass or kept inserted in the manuscript slot of the document reader.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally related to apparatus for dispensing controlled amounts of fluid.
2. Description of the Related Art
Many research and/or manufacturing settings require the delivery of a precise amount of fluid. Precisely controlling the delivery of fluid can be important to producing accurate test results or to producing high quality products, as well as being important in lowering costs associated with such operations. Often, these applications require a large number of repetitive operations. For example, biological or chemical assays may employ hundreds, thousands, or more of individual testing steps. Efficiency, accuracy and repeatability require that these operations be automated. One method of automating is to perform multiple tests at discrete locations on a single plate (i.e., plate, slide, or array). This requires the delivery of very precise amounts of fluids, for example agents or reagents, to hundreds or even thousands of locations on the plate. Other automated methods are of course possible. The cost of high precision automated equipment is typically substantial.
One approach to delivery of a controlled amount of fluid employs pipette tips. The pipette tip relies on capillary action to draw a precise amount of fluid from a reservoir into an internal passage of the pipette tip, for delivery to the desired location. Pipette tips may be particularly suitable for dispensing fluids in the micro-liter range.
U.S. Pat. No. 5,497,670 issued Mar. 12, 1996 discloses a dispensing apparatus including means for loading pipette tips carried by a pipette plate onto dispensing cylinders such that a loading force is maintained during the operation to ensure a hermetic seal. The pipette tips are manually placed on the pipette tip plate, the pipette tip plate being slidingly received within the dispensing apparatus.
U.S. patent application Ser. No. 08/751,859 filed Nov. 18, 1996 discloses a dispensing apparatus. The dispensing apparatus is similar to that disclosed in the aforementioned patent, but substitutes a more conventional pipette tip carrier for the pipette tip plate, which is less expensive, less likely to be contaminated, and easily adapted for robotic operation or automation.
U.S. application Ser. No. 10/027,448 filed Dec. 20, 2001 discloses a dispensing apparatus that employs a modified pipette tip box tray carrier to furnish pipette tips carried in a standard pipette tip box to the apparatus, and includes engagement means to engage pipette tip box tray carrier such that the pipette tips are loaded into corresponding internal cylinders formed in a dispense block head of the dispensing apparatus. The dispense block head comprises a solid block of material having a plurality of internal cylinders to engage the pipette tips in a sealing engagement.
A distinctly different approach to precisely dispensing fluids employs one or more pins to retrieve a desired amount of fluid from a reservoir, and to dispense the retrieved fluid to a desired location. In contrast to pipette tips, these pins do not include an internal passage, but rather retrieve a small sample of the fluid as the pin is removed from a reservoir, the fluid forming a droplet on the outer surface at the end of the pin. The amount of fluid retrieved by the pin is a function of a number of parameters including the size, shape and material of the pin and the viscosity of the fluid, all of which affect surface tension. The pin based approach may be particularly suitable for dispensing fluids in the nano-liter range.
Automating the pin based approach would be highly desirable, as would be the taking advantage of the substantial investment made in existing automated equipment such as pipette based dispensing apparatus.
BRIEF SUMMARY OF THE INVENTION
In one aspect, a pin support assembly includes a pin support frame having a plurality of apertures for supporting an array of pins for dispensing fluids. An actuation assembly engages an end of each of the pins to ensure that the pins are properly seated in the support frame in a planar fashion. Interchangeability of the pin support frame with a pipette box tray carrier allows a single drive mechanism to be employed for different operations, for example dispensing very small amounts of fluid versus dispensing very large amounts of fluid, reducing costs.
In another aspect, a pin support assembly for use with a dispense head apparatus having a movable piston plate includes a pin engagement actuation member selectively positionable with respect to the dispense head apparatus to be moved by the piston plate of the dispense head apparatus, a pin engagement member opposed to the pin engagement actuation member and mounted for movement with respect thereto, a biasing member coupled to bias the pin engagement member and the first pin engagement actuation member away from one another, and a linkage coupling the pin engagement actuation member and the pin engagement member to selectively move the pin engagement member and the first pin engagement actuation member towards one another. The pins are supported for longitudinal or “floating” movement to prevent damage to the pins.
In another aspect, a pin support assembly for supporting pins for use with a dispense head apparatus having a movable piston plate and a carrier plate includes a first pin support surface having a first plurality of apertures of a first diameter, a second pin support surface having a second plurality of apertures of a second diameter, the second diameter smaller than the first diameter, the second pin support surface spaced from and coupled to the first pin support surface to form a pin support frame, a pin engagement member opposed to the first pin support surface and mounted for movement with respect thereto between an engaged position where the pin engagement member contacts a respective end of each of a number of pins received in the first and the second apertures of the first and the second pin support surfaces of the pin support frame, if any, and an unengaged position spaced from the engaged position to disengage the respective ends of the pins received in the first and the second apertures of the first and the second pin support surfaces of the pin support frame, if any; a movable pin engagement actuation member opposed to and spaced across the pin engagement member from the pin support frame, a scissors linkage coupling the pin engagement actuation member and the pin engagement member to selectively move the pin engagement member and the first pin engagement actuation member towards and away from one another, a biasing member coupled to bias the pin engagement member toward the disengaged position, and a set of mounting members sized to receive a set of loading pins on the carrier plate of the dispense head apparatus to selectively position the pin support assembly with respect to the dispense head apparatus such that the pin engagement actuation member is movable by the piston plate of the dispense head apparatus.
In yet another aspect, a dispensing apparatus includes a pin support frame having a plurality of pin receiving apertures, a pin engagement member having a substantially planar pin engagement surface, the pin engagement member selectively movable between an engaged position and a disengaged position spaced from the engaged position, the pin engagement surface being proximate the pin support frame when the pin engagement member is in the engaged position and the pin engagement surface being distal to the pin support frame when pin engagement member is in the disengaged position, a pin engagement actuation member spaced across the pin engagement member from the pin support frame and movable between a first position spaced relatively from the pin support frame and a second position spaced relatively toward the pin support frame, a linkage coupling the pin engagement actuation member and the pin engagement member to selectively move the pin engagement member towards the pin engagement actuation member as the pin engagement member moves toward the disengaged position and to move the pin engagement member away from the pin engagement actuation member as the pin engagement member moves towards the engaged position, and a drive member couplable to selectively move the pin engagement actuation member between the first position and the second position.
In yet a further aspect, a dispensing apparatus includes a pin support frame having a first plurality of pin receiving apertures of a first diameter and a second plurality of pin receiving apertures of a second diameter smaller than the first diameter, each of the pin receiving apertures of the first plurality aligned with a respective one of the pin receiving apertures of the second plurality for supportingly receiving a respective pin for axial movement with respect thereto, and a pin engagement member having a substantially planar pin engagement surface, the pin engagement member selectively positionable between an engaged position to contact the pins received in the pin receiving apertures if any, and a disengaged position spaced from the engaged position.
In yet a further aspect a dispensing apparatus includes a drive assembly including a drive assembly frame, a drive member mounted to the drive assembly frame for axial movement with respect thereto, and a pin support assembly including a pin support frame having a number of apertures for slidingly receiving a plurality of pins, a pin engagement member mounted for movement with respect to the pin support frame between an engaged position and a disengaged position, and a linkage coupled to move the pin engagement member toward the disengaged position when the drive member moves towards the pin support frame and to move the pin engagement member toward the engaged position when the drive member moves away from the pin support frame, wherein the pin support assembly is selectively attachable and detachable to the drive assembly.
In yet an even further aspect, a dispensing apparatus includes pin support means for supporting each of a plurality of pins, a pin engagement member selectively positionable between an engaged position simultaneously engaging in a single plane a respective end of each of a plurality of pins and a disengaged position spaced from the engaged position, and actuating means for moving the pin engagement member between the engaged and the disengaged positions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrary enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements, as drawn are not intended to convey any information regarding an actual shape of the particular elements, and are solely selected for ease of recognition in the drawings.
FIG. 1 is a front elevational view of a fluid dispensing apparatus with a pipette tip box tray carrier in a disengaged position to load a pipette tip box holding a plurality of pipette tips.
FIG. 2 is a partial front elevational view of the fluid dispensing apparatus of FIG. 1 with the pipette tip box tray carrier in an engaged position to engage the pipette tips in the pipette tip box with respective ones of internal cylinders formed in a dispense block head of the fluid dispensing apparatus.
FIG. 3 is a partially exploded top, front, right isometric view of a pin support assembly having a pin support frame and an actuation assembly for use with the fluid dispensing apparatus of FIGS. 1 and 2 , for example, as a substitute for the pipette tip box and pipette tip box tray carrier thereof.
FIG. 4 is a further exploded top, front, right isometric view of a pin support assembly of FIG. 3 .
FIG. 5 is a view of an alternative embodiment of the pin support frame of the pin support frame of FIGS. 3 and 4 .
FIG. 6 is a top, front, right isometric view of the actuation assembly of the pin support assembly of FIG. 3 .
FIG. 7 is a front elevational view of the actuation assembly of FIG. 6 in a pin engaged position.
FIG. 8 is a front elevational view of the actuation assembly of FIG. 6 in a pin disengaged position.
FIG. 9 is a right side elevational view of the actuation assembly of FIGS. 7 and 8 showing the pin engaged (broken line) and disengaged positions (solid line).
FIG. 10 is an top, front, right isometric view of an alternative block of the fluid dispensing apparatus of FIG. 1 .
FIG. 11 is a partial, cross-sectional view along section 11 of FIG. 6 , illustrating complementary mating portions of the coupling members on the pin support assembly and the carrier plate.
FIG. 12 is a partial, cross-sectional view along section line 12 of FIG. 6 , further illustrating the complementary mating portions of the coupling members on the pin support assembly and the carrier plate.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures associated with dispensing apparatus, actuators, motors, motor controllers, and automated systems and devices have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments of the invention.
Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”
The headings provided herein are for convenience only and do not interpret the scope or meaning of the claimed invention.
FIGS. 1 and 2 show a fluid dispensing apparatus 10 that includes a piston plate 12 , a horseshoe plate 14 , and a carrier plate 16 . The fluid dispensing apparatus 10 may employ a pipette tip box 18 that holds a number of pipette tips 20 for retrieving and dispensing defined amounts of fluids. The pipette tip box 18 is detachably coupled to the carrier plate 16 by way of a pipette box tray carrier 22 . In the illustrated example, the pipette box tray carrier 22 includes a pair of L-shaped ears or lugs for engaging and disengaging a set of loading pins 24 of the moveable carrier plate 16 .
In operation, a pipette tip box 18 loaded with a plurality of pipette tips 20 is loaded onto the pipette box tray carrier 22 . The pipette box tray carrier 22 is coupled to the carrier plate 16 . The pipette box tray carrier 22 moves relative to a dispense block head 26 to selectively engage the ends of the pipette tips 20 with respective ones of a number of internal cylinders formed in the dispense block head 26 . The structure and operation of the fluid dispensing apparatus 10 of FIGS. 1 and 2 is further described in U.S. patent application Ser. No. 08/751,859, filed Nov. 18, 1996, and in U.S. patent application Ser. No. 09/442,500, filed Dec. 20, 2001, and thus will not be repeated herein in the interest of brevity and clarity.
FIGS. 3 and 4 show a pin support assembly 30 for use with dispensing apparatus, such as the dispensing apparatus 10 of FIG. 1 . The pin support assembly 30 includes a frame 31 , a pin support frame 32 for supporting a plurality of pins 34 and an actuation assembly 36 for selectively engaging ends 38 of the pins 34 . The frame 31 may support the pin support frame 32 and protect the pins 34 from damage.
Each of the pins 34 has a first portion 40 of a first diameter and a second portion 42 of a second diameter less than the first diameter. The amount of fluid drawn by the pin 34 will in part be a function of the second diameter. In the embodiment illustrated in FIGS. 3 and 4 , the pin support frame 32 includes a first frame member 44 having a plurality of apertures 46 having diameters slightly greater than the first diameter of the first portion 40 of the pin 34 . The pin support frame 32 also includes a second frame member 48 having a plurality of apertures 50 having diameters slightly greater than the second diameter of the second portion 42 of the pin 34 . The apertures 50 of the second frame member 48 are aligned or in registration with a respective one of the apertures 46 of the first frame member 44 . Each of the pins 34 is received in a respective pair of the apertures 46 , 50 for axial movement with respect thereto. The second support frame 48 serves as a stop, engaging an edge formed between the first and second portions 40 , 42 of the pins 34 to limit the axial travel of the pins 34 .
FIG. 5 shows an alternative embodiment of the pin support frame 32 employing a single frame member 52 having apertures 46 formed in an upper surface 54 and apertures 50 formed in a lower surface 56 . The pins 34 are again supported for axial movement, the difference in the diameters of the first aperture 46 and the second aperture 50 forming a stop to limit the axial travel of the pins 34 .
As illustrated in FIGS. 4 , 6 , 7 , 8 and 9 , the actuation assembly 36 includes a pin engagement member 60 mounted for movement with respect to the pin support frame 32 between an engaged position contacting the ends 38 of the pins 34 and a disengaged position spaced from the engaged position. The engaged position is best illustrated in FIG. 8 , and in broken line in FIG. 9 . The disengaged position is best illustrated in FIG. 7 , and in solid line in FIG. 9 . The pin engagement member 60 may include a plate 62 having an engagement surface 63 and a resilient member or pad 64 attached to the engagement surface 63 of the plate 62 .
The actuation assembly 36 includes a linkage 66 coupled to move the pin engagement member 60 toward the disengaged position when a drive member such as the dispense head 26 of the dispensing apparatus 10 moves toward the pin support frame 32 , and to move the pin engagement member 60 toward the engaged position when the drive member moves away from the pin support frame 32 . The linkage 66 may, for example, take the form of a scissor linkage, as illustrated in FIGS. 4 and 9 . The linkage 66 may include two pairs of linkage members, pivotally coupled by a pivot pin 67 , to provide balance and even force across the pin engagement member 60 . The linkage 66 may also includes rollers or bushings 69 at the extremities thereof.
The actuation assembly 36 may also include a pin engagement actuation member 68 , opposed across the pin engagement member 60 from the pin support frame 36 . The pin engagement actuation member 68 may include a plate 70 and resilient member or pad 72 , the resilient pad 72 attached to a surface of the plate 70 which is engaged by the drive member, such as the dispense head 26 . Thus, the linkage 66 couples the pin engagement actuation member 68 and the pin engagement member 60 to move the pin engagement member 60 toward the disengaged position as the pin engagement actuation member 68 moves toward the pin engagement member and the pin support frame 32 , and to move the pin engagement member toward the engaged position as the pin engagement actuation member 68 moves away from the pin engagement member 60 and the pin support frame 32 . The actuation assembly 36 may also include biasing members such as leaf springs or coil springs 71 to bias the pin engagement member 60 toward the disengaged position. The actuation assembly 36 may also include additional biasing members such as leaf springs or coil springs 74 biasing the arms of the linkage 66 into engagement with the plates 62 , 70 in order to prevent unintended “chatter” or movement of the parts. Proper dimensioning of the various holes 75 and fasteners 77 received through the holes 75 , also helps to reduce or eliminate chatter. (Only a small number of the fasteners 77 are illustrated for sake of clarity of the drawings.) As indicated in the Figures, many of the holes 75 may be countersunk, particularly where the holes 75 must accommodate springs 71 .
Thus, the pin engagement member 60 engages the ends 38 of the pins 34 in a single plane in response to movement by a drive member such as the dispense head block 26 , or a pin head block 76 illustrated in FIG. 10 . With reference to FIG. 10 , the pin head block 76 is similar to the dispense head block 26 , however, the pin head block eliminates the internal cylinders 13 found in the dispense head block 26 .
With continuing reference to FIGS. 4 and 6 - 9 , the actuation assembly 36 may include an actuation assembly frame member 78 having a pair of slots 79 through which the linkage 66 is received and mounted via the pivot pins 67 . The actuation assembly 36 also includes coupling members 80 which may have L-shaped ears or lugs 82 or other attachable/detachable coupling structures for selectively coupling the pin support assembly 30 to the carrier plate 16 ( FIG. 1 ) of the fluid dispensing apparatus 10 .
As best illustrated in FIGS. 3 , 4 and 6 , the pin support assembly 30 may include coupling members 80 for selectively engaging and disengaging the loading pins 24 of the movable carrier plate 16 (FIG. 1 ). The coupling members 80 may take the form of two pairs of generally L-shaped ears or lugs. The pin support assembly 30 may include a mating portion having a complementary shape to mate with the loading pins 24 . For example the ears or lugs may include a lip formed at a distal end, defining an interior diameter sized and dimensioned to matingly receive a respective one of the loading pins 24 .
The pin support assembly 30 may further include a mating portion having a complementary shape to mate with a mating potion of the dispense head apparatus 10 . For example, as illustrated in FIGS. 11 and 12 , the coupling members 80 may form all or a part of a mating portion for mating with a portion of the carrier plate 16 . For instance, the coupling members 80 may, as illustrated, be tapered or curved in a first direction parallel to a direction of movement of the pin engagement actuation member 68 and may be tapered or curved in a second direction perpendicular to the direction of movement of the pin engagement actuation member 68 . This ensures precise positioning of the pins 34 with respect to a target such as locations on a plate, slide or array.
Although specific embodiments of an examples for the dispensing apparatus are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the invention, as will be recognized by those skilled in the relevant art. The teachings provided herein of the invention can be applied to other dispensing apparatus, not necessarily the pin dispensing apparatus generally described above.
The various embodiments described above can be combined to provide further embodiments. All of the above U.S. patents, U.S. patent applications and publications referred to in this specification are incorporated herein by reference, in their entirety. Aspects of the invention can be modified, if necessary, to employ systems, circuits and concepts of the various patents, applications and publications to provide yet further embodiments of the invention. These and other changes can be made to the invention in light of the above detailed description. In general, in the following claims, the terms used should not be construed to limits the invention to the specific embodiments disclosed in the specification and the claims, which should be construed to include all dispensing apparatus that operate in accordance with the claims. Accordingly, the invention is not limited by the disclosure, but instead its scope is to be determined entirely by the following claims.
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A pin support assembly includes a pin support frame having a plurality of apertures for supporting an array of pins for dispensing fluids. The pins are supported for longitudinal or “floating” movement to prevent damage to the pins. An actuation assembly engages an end of each of the pins to ensure that the pins are properly seated in the support frame in a planar fashion. The actuation assembly engages the pins as the pins move relatively toward a head block and disengages the pins as the pins move relatively away from the head block.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/555,210, filed Oct. 31, 2006, which in turn is a continuation-in-part of U.S. application Ser. No. 11/454,915, filed Jun. 16, 2006, which in turn is a continuation-in-part of U.S. application Ser. No. 11/141,283, filed May 31, 2005. In addition, this application claims the benefit of U.S. Provisional Application No. 60/765,846, filed Feb. 7, 2006.
TECHNICAL FIELD
[0002] The disclosure relates generally to signal transmission and more particularly to the control of data transmission through pulse position modulation.
BACKGROUND
[0003] Ultra-wideband wireless communication has great promise in that high data rates may be achieved using a relatively low power transmitter. Ultra-wideband wireless communication may also be denoted as impulse radio because of its use of very short pulses (approximately 1 nanosecond or less). By varying individual pulse positions within a waveform of such pulses, high-data-rate information may be transmitted using very low average power such as in the milliwatt range.
[0004] Much interest has been generated for impulse radio because of its low power consumption, extremely high data rate, and excellent multipath immunity. By integrating impulse radio with beamforming capabilities, very low probability of detection performance may be achieved. In contrast to mechanically steered antennas, electronically-controlled beamforming systems are lighter, more agile, and more reliable. A key element of beamforming systems is the design of the phase shifter, which is conventionally implemented using a monolithic microwave integrated circuit (MMIC). However, MMICs are costly and introduce a relatively high insertion loss. As a result, Micro-Electro-Mechanical-Systems (MEMS)-based phase shifters have been developed. But MEMS-based phase shifters are not compatible with conventional semiconductor processes. Moreover, regardless of whether beamforming is provided, the generation of impulses has proven to be extremely difficult to master.
[0005] U.S. application Ser. No. 11/555,210 discloses an advantageous pulse generation architecture that can achieve pulse widths of just tens of picoseconds or smaller. By transmitting such pulses in a high-gain directed beam, the range and signal-to-noise limitations of ultra wideband communication are reduced. However, the necessary control signals such as the beamforming commands as well as the data-to-be-transmitted need to be supplied to the pulse generator/modulator.
[0006] Accordingly, there is a need in the art for improved control of pulse-position-modulated ultra wideband radio communications.
SUMMARY
[0007] In accordance with an embodiment of the invention, a circuit is provided that includes: an impulse generator operable to provide a pulse train; a pulse position modulator having a splitting junction configured to receive the pulse train, the pulse position modulator including a plurality of n transmission lines, wherein n is an integer, the n transmission lines being selectably coupled in parallel between the splitting junction and a combining junction, the impulse generator driving each transmission line having a unique delay such that if the transmission line is selected, each pulse received at the splitting junction is uniquely delayed into a delayed pulse, whereby if all the transmission lines are selected, each pulse received at the splitting junction is uniquely delayed into a corresponding plurality of n delayed pulses; and a controller operable to select the transmission lines responsive to received words of n bits in length, each word arranged from a first bit to an nth bit, and wherein the transmission lines are arranged from a first transmission line to an nth transmission line corresponding to the bits in the received words such that a given bit in a received word controls the selection of the corresponding transmission line.
[0008] In accordance with another embodiment of the invention, a wafer scale antenna module (WSAM) is provided that includes: a substrate, a plurality of antennas adjacent the substrate; and an RF feed network adjacent the substrate, the RF feed network coupling to a distributed plurality of amplifiers integrated with the substrate, wherein the RF feed network and the distributed plurality of amplifiers are configured to form a resonant network such that if a timing signal is injected into an input port of the RF feed network, the resonant network oscillates to provide a globally synchronized RF signal to a plurality of integrated antenna circuits, wherein each integrated antenna circuits includes a corresponding subset of antennas from the plurality of antennas, and wherein each integrated antenna circuit includes: an impulse generator having a plurality of delay paths, each delay path having a unique delay, the impulse generator being configured to rectify and level shift the globally synchronized RF signal through the delay paths to provide a pulse train; a pulse position modulator having a splitting junction configured to receive the pulse train, the pulse position modulator including a plurality of n transmission lines, wherein n is an integer, the n transmission lines being selectably coupled in parallel between the splitting junction and a combining junction, the impulse generator driving each transmission line having a unique delay such that if the transmission line is selected, each pulse received at the splitting junction is uniquely delayed into a delayed pulse, whereby if all the transmission lines are selected, each pulse received at the splitting junction is uniquely delayed into a corresponding plurality of n delayed pulses; and a controller operable to select the transmission lines responsive to received words of n bits in length, each word arranged from a first bit to an nth bit, and wherein the transmission lines are arranged from a first transmission line to an nth transmission line corresponding to the bits in the received words such that a given bit in a received word controls the selection of the corresponding transmission line, wherein each integrated antenna circuit is operable to drive the delayed pulses from its pulse position modulator into its corresponding subset of antennas.
[0009] The invention will be more fully understood upon consideration of the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an illustration of a wafer scale resonant transmitting network;
[0011] FIG. 2 is a schematic illustration of an amplifier for the resonant transmitting network of FIG. 1 ;
[0012] FIG. 3 is a schematic illustration of an impulse generator;
[0013] FIG. 4 is a schematic illustration of a pulse position modulator;
[0014] FIG. 5 is a graphic representation of pulses from the impulse generator and modulator of FIGS. 3 and 4 ;
[0015] FIG. 6 illustrates the multiplexing of data streams to form a serial data stream;
[0016] FIG. 7 is a block diagram of a system for mapping of the serial data stream of FIG. 6 into modulated pulses; and
[0017] FIG. 8 is a block diagram of a beamforming antenna array in which the beamforming is performed in the RF domain.
[0018] Embodiments of the present invention and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.
DETAILED DESCRIPTION
[0019] Reference will now be made in detail to one or more embodiments of the invention. While the invention will be described with respect to these embodiments, it should be understood that the invention is not limited to any particular embodiment. On the contrary, the invention includes alternatives, modifications, and equivalents as may come within the spirit and scope of the appended claims. Furthermore, in the following description, numerous specific details are set forth to provide a thorough understanding of the invention. The invention may be practiced without some or all of these specific details. In other instances, well-known structures and principles of operation have not been described in detail to avoid obscuring the invention.
[0020] An ultra wideband pulse generator and pulse-position modulator is provided that incorporates the pulse shaping advances disclosed in U.S. application Ser. No. 11/454,915 to provide a UWB radar having pulse widths of just tens of picoseconds. However, such extremely narrow pulses will be dispersed if transmitted through a transmission network such as a coplanar waveguide (CPW) network before being propagated by an associated transmitter's antennas.
[0021] To avoid this dispersion, embodiments of the disclosed pulse generator and pulse-position modulator use the distributed oscillator architecture disclosed in U.S. Application. No. 11/536,625, filed Sep. 28, 2006, the contents of which are incorporated by reference. In this fashion, a wafer scale (integrated with a semiconductor wafer) pulse generator and pulse-position modulator is enabled in which a resonant transmission network with distributed amplification is driven by a triggering pulse waveform such that the entire transmission network oscillates acting as a distributed oscillator. Advantageously, the RF signal from the resulting distributed oscillator thereby arrives synchronously at a plurality of integrated antenna circuits coupled to the distributed oscillator. Each integrated antenna circuit may include a pulse generator and pulse-position modulator as will be described further herein. In this fashion, ultra wideband pulses may be propagated from the resulting wafer scale antenna module without incurring dispersion caused by propagation of the pulses through a transmission network. Significantly, however, such ultra wideband pulses may be generated without the need for oscillators such as a voltage controlled oscillator (VCO) in each integrated antenna circuit.
[0022] As set forth in U.S. application Ser. No. 11/536,625, a particularly advantageous transmission network with regard to a wafer scale approach is a coplanar waveguide (CPW) network. Although embodiments of the disclosed pulse generator and pulse-position modulator include the use of any suitable architecture for a transmission network such as CPW, microstrip, and planar waveguide, CPW enjoys superior shielding properties over microstrip. Thus, the following discussion will assume without loss of generality that the transmission network is implemented using CPW. This network may be arranged in an “H” array such that the electrical length from an RF input port to any given integrated antenna circuit is the same as that to all the remaining integrated antenna circuits. Although CPW has superior shielding properties, the RF propagation across a CPW network on a semiconductor wafer such as an 8″ wafer may introduce losses as high as 120 dB. To counteract such losses, a plurality of distributed amplifiers may be coupled to the CPW network as disclosed in U.S. application Ser. No. 11/141,283. For example, a first linear transistor amplifier (which may be denoted as a driving amplifier) amplifies a received RF signal into a length of the CPW network into a second linear transistor amplifier (which may be denoted as a matching amplifier) configured to match its output impedance to the characteristic impedance of the CPW network. Both the gain of the driving amplifier and the gain and the output impedance of the matching amplifier are tuned using reactive loads such as integrated inductors. In this fashion, resistive losses are minimized. These gains may be maintained so that linear operation is achieved. In this fashion, an RF signal driven into an input port of the CPW network is linearly amplified and propagated to the integrated antenna circuits, despite the transmission line losses.
[0023] As disclosed in U.S. application Ser. No. 11/536,625, it has been observed that the combination of the resulting active devices and the transmission network can be tuned to form a resonant network. Because the network is resonant, a globally-synchronized oscillation can be induced by triggering the network with an appropriate timing signal. The distributed amplifiers thus injection lock to each other such that the resonant network forms a distributed oscillator providing each integrated antenna circuit with a globally synchronized sinusoidal RF signal. This sinusoidal RF signal may then be rectified in an impulse generator discussed herein to provide an unmodulated pulse train. The unmodulated pulses may then be pulse-position modulated. In addition, the resulting pulse-position modulated pulse train received at the antennas may be phase shifted for beamforming purposes using a phase shifter such as the analog phase shifter in U.S. application Ser. No. 11/535,928 (the contents of which are incorporated by reference) or any other suitable phase shifter such as disclosed in U.S. Application. No. 11/182,344.
[0024] Turning now to FIG. 1 , a resonant half-duplex transmission network 410 for an 8×8 subarray of antenna elements 170 is implemented in an 8″ wafer scale radar module 400 . The triggering signal to trigger the resonant oscillation is injected into a center feed point 405 . Distributed amplifiers 430 coupled to the network then injection lock to each other such that each antenna 170 may receive a globally synchronized RF signal. The transmission network may be single-ended or differential. In one embodiment, the network may comprise a coplanar waveguide (CPW) having a conductor width of a few microns (e.g., 4 microns). With such a small width or pitch to the network, an array of antenna elements may be readily networked in an 8 inch wafer substrate for, for example, 60 GHz data transmission.
[0025] The design of the distributed amplifiers is not critical so long as they provide sufficient amplification and achieve a resonant operation with the transmission network. An exemplary amplifier 700 is illustrated in FIG. 2 . Amplifier 700 uses NMOS FETs Q 1 710 and Q 2 705 although it will be appreciated that an analogous PMOS or bipolar-based amplifier may also be implemented. The source of transistor Q 1 couples to the drain of transistor Q 2 . The drain of Q 1 couples to an output voltage node Vout and also to an inductor L 1 . Inductor L 1 may be implemented using the metal layers in the semiconductor process used to form amplifier 700 as discussed in U.S. Pat. No. 6,963,307, the contents of which are incorporated by reference. The parasitic capacitance and resistance of inductor L 1 are illustrated conceptually as resistor R 1 and capacitor C 1 . An opposing terminal of inductor L 1 couples to a supply voltage node Vcc that also couples to the gate of transistor Q 1 . An input voltage node Vin couples through a capacitor Cs to the gate of transistor Q 2 . The gate of transistor Q 2 is biased by a voltage source 630 that provides a gate bias voltage Vgb. In a bipolar-based embodiment, voltage source 630 would be replaced by a current source. Each field effect transistor would be replaced by a bipolar transistor of the appropriate doping. For example, NMOS transistors such as Q 1 and Q 2 would be replaced by corresponding NPN bipolar transistors. It will be appreciated that amplifier 700 may also be constructed using PNP bipolar transistors or corresponding p-channel transistors (in a FET-based embodiment. Such dual embodiments (bipolar NPN or PNP, n-channel FET or p-channel FET) may be constructed for all the amplifiers disclosed herein. The source of transistor Q 2 is optionally loaded by an inductor L 2 (not illustrated). Capacitor Cs and inductor L 2 may be formed using semiconductor process metal layers as discussed for inductor L 1 . The values of the various inductances and capacitances depend upon the impedance of the corresponding resonant transmission network, the dimensions of the transistors, and the operating frequency. For example, in a FET-based embodiment having transistor channel dimensions of 2 microns by 0.12 micron, Cs may have a capacitance of 80 fF, L 1 may have an inductance of 80-100 pH (for 40 or 60 GHz operation, respectively), and L 2 may have an inductance approximately 1/10 th that of L 1 . As discussed analogously in, for example, U.S. application Ser. No. 11/536,625, each amplifier is integrated onto the semiconductor substrate (or semiconductor wafer) that supports the resonant integrated network. Similarly, the beam-forming units are also integrated onto the substrate. The antennas may be formed in either a “backside” or “frontside” implementation as discussed in U.S. application Ser. No. 11/567,650, filed Dec. 6, 2006, the contents of which are incorporated by reference.
[0026] The resulting resonant transmission network will sinusoidally oscillate in unison. The result is a globally synchronized sinusoid that may be received by each integrated antenna circuit. The resulting voltage swing on the resonant transmission network may be enhanced by modifying amplifier 700 to include a third transistor as discussed in U.S. application Ser. No. 11/622,813, filed Jan. 12, 2007, the contents of which are incorporated by reference. Regardless of the distributed amplifier design, the globally synchronized sinusoidal signal thereby produced may be received at impulse generators. These impulse generators may be advantageously incorporated in a wafer scale antenna module as will be discussed herein. However, it will be appreciated that the pulse generation, modulation, and control techniques disclosed herein are independent of the actual physical layer implementation used to transmit the resulting pulses. An exemplary integrated antenna circuit's impulse generator 1800 is illustrated in FIG. 3 . The resonant transmission network is illustrated conceptually by oscillator 1805 . An input voltage from oscillator 1805 is received at a rectifying driver amplifier 701 a . Driver amplifier 701 a may be constructed as discussed with regard to amplifier 700 . However, to provide the desired rectification and level-shifting, the driver amplifier 701 a is altered with regard amplifier 700 so as to operate in the saturation mode rather than in the linear mode as discussed in U.S. Application Ser. No. 11/555,210 (the '210 application). Rectifying and level-shifting driver amplifier 701 a differs from driver amplifier 700 in that the output voltage and the output capacitor couple between ground and the source (rather than the drain) of transistor Q 1 . Because transistor Q 1 has approximately a diode drop of voltage across it (approximately 0.7 V), the output is then level-shifted this amount from VCC. The rectification comes about from the biasing of amplifier 701 a such that it does not operate in the linear small-signal mode. Instead, amplifier 701 a operates in the saturation mode. In this fashion, amplifier 701 a shifts and rectifies its sinusoidal input signal into an output signal at a splitting junction 1810 .
[0027] Amplifier 701 a drives transmission lines TL 1 and TL 2 (such as CPW segments) arranged in parallel between splitting junction 1810 and a combining junction 1820 . These transmission lines have different electrical lengths through appropriate configuration. For example, in a CPW embodiment, the widths of the corresponding CPW conductors are varied accordingly. Each transmission line segment ends in a level-shifting and rectifying combiner matching amplifier 1150 as also discussed in the '210 application. A second driver amplifier 701 b receives the output signals from transmission lines TL 1 and TL 2 to provide an output pulse train signal. Loads 1850 and 1806 are constructed as discussed in the '210 application. It will be appreciated that because impulse generator 1800 uses two transmission lines TL 1 and TL 2 , the resulting pulse train has pulse widths corresponding to less than half the frequency of the sinusoidal input signal. By using additional transmission lines, generator 1800 could achieve even narrower pulses but at the same pulse repetition rate as the input sinusoid frequency.
[0028] The pulse train provided by a impulse generator such as impulse generator 1800 may be modulated in a pulse position modulator 1900 illustrated in FIG. 4 . A linear driver amplifier 702 a as discussed in the '210 application drives an amplified pulse train into a splitting junction 1910 . A plurality of n transmission lines TL 1 through TLn couples between splitting junction 1910 and a combining junction 1920 . Each transmission line has a different electrical length to produce a desired amount of delay and is received by a corresponding linear matching amplifier 1151 as discussed analogously in the '210 application. Each matching amplifier 1151 couples through a corresponding switch from switches SW 1 through SWn to combining junction 1920 . A second driver amplifier 702 b amplifies the combined signal at combining junction 1920 into an output node.
[0029] In one embodiment, pulse position modulator 1900 may include four transmission line TL 1 through TL 4 and corresponding switches SW 1 through SW 4 . Transmission line TL 1 may have the shortest electrical length such that its matching amplifier output may be considered to have 0 degrees delay. The second transmission line TL 2 may have a longer electrical length such that its matching amplifier output has 90 degrees of delay. Similarly, the third and fourth transmission lines may have greater and greater amounts of delay such that the corresponding matching amplifier outputs have 180 and 270 degrees of delay, respectively. The resonant transmission line may readily be made to oscillate at 15 GHz. An impulse generator 1800 receiving the resulting sinusoid may readily be constructed so as to produce a 15 GHz pulse repetition rate but with pulse widths of just 10 to 15 picoseconds. These input pulses are shown graphically in solid form in FIG. 5 . If SW 1 is left on, an output pulse of 0 degree delay (shown in phantom form in FIG. 5 ) is produced at the output node of the pulse position modulator. Analogous output pulses of 90, 180, and 270 degrees of delay are produced if the corresponding switches SW 2 through SW 4 are on (these pulses are also shown in phantom form in FIG. 5 ). These delayed pulses may be considered to occur in corresponding time bins. If an output pulse is provided in a time bin (such as for example, the time bin corresponding to the 0 degree delayed pulse), a binary one may be considered to have been transmitted. On the other hand, if a time bin (such as for example, the time bin corresponding to the 90 degree delayed pulse) is empty, a binary zero may be considered to have been transmitted. To keep synchronization in the receiver, switch SW 1 may always be left on such that the corresponding 0 degree delayed pulse acts as a transmitted reference as known in the transmitted reference pulse position modulation schemes. Four possible symbols/words thus result: [1000], [1100], [1110], and [1111], corresponding to the transmission of 2 bits. In such a scheme, if the original pulse repetition rate is 15 GHz, a 30 GHz data rate is achievable. Should a transmitted reference not be used, four bits could be transmitted from each unmodulated pulse such that a 60 GHz data rate is achievable.
[0030] The data to be transmitted using this pulse position modulation as well as beamforming commands and other information may be multiplexed as shown in FIG. 6 . Four sets of 12×1.25 Gbps data streams may be multiplexed in 16 Gbps multiplexers. The output signal may be differential as illustrated or a single-ended embodiment may be used. The resulting four 16 Gbps data streams may then be multiplexed responsive to a 60 GHz clock rate to provide a single 60 Gbps serial data stream. This data stream may either be coupled through a wired or wireless near-field or far-field connection to a demultiplexer to be demultiplexed into four 16 Gbps data streams. These four 16 Gbps data streams may then be demultiplexed into 12×1.25 Gbps data streams.
[0031] Regardless of the data rate in the resulting serial data stream, the serial bits may be mapped into the symbols (words) such as discussed above with regard to FIG. 5 . Turning now to FIG. 7 , the serial data stream such as that produced as discussed with regard to FIG. 6 is mapped into the corresponding words through a shift register that receives the words and drives the switches SW 1 through SWN in pulse position modulator 1900 ( FIG. 4 ) so as to provide the appropriate modulated pulses. In this fashion, extremely high data transmission rates such as 60 Gbps may be achieved that are simply unobtainable with other modulation schemes.
[0032] Although the implementation of the pulse generation and pulse position modulation discussed herein is independent of the physical layer used to transmit the resulting modulated pulses, a wafer scale antenna module (WSAM) embodiment is advantageous because of the enhanced beamforming capabilities yet low cost of integrated circuit manufacture that it offers. Because the beamforming in a WSAM embodiment is performed in the RF domain, the baseband processor needs only a single channel of analog-to-digital conversion, thereby lowering cost and complexity. An exemplary embodiment of a wafer scale beamforming approach may be better understood with regard to the beamforming system of FIG. 8 , which illustrates an integrated RF beamforming and controller unit 130 . In this embodiment, the receive and transmit antenna arrays are the same such that each antenna 170 functions to both transmit and receive. A plurality of integrated antenna circuits 125 each includes an RF beamforming interface circuit 160 and receive/transmit antenna 170 . RF beamforming interface circuit 160 adjusts the phase of the received RF signal from its antenna 170 responsive to control from a controller/phase manager circuit 190 . In addition, in a transmit mode, RF beamforming interface circuit 160 receives the modulated pulse output train from a corresponding pulse position modulator 1900 (not illustrated) and adjusts the phase of the modulated pulse train before the phase-adjusted modulated pulse train is transmitted by the corresponding antenna 170 . Although illustrated having a one-to-one relationship between beamforming interface circuits 160 and antennas 170 , it will be appreciated, however, that an integrated antenna circuit 125 may include a plurality of antennas all driven by RF beamforming interface circuit 160 .
[0033] Although the pulse train generation and pulse position modulation and associated control schemes discussed herein have been described with respect to particular embodiments, this description is only an example of certain applications and should not be taken as a limitation. Consequently, the scope of the claimed subject matter is set forth as follows.
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In one embodiment, a circuit is provided that includes: an impulse generator operable to provide a pulse train; a pulse position modulator having a splitting junction configured to receive the pulse train, the pulse position modulator including a plurality of n transmission lines, wherein n is an integer, the n transmission lines being selectably coupled in parallel between the splitting junction and a combining junction, the impulse generator driving each transmission line having a unique delay such that if the transmission line is selected, each pulse received at the splitting junction is uniquely delayed into a delayed pulse, whereby if all the transmission lines are selected, each pulse received at the splitting junction is uniquely delayed into a corresponding plurality of n delayed pulses; and a controller operable to select the transmission lines responsive to received words of n bits in length, each word arranged from a first bit to an nth bit, and wherein the transmission lines are arranged from a first transmission line to an nth transmission line corresponding to the bits in the received words such that a given bit in a received word controls the selection of the corresponding transmission line.
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TECHNICAL FIELD
[0001] This disclosure relates to illumination systems and to microlithography exposure system that use illumination systems.
BACKGROUND
[0002] Illumination systems are widely used in microlithography to illuminate a reticle with radiation having a desired homogeneity and pupil fill. A projection objective is then used to transfer a pattern from the reticle to a substrate by forming an image of the reticle on a layer of a photosensitive material disposed on the substrate. In general, illumination systems fall into three different classes: dioptric systems; catoptric systems; and catadioptric systems. Dioptric systems use exclusively refractive elements (e.g., lens elements) to shape radiation from a source to have desired properties at an object plane of the projection objective. Catoptric systems use exclusively reflective elements (e.g., mirror elements) to shape the radiation. Catadioptric systems use both refractive and reflective elements to shape the radiation.
SUMMARY
[0003] Microlithography exposure systems are disclosed that feature illumination systems for illuminating reflective reticles. In order to illuminate the reticle, at least the last element in the radiation path of the illumination system is positioned on the same side of the reticle as the projection objective. Accordingly, the optical design of such systems should account for the relative positioning of the last element of the illumination system relative to the elements of the projection objective. In certain embodiments, the last element of the illumination system is a grazing incidence mirror, configured relative to the projection objective to illuminate a relatively large field at the object plane with relatively low incidence angles.
[0004] In general, in a first aspect, the invention features a system that includes a catoptric projection objective having an optical axis and including a plurality of projection objective elements positioned between an object plane and an image plane, the object and image planes being orthogonal to the optical axis, the projection objective being configured so that during operation the projection objective directs radiation reflected at the object plane to the image plane to form an image at the image plane of an object positioned in a field at the object plane, the field having a first dimension of 8 mm or more and a second dimension of 8 mm or more, the first and second dimensions being in orthogonal directions. The system also includes an illumination system including a plurality of illumination system elements, the illumination system being configured so that during operation the illumination system directs the radiation to the field at the object plane, where a chief ray of the radiation has an angle of incidence of 10° or less (e.g., about 9° or less, about 8° or less, about 7° or less, about 6°) at the object plane.
[0005] Embodiments of the system can include one or more of the following features. For example, the chief ray can be the chief ray that intersects the object plane at a central field point.
[0006] In embodiments, the projection objective includes a first projection objective element and the illumination system includes a first illumination system element, the first projection objective element being the first element in a path of the radiation from the object plane to the image plane and the first illumination system element being the last element in the illumination system in the path of the radiation prior to the object plane, where the first projection objective element can be closer to the object plane than the first illumination system element. The first illumination system element can be positioned a distance z min or more from the object plane, where z min is given by the equation:
[0000]
z
min
=
dy
+
y
min
Γ
,
[0000] in which
[0000]
Γ
=
tan
[
arcsin
[
sin
(
arctan
(
(
y
0
-
dy
/
2
)
·
tan
(
CRAO
)
y
0
)
)
-
σ
·
NAO
)
]
]
+
tan
[
arcsin
[
sin
(
arctan
(
(
y
0
+
du
/
2
)
·
tan
(
CRAO
)
y
0
)
)
-
NAO
)
]
]
,
[0000] where NAO is the numerical aperture of the projection objective at the object plane, σ is the relative numerical aperture of the illumination system at the object plane, CRAO is the chief ray angle of a central field point at the object plane, dy is the dimension of the field in the direction orthogonal to the optical axis, y 0 is a distance between the central field point and the optical axis, and y min is a minimum separation between the radiation and either the first illumination system element or the first projection system element. The first illumination system element can be positioned further from the optical axis than the field at the object plane.
[0007] The field at the object plane can be rectangular-shaped or can be arc-shaped.
[0008] The first illumination system element can be a mirror. The mirror can be a plane mirror or a curved mirror (e.g. a torodial mirror). The mirror can be arranged as a grazing incidence mirror.
[0009] In some embodiments, the illumination system includes a field mirror including a plurality of facet mirrors and during operation the illumination system images each facet mirror to the object plane. The facet mirrors can be rectangular mirrors or arc-shaped mirrors
[0010] The first dimension can be 9 mm or more (e.g., about 10 mm or more, about 12 mm or more, about 15 mm or more, about 20 mm or more, about 30 mm or more, about 40 mm or more, about 50 mm or more). The second dimension can be 9 mm or more (e.g., about 10 mm or more, about 12 mm or more, about 15 mm or more, about 20 mm or more, about 30 mm or more, about 40 mm or more, about 50 mm or more). In some embodiments, the first dimension is about 20 mm or less (e.g., about 15 mm or less, about 12 mm or less, about 10 mm or less). In certain embodiments, the second dimension is about 40 mm or less (e.g., about 30 mm or less, about 26 mm or less, about 20 mm or less, about 15 mm or less, about 12 mm or less, about 10 mm or less). The chief ray at a central field point can have an angle of incidence of 10° or less (e.g., about 9° or less, about 8° or less, about 7° or less, about 6°). The projection objective can have an image-side numerical aperture of 0.25 or more (e.g., 0.3 or more, 0.35 or more, 0.4 or more, 0.45 or more, 0.5 or more). In some embodiments, the projection objective has an object side numerical aperture of about 0.06 or more.
[0011] The projection objective can be a reduction projection objective. In certain embodiments, the projection objective is a transfer projection objective. The projection objective can include an even number (e.g., 2, 4, 6, 8, or more) of curved (e.g., convex or concave) mirrors.
[0012] The object can be a reticle. The object can be configured to reflect radiation from the illumination system.
[0013] The system can include a source configured to produce radiation that is directed by the illumination system to the object plane. The radiation can have a wavelength that is less than 400 nm (e.g., about 248 nm or less, about 193 nm or less, about 13 nm or less).
[0014] The system can be a microlithography exposure system (e.g., a scanning microlithography exposure system).
[0015] In general, in another aspect, the invention features a system that includes a catoptric projection objective having an optical axis and including a plurality of projection objective elements including a first projection objective element, the projection objective being configured so that during operation the projection objective directs radiation from an object plane to an image plane to form an image at the image plane of an object positioned in a field at the object plane, the first projection objective element being the first element in a path of the radiation from the object plane to the image plane and the field having a dimension of 8 mm or more in a direction orthogonal to the optical axis. The system also includes an illumination system having a plurality of illumination system elements including a first illumination system element, the illumination system being configured so that during operation the illumination system directs the radiation to the field at the object plane, where the first illumination system element is the last illumination system element in the path of the radiation prior to the object plane. A chief ray of the radiation has an angle of incidence of 10° or less at the object plane, and the first illumination system element is on the same side of the object plane as the first projection objective element. Embodiments of the system can include one or more of the features listed above with respect to the first aspect.
[0016] In general, in another aspect, the invention features a system that includes a projection objective including a plurality of projection objective elements including a first projection objective element, the projection objective being configured so that during operation the projection objective directs radiation from an object plane to an image plane to form an image at the image plane of an object positioned at the object plane, the first projection objective element being the first element in a path of the radiation from the object plane to the image plane. The system also includes an illumination system having a plurality of elements including a grazing incidence mirror, the illumination system being configured so that during operation the illumination system directs radiation to the field at the object plane, the grazing incidence mirror being the last element in the illumination system in the path of the radiation prior to the object plane. The first projection objective element is closer to the object plane than the grazing incidence mirror. Embodiments of the system can include one or more of the features listed above with respect to the first aspect.
[0017] In general, in a further aspect, the invention features a system that includes a catoptric projection objective having an optical axis and including a plurality of projection objective elements positioned between an object plane and an image plane, the object and image planes being orthogonal to the optical axis and the projection objective being configured so that during operation the projection objective directs radiation reflected at the object plane to the image plane to form an image at the image plane of an object positioned in a field at the object plane, the field having a dimension of 8 mm or more in a direction orthogonal to the optical axis. The system also includes an illumination system including a plurality of illumination system elements, the illumination system being configured so that during operation the illumination system directs the radiation to the field at the object plane. A chief ray of the radiation has an angle of incidence of 10° or less at the object plane. The system is a scanning microlithography exposure system and the direction orthogonal to the optical axis is a scan direction of the scanning microlithography exposure system. Embodiments of the system can include one or more of the features listed above with respect to the first aspect.
[0018] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description, drawings, and claims.
DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a schematic diagram of a microlithography exposure system.
[0020] FIG. 2A is a schematic diagram of an illumination system of a microlithography exposure system.
[0021] FIGS. 2B-D are schematic diagrams showing aspects of an illumination system.
[0022] FIG. 2E are plots of different intensity profiles through sections of an illuminated object field.
[0023] FIG. 3A shows an embodiment of a microlithography exposure system.
[0024] FIG. 3B is a schematic diagram showing components of the microlithography exposure system shown in FIG. 3A .
[0025] FIG. 4 is a schematic diagram showing components of a microlithography exposure system.
[0026] FIG. 5 is a diagram of an embodiment of a projection objective configured to image a reticle from an object plane to an image plane and a grazing incidence mirror for directing radiation to the reticle.
[0027] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0028] Referring to FIG. 1 , a microlithography exposure system 100 generally includes a light source 110 , an illumination system 120 , a projection objective 101 , and a stage 130 . A Cartesian coordinate system is shown for reference. Light source 110 produces radiation 112 at a wavelength λ which is collected by illumination system 120 . Illumination system 120 interacts with (e.g., expands and homogenizes) the radiation and directs radiation 122 to a reticle 140 positioned at an object plane 103 . Projection objective 101 directs radiation 142 reflected from reticle 140 onto a light sensitive layer (e.g., a resist) on a substrate 150 positioned at an image plane 102 of projection objective 101 , forming an image of reticle 140 at image plane 102 . Generally, microlithography exposure system 100 is configured to image a certain portion of reticle 140 positioned at a certain region of object plane 103 to image plane 102 . This region of object plane 103 is referred to as the object field and the corresponding portion at image plane 102 is referred to as the image field. The radiation on the image-side of projection objective 101 is depicted as rays 152 . As shown in FIG. 1 , the rays are illustrative only and not intended to be accurately depict the path of the radiation with respect to reticle 140 , for example. Substrate 150 is supported by stage 130 , which moves substrate 150 relative to projection objective 101 so that projection objective 101 images reticle 140 to different portions of substrate 150 . In embodiments where lithography tool 100 is a scanner, the tool includes a reticle stage that moves reticle 140 in a scan direction with respect to illumination system 120 .
[0029] Projection objective 101 includes a reference axis 105 (e.g., an optical axis). In certain embodiments, such as where projection objective 101 is symmetric with respect to a meridional section, reference axis 105 is perpendicular to object plane 103 and passes through the center of the object field. In certain embodiments, axis 105 intersects both the object field and the image field of projection objective 101 . In some embodiments, both the object field and the image field of projection objective 101 are not intersected by axis 105 . Such fields are referred to as off-axis fields.
[0030] In general, projection objective 101 can be designed to provide a desired magnification of the reticle image. In some embodiments, projection objective 101 is a reduction objective. In other words, the image at image plane 102 is smaller than the object being imaged (e.g., reduced 4× or more, 5× or more, 6× or more, 8× or more). In certain embodiments, projection objective 101 is a transfer objective or relay lens, where the object and image are the same size. In some embodiments, the image is larger than the object.
[0031] Projection objective 101 can be designed to have a desired numerical aperture (NA) at image plane 102 . This is referred to as the image-side numerical aperture. In some embodiments, the image-side numerical aperture is about 0.1 or more (e.g., 0.2 or more, 0.3 or more, 0.4 or more). In certain embodiments, projection objective 101 is designed to have a very high image-side numerical aperture. For example, in some embodiments, the image side numerical aperture is in a range from 0.5 to 1 (e.g., about 0.5 or more, about 0.6 or more, about 0.7 or more, about 0.8 or more, about 0.9 or more). In some embodiments, the image-side NA can be greater than 1. For example, where an immersion liquid (e.g., as a liquid lens or planar film of liquid) is used between the final element in projection objective 101 and the substrate at the image plane, the image-side numerical aperture can be more than 1 (e.g., about 1.1 or more, about 1.2 or more, about 1.3 or more).
[0032] Projection objective 101 also has a NA at object plane 103 , referred to as the object-side NA. In general, the object-side NA is related to the image-side NA by the magnification of projection objective 101 . Where projection objective 101 is a transfer objective or relay lens, the object and image-side NA's are the same. Where projection objective 101 is a reduction objective, the object-side NA is smaller than the image-side NA. In some embodiments, projection objective 101 can have an object-side NA of 0.0625 or more (e.g., about 0.08 or more, about 0.09 or more, about 0.1 or more, about 0.15 or more, about 0.2 or more).
[0033] Illumination system 120 has a relative numerical aperture at object plane 103 . [The relative numerical aperture, s, refers to is the quotient between the numerical aperture of the illumination system (NAI) and the numerical aperture of the projection objective (NAO): σ=NAI/NAO. Both NAI and NAO are quantities measured in the object plane of the projection objective. In other words, NAO is the same as the object-side NA discussed above. In general, the value for σ is zero for perfectly coherent illumination (i.e., plane wave illumination propagating along a single direction) and greater than 2 for incoherent illumination. Values between zero and 2 typically describe partial coherent illumination which is typical for microlithography exposure system. In certain embodiments, 0.2<σ<1 holds.
[0034] Light source 110 is selected to provide radiation at a desired operational wavelength, λ, of tool 100 . In some embodiments, light source 110 is a laser light source, such as a KrF laser (e.g., having a wavelength of about 248 nm) or an ArF laser (e.g., having a wavelength of about 193 nm). Non-laser light sources that can be used include light-emitting diodes (LEDs), such as LEDs that emit radiation in the blue or UV portions of the electromagnetic spectrum, e.g., about 365 nm, about 280 nm or about 227 nm.
[0035] Typically, for projection objectives designed for operation in lithography tools, wavelength λ is in the ultraviolet portion of the electromagnetic spectrum. For example, λ can be about 400 nm or less (e.g., about 300 nm or less, about 200 nm or less, about 100 nm or less, about 50 nm or less, about 30 nm or less). λ can be more than about 2 nm (e.g., about 5 nm or more, about 10 nm or more). In embodiments, λ can be about 193 nm, about 157 nm, about 13 nm, or about 11 nm. Wavelengths in the 1 nm to 100 nm range (e.g., 13 nm) are referred to as Extreme UV (“EUV”) wavelengths. Using a relatively short wavelength may be desirable because, in general, the resolution of a projection objective is approximately proportional to the wavelength. Therefore, shorter wavelengths can allow a projection objective to resolve smaller features in an image than equivalent projection objectives that use longer wavelengths. In certain embodiments, however, λ can be in non-UV portions of the electromagnetic spectrum (e.g., the visible portion).
[0036] Typical light sources for wavelengths between 100 nm and 200 nm are excimer lasers, for example an ArF-Laser for 193 nm, an F 2 -Laser for 157 nm, an Ar 2 -Laser for 126 nm and a NeF-Laser for 109 nm. Since the transmission of the optical materials deteriorates with decreasing wavelength, the illumination systems can be designed with a combination of refractive and reflective components (i.e., catadioptric). For wavelengths in the EUV wavelength region, such as between 10 nm and 20 nm, lithography exposure apparatus 100 is designed as all-reflective (i.e., catoptric). Examples of EUV light sources are a Laser-Produced-Plasma-source, a Pinch-Plasma-Source, a Wiggler-Source or an Undulator-Source.
[0037] Referring to FIG. 2A , illumination system 120 includes optical components arranged to form a radiation beam with a homogeneous intensity profile and desired pupil fill. Typically, illumination system 120 includes a collector 210 , configured to collect radiation from source 110 and direct the radiation as a beam along an optical path to beam shaping optics 220 . Typically, collector 210 will produce a collimated or convergent beam.
[0038] In general, the shape and intensity profile of the radiation exiting collector 210 different from a desired shape and intensity profile of the radiation at object plane 103 . For example, with reference to FIG. 2B , a beam profile 212 between collection optics and beam shaping optics 220 is typically substantially circular in shape with an intensity profile that can vary substantially across its width.
[0039] As discussed previously, the object field is the portion of object plane for which reticle 140 is imaged to image plane 102 . In general, the shape of the object field at object plane 103 is determined by projection objective 101 . Usually, the object field corresponds to a region of object plane 103 for which a reticle is imaged to image plane 102 with relatively low aberrations. Typically, the shape of the object field is dependent on the type of projection objective 101 . In stepper-type lithography tools, the object field is generally rectangular in shape. In scanner-type lithography tools, the object field is typically rectangular or arc-shaped. Catoptric projection objectives, for example, typically have an arc-shaped object field.
[0040] Accordingly, beam shaping optics 220 include one or more components configured to provide a beam of radiation at objection plane 103 having a desired intensity profile across the object field and a desired pupil fill. For example, in some embodiments, beam shaping optics 220 can provide a beam having a substantially homogeneous intensity profile across the object field (e.g., the radiation intensity inside the object field varies by about ±5% or less) having the same size and shape as the object field. Other profiles are also possible as discussed below.
[0041] Referring to FIG. 2E , in general, the intensity profile of illumination across the object field can vary. Generally, it is desirable that the intensity is substantially constant in the object field, and substantially zero on either side of the field. This profile corresponds to the curve shown as 222 A. In some embodiments, the radiation intensity inside the object field varies by about ±10% or less (e.g., ±8% or less, ±5% or less).
[0042] Other intensity distributions inside the object field are also possible. For example, the intensity distribution can be approximately trapezoidal (curve 222 B) or approximately Gaussian (curve 222 C). In the case of a scanning system, such a variation in radiation intensity typically can occur in the scan direction.
[0043] In general, the edge of the field is determined as the location where the illumination intensity is half of I max , where I max is the maximum illumination intensity within the field.
[0044] Referring to FIG. 2C , in catoptric systems, such as in microlithography exposure system designed for use at EUV wavelengths, an arc-shaped object field 222 is typically desired. Arc-shaped object field 222 corresponds to a segment of an annulus which is characterized by an inner radius of curvature, IR f , an outer radius of curvature, OR f , and a width, w f . Arc-shaped field 222 is also characterized by a height at the meriodonal plane of the projection objective, d y , which in this case is the difference between OR f and IR f . For arc-shaped object field 222 , IR f and OR f are substantially constant across the width of the field. A Cartesian coordinate system is provided for reference in object plane 103 . Width w f is measured along the x-axis, while height d y is measured along the y-axis (where the y-z plane is the meridional plane of projection objective 100 ). In general, IR f can vary as desired. In some embodiments, IR f is about 40 mm or more (e.g., about 50 mm or more, about 60 mm or more, about 80 mm or more, about 100 mm or more, about 150 mm or more). In certain embodiments, IR f is about 500 mm or less (e.g., about 400 mm or less, about 300 mm or less, about 250 mm or less, about 200 mm or less, about 150 mm or less, about 100 mm or less). IR f can be in a range from about 50 mm to about 250 mm (e.g., in a range from about 100 mm to about 200 mm).
[0045] Referring to FIG. 2D , in some embodiments, object field 222 of microlithography exposure system 100 is rectangular in shape. As for the arc-shaped field, the rectangular field is characterized by width w f and height d y .
[0046] In general, for arc-shaped and/or rectangular field shapes, w f may vary as desired. In certain embodiments, w f can correspond to a reticle die width (or multiples of reticle die widths). For example, w f can be selected so that the field corresponds to one, two, three or more die widths on the wafer. In some embodiments, w f is about 20 mm or more (e.g., about 30 mm or more, about 40 mm or more, about 50 mm or more, about 60 mm or more, about 80 mm or more, about 100 mm or more, about 120 mm or more). In certain embodiments, w f can be in a range from about 50 mm to about 250 mm (e.g., in a range from about 80 mm to about 200 mm).
[0047] Height d y can vary. In certain embodiments, it can be desirable to have a relatively large field height. For example, generally, a larger field height can be used to expose a larger image field on a substrate, reducing exposure time for a substrate and increasing throughput for the microlithography exposure system relative to apparatus with smaller field heights. In scanning system, for example, a larger field height can allow for relaxed dose control, because the exposure time for each resist point is increased. In some embodiments, dy is 4 mm or more (e.g., 5 mm or more, 6 mm or more, 8 mm or more, about 10 mm or more, about 20 mm or more, about 30 mm or more, about 40 mm or more, about 50 mm or more). In certain embodiments, dy is about 100 mm or less (e.g., about 80 mm or less, about 60 mm or less, about 50 mm or less). dy can be in a range from 5 mm to about 100 mm (e.g., in a range from 6 mm to about 60 mm, from 8 mm to about 40 mm, such as from about 10 mm to about 20 mm).
[0048] As discussed above, illumination systems generally include beam shaping optics configured to provide a beam of radiation at object plane 103 having a desired intensity profile across the object field and a desired pupil fill. For example, in some embodiments, beam shaping optics 220 include a field raster plate that directs radiation from collection optics 210 to object plane 103 in a way that provides substantially homogeneous illumination of object field 222 . Moreover, beam shaping optics 220 can include one or more components configured to provide a desired fill of the exit pupil of illumination system 120 , which is located at the entrance pupil of the projection objective 101 . For example, beam shaping optics 220 can include one or more components that provide circular, annular, dipolar, or quadrupolar illumination at the entrance pupil of projection objective 101 . An appropriate pupil raster plate can be used to perform this function.
[0049] In some embodiments, the illumination system includes a grazing incidence mirror that directs radiation from the pupil raster plate to the reticle. As used herein, a grazing incidence mirror refers to a mirror for which a maximum angle of incidence for a chief ray of the projection objective is more than 45°. In some embodiments, the maximum chief ray angle of incidence is about 60° or more (e.g., about 70° or more, about 75° or more, about 80° or more). A chief ray is a path of radiation through a microlithography exposure system that intersects the object plane at a point in the object field and intersects the optical axis of the projection objective at the aperture stop of projection objective.
[0050] The grazing incidence mirror can be a curved mirror. For example, where the field raster elements are rectangular, a curved grazing incidence mirror can be used to form an arc-shaped object field distorting the images of the rectangular raster elements to form arc-shaped images. Examples of curved grazing incidence mirrors are shown in U.S. Pat. No. 7,186,983 B2, entitled “ILLUMINATION SYSTEM PARTICULARLY FOR MICROLITHOGRAPHY,” which issued on Mar. 6, 2007, the entire contents of which is incorporated herein by reference.
[0051] Referring to FIG. 3A , an example of such an illumination system is shown as illumination system 379 , which along with projection system 371 , form a microlithography projection exposure apparatus. Illumination system 379 directs radiation to a reticle 140 positioned at an object plane 381 . Projection objective 371 images a portion of reticle 140 illuminated by the radiation to a wafer 373 positioned at an image plane 383 . Reticle 140 is supported by a reticle stage 369 and wafer 373 is supported by a wafer stage 375 .
[0052] Illumination system 379 includes a source 301 , a collector 303 , a field raster plate 309 , a pupil raster plate 315 , and mirrors 325 , 323 , and 327 . Source 301 produces radiation that is directed by collector 303 towards field raster plate 309 . The path of the radiation is illustrated by a number of rays 340 , including a chief ray 345 . Field raster plate 309 reflects the radiation to pupil raster plate 315 . Field raster plate 309 includes a number of mirrors, each of which is imaged by illumination system 379 onto object plane 381 , overlapping at an object field. Pupil raster plate 315 also includes a number of mirrors, which are arranged to provide a desired illumination shape at each point in the field at object plane 381 . Mirrors 325 and 323 relay the radiation to mirror 327 . Mirror 327 , which is the grazing-incidence mirror, directs the radiation to object plane 381 .
[0053] Projection system 371 includes a first mirror 377 and subsequent mirrors 390 , 391 , 392 , 393 , and 394 arranged along an optical axis 347 . Radiation from illumination system 379 is reflected from reticle 140 , and is sent toward first mirror 377 along a path illustrated by a number of rays, including ray 345 . This radiation is then reflected by first mirror 377 and is subsequently directed to wafer 373 at image plane 383 via mirrors 390 , 391 , 392 , 393 , and 394 , where an image of reticle 140 is formed.
[0054] Referring also to FIG. 3B , as discussed previously, mirror 327 directs rays 340 from toward reticle 140 positioned at object plane 381 . Mirror 327 is arranged at an angle ω with respect to optical axis 347 . Generally, ω is selected based on the direction of rays 340 prior to mirror 327 and the desired illumination angle with respect to object plane 381 . ω can be in a range from about 10° to about 80° (e.g., from about 20° to about 70°, from about 30° to about 60°, from about 40° to about 50°).
[0055] Rays 340 illuminate object field 322 and the illuminated portion of reticle 140 reflects rays 340 toward first mirror 377 . Object field 322 has a height, d y . The central field point of object field 322 is located a distance y 0 from optical axis 347 . Here, the central field point refers to the location equidistant from the edges of the object field in the meridional plane of the projection objective.
[0056] Chief ray 345 intersects object plane 381 at the central field point. Chief ray 345 has an incident angle at the central field point denoted by CRAO with respect to a normal 342 of object plane 381 . In general, CRAO can vary depending upon the specific design of the microlithography exposure system. In general, the microlithography exposure system is designed so that CRAO is greater than 0° so that chief ray 345 is not reflected back towards mirror 327 when the reticle 140 is positioned at object plane 381 . Typically, the microlithography exposure system is designed so that rays 340 reflected from reticle 140 are not blocked by mirror 327 prior to mirror 377 . In certain embodiments, it is desirable to have a relatively low CRAO as high values of CRAO can lead to unwanted imaging effects of the projection objective. For example, high values of CRAO can lead to shadow effects at the reticle that distort the reticle information passed into the projection objective. In certain embodiments, the microlithography exposure system can be designed so that CRAO is about 10° or less (e.g., about 9° or less, about 8° or less, about 7° or less, about 6° or less, about 5° or less).
[0057] Upon reflection from reticle 140 , rays 345 pass mirror 327 before incidence on mirror 377 . The minimum separation between rays 345 before and after reflection from reticle 140 , measured at mirror 327 , is denoted by y min . Generally, the microlithography exposure system is designed so that y min is sufficiently large that, allowing for the physical thickness of the base of mirror 327 , none of rays 340 are occluded by mirror 327 . In some embodiments, y min is about 2 mm or more (e.g., about 4 mm or more, about 5 mm or more, about 6 mm or more, about 8 mm or more, about 10 mm or more, about 15 mm or more, about 20 mm or more).
[0058] The minimum separation between mirror 327 and object plane 381 is denoted by z′. In general, z′ can vary. In certain embodiments, z′ is relatively small, which can allow for a design in which mirror 327 is relatively small. However, in such designs, CRAO tends to increase with increasing field height dy. Accordingly, utilizing a relatively small z′ can limit the dy where a relatively low value of CRAO is desired. Alternatively, in some embodiments, z′ can be selected so that dy is relatively large while and CRAO is relatively small. For example, z′ can be selected so that CRAO is 10° or less (e.g., 8° or less, 6° or less) while dy is more than 8 mm (e.g., about 10 mm or more, about 20 mm or more, about 30 mm or more, about 40 mm or more).
[0059] In certain embodiments, desired values of dy and CRAO can be achieved by making z′≧z min , where z min is given by the formula:
[0000]
z
min
=
dy
+
y
min
Γ
,
[0000] in which
[0000]
Γ
=
tan
[
arcsin
[
sin
(
arctan
(
(
y
0
-
dy
/
2
)
·
tan
(
CRAO
)
y
0
)
)
-
σ
·
NAO
)
]
]
+
tan
[
arcsin
[
sin
(
arctan
(
(
y
0
+
du
/
2
)
·
tan
(
CRAO
)
y
0
)
)
-
NAO
)
]
]
,
[0000] where NAO is object-side numerical aperture of the projection objective and σ is the relative numerical aperture of the illumination system at the object plane.
[0060] While in the foregoing embodiment, mirror 327 was positioned closer to object plane 381 than the first mirror 377 in projection objective 371 , other configurations are also possible. For example, in some embodiments, the grazing incidence mirror that is the last mirror in the radiation path in the illumination system is positioned further from the object plane than the first mirror in the radiation path in the projection objective. Referring to FIG. 4 , which shows an example of such a configuration, grazing incidence mirror 427 is positioned further from object plane 481 than mirror 477 , which is the first mirror in a projection objective. As indicated in the figure, the minimum distance between mirror 427 and object plane 481 is indicated by d G and the minimum distance between mirror 477 and object plane 481 is indicated by d M1 . Here, d G >d M1 . Also shown in FIG. 4 are rays 445 , which are directed by mirror 427 to illuminate an object field 440 at object plane 481 .
[0061] Optical axis 447 of the projection objective is also shown. Mirror 477 extends a distance y M1 from optical axis 447 on the same side of optical axis 447 as mirror 427 . The minimum distance between the base of mirror 427 and optical axis 447 is y G , where y G <y M1 .
[0062] In embodiments where the grazing incidence mirror in the illumination system is further from the object plane than the first mirror in the projection objective, the separation, y min , between rays before and after reflection from the reticle, refers to the minimum separation of the rays at the first mirror in the projection objective, rather than the grazing incidence mirror as defined in FIG. 3B .
[0063] Configurations where the grazing incidence mirror in the illumination system is further from the object plane than the first mirror in the projection objective can include numerous benefits. For example, such configurations can satisfy the z′>z min relationship discussed above, allowing for relatively large field heights (dy) and a relatively low CRAO. Furthermore, because mirror 477 is positioned closer to object plane 481 than mirror 427 , there is no possibility that rays 445 will be occluded by mirror 427 after reflecting from the reticle at object plane 481 . Accordingly, y M1 is not constrained by the physical thickness of the base of mirror 427 , allowing for thicker bases to be used for mirror 427 . In other words, it is not necessary that y G >y M1 . Accordingly, larger, more robust and stable mounts can be used for mirror 427 relative to configurations where thin mirror substrates are used because the base thickness constrains y M1 . The reduced size and space constraints on mirror 427 and its mount can also allow for additional heat shielding to be used between mirror 427 the components of the projection objective, which can reduce imaging aberrations due to heating of the projection objective by mirror 427 .
[0064] Referring to FIG. 5 , an example of a catoptric projection objective 500 and grazing incidence mirror 527 for illuminating a reticle positioned at an object plane 540 , is shown, where mirror 527 is positioned further from object plane 500 than a first mirror 577 in the radiation path in projection objective 500 . Projection objective 500 images an object field at object plane 540 to an image field at an image plane 575 . Projection objective 500 is a catoptric objective and, in addition to mirror 577 , includes mirrors 578 , 579 , 580 , 581 , 582 , 583 , and 584 , presented in order respect to the path of radiation from object plane 540 to image plane 575 . Mirrors 577 - 584 are positioned along an optical axis, labeled OA. As shown in FIG. 5 , each of the mirrors 577 - 584 corresponds to a segment of a rotationally symmetric surface about OA.
[0065] Projection objective 500 has an image side numerical aperture of 0.35, an object side NA of 0.0875, and is a reduction objective with a magnification of 4×. The relative numerical aperture, σ, at object plane 540 of the illumination system is 0.8. The object field has a height, dy, of 40 mm and the CRAO is 6.392°. The distance, y 0 , between the central field point and the optical axis is 158 mm.
[0066] Grazing incidence mirror 527 is positioned further from object plane 540 than first mirror 577 . In particular, the distance between mirror 577 and object plane 540 is 664 mm, while the minimum distance between mirror 527 and object plane 540 is 813 mm. In the meridional plane, the angle, ω, between mirror 527 and the optical axis is 58°.
[0067] The minimum separation, y min , between rays 545 , before and after reflection from the reticle measured at mirror 577 is 4.1 mm.
[0068] Each mirror 577 - 584 in projection objective 500 is an aspherical mirror. Aspherical mirror surfaces can be described by the equation:
[0000]
P
(
h
)
=
δ
·
h
·
h
1
+
1
-
(
1
+
CC
)
·
δ
·
δ
·
h
·
h
+
C
1
h
4
+
…
+
C
n
h
2
n
+
2
,
δ
=
1
R
[0000] where P(h) is a distance of the aspherical surface from a plane perpendicular to the optical axis as a function of a perpendicular distance h from the optical axis, and R is a radius of curvature of the mirror at its apex. The parameter CC is the conic constant of the aspheric surface, and parameters C 1 to C n are aspheric constants.
[0069] Design data for each mirror in projection objective 500 is shown in Tables I and II. Table I provides R values and distances between mirror surfaces as measured along the optical axis (Referred to as “Thickness”). Table II provides a conic constant and aspheric constants for each mirror.
[0000]
TABLE I
Surface
Radius
Thickness
Mode
Object
INFINITY
664.079
Mirror 1
−2248.408
−457.265
REFL
STOP
INFINITY
0.000
Mirror 2
1720.732
607.265
REFL
Mirror 3
410.127
−296.765
REFL
Mirror 4
915.188
1385.693
REFL
Mirror 5
−1017.861
−297.964
REFL
Mirror 6
−918.296
354.963
REFL
Mirror 7
374.571
−254.963
REFL
Mirror 8
329.021
294.957
REFL
Image
INFINITY
0.000
[0000]
TABLE II
Surface
CC
C 1
C 2
C 3
Mirror 1
0.000000E+00
9.827635E−10
−6.947687E−15
7.014244E−20
Mirror 2
0.000000E+00
−8.617847E−11
−2.559048E−15
2.420769E−21
Mirror 3
0.000000E+00
−8.656531E−10
5.405318E−15
4.204975E−20
Mirror 4
0.000000E+00
−5.941284E−11
−1.211262E−18
3.529081E−23
Mirror 5
0.000000E+00
2.650008E−10
3.827055E−16
−7.598667E−22
Mirror 6
0.000000E+00
5.266996E−09
−4.453655E−14
3.218187E−19
Mirror 7
0.000000E+00
8.429248E−09
8.347048E−13
1.580837E−17
Mirror 8
0.000000E+00
2.468501E−10
3.310980E−15
3.228099E−20
Surface
C 4
C 5
C 6
C 7
Mirror 1
−4.375930E−25
−3.576925E−30
8.030189E−35
0.000000E+00
Mirror 2
−3.480416E−24
4.082890E−28
−2.197698E−32
0.000000E+00
Mirror 3
−1.935657E−24
2.726140E−29
−1.533818E−34
0.000000E+00
Mirror 4
−3.324389E−28
5.301103E−34
−4.669457E−40
0.000000E+00
Mirror 5
1.018524E−26
−3.492727E−32
6.035810E−38
0.000000E+00
Mirror 6
2.835576E−24
−1.042146E−28
8.093551E−34
0.000000E+00
Mirror 7
−7.363060E−21
1.659178E−24
−1.489458E−28
0.000000E+00
Mirror 8
3.862187E−25
−2.851222E−31
1.052318E−34
0.000000E+00
[0070] While the embodiments described above relate to catoptric optical systems, in general, the principles disclosed herein can be applied to catadioptric systems as well. For example, in some embodiments, the illumination system can be a catadioptric illumination system. In certain embodiments, catoptric or catadioptric illumination systems can be used in conjunction with catadioptric or dioptric projection objectives.
[0071] As an example, a catoptric illumination system can be used to deliver radiation from a broadband light source, such as a mercury i-line source, to, for example, a dioptric projection objective. The dioptric projection objective can be designed to provide chromatic aberration reduced to a level acceptable for the application for which the system is designed (e.g., for chip packaging applications).
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In general, in one aspect, the invention features a system that includes a catoptric projection objective having an optical axis and including a plurality of projection objective elements positioned between an object plane and an image plane, the object and image planes being orthogonal to the optical axis, the projection objective being configured so that during operation the projection objective directs radiation reflected at the object plane to the image plane to form an image at the image plane of an object positioned in a field at the object plane, the field having a first dimension of 8 mm or more and a second dimension of 8 mm or more, the first and second dimensions being along orthogonal directions. The system also includes an illumination system including a plurality of illumination system elements, the illumination system being configured so that during operation the illumination system directs the radiation to the field at the object plane, where a chief ray of the radiation has an angle of incidence of 10° or less at the object plane.
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PRIORITY STATEMENT
[0001] This patent application claims the benefit of priority under 35 U.S.C. § 119 to co-pending U.S. provisional application serial No. 60/422,634, filed Oct. 30, 2002.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosures, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0003] This present invention pertains generally to computer aided information exchange, and more particularly, devices and methods for client oriented investment advisory services.
BACKGROUND OF THE INVENTION
[0004] The relationship between the investor advisor and the client is important though often unproductive. The diminished productivity is generally a function of the asymmetry in information exchange between the investor and client. The client is justifiably apprehensive about sharing intimate detail about his or her financial situation and risk tolerances to a person that they have just met. Like any other meeting between strangers, that is supposed to blossom into a relationship, it takes time for a level of comfort and trust to develop. In the traditional advisor/investor engagement, however, the investor is introduced to the advisor via referral or cold telephone call. Immediately, the investor is encouraged to bare their sole with respect to their financial life in a way many are not even comfortable disclosing to loved ones.
[0005] Additionally, many individual investors do not have sufficient familiarity with advisor credentialing practices to determine the level of competence of the prospective advisor. These and other concerns have led to the incomplete information, given by investors to advisors. Without comprehensive information about an investor's financial situation, it is difficult for advisors to provide investors with individualized and adequate investment solutions. In order to address these problems, investors and advisors have turned to the Internet as a means of engaging one another without the awkwardness of the initial face-to-face consultation. Unfortunately, quality has suffered precipitously since there still remains the uncertainty of the quality of advisor on the other end of the connection. Moreover, advisors have no real incentive to give individualized and adequate investment advice absent any pecuniary rewards. As a result, the requests for personal and financial information are transferred to the cyber realm where now the investor has less control over where their information may resurface.
[0006] Due to the peculiar nature of investment advice and counsel, there remains a need for a system and method of providing access to investment advisory services and assistance to individuals via intranets maintained by employers/organizations. Therefore, there is an existing need for a computer-aided solution that allows investors to anonymously ask questions and receive answers from registered investment advisors. There is also an existing need for a system that prescreens the advisors to assure the investor users a threshold level of advisor competence. Moreover, there remains a need for a system and method of providing investment advisory assistance to Intranets of corporations that sponsor 401 k or other retirement plans. In particular, the system would allow users of the corporate intranet to submit questions that would be selected and responded to by qualified advisors. After rounds of questions and answers, the investor may initiate contact with one or more advisors to set-up a direct meeting. Absent such investor intervention, the advisors would not know anything about the investor, only the question the investor posed. This insures the investor remains in control of the relationship and also gives the advisors an incentive to not only answer the investor's questions but to answer them accurately and in a manner most likely to engender trust.
SUMMARY OF EXEMPLARY EMBODIMENTS
[0007] Solutions to the problems outlined above are proposed using a device, system and method of routing information. In a preferred embodiment, the investment advisory solution is implemented as a component of an investment related website or corporate intranet. In particular, a closed email circuit that is accessible to the user via their employers Intranet allows for limited two-way communication between a visitor and a community of advisors. The system would allow for each participating advisor to receive the visitor's question, and deliver back to the questioner, an appropriate and timely response that only the visitor will see.
[0008] A principle objective, in accordance with an exemplary embodiment of the present invention, is to provide a system and method that allows investors to get questions answered by registered investment advisors without having to reveal their personal information. In the furtherance of this and other objectives, investors submit questions, via the system, which are scrubbed and presented to a universe of registered advisors without any investor identification information.
[0009] Still another objective of the present invention is to provide a means of allowing investors to assess the competence and compatibility of registered advisors prior to engaging the advisors. In the furtherance of this and other objectives, the investor may ask an indefinite number of questions to advisors to gather the relevant information they would need to determine if a business relationship should be formed. Moreover, the investor would be provided with detailed information about the advisors in addition to the advisor's responses to the posed question(s).
[0010] Yet another objective of the present invention is to provide devices, systems and methods that allow corporations to provide a fringe benefit to their employees by giving them access to competent investment advisors through the corporation's intranet. In the furtherance of this and other objectives, the corporation facilitates the acquisition of essential information by employees, without committing significant in-house resources to the project.
[0011] A further objective of the present invention is to provide a communication device, system and method that increases the symmetry of information flow between investor and advisor. To this end, the investor is comfortable giving financial data for purposes of gaining advice in light of the fact that their identity remains unknown. Additionally, the advisor is more inclined and better able to advise such investors because of the extent of financial information and the potential of a future engagement.
[0012] An additional objective of the present invention is to provide incentives to an investment advisor to give thorough advice to an unknown user. In the furtherance of this and other objectives, the investment advisors, via corporate intranets and websites, are provided with prime opportunities to interact with investors that by their very present indicate their desire to obtain quality investment advice.
[0013] Still another objective of the present invention is to provide a means of allowing users to ask questions that they may be embarrassed to ask an investment advisor in person.
[0014] The number and variability of applications, devices, systems and methods, in accordance with the present invention, are limited only by the imagination of the user.
[0015] Further objectives, features and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS OF PREFFERED EMBODIMENTS
[0016] [0016]FIG. 1 is a flow diagram showing the steps of submitting questions in accordance with one aspect of the present invention;
[0017] [0017]FIG. 2 is a flow diagram showing the steps of answering questions in accordance with one aspect of the present invention;
[0018] [0018]FIG. 3 is a flow diagram showing the steps of routing questions in accordance with one aspect of the present invention;
[0019] [0019]FIG. 4 is a schematic diagram showing the question and answer flow of the system and method in accordance with an exemplary embodiment of the invention;
[0020] [0020]FIG. 5 is a schematic of a screen shot of the user interface in accordance with one aspect of the present invention; and
[0021] [0021]FIG. 6 is a schematic depictions a response screen of the system and method in accordance with an exemplary embodiment of the invention;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The email question and answer (Q&A) system is a substantially closed circuit system designed to allow the visitor to navigate to an appropriate web page on a target Website. Once there, the visitor could ask any question relating to financial matters, but would be encouraged to focus on investment related issues. In a preferred embodiment, the visitor would follow these steps. First, the user would be asked to type in their e-mail address*. Second, from a drop down menu, they would be asked to select their state of residence. Third, the investor would choose from a super category that helps to identify the overall nature and focus of the question. In the fourth step, the visitor will also have the option to select (by check box) to identify the company that he/she works for. Finally, the visitor has a dialogue box that would allow for a question of any length. Once the question has been keyed in, the visitor would simply hit the “go” button.
[0023] Once the “go” button is pressed, a dialogue box appears that asks, “did you mention your name or any identifying information about you or your family?” If yes, the visitor is encouraged to change it. If they desire to make a change they press the change box (the visitor will be returned to the text of his/her question). If no changes are necessary, the go button is pressed and a thank you screen appears for the visitor that indicates that this question has been delivered to all participating advisors. It will also mention that the advisors are working professionals, so please allow a minimum of five (5) working days for a response. We do not guarantee more than one response. Once the question is sent our database captures the visitors' e-mail, and associated information for returning the advisors response(s).
[0024] Once the question has been sent out, all of the participating advisors would receive in their email an html formatted message that says “you have received a question from a visitor to” with a reference to the website or corporate intranet”. The advisor receives that html formatted email and he/she sees a super category, a question, and the originating state. If the visitor has opted for it, the name of the company that employs the visitor may be identified. If an advisor is a state regulated advisor, yet not an advisor for that state,* the advisor may simply disregard that question. By way of non-limiting example, the system may have 100 advisors geographically dispersed in the U.S. Of the 100 advisors, 76 may have opted to participate in this system. However, on this particular occasion, when this visitors question was sent out, only 52 opted to respond.
[0025] The visitor will be encouraged to offer as much information as is reasonable to answer a question without giving away identifying information such as name or city, etc. The system is designed to allow individuals to communicate their questions from behind a veil, which the system provides. The visitors' information, such as email address is retained in a database, so that the system can facilitate the return of the responses to the person that asked the question, not for any other purpose. However, under no circumstances, is that information made available to the advisors. The only identifying information that is shared is the state that the visitor is in, which is for regulatory requirements. The only information, which can be shared by the visitor is the company they work for, which is optioned by the employee via a check box. It is by the IP address of the intranet link via our database that allows the check box to identify the employer. In a preferred embodiment, this will allow for the employers' 401 k or other plan document to be housed in, for example Portable Delivery Format (PDF) that can be opened up by the advisor for the purpose of helping an employee.
[0026] Before the information is sent, a dialogue box will pop up and mention that visitors are actively encouraged not to mention their name, or any other identifying information in the communication. The purpose of which is to keep the identity of the visitor protected.
[0027] When the advisor(s) answer the question, the only thing that they will be able to do is type into the available dialogue box, the answer/suggestion. The information the visitor receives back will be in an html formatted page that has the following information:
[0028] Advisor Response. Contact data for the responding advisor, including name, address, telephone number, etc. in the form of a banner advertisement that if clicked upon takes the visitor over to that advisors applet page.
[0029] Following the banner, would be a repeat of the super category, the actual question and the answer provided by the advisor. This is the limit of that communication. The information that the advisor(s) email back will come back through our system and be logged with an identifier that associates the original question with its answers. For example, the following question is asked: What is the S&P 500? All conditions are fine with the content—no giveaways of information. The question is sent out in html format to the 76 advisors choosing to participate. When the question is sent out, an identifier eg., 06012002-01 (Jun. 1, 2002—question 01) goes along. The first email response, received is tagged 06012002-01 a (meaning that it is the first response to the first question of that day). Each question sent, combined with all answers received will be logged in the database. Also, at the point of origination and with the visitor's approval, the question asked, minus all identifying information may be posted on a website Q&A page along with the first answer. The follow on answers will be accessible via a link, so that if a follow on visitor wants to see if a certain bit of info that might be helpful, but which is not in the first answer, may be in another.
[0030] Once the question has been sent and the response received by the visitor's email and logged onto our Q&A database (minus any identifying information, such as one's name) the circuit is complete. If the response that the visitor receives needs more information to be complete, the visitor will not be able to simply hit the email reply button to receive clarification (because this action may leave open the visitors email address). The visitor will have to hit the “additional comments” button that is only visible on the response page, which automatically takes the visitor to the Q&A page again, but with the information already logged in and ready. The remaining steps will be as they were on the initial question. The purpose for not allowing the visitors information to be revealed is simply protection, anonymity and comfort for the visitor. The benefit for the advisor is the ability to showcase their skills to people that have an express need for an advisor.
[0031] The system and method of posting questions may be adapted from U.S. Pat. No. 5,948,054, which is incorporated herein by this reference. However, the present invention does not require payment information be provided by the user. Moreover, the system does not have to utilize complicated algorithms to select one advisor over another, since the user should make the choice of advisor. In the furtherance of this and other objectives, the user's question is submitted to a universe of registered investment advisors and the user will have the opportunity to benefit from multiple perspectives.
[0032] As shown in FIGS. 1 - 3 the visitor's questions can be routed to an individual advisor, to a universe of advisors or to the system database and/or frequently asked questions database. Moreover, as shown in FIGS. 4 - 6 , the query system can consist of any number of fields that broaden or narrow the universe of advisors, the information to be requested or the database to be accessed. The visitor is given significant control over their search experience.
[0033] In alternative embodiments, the system comprises a database driven question and answer interface that allows the user to submit questions, which is routed through the database to qualified investment advisors in the database. Anonymity is marinated as in the above embodiment with the additional advantage of having a low maintenance relational database distribute questions to relevant advisors. The interaction with the advisors is now driven off of the database, with only notification of receipt of a question/comment (for advisors) or answer (for the visitors). The notifications are sent via email with an embedded link to the database with or without ones codes already logged in (to save a step) from which the advisor or visitor which ever was being notified can then log onto the system and retrieve the question or answer(s).
[0034] The database is designed to allow the user to ask questions without geographical limitations on who provides the answers. Certain financial questions may warrant that the answer be provided not only by a qualified consultant in the user's country but also preferably in the city of the user. However, in other cases the nature of the information request may require that the information be provided by a qualified consultant in another country. For example, if the question pertains to financial transactions in Greece and the user does not live in Greece, it would be necessary to ensure that the consultant is qualified to opine on Greek law. To facilitate this, a preferred module of the database provides language translation so that the user and the consultant can communicate through the database without knowing the respective language of the other. Exemplary languages in the system includes but is not limited to Afrikaans, Aleut, Aninishinaabe (Chippewa/Ojibwe), Arabic, Armenian, Azerbaijani, Basque, Bengali, Bosnian, Braille, Bulgarian, Chamorro, Cherokee, Cheyenne, Chinese, Chinook, Choctaw, Cornish, Cree, Croatian, Czech, Dakota, Dutch, Esperanto, Estonian, Farsi/Persion, Finnish, French, Georgian, German, Greek, Gujarati, Hawaiian, Hebrew, Hindi, Hmong, Hungarian, Hupa, Icelandic, Indonesian, Inuktitut, Inupiaq, Irish (Gaelic) Italian, Japanese, Kikuyu, Kiribati, Korean, Kurdish, Latin, Latvian, Lithuanian, Luganda, Malaysian, Maltese, Maori, Mayan, Miwok, Mohawk, Mon, Mongolian, Nahuatl (Aztec), Navajo, Ndbele, Norwegian, Paiute, Polish, Portuguese, Potawatomi, Quechua, Romanian Russian, Saami (Lapp), Samoan, Scottish Gaelic, Seneca (Mingo), Serbian, Sesotho, Shona, Sign Language, Sinhalese, Spanish, Swahili, Swedish, Tagalog, Tahitian, Tai, Tamil, Tibetan, Tlingit, Turkish, Urdu, Ukrainian, Vietnamese, Welsh, Xhosa, Yiddish, Yupik and Zulu.
[0035] While specific embodiments have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. It is intended that the spirit and scope of the invention are to be defined by reference to the following claims, along with their full scope of equivalents.
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The present invention provides a computer-aided solution that allows investors to anonymously ask questions and receive answers from registered investment advisors. Prescreened advisors are engaged by the system, which employs a method of providing investment advisory assistance to Intranets of corporations that sponsor 401 k or other retirement plans. In particular, the system would allow users of the corporate intranet to submit questions that would be selected and responded to by qualified advisors. After rounds of questions and answers, the investor may initiate contact with one or more advisors to set-up a direct meeting. Absent such investor intervention, the advisors would not know anything about the investor, only the question the investor posed. This insures the investor remains in control of the relationship and also gives the advisors an incentive to not only answer the investor's questions but to answer them accurately and in a manner most likely to engender trust.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system interconnection apparatus and connection method thereof and, more particularly, to a system interconnection power generation apparatus for connecting a power generated by a solar battery or the like to a power system.
BACKGROUND OF THE INVENTION
[0002] As home solar power generation systems proliferate, their cost is decreasing. FIG. 1 is a view showing the arrangement of a typical home solar power generation system.
[0003] Referring to FIG. 1, a DC power output from a solar battery 1 is converted into an AC power by a system interconnection inverter (to be simply referred to as an “inverter” hereinafter) 8 whose inputs and outputs are non-insulated, and connected to a single-phase three-wire 200-V system (to be simply referred to as a “system” hereinafter) 9 whose median potential line (to be simply referred to as a “neutral line” hereinafter) is grounded by a ground line 91 of a pole mounted transformer.
[0004] When an inverter having non-insulated inputs and outputs is used for a system interconnection solar power generation system, the solar battery 1 and system 9 are non-insulated. For this reason, the potential-to-ground of the solar battery 1 is fixed, and a ground fault current flows between one conductor and ground, like a ground fault on the AC side. In order to detect a ground fault at the solar battery 1 , the inverter 8 has a current-detection-type ground fault sensor 89 .
[0005] The power circuit of the inverter 8 is formed as a single-phase two-wire 200-V output to reduce the cost. For this reason, between the inverter 8 and the system 9 , the neutral line is used only to detect the voltages of the remaining two lines, and no current flows to the neutral line.
[0006] Along with the recent expansion of the application range of solar power generation systems, connection to a single-phase 100-V system is required. To most easily meet this requirement, a non-insulated inverter with a single-phase two-wire 100-V output is connected to a single-phase 100-V system. However, development cost is necessary to newly develop a non-insulated inverter with a single-phase two-wire 100-V output. It is therefore preferable to use an inverter having an inverter circuit which outputs a single-phase two-wire 200-V, i.e., a most popular commercially available inverter at present.
[0007] Since an inverter with a single-phase two-wire 200-V output is designed not to flow a current to the neutral line, it is impossible to connect one side (two wires for the 0 -phase and U- or V-phase) of a single-phase three-wire 200-V output to two wires of a single-phase 100-V system.
[0008] To do this, an insulated transformer (to be simply referred to as a “transformer” hereinafter) 10 is used, as shown in FIG. 2. With this arrangement, the inverter 8 with a single-phase two-wire 200-V output and a single-phase 100-V system 4 can be connected. However, this arrangement has the following problems.
[0009] (1) The ground fault sensor 89 assumes that the potential-to-ground of the solar battery 1 is fixed and cannot detect a ground fault between one conductor and ground at the solar battery 1 in the arrangement shown in FIG. 2.
[0010] (2) The transformer 10 is generally large, heavy, and expensive.
[0011] When an inverter with a single-phase two-wire 100-V output is used, the potential-to-ground of a DC circuit is fixed. However, depending on the type of an inverter with a single-phase two-wire 100-V output, if reverse connection on the AC side, i.e., an abnormal connection between a ground-side electrical wire N and a non-ground side electrical wire H occurs, an excessive leakage current is generated through an earth capacitance 11 , and an operation error of the ground fault sensor 89 or trip of an electrical leakage breaker takes place. Especially, for a solar battery integrated with a metal roof, the earth capacitance 11 is large, and a measure for preventing the reverse connection is indispensable.
SUMMARY OF THE INVENTION
[0012] The present invention has been made to solve the above-described problems individually or altogether, and has as its object to make a commercially available inverter usable in a system interconnection apparatus.
[0013] It is another object of the present invention to detect a ground fault between one conductor and ground by a ground fault sensor incorporated in an inverter.
[0014] In order to achieve the above objects, according to a preferred aspect of the present invention, a system interconnection apparatus for connecting a power generated by a solar battery to a power system, comprising a non-insulated inverter, arranged to convert a power supplied from a direct current power supply into a single-phase three-wire alternating current power form, a sensor installed in said inverter, arranged to detect a ground fault, and a transformer, arranged to connect a line of the single-phase three-wire alternating current power to a single-phase two-wire power system with one line grounded, wherein a median potential line of the single-phase three-wire alternating current power is connected to a ground line of the power system is disclosed.
[0015] It is still another object of the present invention to provide a compact, lightweight, and inexpensive system interconnection apparatus.
[0016] In order to achieve the above object, according to another preferred aspect of the present invention, a system interconnection apparatus for connecting a power generated by a solar battery to a power system, comprising a non-insulated inverter, arranged to convert a power supplied from a direct current power supply into a single-phase two-wire alternating current power form, a sensor installed in said inverter, arranged to detect a ground fault, a switch, arranged to connect/disconnect a line of the single-phase two-wire alternating current power to/from a single-phase two-wire power system with one line grounded, and an alarm, arranged to detect an abnormal connection between the power system and the line of the single-phase two-wire alternating current power and generate an alarm is disclosed.
[0017] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a view showing the arrangement of a typical home solar power generation system;
[0019] [0019]FIG. 2 is a view showing the arrangement of a solar power generation system using an insulated transformer;
[0020] [0020]FIG. 3 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the first embodiment;
[0021] [0021]FIG. 4 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the second embodiment;
[0022] [0022]FIG. 5 is a block diagram showing the arrangement of an abnormal connection detection section;
[0023] [0023]FIG. 6 is a view showing the potentials-to-ground of the respective portions of the solar power generation system according to the second embodiment in a normal connection state;
[0024] [0024]FIG. 7 is a view showing the potentials-to-ground of the respective portions of the solar power generation system according to the second embodiment in an abnormal connection state;
[0025] [0025]FIG. 8 is a view showing the potentials-to-ground of the respective portions of a solar power generation system according to the third embodiment in a normal connection state;
[0026] [0026]FIG. 9 is a flow chart showing the operation procedure in connecting the inverter of the second embodiment to a system;
[0027] [0027]FIG. 10 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the third embodiment; and
[0028] [0028]FIG. 11 is a view showing the potentials-to-ground of the respective portions of the solar power generation system according to the third embodiment in an abnormal connection state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] A system interconnection power generation system according to an embodiment of the present invention will be described below in detail with reference to the accompanying drawings.
[0030] A system interconnection solar power generation system will be described below. The present invention can also be applied to a power generation system using not a solar battery but any other DC power supply such as a primary battery, secondary battery, or fuel cell. A DC power obtained by rectifying a power of an AC power supply such as a rotary power generator, or a combination thereof may be used. The DC power supply or AC power supply can be either a voltage source or a current source.
[0031] When a solar battery is used, the solar battery can be made of amorphous silicon, crystallite silicon, polysilicon, single-crystal silicon, a combination thereof, or a compound semiconductor. Normally, a plurality of solar battery modules are combined in series and parallel, thereby forming a solar battery array for obtaining desired voltage and current. The present invention does not depend on the form of the solar battery array or the number of solar battery modules used.
[0032] First Embodiment
[0033] [Arrangement]
[0034] [0034]FIG. 3 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the first embodiment. The same reference numerals as in the FIGS. 1 and 2 denote the same parts in FIG. 3, and a detailed description thereof will be omitted.
[0035] An inverter 8 is a power conversion unit having non-insulated inputs and outputs and a current-detection-type ground fault sensor 89 . The inverter 8 converts a DC power generated by a solar battery 1 into an AC power and outputs a single-phase 100-V AC power by using an inverter section 28 . The inverter 8 has three output terminals in correspondence with a single-phase three-wire scheme. Since the O-phase terminal is not connected to the internal circuit of the inverter 8 , the inverter 8 actually acts as an inverter with a single-phase two-wire 200-V output.
[0036] A transformer 10 has non-insulated inputs and outputs. The transformer 10 converts the single-phase two-wire 200-V output AC power on the inverter 8 side into a single-phase two-wire 100-V AC power and connects it to a single-phase two-wire 100-V system 4 . The system 4 is a single-phase two-wire 100-V commercial power system connected to a system interconnection system. One of the two wires is grounded by a ground line 91 of a pole mounted transformer.
[0037] The inverter 8 mainly comprises a converter section 27 for boosting a DC voltage input between the positive and negative input terminals, the inverter section 28 for converting the output from the converter section 27 into an AC power and outputting it to the U- and V-phase terminals, the ground fault sensor 89 , and an FG terminal for grounding the housing.
[0038] The U- and V-phase terminals are connected to non-grounded terminals of the transformer 10 . The O-phase terminal is connected to the ground terminal of the transformer 10 through a neutral line.
[0039] Each of the converter section 27 and inverter section 28 comprises various self-arc-suppressing switching elements including a power transistor, MOSFET, IGBT, or GTO, or a combination thereof and elements such as an inductor, capacitor, and diode.
[0040] More specifically, the converter section 27 is a general chopper circuit constituted by a switching element 273 , boosting inductor 271 , blocking diode 274 , and smoothing capacitors 272 and 275 .
[0041] The inverter section 28 comprises a full bridge circuit formed from four switching elements 281 to 284 , and inductors 285 and 286 . When these switching elements are appropriately switched, the full bridge circuit generates and outputs a rectangular AC voltage waveform. The inductors 285 and 286 serve as the system interconnection reactors of the inverter 8 , which shape the AC current waveform to be output from the inverter 8 into a sinusoidal waveform.
[0042] The ground fault sensor 89 detects the sum of currents (almost zero in a non-grounded state) flowing to the non-grounded lines (U- and V-phase terminals) of the inverter 8 , thereby detecting a ground fault at the solar battery 1 .
[0043] The transformer 10 is a transformer whose the primary winding (200 V side) and the secondary winding (100 V side) are non-insulated. A terminal to which a ground-side electrical wire N on the secondary side is connected and a terminal (center tap) to which the neutral line on the primary side is connected are connected by a short-circuit (to be referred to as a “non-isolating connection” hereinafter) 12 , thereby non-insulating the primary and secondary windings. The winding ratio of the primary side to the secondary side of the transformer 10 is 2:1.
[0044] A simulated ground fault unit 111 connected between the solar battery 1 and the ground potential is used to check the operation of the apparatus shown in FIG. 3.
[0045] [Operation]
[0046] The operation of the apparatus shown in FIG. 3 will be described next.
[0047] In the system interconnection power generation apparatus shown in FIG. 3, a ground fault at the solar battery 1 is caused by the simulated ground fault unit 111 , and the operation of the ground fault sensor 89 is checked. As experimental conditions, the output voltage of the solar battery 1 is about 200 V, the output power is about 3.2 kW, the output power of the inverter 8 is about 3 kW, and the sum of ground fault resistance of the simulated ground fault unit 111 and the ground resistance of the ground line 91 is about 500 Ω.
[0048] With the above experiment, it was confirmed that a ground fault current of about 0.4 A flowed, and the ground fault current was detected by the ground fault sensor 89 . When the same experiment as described above was conducted for the system interconnection solar power generation system shown in FIG. 2, no ground fault current flowed, and the ground fault sensor 89 detected no ground fault current.
[0049] As described above, in the system interconnection power generation apparatus according to the first embodiment, the inverter 8 having the current-detection-type ground fault sensor 89 and non-insulated inputs and outputs converts a DC power into an AC power and outputs it as a single-phase three-wire 200-V AC power. The single-phase three-wire 200-V AC power is connected to the single-phase two-wire 100-V system 4 through the transformer 10 having non-insulated inputs and outputs. Hence, an inexpensive system interconnection power generation apparatus connected to the single-phase two-wire 100-V system 4 using the inverter 8 having an inverter circuit which outputs a single-phase two-wire 200-V, i.e., a most popular commercially available inverter at present, can be provided. A ground fault at the solar battery 1 can be detected by the ground fault sensor 89 incorporated in the inverter 8 .
[0050] The arrangement of the first embodiment is not limited to the above arrangement as long as the potential-to-ground of the solar battery 1 is fixed.
[0051] For example, as far as the O-phase terminal of the inverter 8 and the sensor tap of the transformer 10 are connected, the U- and V-phase terminals of the inverter 8 and the remaining two terminals on the primary side of the transformer 10 can be arbitrarily connected.
[0052] The non-isolating connection 12 preferably connects the ground-side electrical wire N and the sensor tap of the transformer 10 . Even when one of the remaining two wires (U- or V-phase electrical wire) on the primary side and the non-ground-side electrical wire H are connected, the ground fault sensor 89 functions because the potential-to-ground of the solar battery 1 is fixed. The non-isolating connection 12 may be connected through a resistor or capacitor.
[0053] When the O-phase terminal of the inverter 8 (or the sensor tap of the transformer 10 ) is grounded, the potential-to-ground of the solar battery 1 can be fixed. Hence, the non-isolating connection 12 of the transformer 10 can be omitted, and the ground fault sensor 89 functions.
[0054] The internal arrangement of the inverter 8 is not limited to that shown in FIG. 3. Any other inverter having a current-detection-type ground fault sensor and non-insulated inputs and outputs, which converts a DC power into single-phase two-wire 200-V AC power, can be used.
[0055] Second Embodiment
[0056] A system interconnection power generation system according to the second embodiment of the present invention will be described below. The same reference numerals as in the first embodiment denote almost the same parts in the second embodiment, and a detailed description thereof will be omitted.
[0057] [Arrangement]
[0058] [0058]FIG. 4 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the second embodiment.
[0059] An inverter 9 is a power conversion unit having non-insulated inputs and outputs and a current-detection-type ground fault sensor 89 . The inverter 9 is a single-phase two-wire 100-V inverter for converting a DC power generated by a solar battery 1 into an AC power and outputting a single-phase 100-V AC power. The single-phase two-wire 100-V AC power from the inverter 9 is connected to a single-phase two-wire 100-V system 4 .
[0060] The inverter 9 mainly comprises a converter section 27 for boosting a DC voltage input between the positive and negative input terminals, an inverter section 58 for converting the output from the converter section 27 into an AC power and outputting it, the ground fault sensor 89 , an FG terminal for grounding the housing, an abnormal connection detection section 520 , an alarm section 521 , and a switch 522 for connecting/disconnecting the inverter 9 and system 4 .
[0061] The inverter section 58 is formed from a half bridge circuit constituted by capacitors 581 and 582 and switching elements 583 and 584 , and an inductor 586 . When these switching elements are appropriately switched, the half bridge circuit generates and outputs a rectangular AC voltage waveform. The inductor 586 serves as the system interconnection reactor of the inverter 9 , which shapes the AC current waveform to be output from the inverter 9 into a sinusoidal waveform. The half bridge circuit used in an inverter with a relatively low output power can use switching elements in a number smaller than that in the full bridge circuit described in the first embodiment. Additionally, the inverter 9 uses only one system interconnection reactor. Since the numbers of switching elements and system interconnection reactors are decreased, the inverter becomes compact, lightweight, and inexpensive.
[0062] [Influence of Earth Capacitance]
[0063] [0063]FIGS. 6 and 7 are views for schematically explaining the potentials-to-ground of the respective portions of a solar power generation system. FIG. 6 shows a state wherein the inverter 9 and system 4 are normally connected (the ground side of the system 4 is connected to the N terminal). FIG. 7 shows a state wherein the inverter 9 and system 4 are erroneously connected (the ground side of the system 4 is connected to the H terminal).
[0064] The inverter section 58 generates an AC voltage waveform with an effective value of 100 V as the output of the inverter 9 by defining the N terminal as a zero point. The converter section 27 outputs a DC voltage twice or more of about 141 V as the peak value of the effective value of 100 V. In the second embodiment, the DC voltage is ±175 V with reference to the N terminal because of the circuit arrangement.
[0065] In the normal connection state, when the output voltage of the solar battery 1 is X [V], the average value of the potential-to-ground of the solar battery 1 is DC −175+X/2 [V], as is apparent from FIG. 6. In the abnormal connection state, since the potential-to-ground of the N terminal is AC 100 V, as is apparent from FIG. 7, the average value is DC (−175+X/2)V+AC 100 V.
[0066] Generally, the output voltage of the solar battery 1 is several hundred [V], and the average value consequently becomes DC several hundred [V]. For this reason, in the normal connection state, an insulation resistance of several MΩ or more is ensured between the solar battery 1 and ground. Hence, in the normal connection state, the ground fault current at the solar battery 1 , which flows to ground, is almost zero.
[0067] On the other hand, in the abnormal connection state as shown in FIG. 7, since AC 100 V is applied to the average value of the potentials-to-ground of the solar battery 1 , a ground fault current flows from the solar battery 1 to ground through an earth capacitance 11 , and the electrical leakage breaker of the system interconnection system is activated.
[0068] The earth capacitance 11 is the static capacitance between the solar battery 1 and the ground potential, which is about 1 μF for a solar battery for generating a power of 1 kW by standard sunlight. When the earth capacitance 11 is 1 μF, and the sum of ground resistance of the solar battery 1 and that of the system 4 is 500 Ω, 100/{square root}{square root over ( )}[500 2 +{1/(ω×10 −6 )} 2 ]. Hence, a ground fault current I L of 30 mA or more is generated at 50 Hz, and a ground fault current I L of 40 mA or less is generated at 60 Hz. This current value is sufficient to trip the electrical leakage breaker.
[0069] [Abnormal Connection Detection Section]
[0070] When a ground fault current flows due to the above abnormal connection, the electrical leakage breaker operates to disconnect the inverter 9 from the system 4 . Although connection of the inverter 9 and system 4 can be restored by correcting the abnormal connection, power supply to the load (electrical/power devices) in the subscriber's house that receives the power from the system 4 also stops. Hence, a measure for preventing any trip of the electrical leakage breaker due to an abnormal connection is necessary.
[0071] To connect the inverter 9 to the system 4 , the switch 522 is turned off, and then, the inverter 9 is connected to the system 4 . When the switch 522 is kept off, no ground fault current flows, and the electrical leakage breaker does not operate even when an abnormal connection occur.
[0072] As shown in FIG. 5, in the abnormal connection detection section 520 , a voltage detection section 5201 detects the voltage (absolute value) between the N terminal and the FG terminal of the inverter 9 , and a comparator 5202 compares the detected voltage with a predetermined value (e.g., 20 V). If the detected voltage is more than the predetermined value, the alarm section 521 is driven to warn the user of an abnormal connection.
[0073] As the alarm section 521 , any device capable of transmitting an abnormal connection to a person or information terminal by light, sound, mechanical vibration, electrical signal, optical signal, or the like can be used. The power to the abnormal connection detection section 520 and alarm section 521 can be supplied from either the system 4 or the solar battery 1 or can be supplied from a primary battery or secondary battery.
[0074] [0074]FIG. 9 is a flow chart showing the operation procedure in connecting the inverter 9 to the system 4 .
[0075] In step S 1 , the switch 522 is turned off. In step S 2 , the system 4 and inverter 9 are connected. In step S 3 , it is determined whether an abnormal connection alarm is generated. If YES in step S 3 , connection of the system 4 and inverter 9 is retried (i.e., connections of the N and H terminals are reversed) in step S 4 . In step S 5 , the switch 522 is turned on, and operation of the system interconnection power generation system is started. After connection of the inverter 9 and system 4 is ended, power supply to the abnormal connection detection section 520 and alarm section 521 may be turned off.
[0076] As described above, when the potential-to-ground of the N terminal of the inverter 9 is detected, an abnormal connection between the system 4 and the inverter 9 can be detected, and an alarm can be generated. Hence, a compact, lightweight, and inexpensive system interconnection power generation system which has an abnormal connection preventing function and uses the compact, lightweight, and inexpensive inverter 9 can be provided.
[0077] When the inverter 9 and system 4 are connected in accordance with the operation procedure shown in FIG. 9, no ground fault current flows and the electrical leakage breaker does not trip even when an abnormal connection occurs. Hence, reliable and safe operation is possible.
[0078] If the control section of the inverter 9 has an extra processing capability, the function of the abnormal connection detection section 520 can be assigned to the control section. Hence, a more inexpensive and compact system interconnection power generation system having an abnormal connection preventing function can be provided.
[0079] In the abnormal connection detection section 520 , when the potential-to-ground of the N terminal is detected as digital data, and only the frequency component of the system 4 is detected, the influence of noise can be eliminated, and a detection error can be minimized.
[0080] The internal arrangement of the inverter 9 is not limited to that shown in FIG. 4. Any other power conversion unit can be used as long as it has the current-detection-type ground fault sensor 89 and non-insulated inputs and outputs, and converts a power generated by the solar battery 1 into an AC power and outputs it to the single-phase two-wire 100-V system 4 with one line grounded. That is, any arrangement capable of fixing the potential-to-ground of the solar battery 1 can be used, as in the first embodiment.
[0081] As the switch 522 , a switch of any type such as a mechanical switch or semiconductor switch can be used. When the abnormal connection detection section 520 detects no abnormal connection, the switch 522 may be driven and turned on. With this arrangement, the operability in connection can be improved.
[0082] Third Embodiment
[0083] A system interconnection power generation system according to the third embodiment of the present invention will be described below. The same reference numerals as in the first or second embodiment denote almost the same parts in the third embodiment, and a detailed description thereof will be omitted.
[0084] [0084]FIGS. 8 and 11 show the potentials-to-ground of the respective portions of the system interconnection system, though details of the potentials-to-ground of an inverter 8 and solar battery 1 will be omitted.
[0085] [Arrangement]
[0086] [0086]FIG. 10 is a block diagram showing the arrangement of a system interconnection power generation apparatus according to the third embodiment.
[0087] In the first embodiment, the primary and secondary windings of the transformer 10 are connected by the non-isolating connection 12 whereby the transformer 10 is used as a non-insulated transformer. In the third embodiment, an auto-transformer 13 is used.
[0088] In the system interconnection power generation system of the third embodiment, the inverter 8 which has non-insulated inputs and outputs and a current-detection-type ground fault sensor 89 converts a DC power into an AC power, outputs it as a single-phase three-wire 200-V AC power, and it is connected to a single-phase two-wire 100-V system 4 through the transformer 13 having non-insulated inputs and outputs. Hence, an inexpensive system interconnection power generation system connected to the single-phase two-wire 100-V system 4 using the inverter 8 with a single-phase two-wire 200-V output, i.e., a most popular commercially available inverter at present, can be provided. A ground fault at the solar battery 1 can be detected by the ground fault sensor 89 incorporated in the inverter 8 .
[0089] In the first embodiment, the transformer 10 whose primary and secondary windings which are supposed to be insulated from each other are non-insulated by the non-isolating connection 12 is used. In the third embodiment, the auto-transformer 13 whose primary and secondary windings are non-insulated is used. In the auto-transformer, since only the current difference between the primary current and the secondary current flows to a winding (common winding) common to the primary and secondary sides, the sectional area of the electrical wire of the common winding portion can be small. Hence, the transformer 13 is more compact, light-weight, and inexpensive (about ½) than the transformer 10 , and the system interconnection power generation system also becomes compact, light-weight, and inexpensive.
[0090] According to the above-described embodiments, the following effects can be obtained.
[0091] (1) When an easily commercially available inverter (e.g., a single-phase three-wire 200-V output of a full bridge scheme) having non-insulated inputs and outputs and a current-detection-type ground fault sensor is connected to a single-phase two-wire 100-V system with one line grounded through a transformer having non-insulated inputs and outputs, the ground fault sensor can be directly used, and a compact, lightweight, and inexpensive system interconnection power generation system can be provided.
[0092] (2) When an auto-transformer is used as the transformer having non-insulated inputs and outputs in the arrangement (1), a more compact, lightweight, and inexpensive system interconnection power generation system can be provided.
[0093] (3) When an easily commercially available inverter (e.g., a single-phase two-wire 100-V output of a half bridge scheme) having non-insulated inputs and outputs and a current-detection-type ground fault sensor is connected to a single-phase two-wire 100-V system with one line grounded, the ground fault sensor can be directly used, and a compact, lightweight, and inexpensive system interconnection power generation system can be provided.
[0094] (4) A switch for connecting/disconnecting the inverter and system, and an arrangement for generating an alarm when the potential-to-ground of an output terminal of the inverter, to which the ground-side electrical wire of the system should be connected, is detected, and the detected potential to ground has a predetermined value or more are added to the arrangement (3). With these arrangements, the inverter is connected to the system while keeping the switch OFF, and when an alarm is generated, connection is retried, the switch is turned on, and then, operation of the system interconnection power generation system is started. In this case, any ground fault current generated when the inverter and system are erroneously connected can be prevented, and trip of the electrical leakage breaker can be prevented. That is, a system interconnection power generation system having a function of preventing any abnormal connection between the inverter and system can be provided.
[0095] As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims.
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Along with the expansion of the application range of solar power generation systems, connection to a single-phase 100-V system is required. To most easily meet this requirement, a non-insulated inverter with a single-phase two-wire 100-V output is used. It is preferable to use an inverter with a single-phase two-wire 200-V output, i.e., a most popular commercially available inverter. For this purpose, a power supplied from a solar battery is converted into a single-phase three-wire 200-V AC power form by the inverter. The output from the inverter with non-insulated inputs and outputs is supplied to a system through a transformer arranged to connect the line of the single-phase three-wire 200-V AC power to a single-phase two-wire 100-V system with one line grounded. To make a ground fault sensor incorporated in the inverter function, the median potential line of the single-phase three-wire 200-V AC power is connected to the ground line of the system.
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This is a continuation-in-part of copending application Ser. No. 419,752, filed Sept. 20, 1982, now abandoned.
This invention relates to subsoil in-trench drain systems for use in removing water from soil in agriculture, road building and construction, and in distributing waste water into drainage, irrigation or leach fields.
In agriculture, improved crop yields and prevention of soil salt build-up are obtained by installing subsoil drainage systems traditionally utilizing trenches, filter media such as sand, water transport media such as porous drainage pipe and water gathering media such as gravel.
The installation of such systems is costly and time consuming and can presently only be justified in intensive farming situations yielding high value crops.
Road and highway paving damage is frequently caused by surface water penetrating to the road sub-base causing a decrease in the strength of the soil and piping or washing out of the road bed under the paving joints. In addition, freezing of the road bed causes expansion of the bed under the road surface, leading to reflective cracking and spalling.
In construction, hydraulic pressure due to ground water and weakening of the foundation soil due to washing out or piping of the soil fines can cause early damage to structures. Sub-ground basement flooding and rising dampness are caused by inability to remove penetrating water quickly enough.
A number of prior art systems exist to remove water penetrating a soil mass or to lower the existing ground water table. These systems traditionally include the use of sand and mineral aggregates to filter the soil from the water and to allow it to drain in combination with porous or perforated tubes to collect and lead water away. These systems usually clog after a period of time due to the passage and deposition of fine soil particles into the filter and transport media or into the tube slots or the tube itself, even when the system is carefully designed with the particle size distribution of filter media and aggregate media properly matching the native soil in the region to be drained.
In more recent times, permeable plastic polymer or glass fibre filter cloths generally called "geotextiles" have been developed which can be carefully matched in permeability to native soil characteristics and which can relatively permanently separate the native soils from the coarse aggregate used to conduct the water. Both plastic polymer and fiberglass materials are used for geotextiles. The range of cloth manufacturing techniques used includes weaving, spun bonding and melding. These provide geotextile fabrics with a wide range of properties.
Generally, geotextiles are required to be non-corrodible, rot proof and free from the long term disintegrative effects of water and water borne soil chemicals.
They are also required to have high tensile and burst strengths and have a range of water permeabilities which enable them to be matched to a wide range of native soils to provide for proper long term filtration with freedom from blocking or clogging by fine soil particles.
We refer further to a text by P. R. Rankilor entitled "Membranes in Ground Engineering" (John Wiley & Co., New York, N.Y., 1978) which fully details the technical requirements of that class of textiles defined in common use as "Geotextiles" and which discusses the drainage systems which have been developed especially for use with them.
All current drainage systems utilizing Geotextile wraps over gravel cores still require careful design and troublesome and labour intensive installation procedures and there is a need for prefabricated systems which can simplify and improve the use of geotextiles in the field. For example, it is often desired to provide drainage behind near-vertical walls. In such cases the gravel water transport medium is very difficult to deposit because it tends to slump down. Even in geotextile filter-lined trenches wherein placement of the gravel is easier, the gravel is heavy and expensive to transport, requires labour to grade and place and requires removal from the site, of the native soil it replaces.
Porous drainage tubes which constitute one form of prefabricated drainage systems are often now made of plastic polymer and are frequently protected by filter cloths. These however, give limited water access due to their size and shape, are subject to silting up, provide only very localized water collection, are easily crushed or accidentally disconnected, require special fittings for joints and intersections, require proper grading to maintain flow, and need careful bedding-in. When draining layered strata clay soils, such geotextile fabric covered pipes still require the installation of gravel in the trench above them, in order that they may intercept the water carrying strata.
In order to overcome the above limitations and hence, to reduce costs for installation of drainage systems, a number of prior art prefabricated systems have been developed which utilize vertical fins comprising open plastic core surrounded by polymer filter fabric to intercept and channel the subground water into drainage pipes.
Such systems as described by Healy and Long in U.S. Pat. Nos. 3,563,038 and 3,654,765 (herein incorporated by reference) offer substantially more reliable drainage systems, but are hampered by the need for careful installation and labour intensive on-site assembly of the drainage fins and the tubing into continuous lengths. The drainage tube they necessarily incorporate is an additional cost component, because the filter cloth covered fins themselves do not provide enough in-built flow capacity when subjected to lateral soil pressure, to conduct water away from the site quickly, without the provisions of the additional pipe or conduit.
Hence, the use of such systems has been restricted to specialized drainage situations where higher on-site installed costs can be tolerated. In addition, such systems do not incorporate impermeable membranes when waterproofing of a sub-ground wall or road base is required.
Yet other flat laminated geotextile/plastic core drainage systems, as marketed in Europe and U.K. by Imperial Chemical Industries under the trademark "Filtram" comprise separation of the geotextile fabric surfaces by a laterally connective spacer such as extruded plastic net. Such systems may offer proper soil filtration with a very high ratio of water access, however the internal net spacer provides little internal volume because of its shallow structure. The edges of such a product are not usually clad by filter cloth, hence, soil can enter the system, further reducing its effectiveness. Filter fabric over net must be bonded to the net because a loose face fabric could be easily pressed into the net closing off flow. Also, because of adhesive lamination the bonded composite is stiff and inflexible.
As with the other prior art products discussed, the limited internal volume of this product requires that it drain into a slotted plastics pipe, but sealing such laminar drains into pipes involves complex and cumbersome labour intensive systems involving wrapping the slotted pipe in filter fabric and clamping it by means of bars and pegs.
In the system described by Glasser and Lede U.K. Pat. No. 2,056,236, some of the above limitations of the `Filtram` system have been removed by the use of an impermeable core in which hollow projections and hollows have been formed which support a geotextile surfacing material. The height of the projections and the depth of hollows is not sufficient to provide adequate internal flow to remove the need for an additional drainage tube. In addition, due to inadequate height of the hollow projections in the core form, it is required that the textile be bonded to the shallow core form to facilitate installation and to suspend the cloth against deflection into and subsequently blocking of the core as soil pressure is applied.
Core products are known to the inventor which have provided for the use of a flat sheet on which vertical projections have been formed. For example, in U.S. Pat. No. 4,057,500 to Wager there are proposed continuous solid plastic mouldings which consist of a flat surface on which raised pegs of two heights have been moulded at regular intervals on one or both sides. When wrapped with filter cloth, these systems suffer from not being able to be bent flexibly on a tight radius and they are not able to be joined without the need for special fittings. Such cores also require much more plastic material in their construction than the system of our invention, when subjected to soil pressure the deflecting filter cloth surface is to be supported by the lower height pegs.
Alternative core materials such as those proposed by Hale in U.S. Pat. No. 3,525,663 and Keith in Australian Pat. No. 481,017 provide lighter, more flexible materials which might be utilized in drainage products. However neither of these materials demonstrate a reasonable combination of properties for use in a sub-ground drain as described in the present invention.
Thus, it has now been found that the amount of thermoplastic polymer material to be used in a subsoil drain may be minimized, while the core is able to sustain the necessary loadings imposed on it. It has also been found that the collection ability of a drain will be a more important factor in its design than its flow capacity and that the drainage elements of the invention may be installed to provide increased collection ability with reduced costs over the prior art materials.
SUMMARY OF THE INVENTION
Accordingly the present invention provides an essentially continuous subsoil strip or sheet drainage element comprising an internal supporting formed thermoplastic core strip or sheet of generally planar configuration upon which is disposed on at least one side of the base plane, regularly spaced, hollow, equal depth tapered supporting projections having generally flat tops, said core covered on all four sides with a flexible geotextile filter cloth which is not attached to the projections on the core and is free to move with respect to said projections, the relative depth and spacing of said projections being such as to restrain said filter cloth against being forced into the hollow interiors of the projections.
The depth of the projections is preferably greater than one quarter of their closest spacing and the average diameter of their flat tops may be greater than 0.2 and less than 0.35 of their closest spacing.
Preferably the depth of the hollow tapered projections on one side of the base plane is greater than one-half of said closest spacing between the tops of the projections so that the assembled product can be tightly folded upon itself longitudinally or transversely without damage or significant loss of water carrying capacity.
The supporting projections may occur on both sides of the base plane of the thermoplastic core and be spaced from one-quarter to four inches apart.
The present invention also provides a subsoil drain system in which the drainage element of the invention is installed into a narrow but deep slit trench with said element installed on its edge with the base plane of the element in a substantially vertical plane, with no additional drainage tube or member provided.
The invention provides for an internal supporting spacer or core covered or surrounded by a geotextile filter cloth. The core is open for flow, and has a configuration which enables it to be tightly bent or folded without damage. Such a spacer of our invention takes the general form of a flat sheet optionally perforated, on which projections have been formed on one or preferably both sides.
The projections must be spaced at regular close intervals, typically from one half inch to 4 inches in order to prevent flow reduction when the filter cloth is deflected due to soil pressure. For this reason and for considerations of overall flow capacity, the length of each projection must be at least one quarter of the dimension of the spacing between said projections.
The design of the core and its supporting projections is an important part of this invention. We require that the projections preferably extend from a generally planar sheet as a tapered hollow form with a generally flat top. The method and material of manufacture of such core material is not narrowly critical provided it is not corrodible, is flexible, and is not affected by water. Typically, a plastic polymer material might be chosen, such as unplasticized polyvinyl chloride, polystyrene, polyester or polyolefines such as polyethylene and polypropylene.
The projections are also to be spaced on a uniform grid pattern and these features in combination enable simple but strong joints to be made by overlapping adjacent pieces of core material so the projections nest into each other before replacing the filter cloth back over the join.
The method of assembly of the filter cloth cover over the core is not narrowly critical, it may be wrapped convolutely or helically around the core strip and seamed either with stitching or by means of a glue bead. The material of construction and design of the filter cloth is also not narrowly critical, provided it is of the general category of fabrics known as geotextiles, which have been developed to have adequate strength, durability and filter performance to be incorporated into subground drainage systems.
The filter cloth is not to be bonded or otherwise attached to the core as this causes the drain strip to become rigid and board-like, and reduces its flexibility for bending very substantially.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 shows a perspective view of the drain strip
FIGS. 2a and 2b show how the drain strip can be folded upon itself in either the longitudinal or transverse direction
FIG. 3 shows a single sided core alternative
FIG. 4 is a transverse cross section showing how the strip is installed into an in-ground trench
FIG. 5 is a graphical plot of results for flow within the drain strip core as soil pressure is applied.
FIG. 6 is a graph in which the heights of the water table at the midpoint between two subsoil drains are plotted against time for various drains.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to better describe the invention and to show its preferred embodiments, we refer again to the diagrams.
FIG. 1 shows the assembled drainage strip of our invention, consisting of a filter cloth cover (1) wrapped around a flexible supporting core (2) with formed-in projections (20) having generally flat tops (18) optionally perforated with holes (19) with cover (1) being seamed at (3) by a bead of adhesive (4). The cloth cover is not bonded or otherwise attached to the flat tops (18) of the core projections (20) regularly disposed on each side of the central plane (21).
The core 2 of FIG. 1 is a preferred embodiment, and is preferably made by the cuspation process as disclosed in U.S. Pat. No. 3,963,813 which we herein incorporate by reference. Other core configurations or production methods, such as that disclosed in French Pat. No. 2,462,518 do not enable the achievement of sufficient length in the supporting projections to enable adequate internal water flow in the strip without the provision of additional tubes.
FIG. 2(a) shows a core of wavelength w and depth of projection 1/2 d. For adequate internal drainage we require that d is to be greater than 1/2 w and preferably that d=w. FIG. 2(b) shows how such a core can be folded tightly upon itself without damage. This is also a necessary requirement of our invention if flexibility of installation is to be maintained without substantial flow impairment.
FIG. 3 shows a configuration of core wherein the projections (20) protrude only on one side of the plane (21). This core is less preferred because it will generally require more material in its construction for the internal volume gained, at a given core crush strength.
FIG. 4 shows a transverse cross section of an installation of the drain strip for draining soil. In FIG. 4 the drain strip (1) is placed vertically against the side wall (6) of a narrow slit trench. The originally excavated soil (7) is then replaced as fill in the trench. The deep drain strip intercepts all of the water in any strata which it intercepts, and is especially useful for draining stratified soils. The lower section of the drain strip is optionally covered by an impermeable membrane (22) which prevents transported water from soaking back out of the strip. The deep fin configuration of the drain strip of FIG. 4 has the additional advantage that even if the strip is laid into a level ungraded trench bed, the deep narrow drain strip ensures that the water in it can still flow due to the hydraulic head existing in the depth of the strip itself.
FIG. 5 shows in the upper line how the geotextile wrapped core of one of our preferred configurations performs for flow as soil load is increased. The preferred configuration material has a 0.5 mm high impact polystyrene core at 12 mm depth of draw. A comparison is made (lower line) with "Filtram", a product comprising extruded plastic mesh bond-laminated with geotextile. The Filtram product begins to fail at soil pressures greater than about 10 psi due to the textile deflecting into and closing off the net core. The core material of our drain configuration sustains unimpeded flow at pressures up to 370 KN/m 2 (The apparent rise and fall in flow rate is within the limits of experimental error). Flow impedance in our system only occurs when the core itself begins to collapse due to compression failure, rather than being due to any deflection of the geotextile under soil pressure. The core of our invention comprises projections which are relatively high enough in relation to the spacing, to ensure that the deflected textile surfacing cannot close off the flow, and that the flow itself is substantially higher due to the higher degree of open space which is maintained.
The preferred core for the present pre-fabricated geotextile drainage systems requires considerations of:
COMPRESSIVE CRUSH STRENGTH
This is dependent upon the material thickness, the material distribution in the forming, the material type and the spacing, shape and height of the projections. U.S. Pat. No. 3,963,813 gives an exhaustive treatment of the crush strength of cuspated sheet in relation to polymer, pattern and wavelength. In general, we prefer to use cuspated sheet cores which have compressive crush strengths lying between 10 psi and 80 psi. Cuspated sheet cores have uniquely good properties of compressive strength in relationship to the weight of material in them.
SURFACE AREA SUPPORTING THE TEXTILE
This depends on the size of the generally flat top of the truncated cusp shape and the spacing of the cusps. In coarse patterns of core with say 50 millimeter cusp spacing, relatively large flats are required on the cusps, typically from 10 to 17.5 mm in diameter.
To demonstrate further the advantages of the drainage elements of the present invention, a comparison was made with cores of two closely related prior art materials.
The three alternative cores to be analyzed are the core of Hale (U.S. Pat. No. 3,525,663), the core of Keith (AU 481,017), and the cores preferred for use in the drain of our invention (Flecknoe-Brown). These cores are all formed from flat sheet thermoplastic material, and all consist of regular arrays of hollow projections disposed on each side of a central plane.
(i) Shape
HALE
Large opposed flat tops of diameters greater than half of the closest spacing of the projections on one side of the sheet. Most of the cross sectional area is impeded by the projections.
KEITH
Sharp pointed or small diameter flat tops (if heat flattened). The cross-sectional area is impeded to a much lesser degree by the projections which are, however, too small to properly support an unconnected outer filter cloth layer against soil pressure without penetrating through it.
FLECKNOE-BROWN
Projections having flat tops of diameters between 0.2 and 0.35 of their closest spacing on 1 side of the sheet. The size of the flat projection is sufficient to support the cloth without excessive impedance of the cross-section of the drain by the size of the projection.
(ii) Crush Strength to Core Weight
Three core samples were made on a hydraulic press, under identical forming conditions from identically heated A.B.S. sheet material, according to the three geometric configurations outlined in (i) above. The starting thickness of the sheet, prior to stretching into the respective core shape, was 0.7 mm in each case.
The dimensions of each core and the resulting distribution of material thicknesses in each after stretching to shape, and the measured crush strengths, are detailed below.
______________________________________(i) Core of HalePeak separation = 38.9 mmThickness of peak = 0.54 mmtop wallPeak diameter = 19.0 mmMax. Crush Load = 1670 NewtonSample Size = 29.5 × 13.5 cm.sup.2 = .0398 m.sup.2Max. Crush Pressure = ##STR1## = 4.20 × 10.sup.4 N/m.sup.2 = 6.09 p.s.i.Minimum Side Wall = .17 mmthickness ofProjectionsMaximum Side Wall = .23 mmthickness ofProjectionsAverage Side Wall = .20 mmthickness ofProjectionsWeight of sample = 31.6 gsheetWeight per area of sheet in Test = ##STR2##(To be matched by = 793 g/m.sup.2other materials)Max. Crush Pressure to Unit Weight = ##STR3## = 53.0 N/g(ii) Core of KeithPeak separation = 35.3 mmThickness of peak = 0.65 mmtop wallPeak diameter = 5.0 mmMax. Crush Load = 4545 N(Sample A =815 g/m.sup.2)Sample Size = 15.5 × 33.0 cm.sup.2 = .0512 m.sup.2Max. Crush Pressure = ##STR4## = 8.88 × 10.sup.4 N/m.sup.2 = 12.9 p.s.i.Maximum Crush Pressure to unit weight = ##STR5## = 109 N/gMinimum Side Wall = .30 mmThickness ofProjectionsMaximum Side Wall = .55 mmThickness ofProjectionsAverage Side Wall = .41 mmThickness ofProjections(iii)Core ofFlecknoe-BrownPeak separation = 35.3 mmThickness of peak = 0.58 mmtop wallPeak diameter = 11.0 mmMax. Crush Load = 3100 N(Sample F =792 g/m.sup.2)Sample Size = 12.5 × 30.0 cm.sup.2 = .057 m.sup.2Max. Crush Pressure = ##STR6## = 8.27 × 10.sup.4 N/m.sup.2 = 12.0 p.s.i. = ##STR7##Minimum Side Wall = .30 mmThickness ofProjectionsMaximum Side Wall = .35 mmThickness ofProjectionsAverage Side Wall = .33 mmThickness ofProjections______________________________________
DISCUSSION OF CRUSH RESULTS
As expected, the large area of the flat tops in the core of Hale, leaves a relatively small area of sheet remaining to be stretched. Hence, the average and minimum wall thickness give rise to the lowest core crush strength for a given weight of core.
The surprising result of these above tests is that the core of Keith, in which the area of the flat tops is very small, and the average wall thickness of the projections is highest, is not significantly stronger in crush to weight (Max. Crush Pressure per unit weight) than the preferred core in the drain of our invention. This is evidently due to the inability of the small diameter projections to "pull" the stretching material into even wall thickness. The projections of Keith's core collapse near the peaks.
The core of Flecknoe-Brown, wherein the core peak diameter lies within the range of 0.2 to 0.35 of the closest spacing of the projections (as measured on one side of the central plane) provides adequate cloth support and has the most uniform wall thickness core together with the minimum weight of drains for a given crush strength.
The foregoing demonstrates two unexpected and unique properties of the drain of our invention, when such is utilized for the horizontal drainage of land:
the shape of the drain of our invention together with its method of installation, leads to superior performance over all other types of drain.
support of the surface filter cloth by the core projections of the drain is adequate to prevent damage to the cloth under compressive soil loadings.
the weight of drain is minimized, for a given crush strength.
Yet other configurations of the drain strip of our invention will be perceived by those skilled in the art. For example, wide strips of heavy cored product could be laid side by side, transversely across or longitudinally along the soil under a road or railway bed to provide a separation and drainage layer strong enough to resist crushing due to the combined soil and traffic loads.
The following table gives an approximate comparison of the amount of plastic polymer (and hence cost) saved by the drain of the invention when compared with filter cloth covered tubes.
The dramatic performance improvement exhibited by the land drains of the invention over those existing are thus shown to lead to a more economic drain which should find wide acceptance in land and road edge drainage.
__________________________________________________________________________COMPARISON OF 40 MM THICK DRAIN STRIP WITH STANDARD TUBEDRAINS OF EQUAL WATER TABLE DRAWN DOWN PERFORMANCEStrip Equipalent Typical Weight Weight of PolymerWidth Convoluted of Polymer in Tubes in Drain Strip Core Savings in Polymer(mm) Tube Diameter (Gm. per meter) (Gm. per meter) (Gm. Per meter)__________________________________________________________________________100 100 350 65 285200 150 550 130 420__________________________________________________________________________ The savings in plastic material in the above compared drain results because less polymer needs to be used for adequate crush strength in a vertical core of our configuration than is required to support a circular tube type drain against imposed soil loads or superimposed loads due to surface traffic.
The foregoing discussion has emphasised the importance of the weight of core per meter, and of the flow capacity of the formed drain, as design criteria for any subground drainage system. Water collection performance has been found to be of major importance and this performance is largely dependent on the geometry of the drain.
Seepage normally flows parallel to the surface of the land, roughly horizontally. The rate of seepage in soils is generally very low. For example, in most normal soils (other than sand), water permeates at rates typically less than 1 meter per day. In clay soils, this rate may even be less than 1 meter per year.
These seepage rates typically result in a total outflow of less than 10 liters per minute in a drain tube 100 meters long buried 1 meter down. Hence normal corrugated drain tubes have many times greater flow capacity than is needed for most installations; such tubes are as large as they are to enable more efficient water collection.
However, while seepage flow at large distances towards a drain can be thought of as having parallel and horizontal flow lines, in the vicinity of a tube drain the flow lines will converge towards the drain. The radial flow in the vicinity of a tube drain reduces the collection rate of the drain which is further limited by the restricted number of apertures in the tube allowing water entry.
In a vertical sided drain, the horizontal flow streamlines do not have to "curve" downwards or upwards towards a tube. As lengthening of the seepage flow paths very markedly affects the collection rate of a drain system, the minimal flow path lengths achieved with vertical sided drains make these types of drain more efficient collectors. The drainage elements of the invention are particularly suited to present a vertical-sided uniformed porous surface to the soil.
Despite the foregoing, conventional and commercial wisdom has promoted the use of perforated drain tubes, preferably encased in a filter sock or laid in an aggregate filled trench. FIG. 6 illustrates the results of comparisons between drains made according to the invention and perforated tube drains. In the figure, the heights of the water table at the midpoint between two subsoil drains are plotted against time for various drains. The water table is initially considered to be horizontal (at time=0) at a certain height above the drains, as might be the case after a deluge or irrigation.
In FIG. 6, the letters b and c relate to drains made according to the invention both having strip widths of 40 mm and vertical strip heights of 100 and 200 mm respectively. Letter d relates to a perforated tube drain of 100 mm diameter without a filter sock and laid directly in soil. Letter a relates to a perforated tube drain with a filter sock and having 100 mm diameter.
A perforated tube drain without a filter sock clearly draws the watertable down at the slowest rate since it has the smallest draining surface. It will be noted further that while covering the tube drains with filter cloth does substantially increase their drawdown capabilities, they are still not quite as good as the drains of the invention of similar height to the diameter of circular drain tubes.
The criteria for the design of a drainage system are usually either that the water table should never be allowed above a certain depth below the surface, or that the water table should be drawn down by a certain amount in a specified time. In both cases, the better drainage geometry and functioning of drains of the invention will mean that either the drains can be spaced further apart or that they can be placed in shallower trenches than tube drains. The consequent potential savings in costs in either event will be apparent.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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Subsoil drain strip or sheet elements comprising a core surrounded by a polymer or glass fibre filter cloth. The core has a generally planar configuration with hollow formed-in flat topped projections on one or both sides which create internal volume for flow of water as well as supporting the filter cloth against imposed soil loads. The depth of the supporting projections on each side of the core and their relative spacing is to be such that the surrounding filter cloth is restrained against being forced into the hollow interiors of the projections so that adequate longitudinal flow of water can take place in the strip without the need for additional drainage tubes to be provided. The depth of the projections may be greater than one quarter of their closest spacing. Additionally, the average diameter of the projections may be between 0.2 and 0.35 of their closest spacing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of currently co-pending U.S. patent application Ser. No. 12/125,474, filed May 22, 2008, which application claimed the benefit under 35 USC §119(e) of provisional application 60/939,660, filed May 23, 2007, which copending application and which provisional application are both hereby incorporated by reference. Further, this application also claims the benefit under 35 USC §119(e) of U.S. provisional patent application 61/061,249, filed on Jun. 13, 2008, which provisional application is also hereby incorporated by reference.
FEDERAL RESEARCH STATEMENT
The inventions described herein may be manufactured, used, and/or licensed by the U.S. Government for U.S. Government purposes.
FIELD OF THE INVENTION
The present invention relates to mortar round propellant increment containers and more particularly to such containers manufactured of low residue foamed celluloid.
BACKGROUND OF THE INVENTION
Conventionally mortar increment containers (MICs) used to contain propellant used by the U.S. Army for 60 mm, 81 mm, and 120 mm projectile propulsion systems are manufactured of a felt fiber, which is composed of nitrocellulose (NC), kraft, resin and various additives—that add to the energy imparted to the projectile. Unfortunately, this manufacturing process involves multiple steps including matting, condensing and pressing fibers, which are labor intensive and relatively costly. Further, it is known that moisture can negatively impact the velocity and range of felt MICs by as much as 5%.
An alternative material to felt MICs, which has been adopted by NATO, is non-porous celluloid (hereinafter celluloid), a material which is not significantly affected by moisture, is easily moldable and is relatively low cost—and which still adds to the energy imparted to the projectile. Celluloid is a class of compounds based upon nitrocellulose, a highly flammable compound formed by nitrating cellulose through exposure to nitric acid, or another strong nitrating agent. Typically, celluloid is composed of 70 to 80 parts nitrocellulose, nitrated to an 11% nitrogen, and about 30 parts camphor, which acts as a plasticizer for the nitrocellulose. The nitrocellulose and camphor are mixed in the presence of solvents, such as ethanol or in a mixer, followed by straining, roll milling and “hiding”. A selected number of “hides” are then blocked at a desired pressure and temperature into a fused block, which is then sliced into sheets at desirable thickness after a conditioning period. Celluloid may contain a number of additives such as dyes and fillers for various applications—more common uses today include guitar picks, ping-pong balls, and some writing and musical instruments.
It is known that typical celluloid combustible cases experience residue issues, as well as, having mechanical strength and embrittlement issues, especially at low temperatures. Of these issues the most troubling is residue, as combustible increment containers used in mortar and artillery propulsion systems must burn cleanly, free of after-combustion residue, to avoid creating an obstruction within the launch tube of the projectile system. Any obstruction within the launch tube can lead to misfires or hang fires which could result in the immediate detonation of the projectile, with significant potential for injury or death of the crew.
Thus there is a need in the art for a relatively low cost, easily moldable, MIC material of manufacture that does not suffer from the wetness or manufacturing problems associated with felt, or the embrittlement, mechanical strength or residue problems associated with celluloid. The subject MIC material should contain an energetic constituent as does the felt fiber or celluloid of the prior art.
SUMMARY OF INVENTION
The present invention addresses the needs not met by the prior art, by providing a low residue, energetic, easily moldable MIC material, that is easily manufactured and does not suffer from wetness issue of the present felt MICs, and most importantly, at less than half the cost of the present felt MICs. Specifically, the present invention comprises MICs manufactured of foamed celluloid. Foamed celluloid is composed of 50 to 84% nitrocellulose, having a nitrogen content of from about 10.5 to about 13.5%, and about 15 to about 50% camphor. Such foamed celluloid MICs exhibit the same level of water resistance as non-foamed celluloid MICs while also having enhanced combustion characteristics, impact resistance, mechanical strength, and resistance to old weather embrittlement over the non-foamed celluloid.
The subject foamed celluloid MICs are relatively easy to manufacture from foamed celluloid sheets which are first foamed by the physical and/or chemical processes disclosed herein, and then formed into the desired MIC shape using known thermoforming techniques; wherein the foamed celluloid sheets are heated to a pliable forming temperature, and pressed into the MIC halves in a mold thereof (i.e. a generally u-shaped mold of the top and bottom sections of the MIC). Each thermoformed generally u-shaped half is punched/trimmed out of the sheet from which it was formed, and the two halve joined, using vibration welding to form a single MIC. A fill hole can be left open within the now formed MIC, to allow filling with conventional munition propellants and then sealed using a foamed celluloid plug, paper or nitrated tape, glued into place or sealed using a solvent. A solvent may also be used with or in place of welding of the two halves, by applying the solvent to the edges of one or both sides of the two halves. Preferably, the two halves should be joined by a combination of vibration welding and the use of a solvent, to ensure that the best seam possible is created, to avoid the possibility of a rupture of the seam or an incomplete seam and loss of propellant therefrom.
The nature of the subject invention will be more clearly understood by reference to the following detailed description and the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
The present invention comprises MICs manufactured of foamed celluloid, which foamed celluloid is composed of 50 to 84% nitrocellulose, having a nitrogen content of from about 10.5 to about 13.5%, and about 15 to about 50% camphor. Compared to the non-foamed celluloid MICs, the foamed celluloid MICs exhibit equally good wetness performance and being less dense, there is less mass which needs to be consumed during combustion which in combination with the significantly larger surface area, dramatically increasing flame propagation and released energy. Further, the more flexible foamed structure versus the non-foamed celluloid, enhances the ability of the foamed celluloid to withstand impact and reduces brittleness.
The flame propagation and energy release of the foamed celluloid MICs of the present invention, in comparison to the felt and to non-foamed celluloid MICs of the prior art, can be demonstrated by the combustion performance of these materials, which is commonly characterized by the burn rate (cm/s) obtained in the closed bomb test. Use of closed bomb tests are well known in the art, as demonstrated by a Picatinny Arsenal interim report, Modernization of Closed Bomb Testing for Acceptance of Single Base Propellants, by John K. Domen, May 1976, available from the Defense Technical Information Center Online, www.DTIC.mil, as document ADB015387. The burn rate test results of selected celluloid samples are summarized in Table 1, below.
TABLE 1 Closed Bomb Test Results of Selected Celluloid Compositions. V NC Cam N (at 1,000 bar) System % % % [cm/s] Non-foamed Celluloid 80 20 11.1 2.1 Foamed Celluloid 80 20 11.1 89.0 Felted Fiber ~75 N/A 13.6 120.0
The cost for a foamed celluloid 120 mm mortar MIC is estimated at approximately 40% of that of a current equivalent felt 120 mm mortar MIC considering facilities, manufacturing and materials costs.
As stated above, the subject foamed celluloid MICs are relatively easy to manufacture from foamed celluloid sheets which are formed into the desired MIC shape using known thermoforming techniques. The foamed celluloid sheets are heated to a temperature at which they are pliable enough to be pressed into the generally u-shaped MIC halves using conventional thermoforming equipment such as manufactured by Illig Maschinenbau GmbH & Co Kg, Heilbronn, Germany. Each thermoformed u-shaped half is punched/trimmed out of the sheet from which it was formed, and the two halve joined, using vibration welding to form a single MIC. A fill hole can be left open within the newly formed MIC, to allow filling with conventional munition propellants and then sealed using a cover or plug, which can be manufactured of foamed celluloid or nitrated paper. Such a cover or plug can be affixed in place using a solvent, such as acetone. A combination of vibration welding and application of a solvent may also be used to join the two halves, by applying the solvent to the edges of one or both sides of the two halves. Preferably, the two halves should be joined by a combination of vibration welding and the use of a solvent, to ensure that the best seam possible is created to avoid the possibility of a rupture of the seam, or an incomplete seam, and loss of propellant therefrom.
Two general types of processes are used to foam plastics, the first involves use of a chemical foaming or blowing agent (CBA) that produce foaming or blowing gas through heat-induced decomposition, and the second involves the use of a physical foaming or blowing agent (PBA) that is forced under pressure into a polymer melt, without any chemical change. Foamed celluloid having the cell structure, physical and chemical properties required for the present invention, can preferably be manufactured by either (1) a combination of a chemical blowing agent (CBA) process and a physical blowing agent (PBA) process (detailed in Example 1, below) or (2) a PBA process alone (detailed in Example 2). Either process results in foamed celluloid sheets which can be thermoformed, as described above, into the subject MICs.
Example 1
Preferred Combined CBA/PBA Process for Manufacture of Foamed Celluloid
1. In a mixer that can be heated, such as a Measuring Mixer manufactured by Brabender GmbH & Co., Duisburg, Germany, combine about 50 weight % nitrocellulose (NC), having a nitrogen content of from 10.5 wt. % to 13.5 wt. %, preferably lower than 12.6% and most preferably about 11%; with about 15 wt. % camphor; with about 3% of a chemical blowing agent (CBA) that will generate CO 2 when decomposed, potential CBAs include sodium bicarbonate, azodicarbonamide (commonly referred to as AZ), benzene sulfonylhydrazide, and 5-phenyl tetrazole, and a commercial CBA which is particularly preferred is SAFOAM FPN3-40, manufactured and distributed by Reedy International Corp., Keyport, N.J.; and about 30% by weight of a solvent, such as a 50%/50% mixture of ethanol and methanol;
2. Run the mixer at a moderate agitation of about 30 rpm, for about 25 to about 35 minutes, at about 120 to about 125° F., until the mixture therein appears dough-like;
3. Add an additional quantity of solvent, about 25% of that originally added, increase the rpm of the mixer to about 45 rpm, and increase the temperature to about 150 to about 160° F.;
4. After approximately 30 minutes of additional mixing, for a total of about 60 minutes of mixing at this higher temperature and rotation speed, the mixture is decanted from the mixer onto a flat surface, e.g. a Teflon sheet, and placed within a conventional heated press, capable of temperatures of up to about 200° F. and pressure of over 10,000 lbs of force;
5. Within the heated press, the material is subjected to about 10,000 lbs of force, at about 160° F., until it sets up as a sheet, at the desired thickness of from about 0.1 to about 10 mm, a few minutes;
6. The now formed non-foamed celluloid sheet, containing a CBA, is then placed under vacuum over night to remove the solvent, forming a dried sheet;
7. The dried sheet is placed in a conventional autoclave, capable of temperatures of at least 400° F. and pressures of up to 1500 psi;
8. The autoclave is pressurized to from about 250 psi to about 1,000 psi by the injection of a PBA, such as nitrogen, carbon dioxide, or argon, preferably nitrogen or carbon dioxide, and most preferably carbon dioxide, and set at a temperature between about 250° F. and 350° F., preferably between about 250° F. and about 300° F., for a period of from 90 seconds to 30 minutes, preferably from about 2 minutes to about 20 minutes;
9. The desired foamed celluloid sheet is removed from the autoclave.
Example 2
Preferred PBA Process for Manufacture of Foamed Celluloid
1. A non-foamed celluloid sheet is prepared according to steps 1 through 5, above, except that no CBA ingredient is added;
2. The dried sheet is placed in a convention autoclave, capable of temperatures of at least 400° F. and pressures of up to 15,000 psi;
3. The autoclave is pressurized to from about 2,000 psi to about 12,000 psi, preferably from about 6,000 to about 8,000 psi, by the injection of a PBA, such as nitrogen, carbon dioxide, or argon, preferably nitrogen or carbon dioxide, and most preferably carbon dioxide, and set at a temperature between about 250° F. and about 350° F., preferably between about 250° F. and about 300° F., for a period of from about 10 minutes to about 24 hours;
4. The desired foamed celluloid sheet is removed from the autoclave.
The burn rate of the foamed celluloid can be enhanced by mixing an energetic additive to the initial nitrocellulose mixture of step 1 of Example 1; a preferred additive is an energetic plasticizer, such as BDNP A/F (1:1 mixture of BIS 2,2-Dinitropropyl acetate and BIS 2,2-Dinitropropyl formal), to provide an overall a higher nitration level.
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An economical, low residue, mortar increment propellant container manufactured of foamed celluloid, which is composed of 50 to 84% nitrocellulose, having a nitrogen content of from about 10.5 to about 13.5%, and about 15 to about 50% camphor. The burn rate of the foamed celluloid can be enhanced by the addition of energetic additives, such as energetic plasticizers.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the U.S. of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
Surface and undersea craft as well as shore installations using heavy duty machinery have a complicated network of heavy duty pipes and fittings. It is common to join successive links of pipe and elbows etc. by bolts extending through pipe boss flanges of successive sections. Since liquids and gases are fed through the piping sections the interconnections must be sealed and properly aligned. During the fabrication of new interconnections and the refurbishment of existing connections the holes through which the bolts extend must be properly aligned. Usually this calls for providing elaborate support guides or make shift rigs to guide a standard portable power drill. Particularly, with large surface and undersea craft staging having heavy duty platforms usually need be erected to provide a mounting surface for the support guides and makeshift rigs. The time, materials and other cost factors incurred while erecting the staging and other supportative measures often far exceed the actual work requirements. Heretofore, such expenses were an unavoidable burden that had to be borne when massive pipe boss flanges were located at critical elevations or at precarious locations. There is a continuing need in the state-of-the-art, therefore, for a machine which will drill and tap new and refurbish existing tapped and untapped pipe flange bolt holes which is self-aligning and which doesn't require time consuming and costly supporting structures.
SUMMARY OF THE INVENTION
The present invention is directed to providing an apparatus for drilling holes in pipe boss flanges. A means is shaped for abutting the surface of the pipe boss flange and has a plurality of openings extending therethrough. An expanding means connected to the abutting means is sized to fit within the pipe and is expanded when inserted in the pipe to secure the abutting means in place. An engaging means is rotably carried on the abutting means and is provided with an extension for maintaining a perpendicular attitude. An effecting means is mounted on the engaging means and has a capability for making perpendicular and parallel displacements with respect to the surface of the pipe boss flange. A means mounted on the effecting means bores aligned holes in the pipe boss flange after the engaging means and the effecting means have aligned the boring means with the openings in the abutting means.
It is an object of the invention to provide an improved drilling apparatus for pipe boss flanges.
It is another object of the invention to provide a drilling apparatus requiring no supplementary support guide or makeshift rig.
Another object of the invention is to provide a drilling apparatus which reduces preoperational occupations.
Still another object is to provide a drilling apparatus which is portable and therefore capable of functioning at critical elevations and at precarious locations.
Still another object of the invention is to provide a drilling apparatus which grealy reduces the cost and personnel requirements for making aligned bores in pipe boss flanges.
A further object is to provide a drilling apparatus having a self-alignment capability for close concentricity, perpendicularity and parallelity
Yet a further object of the invention is to provide a drilling apparatus which grealy simplifies alignment of bolt holes and thereby expedites the fastening of sections of pipe together.
Another object is to provide a drilling apparatus employing an expandable holding sleeve and mounting unit which stabilize and maintain a motor driven drill assembly to required machining tolerances.
These and other objects of the invention will become more readily apparent from the ensuing description when taken with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the invention shown partially in cross section.
FIG. 2 is a top view of the invention.
FIG. 3 is a side view of the invention taken generally along lines 3--3 in FIG. 1.
FIG. 4 is a cross sectional view of a detail of the invention taken generally along lines 4--4 in FIG. 1.
FIG. 5 is a top view of the saddle.
FIG. 6 is a top view of the slide.
FIG. 7 is a frontal view of the slide member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown a representative embodiment of a drilling machine 10 resting on a pipe boss flange 11. The machine has been specifically designed to do away with additional jigs, staging and other supportive equipment heretofore required for positioning a conventional drill in an aligned relationship to a pipe boss flange. Five major units mechanically coact to ensure a properly aligned boring and threading of holes in the flanges. These units are a mounting unit 12, an expandable holding sleeve unit 13, a rotatable bracket 14, a vertical feed and traverse mechanism 15 and a driven unit 16.
The interrelated coaction among these five units reduces the problems attendant the boring and refurbishing of flanges. The means by which this is accomplished will now be discussed in full detail.
Mounting unit 12, otherwise referred to as an abutting means, includes as a principal element, a disk-shaped mounting plate 20. Four set screws 21 are carried in threaded holes. Since they are orthogonally disposed about the periphery of the mounting plate, precise leveling and orientation with respect to the exposed surface of a pipe boss flange becomes a simple matter. All that needs to be done is to screw them inwardly or outwardly causing a greater or lesser force to be exerted on the surface of the flange.
A number of drill guide holes 22' and 22" are provided in the mounting plate and each contains a bushing 23. The guide holes and bushings help align a cutting tool as it makes its way to and through the flange. Although the structural components to be elaborated on below do in fact align themselves properly to a degree with respect to the flange, the bushings and guide holes ensure a more precise alignment.
A bore 24 is drilled in the center of the mounting plate and a mounting post 25 is welded in the bore. The post is essentially flush with the surface of the mounting plate lying against the pipe boss flange and extends axially in an opposite direction through the mounting plate. The mounting post is shaped with an internal annular shoulder 26 which functionally cooperates with an expandable holding sleeve unit 13.
The expandable holding sleeve unit is configured to engage the inside of the pipe when the disk-shaped mounting plate abuts the exposed surface of the flange. A draw bolt 27 axially extends through the length of the mounting post and well into the pipe. A nut and washer combination 28 rests on annular shoulder 26 and at the opposite end of the draw bolt a flared portion 29 contacts a plurality of blade inserts 30.
Referring to FIG. 4, the six blade inserts are arranged in a side-by-side relationship to roughly define a cylinder. They are held in this shape by a molded rubber retainer 31 that positions the blades so that they radially extend from an imaginary axis running the length of the holding sleeve unit.
At the opposite end of the blade inserts a cylinder expander 33 rests on the blade inserts. With this combination of elements in the holding sleeve unit, tightening nut 28 draws flared portion 29 of draw bolt 27 toward the nut. The blade inserts simultaneously are cammed radially outwardly by the flared portion and by expander 33. The outwardmost surfaces of the blade inserts are forcefully pressed against the inside of the pipe. Continued tightening of nut 28 assures a secure interconnection to the pipe boss flange. A final adjustment of four set screws 21 assures a precise disposition of the mounting plate on the flange.
Perpendicular orientation of drive unit 16 with respect to the predetermined positioning of the mounting plate is guaranteed by the rotatable bracket 14, otherwise identified as being the rotatably engaging means.
A flat portion 40 is bolted onto a split clamp 41. When the clamp is tightened by a locking screw 42 and when its associated handle 42' is tightened, the split clamp 41 firmly grips mounting post 25. A leg section extending from flat portion 40 is provided with a foot 43 which lies in an arc concentric with the circumference of the mounting plate. This location places the foot on the mounting plate near its edge. This gives the rotatable bracket a longer lever arm and provides greater stability to the other units of the drilling machine.
A plurality of oblong holes 44 is machined at the opposite end of the bracket on an extension of the flat portion for receiving four socket head screws. The screws are inserted through these holes and mates with the tapped-through holes provided on the backside of saddle 50. The eight oblong holes receive the cap screws to allow precise positioning of vertical feed and traverse mechanism 15 in either of two positions parallel with mounting plate 20. The two positions correspond to a lateral alignment of drive unit 16 with the drill guide holes 22' and the drill guide holes 22". The two sets of drill guide holes are on different common bolt circles which would correspond to the hole locations on two different sized pipe boss flanges. Obviously, differently shaped flanges would dictate that the guide holes be disposed accordingly.
Running parallel with the two rows of oblong holes, a key slot 46 is machined in the flat portion. The slot reaches across a saddle 50 and provides support and guidance for vertical feed and traverse mechanism 15.
As mentioned before, the vertical feed and traverse mechanism is connected to flat portion 40 of the rotatable bracket 14 by screws 15 via a saddle 50. In addition to the screws fastening the saddle and flat portion together a lateral key square 51 fits into key slot 46 to allow the saddle to move parallel to the mounting plate as the screws are repositioned. Irrespective of which holes receive the screws the slot ensures that the entire unit is perpendicular to the mounting plate and flange.
The elongate saddle is shaped with a flat back and flat sides and a pair of machined projections 50a run its entire length to form a dove-tailed mortised face. The dove-tail mortise is dimensioned to receive dove-tailed tennons 52a of a slide 52. A sufficient clearance between the dove-tail mortise and the dove-tail tenons allows the slide to move perpendicularly from the mounting plate in the saddle. This movement enables lowering or aising of machine drive unit 16.
The face 52b of the slide has rounded surface to conform to the outer dimensions of the drive unit. A cap 53 also has an internally rounded shape to hold the drive unit in place. Screws reach through the cap and into threaded holes on the slide to assure that the drive unit is firmly secured.
A notch 53a is cut on the side of the slide for receiving a lead screw nut 54. The lead screw nut is retained in the slide notch and a threaded bore 54a in the lead screw nut 54 is sized to mechanically coact with an elongate lead screw 55.
When the lead screw nut 54 is fitted on lead screw 55, rotation of the lead screw imparts perpendicular motion to the slide, cap and drive unit. The lead screw extends nearly the entire length of the slide and its lower end rests on a lead screw bearing 56 which is screwed onto saddle 50.
The mode machine drive unit 16 is perpendicularly displaced by rotating lead screw 55 via a gear mechanism 57. Mechanically cooperating helical gears, gear 58 mounted on the lead screw and a helical gear 59, transmit rotary force and motion to the lead screw when a three handled feed lever 60 is turned. Elaboration on the composition of the gear mechanism is dispensed with at this point, there being a wide variety of such mechanisms available within the state of the art and obvious to the routineer machinist.
In operation the invention quickly demonstrates its versatility and simplicity of operation. In a hard to reach location or otherwise inaccessible place a workman inserts the collapsed expandable holding sleeve unit 13 in the throat of a pipe. Mounting unit 12 is brought to bear against pipe boss flange 11 at which time nut 28 is tightened. The draw bolt 27 forces the blade inserts radially outwardly to firmly engage the inside of the pipe after the workman has rotated the mounting plate 20 so that its drill guide holes are properly located on the flange.
Once the pipe has been gripped by the holding sleeve unit and the drill guide holes have been properly located, a workman checks or repositions the bracket to make sure that screws 45 are in the proper set of oblong holes 44 to align machine drive unit 16 properly. This being done, feed lever 60 is rotated and the cutting tool driven by the machine drive unit is brought toward the surface of the mounting plate. Continued rotation of the feed lever pushes the cutting tool through a bushing 23 in a drill guide hole 22' or 22". Continued rotation of the feed lever brings the cutting tool in contact with the pipe boss flange and a perfectly aligned hole is bored in the flange. A similar direction of the cutting tool ensues if threads are to be cut in a smooth bore or if existing threads need to be refurbished. When boring or tapping is finished, the tool is withdrawn from the flange and split clamp 41 is loosened to release its gripping force on mounting post 25 as the locking screw 42 is backed off. The rotatable bracket 14 is turned to position the cutting tool of the machine unit in line with another guide bushing and locking screw 42 is once again tightened and care is assured that foot portion 43 is positioned to firmly rest on the surface of the mounting plate. The feed lever 60 cranks the motor driven drill assembly to the flange and once again another perfectly aligned hole is bored in the pipe boss flange.
The foregoing steps are repeated until the job is finished. When finished, nut 28 is loosened and the drilling machine is taken from the pipe boss flange to another. No ancillary supportive equipment need be disassembled or reassembled and job efficiency is raised.
Obviously, many modifications and variations of the present invention are possible in the light of the above teachings, and, it is therefore understood that within the scope of the disclosed inventive concept, the invention may be practiced otherwise than as specifically described.
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Properly aligned threaded or smooth bores are machined in a pipe boss fla without requiring supplementary staging or makeshift rigs. An expandable holding sleeve is inserted in the throat of the pipe and a mounting unit is brought to rest on the outer surface of the pipe boss flange. A holding sleeve is expanded to engage the pipe and a bracket grips a projection from the mounting unit at a predetermined angular rotation while an extension of the bracket ensures a perpendicular orientation. A vertical feed mechanism mounted on the bracket directs a motor driven drill assembly through holes located in the mounting plate. After the holes and threads are machined in the pipe boss flange, the expandable sleeve is loosened and the unit is removed at a minimal time and effort expenditure.
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[0001] The application claims priority of the following Chinese patent application:
[0002] 1. Chinese patent application No. 201210002165.3, filed with Chinese Patent Office on Jan. 5, 2012, entitled “Multi-functional On-Site Mixed Loading Truck for Emulsion Ammonium Nitrate Fuel Oil Explosive”.
FIELD OF THE INVENTION
[0003] The application relates to a mixed loading truck for explosives and particularly relates to an on-site mixed loading truck for explosives with different detonation velocities.
BACKGROUND OF THE INVENTION
[0004] A porous granular ammonium nitrate fuel oil explosive is an on-site mixed-loaded bulk explosive obtained by mixing porous granular ammonium nitrate and diesel according to the proportion of 94.5:5.5, has the characteristics of rich raw materials, simplicity in processing, low manufacturing cost, good fluxion property, safety in use, large gas energy and appropriate detonation velocity and is widely applied in open-pit mining blasting operations.
[0005] In spite of low cost, the porous granular ammonium nitrate fuel oil explosive is non-water-proof and non-moisture-proof, so it is suitable for regions with drought and little rain, and needs to perform moisture-proof treatment for construction in rainy seasons and mining areas with rich groundwater, as well as water-containing blast holes and moist blast holes; and furthermore, the relative volume energy and the weight energy are relatively low, so it is not particularly suitable for blasting hard rocks.
[0006] The porous granular ammonium nitrate fuel oil explosive is generally mixed by the on-site mixed loading truck for the porous granular ammonium nitrate fuel oil explosive and directly loaded into the blast hole, when a small amount of water is contained in the blast hole, one method is that, the blast hole is lined with a plastic bag, and then loaded with the explosive, but the method can not realize coupling loading; and another method is that, water in the blast hole is firstly drained, including blasting drainage, water pumping and the like, and then the explosive is loaded, but the method may enable the follow-up incoming water in the blast hole to dissolve ammonium nitrate and cause the failure of the explosive because the blast hole is connected with a nearby groundwater source.
[0007] An emulsion explosive has the characteristics of good waterproof performance, strong waterproof capability, large relative volume energy, high density and high detonation velocity, but the density-modifiable range is small, the explosion performance is stable between 1.05 and 1.35 g/cm 3 , and the emulsion explosive is suitable for blasting rocks above medium hardness; and the emulsion explosive has the shortcomings of high manufacturing cost, high density and high unit consumption of the explosive, the emulsion explosive needs to be loaded section by section when being packaged and can not realize coupling loading, and the on-site mixed-loaded emulsion explosive generally adopts an on-site mixed loading truck for emulsion explosives to realize the loading of the emulsion explosive.
[0008] In blasting construction of a mine, due to the influence of complex and changeable environmental conditions, including variable rock hardness conditions, presplitting blasting requirements, construction in rainy seasons, rock joints and other various conditions, if the existing on-site mixed-loaded ammonium nitrate fuel oil explosive or the emulsion explosive is adopted, it is very difficult to consider the blasting effect while keeping the unit consumption of the explosive unchanged.
SUMMARY OF THE INVENTION
[0009] The invention aims at providing an on-site mixed loading truck for explosives with different detonation velocities. A porous granular emulsion ammonium nitrate fuel oil explosive integrates the advantages of an emulsion explosive and a porous granular ammonium nitrate fuel oil explosive, also overcomes the disadvantages and shortcomings of the existing emulsion explosive; while retaining the good properties of the porous granular ammonium nitrate fuel oil explosive, it also overcomes the defects of poor moisture-proof and water-proof performances of the ammonium nitrate fuel oil explosive, simultaneously overcomes the shortcomings of high density and high unit explosive consumption of the emulsion explosive, and solves predicament of poor density modification performance of the emulsion explosive. The on-site mixed loading truck for the emulsion ammonium nitrate fuel oil explosive of the invention can provide a large range of emulsion explosive density modification and realize the on-site mixed loading truck for explosives with different densities and different detonation velocities.
[0010] The technical solution disclosed by the invention is as follows:
[0011] An on-site mixed loading truck for explosives with different detonation velocities comprises a truck body and a chassis, and further comprises a main bin system, an auxiliary bin system, a double-helix conveying and mixing system and a control system, as well as a main explosive conveying coil, an auxiliary plunger linkage pump and an auxiliary explosive conveying coil, wherein the main bin system comprises an emulsion base bin, an ammonium nitrate bin and a physical density modifier bin, the auxiliary bin system comprises diesel tanks, a sensitizing solution tank and a process water and washing water tank, the diesel tanks are provided with diesel pumps; the emulsion base bin is provided with an emulsion base pump; the sensitizing solution tank is provided with a sensitizing solution pump; the double-helix conveying and mixing system comprises main helix conveyors, an inclined helix conveyor and a mixing side helix conveyor, which are sequentially arranged; the main helix conveyors at least include a main helix conveyor A and a main helix conveyor B; an inlet end of the main helix conveyor A is connected with the bottom of the ammonium nitrate bin; an inlet end of the main helix conveyor B is connected with the bottom of the density modifier bin; the main helix conveyor A and the main helix conveyor B are connected with the inclined helix conveyor, the mixing side helix conveyor and a mixing hopper successively; an outlet end of the mixing side helix conveyor is directly sequentially connected with the mixing hopper; and an outlet end of the mixing hopper is connected with a product pump, a water ring injection device and the main explosive conveying coil.
[0012] Optionally, the main helix conveyor A and the main helix conveyor B are both mounted below a material tank of the mixed loading truck and used for respectively conveying porous granular ammonium nitrate and/or a density modifier.
[0013] Optionally, the main helix conveyor B is provided with a speed regulating device, by means of which the rotational speed of the main helix conveyor B is regulated, and in turn the output speed of the physical density modifier is regulated, to achieve the purpose of regulating different densities.
[0014] Optionally, baffle plates for controlling the bins to discharge or not to discharge are arranged at the joints of the emulsion base bin, the ammonium nitrate bin and the density modifier bin with the main helix conveyor, and opening of each baffle plate is controlled manually or controlled through the control system.
[0015] Optionally, the baffle plates are material flow direction baffle plates for controlling materials to respectively flow to a main material conveying helix A or B.
[0016] Optionally, the emulsion base bin is used for storing and loading the ammonium nitrate or the density modifier, and outputting the ammonium nitrate or the density modifier through the material flow direction baffle plates mounted at the bottom, in producing an ammonium nitrate fuel oil explosive or a density-modifiable heavy ammonium nitrate fuel oil explosive.
[0017] Optionally, output pipelines of an emulsion base and a sensitizing solution comprise the two lines: one line comprises the auxiliary plunger linkage pump, a water ring injector, the auxiliary explosive conveying coil and a static mixer, which are sequentially connected; and the other line comprises an emulsion base screw pump for pumping the emulsion base and the sensitizing solution pump; the emulsion base screw pump and the sensitizing solution pump are respectively connected with the lower end of a vertical outlet section of the inclined helix conveyor through pipelines; the sensitizing solution tank at least comprises three relatively independent sensitizing solution tanks for respectively providing the different concentrations of sensitizing solution, and one or two of the sensitizing solution tanks is/are used for providing the sensitizing solution through the auxiliary plunger linkage pump.
[0018] Optionally, the mixed loading truck for explosives is further provided with a power takeoff hydraulic oil loop control system, which comprises a power takeoff connected with a gearbox of the truck body, a transmission rod, a hydraulic pump, a hydraulic oil splitter, a hydraulic oil cooler, a hydraulic oil filter, a hydraulic oil tank, a pressure gauge, a thermometer, a hydraulic pipeline and other hydraulic system components.
[0019] Optionally, the diesel tanks and the output pipelines are connected with the upper end of the vertical outlet section of the inclined helix conveyor through pipelines and spouts.
[0020] Optionally, a vertical helix conveying section/sections is/are arranged at one end or two ends of the inclined helix conveyor. The control system comprises an automobile power takeoff hydraulic oil loop control system, a pump flow control system, a material output control system, an equipment switch control system, a programmable controller, a mixing proportion control system, an electric potential control system, a bulk explosive information processing system, a bulk explosive monitoring system and a control panel.
[0021] Optionally, heat insulation layers/a heat insulation layer are/is arranged on the inner side and/or the outer side of the wall of the emulsion base bin.
[0022] Optionally, the mixed loading truck for explosives further comprises a process water and washing water system, and the process water and washing water system comprises a water tank and a water pump.
[0023] Optionally, the mixing hopper is a temporary storage tank which is used before the explosives are loaded to the bottom of a blast hole in production of a heavy emulsion explosive or a low density emulsion explosive, and the stored explosives are pumped through the product pump and further loaded to the bottom of the blast hole through the water ring injection device and the main explosive conveying coil.
[0024] Optionally, the mixing side helix conveyor rotates horizontally, an explosive product after mixing is directly loaded into the blast hole, and the mixing side helix conveyor is mounted on one side of a driver or at the top of a compartment.
[0025] Optionally, the truck further comprises the auxiliary plunger linkage pump and the auxiliary explosive conveying coil for loading the pure emulsion explosive, wherein the diameter of a hose of the auxiliary explosive conveying coil is less than 32 mm.
[0026] Optionally, the water ring injection device forms a water ring on the outer side of an explosive column in an explosive conveying pipe when the explosives are injected to the bottom of the hole by using the main explosive conveying coil.
[0027] Optionally, the emulsion base, also known as a latex base, is prepared by emulsifying a salt water solution of an oxidizer and an oil phase material by an emulsifier, and the sensitizing solution is prepared by mixing a chemical sensitizing agent and water.
[0028] Optionally, the ammonium nitrate is porous granular ammonium nitrate, the physical density modifier is particles prepared by a thermoplastic polymer, such as polystyrene particles or coarse perlite particles or plant seed particles or plant seed husks. Preferably, the particle size is 1-3 mm, and the bulk density is 0.01-0.2 g/cm 3 .
[0029] The invention has the following technical effects:
[0030] By providing a plurality of bins on the truck body of the on-site mixed loading truck for explosives with different detonation velocities, the emulsion base, the ammonium nitrate, the physical density modifier, diesel, the sensitizing agent, the process water and the washing water can be respectively stored in the bins, and the conveying and mixing system comprises the main helix conveyor, the inclined helix conveyor and the mixing helix conveyor, wherein the main helix conveyors at least include the main helix conveyor A for connecting and conveying the ammonium nitrate material and the main helix conveyor B for connecting and conveying the physical density modifier material, respectively.
[0031] In addition, in the invention, on the one hand, the purpose of direct on-site mixed loading of the emulsion explosive is achieved by directly connecting with the water ring injector, the auxiliary explosive conveying hose and the static mixer through the base pump and the sensitizing solution pump; on the other hand, the emulsion base and the sensitizing solution are directly conveyed to a vertical output section of the inclined helix conveyor through pipelines of another base pump and the sensitizing solution pump, and after subjected to mixing side helix mixing, the emulsion base and the sensitizing solution are directly conveyed into the mixing hopper, and the explosives are sent into the bottom of the blast hole via the product pump, the water ring injector and the main explosive conveying coil.
[0032] In the on-site mixed loading truck for explosives with different detonation velocities of the invention, the technical purpose of on-site mixed loading of various explosives can be realized by using the different combinations of the bins and the output pipelines.
[0033] The varieties of the explosives mixed loaded by the on-site mixed loading truck for explosives with different detonation velocities of the invention comprise:
[0034] Function 1: heavy emulsion explosive: the main helix conveyor A outputs the porous granular ammonium nitrate, the diesel is sprayed into the vertical section of the inclined helix, then the emulsion base and the sensitizing solution are injected into the vertical section of the inclined helix, the materials are mixed by the mixing helix conveyor and then enter the mixing hopper to form the heavy emulsion explosive with the content of porous granular ammonium nitrate (weight ratio) of 10%-49%, the heavy emulsion explosive is injected into the bottom of the blast hole via the product pump, the water ring injector and the main explosive conveying coil, and the accumulated water in the hole is simultaneously drained; and the heavy emulsion explosive is suitable for blasting of hard rocks and water-containing blast holes.
[0035] Function 2: density-modifiable heavy emulsion explosive: the main helix conveyor A outputs the porous granular ammonium nitrate, the main helix conveyor B outputs the physical density modifier, the diesel is sprayed into the vertical section of the inclined helix, the emulsion base and the sensitizing solution are injected into the vertical section of the inclined helix, the density-modifiable heavy emulsion explosive is formed after mixing by the mixing helix conveyor, the density-modifiable heavy emulsion explosive enters a product hopper, is injected into the bottom of the blast hole via the product pump, the water ring injector and the main explosive conveying coil, and the accumulated water in the hole is simultaneously drained; and the density-modifiable heavy emulsion explosive is suitable for blasting of water holes below medium hardness.
[0036] Function 3: low density emulsion explosive: the main helix conveyor B outputs the physical density modifier, and the emulsion base and the sensitizing solution are simultaneously sprayed into the vertical section of the inclined helix conveyor, mixed by the mixing side helix conveyor, and then sent into the blast hole or are mixed by the mixing side helix conveyor when loaded in the water hole, then enter the product hopper and are injected into the bottom of the blast hole via the product pump, the water ring injector and the main explosive conveying coil. In this function, the low density emulsion explosive can be prepared by modifying the output parameter of the physical density modifier, and the density modification range is 0.4-1.30 g/cm 3 to be applicable to changes in different blasting environments, rock hardness and joint development.
[0037] Function 4: ultra-low density emulsion explosive: the output parameter of the physical density modifier in the function 3 is increased to improve the content of the physical density modifier in the emulsion explosive and prepare the ultra-low density emulsion explosive. The density-modifiable range is 0.2-0.4 g/cm 3 , and the ultra-low density emulsion explosive is suitable for pre-splitting blasting and smooth blasting, as well as blasting of soft rocks and extreme joints.
[0038] Function 5: heavy ammonium nitrate fuel oil explosive with the weight ratio of porous granular ammonium nitrate fuel oil explosive of more than 50%: the main helix conveyor A conveys porous granular ammonium nitrate material, the diesel is sprayed into the vertical section of the inclined helix conveyor, then the emulsion base and the sensitizing solution are simultaneously sprayed into the vertical section of the inclined helix conveyor, and the heavy ammonium nitrate fuel oil explosive is formed after mixing by the mixing helix conveyor, and sent into the blast hole via the mixing helix conveyor.
[0039] The heavy ammonium nitrate fuel oil explosive has certain moisture resistance and water resistance, and is suitable for blasting rocks below medium hardness. Dry holes, moist holes and blast holes containing a small amount of water are applicable to loading the heavy ammonium nitrate fuel oil explosive.
[0040] Function 6: density-modifiable heavy ammonium nitrate fuel oil explosive: on the basis of function 5, the physical density modifier is output by the main helix conveyor B to adjust the density of the heavy ammonium nitrate fuel oil explosive. Preferably, the density modification range is 0.45-1.15 g/cm 3 , and the density-modifiable heavy ammonium nitrate fuel oil explosive is suitable for blasting moist holes, blast holes containing a small amount of water, soft rocks and rocks which relatively developed joints or blasting for different rock properties in the same blast hole.
[0041] Function 7: porous granular ammonium nitrate fuel oil explosive: the main helix conveyor A conveys the porous granular ammonium nitrate material, the diesel is sprayed into the vertical section of the inclined helix conveyor, and the porous granular ammonium nitrate fuel oil explosive is formed after mixing and sent into the blast hole via the mixing helix conveyor. The porous granular ammonium nitrate fuel oil explosive is suitable for dry holes, drought regions and environments with water-free operations in winter, and blasting of rocks below medium hardness.
[0042] Function 8: density-modifiable porous granular ammonium nitrate fuel oil explosive: on the basis of function 7, the physical density modifier is output by the main helix conveyor B to adjust the density of the porous granular ammonium nitrate fuel oil explosive. The modification range is 0.4-0.9 g/cm 3 , and the density-modifiable porous granular ammonium nitrate fuel oil explosive is suitable for blasting dry holes, soft rocks and rocks with relatively developed joints.
[0043] Function 9: pure emulsion explosive: the emulsion base and the sensitizing solution pass through the auxiliary plunger linkage pump, the water ring injector, the auxiliary explosive conveying coil and the static mixer to prepare and output the pure emulsion explosive, the pure emulsion explosive is output through the small-diameter explosive conveying hose, the distance is 50 m, the farthest distance can achieve 60 m, and when the on-site mixed loading truck can not reach the vicinity of the blast hole, the function is more applicable. The pure emulsion explosive is simultaneously suitable for blasting water holes and blasting hard rocks, when the blast hole is blocked, the small-diameter explosive hose can still load the explosive, the pure emulsion explosive is simultaneously suitable for blasting roots and blasting masses, and the explosive loading is flexible. Compared with a loading system of a large coil machine, the system is a relatively independent system, and the two do not conflict with each other during operations.
[0044] The on-site mixed loading truck for explosives with different detonation velocities of the invention is provided with the main explosive conveying coil and the auxiliary explosive conveying coil, wherein the pipe diameter of the auxiliary explosive conveying coil is smaller than that of the main explosive conveying coil, and the pipeline is relatively long, so that the auxiliary explosive conveying coil can output the explosive when the explosive truck is difficult to achieve a position, complete loading under the situation that the little emulsion base remains or on the premise that the main explosive conveying hose can not complete loading, send the explosive to the bottom of the blast hole and flexibly output the emulsion explosive.
[0045] The control system of the invention comprises the automobile power takeoff hydraulic oil loop control system, the pump flow control system, the material output control system, the equipment switch control system, the programmable controller, the mixing proportion control system, the electric potential control system, the bulk explosive information processing system, the bulk explosive monitoring system and the control panel. The control system further comprises a temperature and pressure sensor, an ammonium nitrate tachometer, a rotational speed control meter of the emulsion base pump, the rotational speed control meter of the sensitizing solution pump, a water flow control meter of process water, rotor flowmeters of diesel, sensitizing solution and process water, an electronic proportional control valve, a manual material control valve and other control valves and meters, and can precisely display and control the discharge speeds and the flow rates of all the materials and ensure the proportion and the quality of a mixed loaded explosive product by precise measurement; and the stability, safety and reliability in the mixing preparation process and the output process of the explosives are ensured by precise control of the pumps and the helix conveyors.
[0046] A plurality of the functions of the on-site mixed loading truck for explosives with different detonation velocities of the invention are described above. Compared with the prior art, the truck has more extensive preparation modes and a wider application range, and has the characteristic of multiple functions in one machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a structure diagram of an explosive mixed loading truck of the invention.
[0048] FIG. 2 is a back diagram of the mixed loading truck as shown in FIG. 1 .
[0049] FIG. 3 is a right diagram of the mixed loading truck as shown in FIG. 1 .
[0050] FIG. 4 is a top diagram of the mixed loading truck as shown in FIG. 1 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0051] The invention is further illustrated in conjunction with the following accompanying drawings.
[0052] FIGS. 1 , 2 , 3 and 4 shows structure diagrams of an embodiment of an explosive mixed loading truck of the invention.
[0053] The on-site mixed loading truck for explosives with different detonation velocities shown in the figures comprises:
[0054] An automobile truck body and an automobile chassis 1 , as well as an automobile power takeoff device 2 connected with an automobile gearbox, wherein the automobile power takeoff device 2 comprises a hydraulic oil pump 21 connected with the automobile gearbox, a hydraulic oil splitter, a hydraulic oil cooler 41 , a hydraulic oil cooling pump 43 , a hydraulic oil filter and a hydraulic oil tank 30 , wherein the hydraulic splitter is used for respectively connecting hydraulic oil produced by a hydraulic pump to different hydraulic pumps and different hydraulic motors to output power, and control elements of hydraulic oil lines are arranged in a control cabinet 33 of the hydraulic system in a centralized manner.
[0055] The bin part comprises a bin 5 , a bin 6 , a bin 7 and a bin 8 , the above bins can respectively accommodate porous granular ammonium nitrate, a physical density modifier and an emulsion base according to actual blasting conditions, a bin top cover 25 is arranged on each bin, a heat insulation layer 36 is arranged on the outer wall or the inner wall of each bin, and the bin part further comprises a sensitizing solution tank 40 , a washing water tank 11 , a diesel tank 4 , a diesel tank 31 and a water tank cover 10 .
[0056] A boom 9 is arranged on one side of the washing water tank 11 , and the boom 9 is driven by a boom hydraulic cylinder 15 .
[0057] Washing water in the washing water tank 11 is pumped out by a washing water pump 19 .
[0058] A conveying and mixing part comprises main helix conveyors 27 and a main helix conveyor 28 , wherein the main helix conveyor 27 and the main helix conveyor 28 are respectively connected with the bottom parts of the bin 5 , the bin 6 , the bin 7 and the bin 8 ; baffle plates are arranged at the joints; and the baffle plates can be controlled manually to open or controlled by an electrical control system 46 to open.
[0059] The main helix conveyor 27 and the main helix conveyor 28 are arranged in parallel, and the outlet ends thereof are sequentially connected with an inclined helix conveyor 13 and a mixing helix conveyor 14 , wherein vertical sections are respectively arranged at the front end and the back end of the inclined helix conveyor 13 . An outlet end of the mixing helix conveyor 14 is connected with a mixing hopper 17 ; a mixing device is arranged in the mixing hopper 17 , and an outlet thereof is connected with a main explosive conveying coil 3 ; a product after mixing is pumped into a blast hole by a product pump 16 , and a terminal 47 of the main explosive conveying coil 3 can send a finally generated explosive into the bottom of the blast hole.
[0060] The main helix conveyor 27 is driven by a hydraulic motor 44 , the main helix conveyor 28 is driven by a hydraulic motor 45 , the inclined helix conveyor 13 is driven by a hydraulic motor 12 , the mixing helix conveyor 14 is driven by a hydraulic motor 18 , the main explosive conveying coil 3 is driven by the hydraulic motor 29 , all the hydraulic motors are connected with the hydraulic splitter for inputting the power, the hydraulic oil splitter is connected with the hydraulic pump, the hydraulic pump is connected with a transmission rod, the transmission rod is connected with the automobile power takeoff device 2 , and the automobile power takeoff device 2 is connected with the automobile gearbox for obtaining a power source.
[0061] In this case, an emulsion base screw pump 37 is arranged at the outlet end of an output pipe of the bin accommodating the emulsion base, the sensitizing solution tank 40 is provided with a sensitizing solution pump 39 and a sensitizing solution pump 42 , the emulsion base pump 37 and the sensitizing solution pump 39 comprise two pipelines: one line is connected to the vertical section of the inclined helix conveyor 13 through a pipeline and a spout and respectively connected with a base injection port 22 and a sensitizing solution injection port 23 ; and the other line is directly connected with a base plunger pump, a water ring injector, an auxiliary explosive conveying coil 4 and a static mixer, wherein the sensitizing solution pumps are driven by a 24V direct current motor.
[0062] The diesel tank 4 is provided with a diesel pump 20 , and the diesel pump 20 is connected with a diesel injection port 24 at the upper end of the vertical section at the outlet end of the inclined helix conveyor 13 through a pipeline and a spout to output and spray diesel to be mixed with porous granular ammonium nitrate.
[0063] In order to facilitate maintenance and operation, a toolbox 38 , a walkway and a walkway guardrail 32 are arranged on the truck body, and the walkway is provided with a ladder 26 for enabling staff to go up and down, and further comprises a guardrail lifting cylinder 34 and a pneumatic system 35 .
[0064] The implementation ways of the explosive mixed loading truck of the invention are described in conjunction with the following different functions of the on-site mixed loading truck for explosives with different detonation velocities.
[0065] Function 1: Heavy Emulsion Explosive
[0066] The emulsion base is loaded into the bin 7 and the bin 8 , and the porous granular ammonium nitrate is loaded into the bin 5 and the bin 6 , wherein the porous granular ammonium nitrate is output by the main helix conveyor 27 , the diesel is pumped out by the diesel pump and sprayed into the vertical section at the outlet end of the inclined helix conveyor 13 to mix with the porous granular ammonium nitrate to form an ammonium nitrate fuel oil explosive, and the emulsion base is pumped out by the emulsion base screw pump, sprayed into the vertical section of the inclined helix conveyor 13 to mix with the ammonium nitrate fuel oil explosive in the mixing helix conveyor 14 and directly sent into the blast hole via the mixing helix conveyor 14 . The heavy emulsion explosive prepared by the implementation way is suitable for dry blast holes or moist blast holes; and the heavy emulsion explosive can also be sent into the mixing hopper 17 via the mixing helix conveyor 14 , then pass through the water ring injector and enter the blast hole via the main explosive conveying coil 3 along with a water ring. The heavy emulsion explosive prepared by the implementation way is suitable for water-containing blast holes.
[0067] In the implementation way, the content (weight ratio) of the porous granular ammonium nitrate in the prepared heavy emulsion explosive is 10%-49%, preferably 10%, 30% and 45%.
[0068] Function 2: Density-Modifiable Heavy Emulsion Explosive
[0069] The emulsion base is loaded into the bin 7 and the bin 8 , and the porous granular ammonium nitrate and the physical density modifier are respectively loaded into the bins 5 and 6 , wherein the main helix conveyor 27 outputs the porous granular ammonium nitrate, the main helix conveyor 28 outputs the physical density modifier, the diesel is sprayed into the vertical section at the outlet end of the inclined helix conveyor 13 , and the emulsion base is pumped out by the emulsion base screw pump, sprayed into the vertical section of the inclined helix conveyor 13 along with a sensitizing solution, mixed by the mixing helix conveyor 14 and directly sent into the blast hole via the mixing helix conveyor 14 . The density-modifiable heavy emulsion explosive prepared by the implementation way is suitable for dry blast holes or moist blast holes of slightly soft rocks; and the density-modifiable heavy emulsion explosive can also be sent into the mixing hopper 17 by the mixing helix conveyor 14 , then pass through the water ring injector and be sent into the blast hole via the main explosive conveying coil 3 along with the water ring. The density-modifiable heavy emulsion explosive prepared by the implementation way is suitable for water-containing blast holes of the slightly soft rocks.
[0070] The density-modifiable heavy emulsion explosive prepared by the implementation way has the density of 0.6-1.2 g/cm 3 and is suitable for blasting for different rock properties.
[0071] Function 3: Low Density Emulsion Explosive
[0072] The emulsion base is loaded into the bin 7 and the bin 8 , pumped out by the emulsion base screw pump and sprayed into the mixing helix conveyor 14 along with the sensitizing solution, and the physical density modifier is loaded into the bin 5 and the bin 6 , output by the main helix conveyor 28 , mixed with the emulsion base in the mixing helix conveyor 14 and then sent into the blast hole by the main explosive conveying coil 3 .
[0073] The low density emulsion explosive produced by using the implementation way has the density of 0.3-1.2 g/cm 3 and relatively good water resistance and is suitable for blasting water holes; and furthermore, as the density is lower, the low density emulsion explosive is particularly suitable for pre-splitting blasting or blasting rocks with severe degree of weathering.
[0074] Function 4: Ultra-Low Density Emulsion Explosive
[0075] The emulsion base is loaded into the bin 7 or 8 , and the physical density modifier is loaded into other bins. Being the same with the process flow of the low density emulsion explosive, the emulsion base is pumped out by the emulsion base screw pump and sprayed into the vertical section of the inclined helix conveyor 13 along with the sensitizing solution, and the physical density modifier is output by the main helix conveyor 28 , mixed with the emulsion base in the mixing helix conveyor 14 and then sent into the blast hole via the main explosive conveying coil 3 .
[0076] The ultra-low density emulsion explosive produced by using the implementation way has the density of less than 0.3 g/cm 3 and is only suitable for pre-splitting blasting or smooth blasting.
[0077] According to the implementation way, the emulsion base can be loaded into the bins 7 and 8 , the physical density modifier can be loaded into the bin 5 and the bin 6 , the rotational speed is output through the main helix conveyor 28 , and then the ultra-low density emulsion explosive is further produced.
[0078] Function 5: Heavy Ammonium Nitrate Fuel Oil Explosive
[0079] The emulsion base is loaded into the bin 7 and the bin 8 , and the porous granular ammonium nitrate is loaded into the bin 5 and the bin 6 , wherein the porous granular ammonium nitrate is output by the main helix conveyor 27 , the diesel is sprayed in at the upper end of the vertical section at the outlet end of the inclined helix conveyor 13 , and the emulsion base is pumped out by the emulsion base screw pump, sprayed into the vertical section of the inclined helix conveyor 13 along with the sensitizing solution, mixed by the mixing helix conveyor 14 , then enter a product hopper and is further sent into the blast hole via the product pump, the water ring injector and the main explosive conveying coil 3 . When in operations in dry holes and moist holes, the emulsion base is directly sent into the blast hole via the mixing helix conveyor 14 .
[0080] By adopting the implementation way, the sensitizing solution is added before the base is added into the mixing helix conveyor 14 .
[0081] By adopting the implementation way, the heavy ammonium nitrate fuel oil explosive with the different contents of the emulsion base can be prepared by regulating the rotational speed of the main helix conveyor 27 .
[0082] In the heavy ammonium nitrate fuel oil explosive, the weight ratio of the emulsion base to the porous granular ammonium nitrate fuel oil explosive is 10-49%, preferably, the content (weight ratio) of the emulsion base is 10%, and the explosive is characterized by moisture resistance; the content (weight ratio) of the emulsion base is 30%, and the explosive is characterized by moisture resistance and certain water resistance, and is suitable for blasting medium-hardness rocks; and the content (weight ratio) of the emulsion base is 45%, and the explosive is characterized by relatively good water resistance and suitable for blasting rocks of medium hardness or above medium hardness.
[0083] Function 6: Density-Modifiable Heavy Ammonium Nitrate Fuel Oil Explosive
[0084] The emulsion base is loaded into the bin 7 and the bin 8 , the porous granular ammonium nitrate is loaded into the bin 5 , the physical density modifier is loaded into the bin 6 , the emulsion base and the physical density modifier can also be respectively loaded into the bins 7 and 8 , the porous granular ammonium nitrate is loaded into the bin 6 and the bin 5 , and the difference with the heavy ammonium nitrate fuel oil explosive is that, in the implementation way, the physical density modifier is simultaneously output by the main helix conveyor 28 and mixed in the inclined helix conveyor 13 , then the diesel is firstly sprayed in, and then the emulsion base and the sensitizing solution are sprayed in. In the implementation way, the output speed of the physical density modifier can be regulated to correspondingly adjust the density of the heavy ammonium nitrate fuel oil explosive, wherein, the weight ratio of the emulsion base to the sensitizing solution is preferably 100: (1-3), and the explosive is characterized by moisture resistance and certain water resistance and suitable for blasting rocks of medium hardness and above medium hardness; and furthermore, the density of the explosive can be adjusted according to different blasting construction environments.
[0085] Function 7: Porous Granular Ammonium Nitrate Fuel Oil Explosive
[0086] The porous granular ammonium nitrate is loaded into one or more of the bin 5 , the bin 6 , the bin 7 and the bin 8 and output by the main helix conveyor 27 , the diesel is sprayed in at the vertical section at the outlet end of the inclined helix conveyor 13 , and the materials are mixed by the mixing helix conveyor 14 and then sent into the blast hole.
[0087] In this case, the bin 7 and the bin 8 loading the emulsion base, need to close emulsion base outlets, and the baffle plates are mounted in the bins at the upper part of the main helix conveyor to guide the porous granular ammonium nitrate to flow to the main helix conveyor 13 .
[0088] In this case, the weight ratio of the porous granular ammonium nitrate to the diesel is preferably 94.5:5.5. The explosive is suitable for dry hole blasting, frozen soil blasting and water-free blast hole blasting operations.
[0089] Function 8: Density-Modifiable Porous Granular Ammonium Nitrate Fuel Oil Explosive
[0090] The porous granular ammonium nitrate and the physical density modifier are respectively loaded into the bin 5 , the bin 6 , the bin 7 and the bin 8 . The difference with the porous granular ammonium nitrate fuel oil explosive is that, in the implementation way, the physical density modifier is simultaneously output by the main helix conveyor 28 , the diesel is sprayed in at the vertical section at the outlet end of the inclined helix conveyor 13 , and the materials are mixed by the mixing helix conveyor 14 and then sent into the blast hole.
[0091] In the implementation way, the density of the porous granular ammonium nitrate fuel oil explosive is correspondingly adjusted by regulating the output speed of the physical density modifier.
[0092] It is noted that, if the output of the physical density modifier is too large, the performances of the porous granular ammonium nitrate fuel oil explosive will be unstable, and the density range of the ammonium nitrate fuel oil explosive is 0.5-0.9 g/cm 3 , preferably 0.7, 0.8 and 0.9.
[0093] Function 9: Pure Emulsion Explosive
[0094] The emulsion base is loaded into the bin 7 and the bin 8 , the emulsion base and the sensitizing solution are pumped out by an emulsion base auxiliary plunger linkage pump, an emulsion base explosive column is output by the water ring injector and enters the auxiliary explosive conveying coil 4 , the emulsion base explosive column is wrapped with a sensitizing solution water ring, the outlet of the auxiliary explosive conveying coil 4 is connected with the static mixer, the emulsion base explosive column and the sensitizing solution water ring are mixed in a fast and static manner and sent into the blast hole for 15-20 min so as to be sensitized become the explosive, and the pure emulsion explosive is suitable for 50 m long-distance transportation, blasting in blasting operation regions which the explosive trucks can not arrive and blasting when the blast holes are blocked.
[0095] The conventional pure emulsion explosive is produced by the implementation way, but the density adjustment is only limited to chemical sensitization, and the adjustment range is 1.00-1.30 g/cm 3 .
[0096] In the equipment of the invention, obviously, all the parts can be decomposed, combined and/or re-combined after decomposition. The decompositions and/or re-combinations should be considered as the equivalents of the invention. Simultaneously, in the above description of the specific embodiments of the invention, the description and/or the features for one implementation way can be used in one or more of other implementation ways in the same or similar way and combined with the features in other implementation ways or used for replacing the features in other implementation ways.
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Provided is a site vehicle for mixing and loading multiple kinds of explosives with different detonation velocities. The vehicle contains a double-helix conveying system, a plurality of storage bins ( 5 - 8 ) and multiple sets of pipelines. Emulsified bases, porous granular ammonium nitrate and physical density modifier are stored in the main material storage bins, an adjuvant storage bin is provided with a diesel tank ( 4, 31 ), a sensitizing solution tank ( 40 ) and a washing water tank ( 11 ), and the technical effect that multiple kinds of explosives with different detonation velocities are mixed and loaded can be realized by using the different combinations of the different raw materials of the storage bins and various output pipelines and some baffle plates. The vehicle has the advantages of multiple purposes, capability of producing heavy emulsion explosive, density-modifiable heavy emulsion explosive, low density emulsion explosive, ultra-low density emulsion explosive, heavy ammonium nitrate fuel oil explosive, density-modifiable ammonium nitrate fuel oil explosive, porous granular ammonium nitrate fuel oil explosive, density-modifiable porous granular ammonium nitrate fuel oil explosive, and minor-diameter and long-distance conveying emulsion explosive, and applicability to the needs of various blasting operation environments and loading different kinds of explosives in the same blast hole.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 675,181, filed Apr. 8, 1976 which is in turn a continuation of application Ser. No. 527,014 dated Nov. 25, 1974, both now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to roadway structures in the form of continuous multi-layer composite slabs that are supported by an elastic foundation.
One known arrangement of this type is described in U.S. Pat. No. 2,083,900. In such arrangement, a three-layer slab is described wherein the superposed layers are all approximately equal in thickness (e.g., 1-2 inches). Additionally, the porosity of the composite layer of the structure described in such patent decreases progressively from the lower to the upper layers of the structure.
One disadvantage of such known structure is that, because of the relatively high porosity of the lowermost layer of the slab, water and mud in the underlying foundation are permitted to seep upwardly through the several layers of the slab, thereby exerting a weakening effect thereon. In addition, with the successively increasing porosity of the slab toward the bottom thereof, extremely low atmospheric temperatures can rather easily propagate from the surface of the slab down to the foundation, thereby setting up a destructive freezing-thawing phenomenon.
SUMMARY OF THE INVENTION
Such disadvantages are overcome with the improved, three-layer slab roadway structure of the present invention. In an illustrative embodiment, the intermediate layer of the slab is made significantly more porous and thick than each of the upper and lower layers, so that the intermediate layer will serve as an effective thermo-insulating layer for the composite slab to prevent the penetration of low ambient temperatures, e.g., temperatures below 0° F., from the roadway surface to the underlying elastic foundation, thereby effectively avoiding the above-mentioned destructive freezing-thawing phenomenon. Moreover, because of the high density (e.g., low porosity) of the lower layer relative to the overlying intermediate layer, the migration of water and mud from the foundation into the slab is effectively inhibited.
Advantageously, the lower layer of the composite slab is formed from a poured asphaltic concrete having a porosity less than 6%. The intermediate layer is typically compacted, calibrated natural crushed stone or granulated broken stone, sprayed with fluid bituminous or a bituminous-gasoline mixture. The upper layer, like the lower layer, may be formed of poured asphaltic concrete, and has a porosity less than 15%.
In relative terms, the upper layer may constitute about 15-25% of the total slab thickness; the intermediate layer, 55-75%; and the lower layer, 10-20%.
BRIEF DESCRIPTION OF THE DRAWING
The invention is further set forth in the following detailed description taken in conjunction with the appended drawing, in which:
FIG. 1 is a fragmentary vertical section through a first embodiment of a roadway structure in accordance with the invention;
FIG. 1a is a fragmentary vertical view of a second embodiment of roadway structure in accordance with the invention;
FIG. 2 is a graph illustrating a percentage distribution, by particle size, of natural crushed stone particles suitable for use in the intermediate layer of the composite three-layer slab of the roadway of FIG. 1 or FIG. 2; and
FIG. 3 is a schematic comparative representation of three illustrative roadway constructions A, B and C in accordance with the invention juxtaposed with three corresponding prior art roadway constructions A', B' and C', respectively, giving the comparative savings in cost of construction and fuel consumption provided in each case by the inventive structures.
DETAILED DESCRIPTION
Referring now to the drawing, FIG. 1 illustrates an illustrative roadway construction including an elastic foundation 1, which may be formed of well-compacted stone and which may have a thickness lower than that typically employed in similar constructions; in particular, the thickness of the foundation 1 may be in the order of 10-15 cm.
The upper surface of the foundation 1 is coated with a thin layer 2 of crushed stone, whose particles may exhibit a diameter of 1-1.15 cm on the average. The total thickness of the layer 2 on the foundation 1 is in the range of 1-2 cm.
A composite, three-layer slab, constructed in accordance with the invention, overlies the coated foundation 1. The thickness of the composite slab is significantly greater than that of the foundation 1. Typically, the thickness of the slab is in the range of 15-35 cm.
The lower layer (designated 3) of the composite slab is preferably formed from a cohesive, substantially impermeable material of high mechanical strength, such as poured asphaltic concrete having a porosity less than 6%, and preferably in the 3-4% range. The binder employed in the concrete may be bituminous, of such composition as to have a penetrability in the 50-100 range.
Because of the extremely low porosity of the layer 3, water and mud are effectively prevented from migrating upwardly from the foundation 1 into the interior of the composite slab.
As alternative materials for the layer 3, dense polymeric concrete or compact cement concrete can be used; in any case, the employed concrete may be plain or reinforced, with the reinforcement consisting, e.g., of polyester or steel wire mesh.
The thickness of the layer 3 should be about 10-20% of the total slab thickness. In the event that reinforcements are employed in the concrete, it is possible to reduce the thickness, but not beyond the point where the layer becomes permeable to the water and mud in the foundation.
As shown in FIG. 1, it may be preferable to locally thicken the layer 3 in the area of the curb of the roadway, as illustrated at a. Such thickened portions provide adequate support for an overlying framing curb 4, which may be formed from cement concrete. A layer 5 of asphalt mortar may be disposed between the lower surface of the curb 4 and the upper surface of the thickened portion a of the layer 3. Advantageously, the curb 4 may further be connected to the roadway by wire reinforcements b, to provide a supplementary anchorage of the curb 4 in the composite slab.
An intermediate layer 6 of the composite slab is formed from a material which may have a lower mechanical strength, and thereby a lower cost, than the material of the underlying layer 3. The thickness and porosity of the layer 6 is, in accordance with the invention, made much greater than that of the underlying layer 3 and the overlying top layer (designated 7) of the composite slab, so that such intermediate layer can constitute an effective thermo-insulating layer that prevents sub-zero ambient temperatures above the slab from propagating downwardly through the slab to the foundation, thereby subjecting the latter to the destructive phenomenon of successive freezing and thawing.
Illustratively, the material of the layer 6 may be compacted natural crushed stone having particles distributed in the 40-60 mm range, with the percentage distribution of the various sized particles conforming, e.g., to the curve of FIG. 2. Alternatively, granulated broken stone or sandy or clay earth found in the environment of the road-building area may be employed. The stone of the layer 6 may advantageously be presprayed with fluid bituminous or a bituminous-gasoline mixture. The relative thickness of the layer 6 is made about 55-75% of the total thickness of the composite slab. In addition, the material of the layer 6 should exhibit a porosity in the 12-50% range (illustratively 20%), with a binder penetration in the 150-250 range.
The upper layer 7, like the lower layer 3, should be made of a cohesive impermeable material such as dense, poured asphaltic concrete or polymeric concrete, with a porosity less than 15% (typically 2-4%) and a binder with a penetrability in the 30-70 range. The upper layer 7, like the lower layer 3, exhibits locally thickened zones c (FIG. 1) in the vicinity of the curb 4, in order to sustain the increased stresses in these areas. (As indicated, a road shoulder 10 can serve as an effective buttress for the curb 4 against the stresses imposed at the locally increased thickness portion c.
The roadway structure shown in FIG. 1a is substantially similar to that shown in FIG. 1, except for the manner of construction of the curb itself. Thus, in FIG. 1a, conventional curbs 8 are laid, on the right-hand edge of the roadway, on a foundation 9 of cement concrete, which abuts the thickened right-hand portion a of the bottom layer 3.
FIG. 3 illustrates the results of a comparative study between three typical constructions A, B and C in accordance with the invention, and corresponding prior-art roadways A', B' and C'. The corresponding roadways A, B and C and A', B' and C', respectively, differ from each other in their load-bearing capacities, with the roadways A, A' being light-duty, the roadways B, B' being medium-duty, and the roadways C, C' being heavy-duty.
As indicated in the tables in the lower part of FIG. 3, the light-duty roadway A achieved a cost saving of 39% and a fuel saving of 34% as compared to the corresponding prior-art roadway A'. In like manner, the medium-duty roadway B achieved a cost saving of 44% and a fuel saving of 39% as compared to the corresponding prior-art roadway B'. Also, the heavy-duty roadway C achieved a cost saving of 51% and a fuel saving of 47% as compared to the corresponding prior-art roadway C'.
Such cost and fuel savings exhibited by the structures of the invention are due, in part, to the reduced foundation thickness allowable with the novel composite three-layer overlying slab of the invention. In addition, it has been found that the working life of the roadways of the invention, and the periods between required maintenance over long periods of use, are much greater in the case of the inventive structures than in the case of the prior-art structures.
In the foregoing, an illustrative arrangement of the invention has been described. Many variations and modifications will now occur to those skilled in the art. It is accordingly desired that the scope of the appended claims not be limited to the specific disclosure herein contained.
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An improved three-layer slab supported by a reduced-thickness elastic foundation for roadway applications is described. The intermediate layer of the slab is significantly thicker and more porous than each of the adjacent upper and lower layers, and serves as a thermo-insulating layer to prevent the propagation of extremely low temperatures to the elastic foundation of the slab. The slab has a thickness significantly greater than that of the foundation. Typically, the upper and the lower layers of the slab are formed from poured asphaltic concrete, while the intermediate layer is formed from compacted natural crushed stone or granulated broken stone sprayed with fluid bituminous or a bituminous-gasoline mixture.
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This application is a continuation of application Ser. No. 07/586,939, filed Sep. 24, 1990, now abandoned.
This invention relates to the determination of article orientation in an article handling system, and more particularly relates to a procedure for locating positions along the length of an article where maximum differences occur depending upon article orientation.
BACKGROUND
In Turcheck et al, U.S. Pat. No. 4,784,493, an apparatus and method are disclosed for recognition of an article and its orientation on a conveyor. To determine orientation of a work article, a number of possible orientations are first recorded as a preliminary procedure in a memory. All of the data stored in the memory for each orientation is then compared with data scanned the work article as it moves along a conveyor path. Orientation of the work article is determined by matching the compared data.
The time required for making such article orientation determinations restricts the number of articles that can be processed in a unit of time. Such restriction may be the limiting factor of a production line. Prior efforts at reducing data processing time have included human operator participation in manually selecting partial areas along the article length which will be examined by use of a computer keyboard, mouse or the like. This requires a skill level not always present in the work environment and re-selecting procedures must be undertaken each time there is a change in the article being processed.
SUMMARY OF INVENTION
It is an object of this invention to reduce the processing time for determining article orientation by using only a portion of the object for comparison with stored data where the portion is selected automatically without requiring a skilled operator.
Another object is to provide a novel method of selecting a few spaced windows along the article length which are effective in making orientation determinations.
In accordance with one feature of the invention, stored article information data in one orientation is compared with the corresponding data for a second orientation and a point of maximum difference in the edge point profile information is calculated. The position of the edge point having the maximum difference is recorded as a window. Thereafter, in real time, the profile information data from a work article is examined only at that window to determine whether the difference is zero or a value and therefore the orientation of the article.
Where the articles have several possible orientations, the setting procedure can involve the stored information orientation data for each orientation with each other possible orientation so that several windows are determined, one for each different comparison. In the case of four possible orientations, there will be three windows for each of the four orientations which can result in twelve windows in the event each window is at a different longitudinal position along the article. When a work article is to be examined in real time, the orientation is determined by examining the data only at the window positions and is recognized by a total score that is the lowest. Other advantages and features of the invention will become apparent from the claims and from the description as it proceeds in conjunction with the drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a pictorial view of a conveyor system having an article diverter;
FIG. 2 is a flow diagram of a procedure for generating windows; and
FIG. 3 is a pictorial view of four possible orientations of the object whose orientation is to be identified.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described as a feature that is adapted for use with the article or part recognition and orientation system disclosed in Turcheck et al U.S. Pat. No. 4,784,493. The general environment of the reorientor is diagrammatically illustrated in FIG. 1. The reorientor system may generally comprise a frame supported continuous belt 12 entrained around a driver roll 14 and a idler roll 16. Work pieces such as 18, 20, and 22 are similar parts having three different orientations. The simplest form of reorientor is shown in this figure, that being a stepping motor driven single axis (Y-axis) reorientor having a lower chamber 26 that can be rotated 180 degrees. Other orientors including multiple position reorientors are known in the art and may be advantageously used with the present invention.
Adjacent the continuous belt 12 at one edge thereof is a fence 28 running the length of the belt but having several breaks therein. On the inbound side of the reorientor means 24 there is a first break in the fence to accommodate a recognition sensor 30 which may be a 16×1 array of vertically stacked fiber optic elements connected to 16 individual phototransistors each having a hard wired connection to a vision controller or microprocessor input port 32. An infrared light source 34 composed of dual infrared LEDs adjusted to different angles is directly across the belt from the recognition sensor 30 and provides the necessary illumination to switch the phototransistors related to each of the 16 fiber optic filaments depending upon whether the individual filament is illuminated or shadowed by the work article.
Alternatively, the linear array of sensors may comprise a column of CCD units which provide a pixel density of between about 1000 and 4000 pixels per inch and preferably about 2000 pixels per inch thereby to provide a high resolution sensor. The CCD units are scanned at a frequency between about 1 MHz and 40 MHz and preferably about 10 MHz to produce an analog signal that is digitized and converted to a count value as disclosed in copending application Ser. No. 046,888, filed May 17, 1994, now U.S. Pat. No. 5,311,977 and Ser. No. 586,167, filed Sep. 21, 1990, now U.S. Pat. No. 5,157,486, the disclosures of which are hereby incorporated by reference. Hardware compaction of data applied to the microprocessor allows for improved image resolution to be obtained while reducing the processing time and memory size requirements. The present invention is equally usable with the systems disclosed in those applications.
The second break in fence 28 is provided to accommodate a first infrared thru beam optical switch composed of a receiver 36 and a light source 38.
Immediately prior to the entry port of the orientor means 24 there may be optionally positioned at a third break in the fence 28, a second infrared thru beam optical switch means having a receiver 40 and a light source 42.
The recognition sensor communicates via a conduit line 48 with a vision controller 44 which in turn is in communication with an orientation controller 46.
Vision controller 44 is hard wired to the work article sensors 30 while the orientation controller 36 is wired to the article recognition sensors 36 and 40 and reorientor 24. A signal related to the movement of the conveyor belt is supplied by lead 58 to orientation controller 46. Control and monitoring of the belt speed maybe by shaft encoder 62 which is connected by lead 60 to vision controller 44, since a constant belt speed is important for maintaining image resolution in this embodiment.
The identical sample work pieces 18, 20, and 22 chosen for explanatory purposes of the specification are shown in FIGS. 1 and 3 and comprise a plastic article having a length of about 3 inches provided with a blunt end surface which may be either at the trailing end as shown at 18 in FIG. 1 to provide orientation A or the leading end as is the case for work article 20 to provide orientation B. The work article 22 is shown with a third orientation C. Up to seven orientations may be determined by the program described below.
In operation, work articles 18, 20, and 22 moving along the path or the conveyor belt 12 may be inspected for conformity with a desired and acceptable work piece. In conjunction with such inspection, it is necessary to identify article orientation and make such position changes as are necessary so that all work articles leave the discharge side of the reorientor 24 with the same orientation.
Memory resident in the programmable vision controller 44 is "taught" a plurality of up to seven possible orientations of a work article in a setting procedure prior to the production run. The present invention is especially adapted for reducing the time required for making the determination of the actual orientation of work pieces, or article identification as the case may be.
As explained in the '493 patent, the capacity for data storage in the division controller 44 is sufficient to store information concerning the edge points of an article as it passes scanner 30. The standard recognition device operates in a silhouette mode so that only profile information data is needed. Each scan represents a slice of the article and produces at least one edge point on the profile. The number of slices per article, for example, may be 1000 depending upon conveyor speed, article length and microprocessor programming.
To operate in accordance with the present invention, an article having acceptable dimensions is fed by the conveyor past the array 30 in a first orientation A. This information is stored in a "learn" mode. Typically this procedure is repeated at least once and optionally up to about ten (10) times to obtain an envelope of values or average value for the first orientation.
Next the system is taught to recognize a second orientation B of the same article by the same procedure.
Additional orientations C, D . . . of the same article up to a total of seven (7) different orientations can be processed by the system of the prior '493 patent. When all of the required orientations are taught, i.e. stored in vision controller memory 44, the system is advanced from the "learn" mode to a "windows generation" mode before moving on to an "operation" mode allowing the repetitive feeding of work articles. Since the conveyor belt speed is carefully controlled, once the article leading edge has been detected, information data for corresponding points that are acquired by successive slice scanning can be identified by slices numbered between one and 1000 in the illustrated example. The edge point data are compared to determine which of the orientation data matches the work article data.
Since the time required for processing the edge point data information has been a factor limiting the speed at which the conveyor 12 may operate, various efforts have been made in the past to reduce the processing time to allow faster classification of objects by the computer. One previous approach has been to have the operator manually set areas of interest with a keyboard, a mouse, or the like. By the present invention, the computer automatically locates the areas of maximum difference between the stored object information data and the collective article information data without the need for operator participation.
Reference is made to FIG. 2 which shows a flow chart for generating the windows that correspond to numbered slice scans for a specific article whose orientation is to be determined.
The procedure illustrated in FIG. 2 will be described in connection with an article that may have four orientations that must be separately ascertained. The program is capable of detecting up to seven orientations as described above. The four orientations A, B, C, and D are shown in FIG. 3. Before starting the program, the orientations are stored just as described in the prior '493 patent.
With the use of the program of FIG. 2, the scan slices 2-999 where maximum deviation between the marginal edges that are presented in the several orientations are identified. The article has an arbitrary length of 1000 scan slices that are oriented along the X axis. The article height is arbitrarily designated to be 400 along the Y axis. The thickness of the parts of the article is assumed to be 100 units as measured along the Y axis.
With continued reference to FIG. 2, the process is initialized by setting a first loop counter A to zero at step 102. At step 104, the counter is incremented and connected to the register where the orientation A data is stored. At steps 106 and 108, the leading edge and the trailing edge scan slices corresponding to X axis positions of 1 and 1000 in FIG. 3 are stored. This corresponds to scan slices 1 and 1000 assuming that a three inch article will be sequentially scanned a thousand times as it passes the sensor 30 of FIG. 1. In this embodiment, scan slices 1 and 1000 are always stored. At step 110 in FIG. 2, orientation A stored information is retrieved.
At step 112, a second loop counter B is set to zero and incremented at step 114 to a position for an iteration with respect to orientation A data collected at step 110. Iteration completes learned data of orientation A with learned data of orientation A by starting with scan slice 2 of both orientation A and orientation A data. The number of differences in this pixel data at scan slice 2 for orientation A and orientation A is determined and is called a score. The same procedure is followed for scan slices 3 through 999. In all, 998 scores are determined at step 116.
At step 118, the maximum score is determined should be zero, also same value less than 10 may be maximum score and its scan slice number is stored as a window. While a reading from only one window is theoretically sufficient to determine that a Dart orientation does not match a stored known orientation, in practice several slice numbers, for example up to about 20, may be stored where the scores are the largest to reduce the likelihood of ambiguity in the results. This determination is made at step 126.
Orientation A data is then compared with orientation B data in the same manner and a new maximum difference at a new slice scan location is generated. This slice scan number is stored as a second window. Another signal on lead 124 increments loop counter B at step 114 to receive orientation C data after which the slice number for a third window is generated. The loop counter B at step 114 continues incrementing until B is equal to the number of orientations stored.
At step 126, a determination is made as to whether a sufficient number of windows has been generated. If not, the same procedure is repeated If "yes" the procedure advances to step 130 to determine whether counter A is equal to the total number of orientations that have been learned. In this example, stored information corresponding to orientations B, C and D must be compared with all of the learned orientation data before this program is completed. At that time orientations A, B, C and D will each have been individually compared with stored orientation data for the same orientations A, B, C and D.
At the end of the setting-up procedure, at least 12 scan slice numbers will be identified as windows since each of the four article orientations will have three maximum differences which each produce three windows. Some of the windows appear at the same scan slice.
Turning to FIG. 3, windows are established by the program of FIG. 2 without operator selection at counts 99, 199, 799 and 899. These are the windows of importance for article orientation determination in the specific example here being described.
Once the windows have been identified, it has been found useful to expand each window to have a width of three or five scan slices centered about the scan slice. Thus, widening of a window compensates for possible data misalignments which can occur in some systems due to mechanical wear and other changes which occur during a continuous operation over several weeks.
After the windows are generated as a setting operation, work articles are fed past scanner 30 to identify edge points on the article profile. A comparison operates in real time to determine article orientation during an interval that corresponds to the interval between successive work articles on the conveyor.
When a work article is moved past sensor 30 of FIG. 1 which has an orientation A as shown in FIG. 3, a comparison of the work article profile data with each of the learned orientations A, B, C and D is made at the windows previously selected by the program of FIG. 2. Comparing the work article orientation A profile data with stored orientation A data gives a total score of zero. A similar comparison of the same work article data with the stored orientation B data gives a score of 300 at each of the four windows 99, 199, 799 and 899 to thereby produce a total score of 1200. The same comparison with the stored orientation C data gives a total score of 400 and with the orientation D data gives a total score of 1000.
From FIG. 3 it can be seen that regardless of which orientation the work article assumes, one stored orientation match with a score at or near zero will be obtained and the orientation of the work article thereby recognized. Where each window is three or five scan slices wide, the score for orientation mismatches increases while remaining essentially at zero for the actual orientation. The results obtained with a comparison of only four or up to about twenty windows along the length of a three inch article can be accomplished with less memory and less time than where all pixel information is processed while at the same time the performance is fully as reliable. Where the high resolution system disclosed in the companion co-pending applications is used, even greater speeds can be obtained which can allow a greater number of articles to be processed per unit time.
While only a single embodiment has been illustrated, it is apparent that changes and modifications will be apparent to those skilled in this art. All such modifications and changes which fall within the scope of the claims and equivalents thereof are intended to be covered thereby.
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In an article handling system that functions to make article discrimination-identification determinations, the possible article orientations A, B, C . . . are stored and compared to establish maximum pixel difference numbers and identification of longitudinal window position along the article where such maximum difference occurs. Each of the possible orientations is compared with all other possible orientations so that a small number of windows is identified as part of a setting procedure. When operating, the work articles are scanned and only the data at window locations are used to make article orientation identifications to reduce time and memory requirements for data processing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of the priority from the prior Japanese Patent Application No. 2002-375979, filed Dec. 26, 2002, and this application is a divisional of application Ser. No. 10/743,003, filed Dec. 23, 2003, now U.S. Pat. No. 7,094,612. The entire contents of these applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a semiconductor device using, for example, a stencil mask as a transfer mask and an apparatus for manufacturing the semiconductor device.
2. Description of the Related Art
There has been known a method in which in semiconductor device manufacturing process, a stencil mask having a predetermined pattern is set above a substrate to be processed at a predetermined distance and charged particles such as electrons or ions are projected onto the substrate through openings defining the pattern of the stencil mask. In the method, charged particles (ion beam) such as ions accelerated from a particle source by a predetermined energy pass through a scanner and a magnet to be formulated into a patterned ion beam. The patterned ion beam is projected onto the substrate through the openings formed in the stencil mask. The substrate to be processed mentioned here is a semiconductor substrate, on the surface of which a semiconductor device is to be formed or has been formed, not shown.
There is a disadvantage that, when a substrate is processed using the charged particles, residue charges are accumulated on the substrate so that the semiconductor device formed on the substrate may be destroyed by being charged due to the accumulated charges. A conventional method is known to overcome this disadvantage (Jpn. Pat. Appln. KOKAI Publication No. 9-283411, see page 4). In this method, secondary electrons or plasma electrons are generated to neutralize the accumulated charges, thus preventing the destruction of a substrate due to the accumulated charges.
Jpn. Pat. Appln. KOKAI Publication No. 2002-203806 (FIGS. 29 and 35) discloses a method of controlling the amount of charges accumulated on a substrate to be processed. In the method, a distance and a potential difference between a stencil mask and the substrate to control the amount of charges accumulated on the substrate. The controlling of the amount of charges is carried out by providing a power supply between the stencil mask and the substrate, or by providing a power supply between the stencil mask and the ground and also another power supply between the substrate and ground.
However, neutralizing the accumulated charges by generating secondary electrons or plasma electrons is sensitive to the amount of charges on the substrate and the stencil mask, the amount of energy on charged particles, degree of vacuum in the apparatus, etc., and the amount of neutralized charges greatly changes depending on these factors. As a result, with the method of neutralizing the accumulated charges by generating secondary electrons or plasma electrons, the neutralized charge amount may be insufficient or an excessive amount of electrons may be supplied to cause negative charging, which possibly destroy the semiconductor devices. Further, the charge neutralizing mechanism, which generates the secondary electrons or plasma electrons, is complicated in structure.
On the other hand, according to the method of controlling the amount of the charges accumulated on the substrate by changing a distance and a potential difference between the stencil mask and the substrate, yield is improved. However, it is necessary to set up the distance and the potential difference between the stencil and the substrate before an ion implantation process is carried out. There is no problem if the irradiation condition of the charged particles is stable and the state of the apparatus is stable during the processing. However, if the apparatus is unstable, and the irradiation amount (current amount) of the charged particles per unit time changes during the processing, the neutralized charge amount may be insufficient, or an excessive amount of electrons may be supplied to cause negative charging, which leas to a possible destruction of the semiconductor devices.
BRIEF SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is provided a method of manufacturing a semiconductor device comprising:
setting a stencil mask above a substrate to be processed in confronting to the substrate, the stencil mask having an opening; and
irradiating the substrate with charged particles through the opening of the stencil mask, while adjusting a potential difference between the stencil mask and the substrate depending on a value of a current flowing between the substrate and the stencil mask.
According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device comprising:
setting a stencil mask above a substrate to be processed in confronting with the substrate, the stencil mask having an opening; and
irradiating the substrate with charged particles through the opening of the stencil mask, while adjusting a potential difference between the stencil mask and the substrate depending on a ratio between a value of a current flowing in the substrate and a value of a current flowing in the stencil mask.
According to a further aspect of the present invention, there is provided a manufacturing apparatus of a semiconductor device, comprising:
a stencil mask set above a substrate to be processed in confronting to the substrate, the stencil mask having an opening;
a particle source which irradiates the substrate to be processed with charged particles through the opening of the stencil mask;
a first power supply which is connected to the stencil mask and changes a potential of the stencil mask; and
a first ammeter connected to the substrate to be processed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagram showing part of a semiconductor device manufacturing apparatus according to a first embodiment of the present invention;
FIG. 2 is a diagram showing part of a semiconductor device manufacturing apparatus according to a second embodiment of the present invention; and
FIG. 3 is a diagram showing part of a semiconductor device manufacturing apparatus according to a third embodiment of the second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
First Embodiment
FIG. 1 shows a semiconductor manufacturing apparatus according to a first embodiment of the present invention.
In a semiconductor manufacturing process, a stencil mask 11 having a predetermined pattern formed by openings formed in the stencil mask is set above a substrate 12 to be processed at a distance. Charged particles 13 (ion beam) such as ion accelerated by an energy pass through a scanner and a magnet are formulated into a pattern of charged particles. The patterned ion beam 13 is irradiated onto the substrate 12 through the openings formed in the stencil mask. The substrate 12 to be processed mentioned here is a semiconductor substrate, in which a semiconductor device is to be formed or has been formed, not shown.
The stencil mask 11 is connected to a power supply 14 which is also connected to ground. Thus, a potential of the stencil mask 11 can be controlled, with an outer wall of the apparatus or ground as a reference potential. The substrate 12 is connected to the outer wall of the apparatus or ground through an ammeter 15 . Thus, current flowing from the substrate can be measured by the ammeter 15 .
When the irradiation amount of the ion beam 13 is not changed in a semiconductor manufacturing process such as an ion implantation process, that is, when the quantity of the charged particles applied to the substrate 12 is constant, a current I 1 measured by the ammeter 15 is also constant. That is, an appropriate current value for processing condition of processing the substrate 12 exists and the appropriate current value is usually constant. Although most preferably, the constant value of the current I 1 is 0(A), it is not restricted to this value but may be other constant value than 0(A).
If electrical balance between the stencil mask 11 and the substrate 12 is get out due to factor variations of the apparatus so that the neutralizing effect is lowered, excessive positive charges may begin to be accumulated on the surface of the substrate 12 . The excessive positive charges accumulated on the surface of the substrate 12 flow to the outer wall of the apparatus so that the current I 1 increases. Thus, according to this embodiment, the current I 1 flowing to the substrate 12 is measured and if the current I 1 becomes larger than the appropriate current value for some reason during ion implantation, the positive charges which begin to be accumulated on the substrate 12 can be neutralized by lowering a potential of the stencil mask 11 by the power supply 14 . If the potential of the stencil mask 11 is lowered too much when the potential of the stencil mask 11 is adjusted, negative charges are then accumulated on the surface of the substrate 12 , and a current I 2 becomes smaller than an appropriate current value. The current I 2 is a current flowing through the power supply 14 . In this case, the negative charges which begin to be accumulated on the substrate 12 can be neutralized by increasing the potential of the stencil mask 11 by the power supply 14 .
Thus, according to this embodiment, even if the neutralizing condition changes due to an instable state of the apparatus, in the semiconductor manufacturing process using the charged particles such as ion implantation process, the potential of the stencil mask can be changed following the state of the apparatus. Consequently, the possibility that the semiconductor device may be destroyed due to the charges accumulated on the substrate is reduced, thus yield is improved.
Second Embodiment
FIG. 2 shows a semiconductor manufacturing apparatus according to a second embodiment of the present invention. Reference numerals corresponding to those used in FIG. 1 are attached to the corresponding components, and description thereof is omitted.
In a semiconductor manufacturing process, a stencil mask 21 having a predetermined pattern formed by openings formed in the stencil mask is set above a substrate 22 to be processed at a distance. Charged particles 23 (ion beam) such as ion accelerated by an energy pass through a scanner and a magnet are formulated into a pattern of charged particles. The patterned ion beam 23 is irradiated onto the substrate 22 through the openings formed in the stencil mask. The substrate 22 to be processed mentioned here is a semiconductor substrate, in which a semiconductor device has been formed, not shown.
The stencil mask 21 is connected to a power supply 24 which is also is connected to ground (i.e. an outer wall of the apparatus) through an ammeter 25 . Thus, a potential of the stencil mask 21 can be controlled, with the outer wall of the apparatus or ground as a reference potential. Further, a current flowing from the stencil mask 21 can be measured by the ammeter 25 . The substrate 22 is connected to ground (i.e. an outer wall of the apparatus.) through an ammeter 26 . Thus, a current flowing from the substrate can be measured by the ammeter 26 .
When the irradiation amount of the ion beam 23 is not changed in a semiconductor manufacturing process such as an ion implantation process, that is, when the quantity of the charged particles applied to the substrate 22 is constant, a current I 1 measured by the ammeter 25 is also constant. That is, an appropriate current value for processing condition of processing the substrate 22 exists and that the appropriate current value is usually constant. Although most preferably, the constant value of the current I 1 is 0(A), it is not restricted to this value but may be other constant value than 0(A).
However, if the irradiation amount of the ion beam 23 per unit time changes with time in the semiconductor manufacturing process such as an ion implantation process, the quantity of the charged particles applied to the substrate 22 per unit time also changes, so that the current I 1 measured with the ammeter 26 also changes. On the other hand, the ratio of the current I 1 flowing from the substrate 22 with respect to the current I 2 flowing from the stencil mask 21 , that is, a current ratio I 1 /I 2 , is constant, since the neutralizing effect is maintained if the electrical balance between a stencil mask 21 and the substrate 22 is stabilized. That is, an appropriate current ratio depending on the processing condition of processing the substrate 22 exists, and usually that value is constant.
If electrical balance between the stencil mask 21 and the substrate 22 is get out due to factor variations of the apparatus so that the neutralizing effect is lowered, excessive positive charges may begin to be accumulated on the surface of the substrate 22 . If excessive positive charges begin to be accumulated on the surface of the substrate 22 , the ratio of the current I 1 flowing from the substrate 22 with respect to the current I 2 flowing from the stencil mask 21 , that is, the current ratio I 1 /I 2 is increased. Then, according to this embodiment, the current ratio I 1 /I 2 is measured and if the current ratio I 1 /I 2 becomes larger than its appropriate current ratio for some reason in the ion implantation process, the positive charges which begin to be accumulated on the substrate 22 can be neutralized by lowering the potential of the stencil mask 21 through a power supply 24 . If the potential is lowered too much when the potential of the stencil mask 21 is adjusted, negative charges are accumulated on the surface of the substrate 22 , and the current ratio I 1 /I 2 becomes smaller than the appropriate current ratio. In this case, the negative charges which begin to be accumulated on the substrate 22 can be neutralized by lowering the potential of the stencil mask 21 by the power supply 24 .
Thus, according to this embodiment, even if the irradiation amount of the ion beam changes with time in the semiconductor manufacturing process using the charged particles such as an ion implantation process, yield can be improved by reducing the possibility that the semiconductor device may be destroyed due to the charges accumulated on the substrate.
Third Embodiment
FIG. 3 shows a semiconductor manufacturing apparatus according to a third embodiment of the present invention. Reference numerals corresponding to those used in FIG. 1 are attached to the corresponding components, and description thereof is omitted.
In a semiconductor manufacturing process, a stencil mask 31 having a predetermined pattern formed by openings formed in the stencil mask is set above a substrate 32 to be processed at a distance. Charged particles 33 (ion beam) such as ion accelerated by an energy pass through a scanner and a magnet are formulated into a pattern of charged particles. The patterned ion beam 33 is irradiated onto the substrate 32 through the openings formed in the stencil mask. The substrate 32 to be processed mentioned here is a semiconductor substrate, in which a semiconductor device has been formed, not shown.
The stencil mask 31 is connected to a power supply 34 which is also is connected to ground (i.e. an outer wall of the apparatus) through an ammeter 35 . Thus, a potential of the stencil mask 31 can be controlled, with the outer wall of the apparatus or ground as a reference potential. Further, a current flowing from the stencil mask 31 can be measured by the ammeter 35 . The substrate 32 is connected to a power supply 36 which is also is connected to ground (i.e. an outer wall of the apparatus) through an ammeter 37 . Thus, a potential of the substrate 32 can be controlled, with the outer wall of the apparatus or ground as a reference potential. Further, a current flowing from the substrate 32 can be measured by the ammeter 37 .
When the irradiation amount of the ion beam 33 is not changed in a semiconductor manufacturing process such as an ion implantation process, that is, when the quantity of the charged particles applied to the substrate 32 is constant, a current I 1 measured by the ammeter 35 is also constant. That is, an appropriate current value for processing condition of processing the substrate 32 exists and the appropriate current value is usually constant. Although most preferably, the constant value of the current I 1 is 0(A), it is not restricted to this value but may be other constant value than 0(A).
However, if the irradiation amount of the ion beam 33 per unit time changes with time in the semiconductor manufacturing process such as an ion implantation process, the quantity of the charged particles applied to the substrate 32 per unit time also changes, so that the current I 1 measured with the ammeter 36 also changes. On the other hand, the ratio of the current I 1 flowing from the substrate 32 with respect to the current I 2 flowing from the stencil mask 31 , that is, a current ratio I 1 /I 2 is constant, since the neutralizing effect is maintained if the electrical balance between a stencil mask 31 and the substrate 32 is stabilized. That is, an appropriate current ratio depending on the processing condition of processing the substrate 32 exists, and usually that value is constant.
If electrical balance between the stencil mask 31 and the substrate 32 is get out due to factor variations of the apparatus so that the neutralizing effect is lowered, excessive positive charges may begin to be accumulated on the surface of the substrate 32 . If excessive positive charges begin to be accumulated on the surface of the substrate 32 , the ratio of the current I 1 flowing from the substrate 32 with respect to the current I 2 flowing from the stencil mask 31 , that is, the current ratio I 1 /I 2 is increased. Then, according to this embodiment, the current ratio I 1 /I 2 is measured and if the current ratio I 1 /I 2 becomes larger than its appropriate current ratio for some reason in the ion implantation process, the positive charges which begin to be accumulated on the substrate 32 can be neutralized by decreasing the potential difference between the stencil mask 31 and the substrate 32 through power supplies 34 , 36 . If the potential difference is lowered too much when the potential difference between the stencil mask 31 and the substrate 32 is adjusted, negative charges are then accumulated on the surface of the substrate 32 , and the current ratio I 1 /I 2 becomes smaller than the appropriate current ratio.
According to the present embodiment, the negative charges which begin to be accumulated on the substrate 32 can be neutralized by adjusting the power supplies 34 , 36 to thereby increase the potential difference between the stencil mask 31 and the substrate 32 . At this time, considering an influence upon the semiconductor device, it is preferable that the power supply 36 connected to the substrate 32 is used as a supplement of the power supply 34 . An optimum neutralization can be attained since the potentials of the stencil mask 31 and the substrate 32 can be independently adjusted by using the power supplies 34 , 36 connected to the stencil mask 31 and the substrate 32 . Thus, according to the present embodiment also, the possibility that the semiconductor device may be destroyed due to the charges accumulated on the substrate is lowered and thus yield can be improved, even if the irradiation amount of the ion beam changes with time in the semiconductor manufacturing process using the charged particles such as ion implantation process.
As described in detail above, according to the embodiments of the present invention, the possibility that the semiconductor device may be destroyed by the charges accumulated on the substrate in the semiconductor manufacturing process using the charged particles such as the ion implantation process can be decreased, thereby improving the yield.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A method of manufacturing a semiconductor device is disclosed, which comprises setting a stencil mask above a substrate to be processed in confronting to the substrate, the stencil mask having an opening, and irradiating the substrate with charged particles through the opening of the stencil mask, while adjusting a potential difference between the stencil mask and the substrate depending on a value of a current flowing between the substrate and the stencil mask.
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This is a continuation of Ser. No. 800,939, filed 11/22/85, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a process for biological water treatment, in particular for denitrification of raw water to produce potable water. The invention also relates to equipment suitable for biological denitrification, in particular of potable water.
2. Description of the Related Art
The raw water used for the production of potabler water, for example ground water, is increasingly subject to environmental pollution. Above all, nitrates from fertilizers, manure or the like pass into the ground water. The potable water produced from the latter must therefore be freed from nitrate (denitrified) before consumption or at least to such an extent that it meets the statutory requirements. It can also become necessary to denitrify treated industrial water.
Multi-stage denitrification is known, in which the nitrate-containing raw water is first passed, with the addition of a reducing agent, for example ethanol, glucose or the like, into an anoxic reactor packed with carrier materials. As a result of the added reducing agent, bacteria which reduce the nitrate to molecular gaseous nitrogen are formed on the carrier material. At the same time, the carbon-containing reducing agents provide an organic carbon supply, namely as an energy carrier, for the bacteria in the reactor. The potable water pretreated to this extent then requires an aerobic, biologically active filtration. In such a filter, the excess substances added as reducing agents and biomass are to be removed from the potable water, with addition of oxygen.
A disadvantage of this known process is the discontinuous course of the denitrification. This results from the fact that the reactors must be washed at regular intervals in order to remove the excess biomass produced. Moreover, the quality of the treatment in the first process stage depends on the age of the biomass in the anoxic reactor. An expensive combination of processes for final purification of the denitrified water is therefore necessary in every case. For this reason, the known biological denitrification process requires careful process supervision and intensive servicing of the unit. With known static carrier material packing, there is a risk, in the event of uneven flow through it, of the biomass caking, as a result of which undesired nitrite can be formed.
This known process also has disadvantages in respect of equipment. In fact, in order to avoid the complete close-down during the frequently necessary washing of the reactors, several reactors should be provided, of which alternately one reactor is always in operation, while the other reactor is being back-washed.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide a process which is easy to control, in particular a continuous process, and inexpensive equipment of simple structure for the denitrification, in particular of potable water.
To achieve this object, the process according to the invention has the result that, in the second stage with-supply of oxygen, the aerobic microorganisms degrade the secondary matter from the first stage, namely excess reducing agents and a part of the biomass discharged from the anoxic reactor. This has the advantage that, in the process according to the invention, a simple mechanical filter can be used as the downstream filter, that is to say a biological filter, such as is necessary in the denitrification process of the state of the art, which is difficult to control on line, can be omitted. Since the secondary matter is biologically degraded, the residual biomass which may still be present in the potable water after the mechanical filtration is very largely harmless.
According to the process, it is also proposed to use rotary submerged drum reactors in both water treatment stages, namely the first anoxic biological stage and the second aerobic biological stage. Due to the continuous rotary movement of the reactors in the vessel with the potable water to be treated, excess biomass or reducing agents are continuously washed out of the immersion bodies located in the submerged drum reactors. Only a thin, but biologically active layer of bacteria thus remains on the immersion body surfaces. The back-washes required in the state of the art are accordingly unnecessary. Therefore, the denitrification process according to the invention allows virtually uninterrupted operation of the unit. Blockages of the immersion bodies are prevented, since they continuously move in the potable water to be treated.
At the same time, on the one hand, there is even continuous washing through the immersion bodies and, on the other hand, controlled flow of the water to be treated through the vessels of the individual treatment stages takes place, so that optimum nutrient absorption and optimum gas exchange are obtained.
The equipment according to the invention for achieving this object consists of conventional components. The submerged drum reactors can easily be installed into and removed from the appropriate vessels and are easy to control.
According to a further proposal of the invention, the submerged drum reactors in the individual vessels are of approximately identical design and are mounted on a common drive shaft. Since identical submerged drum reactors are used, these can be economically mass-produced. The mounting on a common drive shaft provides a compact installation which requires only one drive. Depending on the capacity of the unit, one or several submerged drum reactors can be arranged in series within one vessel, that is to say within one treatment stage.
Advantageously, the vessels, receiving the submerged drum reactors, for the individual treatment stages should be arranged, for space reasons, either immediately side by side or at a small spacing.
According to the invention, the submerged drum reactors are composed of a three-dimensional support structure and the immersion body arranged therein. In an advantageous embodiment of the invention, the immersion bodies in turn consist of a plurality of immersion body segments. In this way, the submerged drum reactors can be assembled from smaller components (which are easy to handle). In the event of faults occurring in the submerged drum reactor, individual segments can be replaced.
The support structure is composed of profile bars which run radially to the longitudinal centre axes of the submerged drum reactors and are arranged in such a way that they guide the individual immersion body segments along their radially directed edges. To secure the individual immersion body segments against dropping out of the drum reactors, clamping rings are used which surround the outer periphery of the drum reactors and, formed either integrally or likewise as segments, are connected to the free ends of the profile bars of the support structure.
In the first, anoxic biological stage, operating with exclusion of oxygen, the vessel receiving the submerged drum reactor is preferably designed to be gastight. In this stage, about half of the submerged drum reactor can be immersed into the water to be treated. As a result, the bacteria growing on the immersion body can start nitrate respiration after a short initial phase, that is to say reduce the nitrate ion to gaseous nitrogen by utilizing the three oxygen atoms bonded in the ion. Since air is excluded from the vessel, the brief emergence of a part of the submerged drum reactor from the water does not adversely affect the activity of the bacteria film. Alternatively, the denitrification in the first, biological stage can also be carried out in an open vessel, but with a submerged drum reactor which is completely immersed into the water to be treated. In this case, the continuing exclusion of oxygen feed from the biological film, as necessary for the nitrate reduction, is the result of the fact that the immersion body segments are continuously immersed in the water to be treated.
In the second, aerobic biological stage, the treatment takes place in an open vessel with oxygen supply. In this treatment stage, about half of the submerged drum reactor is immersed into the denitrified water. Due to the rotation of the submerged drum reactor, the water is continuously aerated for the formation of an aerobic bacteria film on the immersion body of this treatment stage. The aerobic bacteria thus consume the remainder of the excess reducing agent metered into the first treatment stage and a part of the biomass discharged during the denitrification from the first submerged drum reactor.
According to the invention, the vessels of the two treatment stages are mutually connected by an overflow. The latter is arranged in such a way that a water level which is higher than that in the second treatment stage is automatically established in the vessel of the first treatment stage, in order to ensure the required depths of immersion of the submerged drum reactors which effect different treatments. As a result, expensive control systems for adjusting the required levels in the individual treatment vessels can be omitted.
Finally, the invention proposes to place the overflow, a water feed into the first treatment vessel and a water discharge from the second treatment vessel in the vicinity of the corners of the vessels, especially in a zig-zag form, so that the water feed and water discharge are approximately diagonally opposite in each vessel. In this way, a formation of dead zones and short-circuit flows while water flows through the individual vessels is avoided. As a result, there is intensive flow around the biological film on the immersion bodies. At the same time, the formation of dead zones with stagnant water in the vessels is avoided, in favour of likewise intensive treatment of the potable water.
Further features of the invention relate to the constructional design of the support structure and of the immersion body segments of the drum reactors.
DESCRIPTION OF THE DRAWING
An illustrative embodiment of the invention is explained in more detail below by reference to the drawings in which:
FIG. 1 shows a diagrammatic side view of the equipment,
FIG. 2 shows a diagrammatic plan of the equipment according to FIG. 1,
FIG. 3 shows a perspective overall view of a submerged drum reactor,
FIG. 4 shows a cross-section, partially shown enlarged, through the submerged drum reactor according to FIG. 3,
FIG. 5 shows a partial side view of the submerged drum reactor according to FIG. 4,
FIG. 6 shows a perspective illustration of an immersion body segment,
FIG. 7 shows a side view of a section of an open-mesh pipe, and
FIG. 8 shows a cross-section VII--VII through the open-mesh pipe according to FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present illustrative embodiment relates to compact equipment for the biological denitrification of potable water. The equipment consists of a (first) anoxic biological stage 10 with a vessel 11, in which two submerged drum reactors 12 are arranged side by side, of a (second) aerobic biological stage 13 with a vessel 15 containing a submerged drum reactor 14, and of a mechanical filter unit 16 of a design type known per se.
The vessel 11 of the first biological stage 10 is designed to be sealed gas-tight by a cover 17 which closes the upper opening of the vessel 11 (FIG. 1). In cross-section (not shown), the lower half of the vessel 11 approximately matches the curvature of the submerged drum reactors 12, that is to say, in the lower half, the wall of the vessel 11 extends at a spacing from and approximately parallel to the submerged drum reactors 12.
In the present illustrative embodiment, the water level 18 in the vessel 11 of the first biological stage 10 is above the horizontal longitudinal centre axes 19 of the submerged drum reactors 12, especially by about 20% of the diameter thereof. An overflow pipe elbow 20 connecting the vessels 11 and 15 serves for maintaining the envisaged water level 18 in the vessel 11. For this purpose, a horizontal section, ending in the vessel 11, of the overflow pipe elbow 20 is arranged at a height above the water level 18. A vertical pipe section, leading into the vessel 15, of the overflow pipe elbow 20 ends below the water level 21 in the vessel 15 of the second biological stage 13.
The water to be treated, namely the ground water provided with reducing agents, passes through a feed pipe elbow 22 into the vessel 11 of the first biological stage 10. In this illustrative embodiment, the horizontal pipe section of the feed pipe elbow 22 enters an upper region of the vessel 11 and its (long) vertical pipe section protrudes deep into the water which is to be denitrified in the first biological stage 10. In the present illustrative embodiment, the feed pipe elbow 22 enters the water from above, at about one third of the height of the water level 18. The overflow pipe elbow 20 and the feed pipe elbow 22 are allocated to approximately diagonally opposite corner regions of the vessel 11 of the first (anoxic) biological stage 10.
The upper side 23 of the vessel 15, which in this case has only one submerged drum reactor 14, of the second (aerobic) biological stage 13 is not closed. Thus, in contrast to the vessel 11, aeration of the water to be treated is possible in this vessel 15. The water level 21 in the vessel 15 is slightly above the longitudinal centre axis 19 of the drum reactor 14. The water level 21 of the second biological stage 13 is thus below the water level 18 of the first biological stage 10. The envisaged water level 21 in the level 15 is maintained--as in the vessel 11--by means of a discharge pipe 24 arranged at an appropriate height. The denitrified potable water passes through this discharge pipe into the mechanical filter unit 16. Commercially available, mechanical filter units can be used for this purpose, provided that they do not conflict with continuous operation of the biological stages 10 and 13.
In the present illustrative embodiment, the vessels 11 and 15 have identical--approximately trough-shaped--cross-sections. The vessels 11 and 15 are arranged one immediately behind the other, with a common central partition 25. The discharge pipe 24 in turn is arranged in the corner region of the vessel 15, diagonally opposite the overflow pipe elbow 20. The feed pipe elbow 22 for the vessel 11 and the discharge pipe 24 in the vessel 15 are therefore approximately opposite one another (FIG. 2). With respect to height, the discharge pipe 24 and the overflow pipe elbow 20 are offset corresponding to the different water levels 18 and 21 in the vessels 11 and 15 respectively, since the discharge pipe 24 is in fact arranged lower down.
The two submerged drum reactors 12 in the vessel 11 and the submerged drum reactor 14 in the vessel 15 are mounted on a common, continuous drive shaft 26 (FIGS. 1 and 2). The shaft extends along the longitudinal centre axes 19 of the submerged drum reactors 12 and 14, so that the latter are located in series at the same height.
All the submerged drum reactors 12, 14 are driven by a common electric motor 27 which is arranged outside the vessels 11 and 15 (FIGS. 1, 2, 4). To reduce the motor speed to a relatively low drive speed of the drum reactors 12, 14, a gearbox 28 (FIGS. 1, 2) between the drive shaft 26 and the drive motor 27 or alternatively an open cog wheel drive, consisting of a relatively large cog wheel 28 allocated to the front submerged drum reactor 12 in the vessel 11 and of a small pinion 29 associated with the drive motor 27, can be provided (FIG. 4).
In the present illustrative embodiment, the three submerged drum reactors 12, 14 are of the same design. Each submerged drum reactor 12, 14 consists of a three-dimensional cylindrical support structure 30 which receives the immersion body consisting in the present illustrative embodiment of a total of ten immersion body segments 31 (FIG. 3).
The support structure 30 consists of radially directed, T-shaped profile bars 32 which are located in two mutually spaced, upright (end) planes of the submerged drum reactors 12, 14. The ends, pointing to the centre of the submerged drum reactors 12, 14, of the profile bars 32 are joined to the drive shaft 26 by collars 33 fitted thereto (FIG. 4). At the end faces of the submerged drum reactors 12, 14, the profile bars 32 are braced to one another by transverse struts 34 (FIG. 5). In the radially directed plane, transversely thereto, between two immersion body segments 31, the profile bars 32 mutually adjacent in pairs are also strutted, namely by a bracing 35 which extends in the shape of an X to the ends of the profile bars 32 (FIG. 4).
The dimensions of the support structure 30 and the arrangement of the profile bars 32 are such that the total of ten immersion body segments 31, provided in this illustrative embodiment, can be inserted from the outside into the support structure 30. For doing this, the immersion body segments 31 are guided in the corner regions of the radially directed longitudinal edges by the T-shaped profile of the profile bars 32.
In the region of the hub of the support structure 30, cross struts 36 extending parallel to the drive shaft 26 at a distance are provided. These limit the depth of insertion of the immersion body segments 31 into the support structure 30.
On the outer periphery, the support structure 30 has two clamping rings 37, which are each allocated to an (end) plane formed by the profile bars 32. In the present illustrative embodiment, the clamping rings 37 are each assembled from ten ring segments 38. These ring segments each connect the outer free ends of two profile bars 32 lying in one plane. For this purpose, each profile bar 32 has, on its free outer end, a bracket 39 to which two opposite ring segments 38 are bolted. The arrangement of the ring segments 38 of the support structure 30 is such that these segments cover the edge regions of the outer curved surface of the immersion body segments 31 from the outside of the submerged drum reactors 12, 14, in order to secure the immersion body segments 31 in the submerged drum reactors 12, 14.
Each immersion body segment 31 consists of a multiplicity of open-mesh pipes 40 which run parallel to the longitudinal centre axis 19 of the submerged drum reactors 12, 14 (FIG. 3, FIG. 6). The individual open-mesh pipes 40 packed together to give an immersion body segment 31 are mutually joined by welding of the opposite end faces.
The diameters of the individual open-mesh pipes 40 of an immersion body segment 31 can differ. For example, open-mesh pipes 40 of larger diameter can be arranged towards the interior of the submerged drum reactor 12, 14, whereas open-mesh pipes 40 of smaller diameter are used on the outside (FIG. 6). Alternatively, it is also conceivable to provide smaller open-mesh pipes 40 in the interior of the submerged drum reactor 12, 14 than on the outside. This gives a geometrical surface area of approximately the same size in all the regions of the submerged drum reactor 12, 14. The diameters of the open-mesh pipes 40 can be 10 mm-70 mm. This can give a geometrical surface area per segment volume of between 100 m 2 /m 3 and 400 m 2 /m 3 .
The open-mesh pipes 40 consist of longitudinal fibers 42 crossing circular fibers 41 of approximately the same cross-sectional dimensions (FIG. 7). Between the longitudinal fibers 42, the open-mesh pipes 40 have in each case a longitudinal web 43. The latter has a pointed, triangular cross-section with radially inward-directed spikes 44 protruding into the open-mesh pipe 40 (FIG. 8).
The equipment of the illustrative embodiment described operate as follows:
The ground water to be treated is passed via the feed pipe elbow 22 with addition of reducing agents into the vessel 11 of the first (anoxic) biological stage 10. In the latter, the bacteria forming on the open-mesh pipes 40 reduce the nitrate content in the ground water to gaseous nitrogen. The potable water denitrified in this way then passes through the overflow pipe elbow 20 into the vessel 15 of the second biological stage 13. The excess reducing agents and the bacteria, washed out of the first biological stage 10, in the aerated water are biodegraded here. Finally, water treated in this way passes via the discharge pipe 24 from the second biological stage 13 into the mechanical filter unit 16. The latter filters the excess biomass, purely mechanically, out of the potable water. A final biological treatment in the mechanical filter unit 16 is no longer necessary.
Due to the common drive of the submerged drum reactors 12, 14 from the drive shaft 26, the submerged drum reactors 12, 14 in both biological stages 10, 13 are moved continuously at the same speed for even washing through the immersion body segments 31.
Alternatively, the equipment according to the invention can be used for denitrifying effluents. An artificial addition of reducing agents or nutrients for the bacteria in the biological treatment stages can then sometimes be omitted, since in most cases these are already present in the effluent.
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Known types of equipment for the biological denitrification of potable water require (back) washing of the reactors from time to time. These denitrification processes proceed therefore in a discontinuous manner. The invention proposes a continuously operating denitrification process with a simple equipment arrangement. This is achieved by submerged drum reactors (12, 14) which rotate in a first, anoxic biological stage (10) and in a second, aerobic biological stage (13). The immersion bodies (immersion body segments 31) contained in these reactors are, due to the rotation, continuously washed during the treatment of the potable water. Moreover, the submerged drum reactors (12, 14) of the two biological stages (10, 13) are arranged according to the invention on a common drive shaft (26) with a drive element (drive motor 27).
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FIELD OF THE INVENTION
The invention relates to a process for the preparation of polymers having the general formula: ##STR3## wherein n+m=1 through 5, and x denotes the degree of polymerization.
BACKGROUND OF THE INVENTION
Polymerization processes which are based on unsaturated esters are well documented in the art. Controlling the polymer's physical properties, such as thermal stability, is a complicated task, because physical properties are affected by several parameters which are not always recognized or simple to handle.
The invention, as said, is concerned with the preparation of polymers of Formula I. Production of the monomeric unit is, of course, the first step in the polymerization process. IL 89791 discloses a process for the preparation of bromo-substituted aromatic esters of certain α,β-unsaturated acids. GB 1,516,212 discloses a procedure for preparing unsaturated esters, which may later serve as reactive monomers for polymeric materials. One Example of such an unsaturated ester is pentabromobenzyl acrylate (PBB-MA), obtained by reacting, according to the procedure given in GB 1,516,212, pentabromobenzyl chloride with an alkali metal salt of α,β-unsaturated acid, in particular, an acrylic acid. This process is carried out in a protic solvent (methoxyethanol). Direct polymerization, when performed according to a procedure disclosed in the art (GB 1,547,839) yields a polymer, poly(pentabromobenzyl acrylate), the thermal stability of which is limited. The Isothermal Gravimetric Analysis (ITGA 290° C./30 min) parameter of the aforementioned polymer is of the order of 35%-50% weight loss.
It is a purpose of the present invention to provide a process for the preparation of polymers of Formula I, characterized by an improved thermal stability.
It is another object of the invention to provide polymers which exhibit high thermal stability.
It is a further object of the invention to provide a one-pot process, in which the polymeric product is obtained from the monomeric unit of formula Ia: ##STR4## wherein n+m=1 through 5, which is made in situ from a compound of the following formula: ##STR5## wherein n+m=1 through 5.
It is yet another object of the invention to provide a one-pot process, in which the polymeric product is obtained from the monomeric unit which is made from a compound of Formula II. The compound of formula II, in turn, is prepared in situ from a compound of formula (III): ##STR6## wherein n+m=1 through 5.
Other objects of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
As explained above, the inventors have surprisingly found that it is possible to prepare polymers of formula I, which exhibit substantially improved thermal stability, by carrying out the polymerization reaction in a non-protic solvent. The term non-protic solvents refers to aprotic solvents (≡solvents that are not capable of proton transfer in water or methanol) and to aliphatic solvents. The improvement is dramatic, as the ITGA of the final product is 4-10 times better (lower) than that which is obtained according to the prior art, when the polymer is produced in a protic solvent.
As will be apparent to the skilled chemist from the description to follow, the invention provides the further advantage of permitting to carry out a one-pot process, in which the monomeric units which make up the polymer of Formula I, are prepared in situ. The process for the preparation of the thermally stable polymers according to the invention comprises polymerizing the monomeric units of formula Ia in a non-protic solvent.
DETAILED DESCRIPTION OF THE INVENTION
As stated, the invention comprises a polymerization reaction which is carried out in an a non-protic solvent. According to one preferred embodiment of the invention, the non-protic solvent may be an aprotic solvent of any suitable type, e.g., a ketone, or an ether. According to another preferred embodiment of the invention the non-protic solvent may be an aliphatic solvent. Illustrative but non limitative examples of suitable solvents include cyclohexane, diethylenglycol dimethylether, ethylenglycol dimethylether, 2-butanone (MEK), 4-methyl-2-pentanone (MIBK) and p-dioxane. Other suitable non-protic solvents will be easily recognized by the skilled chemist.
According to one possible embodiment of the invention, the polymerization of the monomers of Formula Ia is carried out in the presence of a polymerization initiator. Examples of suitable initiators are benzoyl peroxide and dicumyl peroxide. According to another preferred embodiment of the invention, the polymerization process can also be carried out without the presence of an initiator.
The reaction temperature varies according to the solvent and reagents employed. Generally, the polymerization can be conveniently carried out in the temperature range of 70° C.-120° C., although other temperatures can be employed.
According to a preferred embodiment of the invention the monomer of Formula Ia, is produced in situ, by esterifying a compound of Formula II with acrylic acid or a salt thereof. According to another preferred embodiment of the invention, the compound of Formula II is also made in situ by brominating a compound of Formula III.
A polymer of particular interest is poly-pentabromobenzyl acrylate (PBB-PA). This polymer is produced, according to a preferred embodiment of the invention, by polymerizing, in a non-protic solvent, pentabromobenzyl acrylate (PBB-MA) which can be obtained in situ by esterifying pentabromobenzyl bromide (PBB-Br), which, in turn, can be made in situ by bromination of pentabromotoluene (5BT). Of Course, both PBB-MA and PBB-Br can be used also if they have not been made in situ, although it will be appreciated that, under many circumstances, in situ intermediate production can be industrially useful and desirable.
The invention also encompasses polymers, the monomeric unit of which is given in Formula Ia, of high thermal stability, which are characterized by an ITGA (290° C., 30 min) of less than 34% weight loss.
All the above and other characteristics and advantages of the invention will be better understood through the following illustrative and non-limitative description of preferred embodiments thereof.
EXPERIMENTAL APPARATUS
1) In a Thermal Gravimetric Analysis apparatus (Mettler TC10A+TG50) the sample is heated from room temperature to 290° C. at a rate of 50° C./min. than the sample is kept at temperature of 290° C. for 30 min, all under a nitrogen stream. The ITGA parameter, which defines the weight loss of the sample (in percents) under the above conditions, was then measured.
2) GPC apparatus (Waters 150 C.), with refractive index detector of Waters, differential viscometric detector of Viscotec, and column of Plgel (Polym. Lab. 5μ and 10μ) was used for the determination of molecular weight.
EXAMPLE 1 (Comparative)
Esterification of PBB-Br to PBB-MA and Polymerization of PBB-MA to PBB-PA in methoxyethanol
PBB-MA was prepared according to the procedure described in GB 1,516,212, but using PBB-Br instead of PBB-CL. The following procedure was used: 1000 ml 4-necked jacketed reactor equipped with a digital reading mechanical stirrer, a condenser, a thermocouple probe and a gas inlet tube was charged with 257 g (267 ml) 2-methoxyethanol, 25.23 g (0.350 mole) distilled acrylic acid and 0.667 g hydroquinone. With slow stirring the contents are degassed. Na 2 CO 3 17.75 g (0.1675 mole) is added in small portions through a solid addition funnel with rapid stirring. Because the temperature begins to rise, the contents are cooled to 20° C. by a cooling oil bath. The nitrogen source is closed, so that bubbling reflects only CO 2 evolution. About 30 minutes are needed to complete the evolution of CO 2 from the beginning of addition. The nitrogen stream is then resumed, and PBB-Br 189 g (0.333 mole) is added over a period of 5 minutes. The flasks content is brought 110° C. and kept at this temperature for 3.5 hours with a stirring rate of 600-700 rpm. Another 333 ml 2-methoxyethanol are then added under a swift stream of nitrogen, followed by 3.33 g dicumyl peroxide. The internal temperature is raised to 120° C. and the reactor contents are maintained at this temperature with stirring (350 rpm) for 15 hr. After cooling the flasks content the resulting polymer product is removed from the reactor, washed with 2-methoxyethanol and then with water, and dried to constant weight at 120° C./5 torr. Reaction conditions and results are shown in Table I.
TABLE I______________________________________ Mole Mole Excess Exp. Acrylic Sodium Mole Acid salt No. Acid Carbonate PBB-Br mole % mole % % Yield______________________________________ 1 0.350 0.335 0.333 4.50 0.60 74.2 2 0.350 0.335 0.333 4.50 0.60 74.6 3 0.350 0.335 0.334 4.49 0.30 98.8 4 0.350 0.335 0.334 4.49 0.30 90.2 5 0.383 0.366 0.334 5.09 9.53 85.0 6 0.395 0.376 0.334 5.69 12.57 82.8______________________________________Esterfi- cation/ Polymer- ITGA ization 290° parameters C/ [time % 30 (h) and Resi- min temper- m.s. dual (% Exp. ature (deg mon- weight Mw Mn Mz No. (deg° C.)] LOD % C) omer loss) ×10.sup.5 ×10.sup. 3 ×10.sup.5______________________________________ 1 3.5 h, nd 200 13.2 34.1 110 C/ 15 h, 120 C 2 3.5 h, nd 186 14.6 40.8 110 C/ 15 h, 120 C 3 3.5 h, 1.46 197 <2.0 78.26 1.28 7.92 3.98 110 C/ 15 h, 119 C 4 3.5 h, 1.70 199 <2.0 45.29 0.714 2.01 3.09 110 C/ 15 h, 119 C 5 0.5 h, 0.38 207 <2.0 38.3 0.857 1.85 2.38 110 C/ 12 h, 120 C 6 0.166 h, 0.55 210 <2.0 59.18 1.08 5.07 5.19 110 C/ 15 h, 119 C______________________________________ m.s.:temperature at which melting starts nd:not determined
EXAMPLE 2
Polymerization of PBB-MA in MEK
A 500 ml 4-necked jacketed reactor equipped with a digital reading mechanical stirrer, a condenser, a thermocouple probe and a gas inlet tube was charged with 20 g PBB-MA and 350 ml MEK. The contents are degassed at room temperature with a stream of nitrogen at low stirring rate (200 rpm) for at least 30 min. The contents of the reactor are heated to 75° C. and 0.20 g of benzoyl peroxide are added under a swift stream of nitrogen. After stirring (500 rpm) three hours at 75° C. another 0.20 g of benzoyl peroxide are added and the reaction is continued for another three hours. After cooling to room temperature the solid is filtered, washed with toluene, with methanol and dried to constant weight at 120° C./50 torr. Yield of dry polymer 75% by weight. Reaction parameters and product characteristics are summarized in Table II below:
TABLE II______________________________________ ITGA 290° C./ 30 min PBB-MA Temp Time Yield Tg (% weight Mw Mn (mol/l) (°C.) (hr) (%) (°C.) loss) ×10.sup.4 ×10.sup.3______________________________________0.1 75 6 75 164 14.5 15.5 8.9______________________________________
EXAMPLE 3
Polymerization of PBB-MA in MIBK
A 500 ml 4-necked jacketed reactor equipped with a digital reading mechanical stirrer, a condenser, a thermocouple probe and a gas inlet tube was charged with 20 g PBB-MA and 350 ml MIBK. The contents were degassed at room temperature with a stream of nitrogen at low stirring rate (200 rpm) for at least 30 min. The contents of the reactor were heated to 110° C. and 0.20 g of dicumyl peroxide were added under a swift stream of nitrogen. After stirring (500 rpm) three hours at 110° C. another 0.20 g of dicumyl peroxide were added and the reaction was continued for another three hours. After cooling to room temperature the solid was filtered, washed with toluene, with methanol and dried to constant weight at 120° C./50 torr. The product was obtained in 80% yield and its ITGA parameter was 12.1% weight loss.
EXAMPLE 4
Esterification of PBB-Br to PBB-MA and Polymerization of PBB-MA to PBB-PA (one pot) in MEK
In a reactor as described in Example 2 above were placed 100 ml MEK (with a water content of 10 w %), and 3.35 g (83.75 mmol) NaOH. 6.19 g (86 mmol) acrylic acid were added dropwise with slow stirring and a mild increase in temperature. A slurry of sodium acrylate in MEK was obtained. 46.2 g of PBB-Br (81.6 mmole) were added while stirring at 400 rpm. After 2 hours the condensation was completed, 0.14 g of dicumyl peroxide were added and the temperature was raised to reflux temperature for 3 hours. The resulting polymer was obtained as a slurry in the solvent. After workup and drying a yield of 80% was obtained. The ITGA value was 6.3% weight loss (290° C./30 min).
EXAMPLE 5
Preparation of PBB-Br from 5BT and Esterification of PBB-Br to PBB-MA in Chlorobenzene, and Polymerization of PBB-MA to PBB-PA in MEK
In a 2 l three-necked flask equipped with thermometer, mechanical stirrer and condenser, were placed 250 g (0.51 mole) pentabromotoluene (5BT), 500 ml chlorobenzene, 80 ml water, 100 g (0.63 mole) bromine and 2.7 g 2,2'-azobis(isobutyromtrile) (AIBN). The mixture was heated to 75° C. for 5 hours. When the PBB-Br content reached more than 99% (area by GC) the reaction mixture was cooled to 50° C. and 37% NaHSO 3 was added slowly to destroy excess bromine. Aqueous NaOH solution was added to neutralize the reaction mixture and the aqueous, upper layer was separated. A Dean Stark distillation head was connected to the flask and the mixture was heated to 90° C. Residual water was distilled until less than 500 ppm of water were left. The flask contents were cooled to room temperature and anhydrous K 2 CO 3 , 47 g (0.34 mole), tetrabutylammonium bromide (TBAB) 4.1 g and 48% NaOH solution, 5.8 ml were added. Acrylic acid, 47.7 g (0.66 mole), was added slowly from a dropping funnel to prevent foaming and exotherm. When addition was completed the mixture was heated to 70° C. with vigorous stirring for 3 hours, until the reaction was completed according to GC analysis. The organic layer was washed with water to remove KBr and NaBr and the organic layer was cooled to permit crystallization of PBB-MA. Temperature at which melting of the product started was determined to be 122° C., while GC analysis showed 99% (by area) of PBB-MA. The PBB-MA was now used, as according to Example 2, for production of PBB-PA. ITGA value of the polymer was 14.5% weight loss.
EXAMPLE 6
Polymerization of PBB-MA in Cyclohexane
Example 2 was repeated, but MEK was replaced by cyclohexane and the reaction temperature was raised to 81° C. Reaction parameters and product characteristics are summarized in Table III:
TABLE III______________________________________ ITGA 290° C./ 30 min PBB-MA Temp Time Yield Tg (% weight Mw Mn (mol/l) (°C.) (hr) (%) (°C.) loss) ×10.sup.4 ×10.sup.3______________________________________0.08 81 7 80 165 5 4.8 9.3 0.08 81 7 80 166 8.7 n.a. n.a.______________________________________ n.a:not available
EXAMPLE 7
Polymerization of PBB-MA in Diethylenglycol Dimethylether
Example 2 was repeated, but MEK was replaced by diethylenglycol dimethylether and the reaction temperature was raised to 80° C. Reaction parameters and product characteristics are summarized in Table IV:
TABLE IV______________________________________ ITGA 290° C./ 30 min PBB-MA Temp Time Yield Tg (% weight Mw Mn (mol/l) (°C.) (hr) (%) (°C.) loss) ×10.sup.4 ×10.sup.3______________________________________0.04 80 7 5 159 4.6 11.6 4.6______________________________________
EXAMPLE 8
Polymerization of PBB-MA in Ethylenglycol Dimethylether
Example 2 was repeated, but MEK was replaced by ethyleneglycol dimethylether, and reaction temperature was raised to 70° C. Reaction parameters and product characteristics are summarized in Table V:
TABLE V______________________________________ ITGA 290° C./ 30 min PBB-MA Temp Time Yield Tg % weight Mw Mn (mol/l) (°C.) (hr) (%) (°C.) loss) ×10.sup.4 ×10.sup.3______________________________________0.04 70 8 34 164 33.5 0.34 1.7______________________________________
EXAMPLE 9
Polymerization of PBB-MA in p-Dioxane
Example 2 was repeated, but MEK was replaced by p-dioxane and the reaction temperature was raised to 70° C. Reaction parameters and product characteristics are summarized in Table VI:
TABLE VI______________________________________ ITGA 290° C./ 30 min PBB-MA Temp Time Yield Tg (% weight Mw Mn (mol/l) (°C.) (hr) (%) (°C.) loss) ×10.sup.4 ×10.sup.3______________________________________0.36 70 8 50 99 12.3 0.43 3.5 0.11 70 8 32 156 14.3 1.16 6.6______________________________________
EXAMPLE 10
Preparation of Poly-(2,4-dichloro-tribromobenzyl) acrylate from 2,4-dichloro-tribromobenzyl acrylate in MIBK
5 g of 2,4-dichloro-tribromobenzyl acrylate (m.p. 89° C.-92° C., % Br=51.54, % Cl=14.9) were dissolved in 20 ml MIBK and polymerized as described in Example 4. Yield of dry polymer was 72% by weight ITGA value (290° C./30 min) was 6.1% weight loss.
EXAMPLE 11
Preparation of Poly-(2-chloro-tetrabromobenzyl) acrylate from 2-chloro-tetrabromobenzyl acrylate in MIBK
5 g of 2-chloro-tetrabromobenzyl acrylate (m.p. 103° C.-107° C., % Br=59.72, % Cl=6.62) were dissolved in 20 ml MIBK and polymerized as described in Example 4. ITGA value (290° C./30 min) was 8.8% weight loss.
EXAMPLE 12
Preparation of Poly-(4-chloro-tetrabromobenzyl) acrylate from 4-chloro-tetrabromobenzyl acrylate in MIBK
5 g of 4-chloro-tetrabromobenzyl acrylate (m.p. 95° C.-99° C., % Br=59.98, % Cl=6.56) were dissolved in 20 ml MIBK and polymerized as described in Example 4. ITGA value (290° C./30 min) was 6.9% weight loss.
All the above description and examples have been provided for the purpose of illustration, and are not intended to limit the invention in any way. Many modifications can be effected in the process: for instance, different solvents and reaction temperatures can be used, or different polymerization initiators can be applied, and different polymers can be prepared from different monomers, all without exceeding the scope of the invention.
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A process for the preparation of thermally stable polymers of the formula I: ##STR1## wherein n+m=1 through 5, and x denotes the degree of polymerization, comprises polymerizing monomers of the formula Ia: ##STR2## wherein n+m=1 through 5, in a non-protic solvent.
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BACKGROUND OF THE INVENTION
Sausage stuffing devices ranging from relatively simple hand operated mechanisms to large, fairly complex automated devices are well known and commonly utilized throughout the industry. Such devices necessarily include means for holding and pressurizing the sausage mix and some confining conduit normally referred to as a horn whereby sausage mix may be direced into a sausage casing and the like in order to form a finished product. Dependent, of course, upon the source or sources of the material comprising the sausage mix such material may include in addition to edible portions such as both skeletal and non-skeletal meat, material normally considered edible such as relatively hard or tough components including bone, gristle, tendons, etc. Naturally, the less such hard particles present in the finished sausage product enables a more appetizing and easily chewed and digested product to be presented to the consuming public. Also substantial removal thereof would serve to additionally reduce potential injury to consumers i.e., damaged teeth and/or dentures.
Accordingly, attempts have been made in the past to reduce or limit the amount of such undesirable hard particles within finished products. Generally, such attempts took the form of the inclusion of a strainer element logically positioned downstream of the mix reservoir and upstream of the stuffing horn. Various such strainer configurations are depicted in the following U.S. Pat. No.: 80,035 issued July 14, 1868; U.S. Pat. No. 1,796,667 issued Mar. 17, 1931; and U.S. Pat. No. 2,253,465 issued Aug. 19, 1941.
In addition to such above-indicated devices, it is also known to remove totally foreign material from such sausage mix as by the magnetic removal thereof as indicated in U.S. Pat. No. 2,619,674 issued Dec. 2, 1952. Also, more recently, devices which attempt a higher recovery of edible meat portions from material containing both edible and normally inedible components have been introduced such as the devices et forth in U.S. Pat. No. 2,734,540 issued Feb. 14, 1956 and U.S. Pat. No. 3,906,118 issued Sept. 16, 1975.
No straightforward, relatively simple device, however, exists for removing hard particles from sausage mix wherein the strainer orifices thereof are not unduly restrictive to continued flow mix or which otherwise do not require overly complex or expensive machinery.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a device of the aforementioned type which can effectively and simply remove hard particles from sausage mix in a relatively inexpensive manner and one in which does not interfere with the continued flow of mix for the stuffing of sausages and the like.
A further object of the present invention is the provision of a device having means by which hard particles contained within a sausage mix passing through a flow passage under pressure may be temporarily restrained or suspended in such flow passage in such a manner that they may be periodically removed in a simple and uncomplicated fashion at periodic intervals during the use of the sausage stuffing device incorporating such invention.
A still further object of the present invention is the provision of a device for removing hard particles from sausage mix wherein a strainer member is positioned generally normal to the flow of sausage mix through a first conduit in such a manner that relatively hard particles restrained thereby are moved to positions within a second conduit laterally offset from the flow passage so as not to interfere with continued flow of sausage mix therethrough.
Still another object of the present invention is the provision of a device of the immediately aforementioned type wherein such restraining member may be positioned in alternate operational modes within its encompassing second conduit in such a manner so as to facilitate its removal and/or reinsertion thereinto.
These and other objects of the present invention are accomplished by a device for removing hard particles from sausage mix and the like comprising, a longitudinally orientated first tubular conduit forming a flow passage for said sausage mix under pressure therethrough, a laterally orientated second tubular conduit intersecting and disposed generally normal to said first conduit so that at least portions of said second conduit are laterally offset from said flow passage, a member positioned within said second conduit and extending entirely across said flow passage, said member including a plurality of continuous slotted openings having a cross-sectional configuration narrowing in the flow direction of said mix disposed therethrough, at least portions of said openings extending at least partially across said flow passage and extending laterally outwardly of said flow passage at least partially into said second conduit.
Additionally, other features and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrated drawing.
DESCRIPTION OF THE DRAWING
In the drawing which illustrates the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a partial front elevational view in somewhat stylized form of a sausage stuffing machine incorporating the device of the present invention;
FIG. 2 is a front elevational view similar to FIG. 1 but on a larger scale showing the device of the present invention with parts broken away and sectioned for purposes of clarity;
FIG. 3 is a side elevational view of the device shown in FIG. 2 also with parts broken away and sectioned and the alternate positioning of the removable member shown in phantom lines;
FIG. 4 is a sectional view on still a larger scale taken along the line 4--4 of FIG. 1;
FIG. 5 is a top plan view of one form in which the strainer member of the present invention may take; and
FIG. 6 is a top plan view of another form which such strainer member may take.
DESCRIPTION OF THE INVENTION
Referring now to the drawing and particularly FIG. 1 thereof, the device 10 of the present invention is depicted as mounted on the exit end of a stuffer horn 11 of a sausage stuffing machine (not entirely shown.) The device 10 may take the form as depicted of a cross-T connection having a first conduit 12 including an upper section 14 adapted to receive sausage mix under pressure and an exit portion or horn extension 16 through which the treaded sausage mix is adapted to outwardly pass as into a sausage casing 18. The outer configuration of the horn extension 16 may be altered to better accept the reduced neck portion of the sausage casing 18 for positioning thereon as by an elastic member 20 as is known in the art. The overall construction of the device 10 may be from stainless steel so as to be readily acceptable in the food industry or in those cases where the device may be utilized to strain hard particles from nonfood products various other suitable material may be utilized. It should also be pointed out that the term sausage mix as used herein includes other comestibles such as hamburg and may as well include noncomestibles having similar physical characteristics.
The upper section 14 generally is further provided with a threaded terminal portion or boss 22 for connection with a mating portion or collar 24 provided on horn 12 for interconnection therewith. Such first conduit 14 in effect forms a passage 26 therethrough. The device 10 also includes a second conduit 28 intersecting with and generally positioned normally to the first conduit 14 and provided at least at one end thereof with a removable end cap or other closure means 30 suitably secured thereto as through the provision of an outwardly threaded reduced neck portion 32. The other end thereof is preferably also provided with a similar construction so as to include an opening which also may be closed by an end cap 30 disposed on a similar reduced outwardly threaded neck portion 34 and in such a manner it insures that the internal portions of the second conduit 28 are completely accessible for cleaning through such end openings.
As best may be seen by reference to FIGS. 2 through 4, the internal passage 35 of the second conduit is provided with a pair of recesses 36 disposed in opposed position from each other and in turn adapted to receive in slidable engagement therewith the outwardly extending flanges 38 of a strainer member 40. As depicted, the strainer member 40 is adapted for positioning in a generally normal position to the flow of mix passing through the passageway 26 of the first conduit 14 and is, as best shown by FIGS. 5 and 6 provided with a plurality of slotted openings 42 disposed in generally parallel relationship to each other laterally across the width of such member 40. The openings may be disposed longitudinally generally along the entire length of the member 40 as shown by opening 42a of FIG. 6 or may be separated as shown by slots 42b in FIG. 6 so as to define an integral web 44 disposed therebetween. Such web is disposed generally centrally of the flow passage 26 when the member 40 is positioned within the second conduit 28 and extends generally normal to such passage and provides portions thereof that laterally outwardly extend into the second conduit proper.
The cross-sectional configuration of the openings 42 is preferably that of an hourglass having inwardly sloping entrance portions 46 and a midsection 48 of reduced diameter. In this way then, sausage mix moving along the passage 26 is free to move through the openings 42 and thus into the casing 18, the pressure under which such action is accomplished tending to flatten out soft meat particles so that they are forced through the slot 42 whereas harder particles such as gristle or bone become hung up, wedged, or caught therein so as to become temporarily suspended within passageway 26 by reason of the member 40. Naturally if several hard particles become suspended as above indicated, such could reduce the available area through which the mix may pass and accordingly the slots 42 are of a longitudinal extent which is substantially greater than that of those portions of the passageway 26 in which they are positioned so that the flow of mix passing centrally tends to be diverted along outwardly directed paths by means of the central web 44 and in this manner tend to force the hard particles hung up within the slots 42 outwardly in either direction away from the passageway 26 and into outer portion of the second conduit 28. Such action and configuration of the slotted member 40 enables longer stuffing intervals to be conducted before the necessity of cleaning the member arises. Such cleaning is facilitated by the openings provided by the removable end caps 30 above discussed whereupon the member 40 may simply be forced laterally outwardly from the second conduit 28, cleaned and reinserted.
Inasmuch as the entire internal cavity of the device 20, that is, both conduits 14 and 28 are filled at least to some extent with mix during operation, the possibility exists that the recesses or one of the openings when only one end cap 30 is removed may become plugged with material and in order to facilitate the reinsertion of the strainer member 40 along such recesses, the flanges 38 thereof are purposely not centered along the thickness of the plate so as to present alternate surfaces 50 and 52 which may be presented to the oncoming stream of mix. One such surface i.e., 52 is shown supported upon a reduced width portion 54 of the plate 40 so that such reduced width portion 54 may be alternately upwardly disposed (as shown by the phantom lines in FIG. 3) within the second conduit 28 and in this way in case its reinsertion is blocked in one such position it can be turned over and reinserted in the alternate position.
It should be pointed out that the width of the slots 42 can be varied depending on the density and particle size of the Furthermore, it has been specifically found that a slot having an 1/8 inch opening at the reduced portion 48 thereof is suitable for a mix having meat particles ranging from 1/4 to 1/2 inch along their largest dimension and that openings 3/16 of an inch wide are suitable for meat particles in 3/4 inch chunks. Use of the device of the present invention resulted in sausages in which upon examination almost no hard particles i.e. bone or gristle were found.
It is accordingly believed that the construction set forth above presents a simple, straightforward, easily cleaned, and quickly manageable device which accomplishes the desired objectives of the present invention and one which is not overly expensive to produce.
While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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A device for use with a sausage stuffer having a first tubular conduit forming a flow passage for sausage mix and a laterally orientated second tubular conduit intersecting and disposed generally normal to said first conduit and laterally offset therefrom, a member positioned within the second conduit and extending entirely across the flow passage and laterally outwardly thereof into said second conduit, said member being provided with a plurality of slotted openings of reduced cross-sectional configuration to entrap undesirable hard particles within sausage mix such as bone, gristle, and the like so that such may be subsequently removed by way of said second conduit.
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RELATED APPLICATIONS
An application entitled "Washing Machine with Snubbers for Limiting Unbalanced Load Vibration Excursions" was filed on Aug. 1, 1994, as U.S. application Ser. No. 08/283,726 and still pending. The application is assigned to the same assignee as the present application.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to a washing machine, and, more particularly, to a coil spring and snubber suspension system for a clothes washer.
BACKGROUND OF THE INVENTION
During operation of a washing machine, an unbalanced load of clothes or other articles may cause the basket to spin or rotate off-axis and may cause the tub containing the basket to vibrate. The vibration excursions tend to be especially acute during the start of the spin cycle. At the beginning of the spin cycle, the excursions may become large enough, as the machine passes through resonance of the suspension, for the tub to bang against the washer housing. As the washer spin cycle progresses, the rotational speed of the baskets increases, and the excursions tend to be limited because the clothes redistribute themselves and because the machine passes through resonance of the suspension. Stiffening the suspension will keep the tub aligned, but permanently stiffening the suspension will increase the suspension frequency causing the machine to pass through resonance at a higher, more damaging speed. Accordingly, it will be appreciated that it would be highly desirable to temporarily stiffen the washer suspension to keep the tub aligned without permanently increasing the stiffness of the suspension.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, according to one aspect of the invention, a washing machine comprises a housing, a mounting platform within the housing, a tub having a vertical axis and mounted on the platform within the housing, a basket in the tub for holding articles to be washed, an agitator within the basket to facilitate washing of the articles, apparatus for imparting oscillating motion to the agitator, apparatus for rotating the basket, and a plurality of coil spring and snubber suspensions. Each suspension has a coil spring with a snubber mounted therein. The coil spring has an extension rod. The snubber sidewall defines an orifice providing a passageway for metering egress and ingress of air from the snubber cavity during a change in volume of the snubber cavity so that the resiliency of the snubber increases for high frequency excursions to thereby stiffen the coil spring body during high frequency excursions.
These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of a washer according to the present invention with a right side panel removed to illustrate a preferred embodiment of a coil spring and snubber suspension.
FIG. 2 is a diagrammatic top view of the washer of FIG. 1 illustrating tub excursions; and
FIG. 3 is an enlarged perspective view of one of the suspensions shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a washing machine 10, for washing a load of articles of clothing and the like, has a housing 12 containing front and rear panels, 14, 16, left and right panels 18, 20, and a top panel 22. An opening 23 is provided in top panel 22 for loading articles in machine 10. A pivotal closure panel 24 is provided for opening 23. Typically, one of the front and rear panels 14, 16 is removable for access to the interior mechanisms of the washing machine 10. Within the housing 10 is a mounting platform 25 with a motor 26, a transmission assembly 28 and a tub assembly 30 mounted thereon. As illustrated, the motor 26 and transmission 28 are positioned on a lower portion of the platform 25 while the tub 30 is mounted on the platform 25 above the motor 26 and transmission 28. As is known in the art, the transmission 28 and wash basket 38 are connected via a shaft. Positioning the transmission 28 on the platform 24 below the tub 30 lowers the center of gravity of the washer 10 which encourages more stable operation.
The tub assembly 30 has a tub 32 with a top edge portion 34 and vertical axis 36 and is positioned on the platform 25 in the housing 12 so that it is spaced from the housing panels 14, 16, 18, 20. The tub assembly 30 contains a basket 38 that is positioned in the tub 32 for holding the articles to be washed. The basket 38 contains an agitator 40 connected to the transmission 28 via a shaft. The transmission 28 transfers energy from the electric motor 26 for operating the basket 38 and agitator 40 during the various cycles of operation of the washer 10.
During a spin cycle, for example, the transmission 28 rotates the basket 38 about the vertical axis 36 in a circular path with the basket 38 remaining vertically upright when the articles to be washed form a balanced load in the basket. When the articles in the basket form an unbalanced load, the basket 38 has a tendency to rotate askew of the vertical axis 36 in a noncircular path with the basket being urged from vertical on excursions. The basket excursions urge the tub 32 from its spaced position relative to the housing panels 14, 16, 18, 20.
At the beginning of a spin cycle, when the load is unbalanced, there may be severe excursions wherein the tub contacts a housing panel. Severe excursions are not only noisy and potentially damaging to the washer, but may cause the washer to move from its position on the floor and walk across the floor, especially where the floor is weak or uneven. Accordingly, most washers are equipped with a shut down system to turn the machine off when the excursions reach a predetermined magnitude or intensity.
As shown in FIG. 1 and in enlarged detail in FIG. 3, a plurality of coil spring and snubber suspensions 42 provide support for tub 32 and basket 38 to minimize vibration. While two such suspensions are effective, three minimize most effectively the basket excursion effects. The three suspensions are positioned 120° apart around the tub 32. If four such suspensions are used, they are equally spaced around the tub 32 in a preferred embodiment.
Each coil spring and snubber suspension 42 has a coil spring 44 with mounting loops 46 and 48 at opposite ends thereof and an extension rod 50. A first snubber 52 is positioned inside the coil spring 44. The snubber 52 is a resilient member that has a first end portion with a mounting lug 54, a second end portion with a mounting lug 56, and a resilient middle portion 58 intermediate the end portions. Each of the lugs 54 and 56 contain an aperture 60. The snubber 52 is preferably constructed of a synthetic resinous material that can be molded into the configuration desired, such as polypropylene, for example.
Preferably, the resilient middle portion 58 of the snubber 52 has a sidewall defining a first cavity and also defining at least one orifice 62 that provides a passageway for ingress and egress of air to the cavity during a change in volume. The orifice meters the air so that the resiliency of the snubber middle portion 58 is greater for low frequency excursions than for high frequency excursions. The sidewall may be thickened around the orifice 62 for reinforcement. The orifice may be fitted with or formed with a nipple for directing the air to an out of balance load sensor which shuts down the washer during certain conditions.
Preferably, the snubber has an enclosure with walls in which the sidewall has folds, like a fan or like the bellows of an accordion, to easily accommodate the change in volume and to easily fit in the coil spring 44. The snubber may have a plurality of cavities. Where there are a plurality of cavities, more than one cavity may have an orifice. Cavities may have multiple orifices, a single orifice, or no orifice at all. Cavities not having an orifice may still change in volume by compressing or expanding the air confined therein.
The first snubber 52 is positioned inside the coil spring 44 and has its first lower end lug 54 attached to the mounting loop 46 of the coil spring 44 by a rivet through loop 46 and aperture 60 in lug 54. Other means of attachment such as a nut and bolt, can be employed. The second upper end lug 56 is attached through its aperture 60 to the mounting loop 48 of the coil spring by a rivet through loop 46 and aperture 60 in lug 56. The rivet attaches also to the upper end of the coil spring 44 to the upper edge 62 of platform 25. The extension rod 50 of suspension 42 extends from the lower end of spring coil 44 and is attached to the inner surface of top panel 22. The middle portion 58 has a sidewall defining a first cavity therein which changes in volume in response to predetermined basket excursions to thereby minimize effects of the basket excursions. The sidewall defines at least one orifice 62 providing a passageway for metering air from the cavity during a change in volume so that the resiliency of the snubber increases for high frequency excursions to thereby stiffen the coil spring body during high frequency excursions.
A second snubber 64 of the same size or different size from first snubber 52 has a first end portion with a mounting lug 64, a second end portion with a mounting lug 66, and a resilient middle portion 66 intermediate the end portions. Both lugs have an aperture 68 therein. The second snubber is made of the same material as the first snubber. The middle portion 66 has a sidewall defining a first cavity therein which changes in volume in response to predetermined basket excursions as does the first snubber. Orifice 70 provides an air passageway. The first and second snubbers may be separate units or may be integrally formed
The second snubber 64 has lug 66 affixed to the inner surface of one of the washing machine panels by means, for example, of a hook 70 extending through aperture 68 and welded to the panel. The opposite end lug 64 is attached through its aperture 68 to upper lug 56 of first snubber 52 prior to riveting lugs 64 and 56, and loop 48 together and to the upper edge 62 of platform 25.
During operation, in response to large, low frequency tub excursions at the start up of a spin cycle, air in each snubber enters and exits through its orifice as the volume of the cavity changes to absorb the energy of the excursion. The second snubber limits the final volume of its cavity and the rate at which air enters and exits the cavity to control excursions. The first snubber works directly in cooperation with the coil spring. Initially, with the coil in its normal compression, a low frequency excursion tending to further compress the spring must also compress the first snubber. The first snubber is free to compress to empty its cavity, then it stiffens the spring making the spring more resistant to compression from excursions. The spring works alone for taking up compressive low frequency excursions. With the coil in its normal compression, a low frequency excursion tending to expand the spring must also expand the first snubber. The first snubber is free to expand to fill its cavity, then it stiffens the spring making the spring more resistive to expansion from excursions. The spring works alone for resisting expansive low frequency excursions. Of course, it will be understood by those skilled in the art that the resiliency of the snubber or size of the orifice or cavity may be changed to achieve a desired low frequency response with a particular coil spring.
In response to high frequency tub excursions after the start up of a spin cycle, air entering and exiting each snubber through its orifice to change the volume of the cavity to absorb the energy of the excursion is restricted by the size of the orifice. The second snubber stiffens to control high frequency excursions. The first snubber works directly in cooperation with the coil spring. Initially, with the coil in its normal compression, a high frequency excursion tending to further compress the spring must also compress the first snubber. The first snubber is not free to empty its cavity because the orifice is too small; so, it stiffens the spring making the spring more resistant to compression from high frequency excursions. With the coil in its normal compression, a high frequency excursion tending to expand the spring must also expand the first snubber. The first snubber is not free to expand to fill its cavity because the orifice is too small; so, it stiffens the spring making the spring more resistant to expansion from high frequency excursions.
While the invention has been described with particular reference to the preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements of the preferred embodiments without departing from invention. For example, other configurations of snubbers other than cylindrical may be used and the snubbers and spring may be attached at locations along the panels, tub and platform other than those illustrated. In addition, many modifications may be made to adapt a particular situation and material to a teaching of the invention without departing from the essential teachings of the present invention.
As is evident from the foregoing description, certain aspects of the invention are not limited to the particular details of the examples illustrated, and it is therefore contemplated that other modifications and applications will occur to those skilled the art. For example, the resiliency of the snubber or size of the orifice or cavity may be changed to achieve a desired high frequency response with a particular coil spring. It is accordingly intended that the claims shall cover all such modifications and applications as do not depart from the true spirit and scope of the invention.
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A suspension spring assembly for a washing machine employs a coil spring in compression. The suspension spring system uses a snubber mounted inside the coil spring to help dampen and isolate unbalanced load excursions by using the positive displacement pumping action of air being forced through an orifice in the snubber. A second snubber may be employed with the coil spring.
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RELATED APPLICATIONS
The present invention claims priority to U.S. Ser. No. 61/236,656 filed Aug. 25, 2009, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to ground-based conditioned air systems for aircraft.
BACKGROUND
It is generally known to supply commercial aircraft with conditioned air for heating and cooling when the aircraft is stationary at a gate. In this application, the term gate is meant to refer to any place that an aircraft receives or discharges passengers or cargo. This may be by way of a telescoping corridor (also referred to as a walkway, bridge way, jet bridge), stairs, or any other facility. Typically, conditioned air is supplied to the aircraft from a pre-conditioned air (PCA) unit associated with the gate that is a part of the airport terminal. The PCA unit may produce heated air or cooled air depending on the needs of the aircraft it is servicing. The PCA outputs its air into a duct that may be rigid or flexible, and then the air is delivered from the gate to the aircraft with a flexible and usually insulated air hose. When not in use, the hose is usually stored under the terminal. In some installations a branch of the same duct, or a separate one, may be used to supply preconditioned air to the enclosed walkway that passengers walk through to access the airplane. In such a case, there may also be a return air duct from the walkway to the PCA unit, or there may not be one.
A problem arises if the PCA unit starts to malfunction and fails to supply the cooled air or the heated air of which it is capable. It is easy for this condition to go undetected, because a PCA unit is not used like a typical building heating, ventilation, and cooling (HVAC) unit. In the latter, the HVAC is permanently connected and typically running per the commands of a thermostat that is sensing room air temperature. The HVAC unit services a building of a given size, with a permanent ducting system that is never kinked, improperly connected, or torn. Usually there is a steady group of occupants, and a designated maintenance person to pay attention to the HVAC system. If the occupants become uncomfortable, it is quickly evident that the HVAC system is probably not cooling or heating to its usual ability, and corrective action is taken. But the situation with a PCA unit is different. For example, the PCA unit is called upon to service aircraft of different sizes. The flexible hose is often kinked because usually a single length hose is used to hook up aircraft with connections at varying distances from the PCA unit. The hose may be torn. There may be a delay in how quickly the PCA unit is hooked up to the aircraft and turned on. It may only be hooked up for a short time. Somebody may fail to turn the PCA unit on. The PCA unit may be switched off overnight even though an aircraft is parked at the gate, and the aircraft heats up in the sun the next morning, or cools down excessively overnight. For these and various other reasons a complaint of “too hot” or “too cold” by the people using the aircraft and the walkway may be considered of limited value by the ground based personnel who have to keep many PCA units operating. A decrease in operating performance by a PCA unit is likely to go unnoticed and unattended to by the people who could fix it before complete failure.
SUMMARY OF THE INVENTION
Thus, there is a need for a device that measures the output temperatures of a PCA unit close to the aircraft, so the measurement provided is unaffected by the vagaries of aircraft changes, air hose installations, and other conditions. Further, the device should alert people of a problem so that corrective action can be taken.
In accordance with principles of the present invention, the performance of a PCA unit associated with an airport gate is monitored by a temperature sensor in the stream of output air leaving the PCA unit, to produce a signal indicative of the temperature of the output air that may be compared to an acceptable range of values, or to the temperature of air input to the PCA unit (as measured by a second temperature sensor). An alert is generated to a human operator if the temperature measured does not compare favorably with the desired range.
Particular aspects involve both the apparatus for monitoring and the monitoring method described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view illustrating an embodiment of the present invention installed at a PCA unit under an airport bridge way.
FIG. 2 is a perspective detail view of the control unit of the embodiment of FIG. 1 .
FIG. 3 is a perspective detail view of the control unit of FIG. 3 with an access door open.
FIG. 4 is a perspective view illustrating a second embodiment of the present invention installed at a PCA unit under an airport bridge way.
FIG. 5 is a partial electrical schematic of the embodiment of FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 illustrates a preconditioned air (PCA) temperature monitor 10 having a main box 11 (see FIG. 2 ) mounted near a PCA unit 12 on an airport bridge way 14 . The PCA unit 12 blows preconditioned air into a duct 16 that runs to a PCA hose and airplane 18 . A smaller duct 20 supplies air to the bridge way 14 , although in many installations this smaller duct 20 may not exist or may be separate from the duct 16 . Not all bridge ways 14 are supplied with air by a PCA unit 12 . The PCA unit 12 has a temperature sensor 22 in the duct 16 to measure the temperature of air leaving the PCA unit 12 . In one embodiment the temperature sensor 22 is a thermistor, although it could be another type of device. As illustrated, the temperature sensor 22 is remote from the main box 11 , but it could be integral, depending on the specific design and mounting location. An electrical connection 24 from the PCA unit 12 provides a signal 26 to the PCA monitor 10 whenever the PCA unit 12 turns on. In some embodiments, the signal 26 may include information as to whether the PCA unit 12 is running in heating mode or cooling mode. A signaling device 28 in the form of a rotating or flashing light beacon is located in the operator's station of the bridge way 14 . The signaling device 28 could be located in other places and take other forms. It may be wireless.
FIGS. 2 and 3 schematically illustrate various portions of the main box 11 . The front panel 30 has a cool cycle indicator 32 , a heat cycle indicator 34 , an over temperature indicator 36 an under temperature indicator 38 , and a light test button 39 . A display window 40 is aligned with a heat cycle display 42 and a cool cycle display 44 . Fittings along the bottom accept connections to the temperature sensor 22 , the PCA unit 12 , and the signaling device 28 . A timing circuit 46 determines when the PCA unit 12 has been on long enough that it and the path to the temperature sensor 22 should be at a steady state, rather than significantly changing. Alternatively, the timing circuit 46 used to predict steady state could be external to the PCA unit 12 , or, steady state could be determined by the rate of change at the temperature sensor 22 and not be estimated by the elapsed time. Because an electrician of ordinary skill in the art could wire the PCA monitor 10 to the circuitry of the PCA unit 12 , the wiring will not be further described here. What is important is that the PCA monitor 10 determine when the PCA unit 12 is operating and at steady state.
At least one settable memory device 48 has a value for an appropriate cooling cycle high temperature limit 50 and an appropriate heating cycle cold temperature limit 52 . Heat cycle display 42 and cool cycle display 44 , visible through the display window 40 , show the limit values, and if desired the actual values. The limits are input either by inputting them into the box directly or remotely.
The PCA monitor 10 further comprises processing circuitry 54 and comparison circuitry 56 to compare the signal from the temperature sensor 22 to the temperature limits. Values that do not meet the limits will trigger the over temperature indicator 36 or the under temperature indicator 38 and the signaling device 28 .
In use, a person, usually in a maintenance department, will set the cooling cycle high temperature limit 50 and the heating cycle cold temperature limit 52 to values based on the PCA unit's manufacturing specifications, or experience. Ordinarily the over temperature indicator 36 and the under temperature indicator 38 will remain off. Only if the PCA unit 12 is unable to precondition the air to the limits do the lights illuminate. The test button 39 activates test circuitry to confirm the lights are in working order.
If desired, the circuitry could be arranged differently. For example the indicator 36 and indicator 38 could be set to illuminate when things are working properly, and extinguish if they are not.
FIG. 4 illustrates a second embodiment of a PCA monitor 210 that may enhance the ability to choose the cooling cycle high temperature limit 50 and the heating cycle cold temperature limit 52 that are more exact and work under a greater variety of conditions without giving false alarms.
One consideration when measuring only the temperature of the output air, as in FIG. 1 , is that the temperature of air that PCA unit 12 outputs is affected by the temperature of the air it is receiving to heat or cool. For example, the output temperature of a PCA unit 12 in cooling mode when cooling one hundred ten degree outside air is different than when cooling seventy-five degree outside air. In general, a PCA unit 12 should be able to change the air temperature a given amount, often referred to as a “ΔT” (Δ meaning difference, and T meaning temperature), the difference in output air temperature verses input air temperature.
To that end PCA monitor 210 comprises an ambient air sensor 58 located away from any influences such as sunlight or thermal exhausts. It may be put directly in an entrance 60 to the PCA unit 12 , although it is not shown that way in this illustration. If a bridge way 14 has a return duct 62 to the PCA unit 12 , it may have a return temperature sensor 64 . The PCA monitor 210 has a main box 211 that includes processing circuitry 54 to determine a value indicative of delta T, and the memory device 48 similarly contains acceptable limits for delta T.
Although the main box 211 is illustrated as different from the main box 11 , it is contemplated that a single main box 211 may be manufactured, and the features either not used or fully used, depending upon the actual installation.
FIG. 5 is an electrical schematic of the embodiment 10 , with numerals corresponding to those described with reference to previous figures.
The invention has been described herein with reference to specific embodiments, and those embodiments have been explained in substantial detail. However, the principles of the present invention are not limited to such details which have been provided for exemplary purposes. Further, the monitoring system although specifically described in terms relevant to a PCA unit 12 at an airport, may apply to other devices heating and cooling air or another gas or liquid.
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The performance of a PCA unit associated with an airport gate is monitored by a temperature sensor in the stream of output air leaving the PCA unit, to produce a signal indicative of the temperature of the output air that may be compared to an acceptable range of values, or to the temperature of air input to the PCA unit (as measured by a second temperature sensor). An alert is generated to a human operator if the temperature measured does not compare favorably with the desired range.
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TECHNICAL FIELD
The present relation relates to an improved method and apparatus for dispensing a rinse water additive in an automatic washing machine.
The present invention further relates to such a method and apparatus which is especially suited to highly concentrated rinse water additives which are added in relatively small volume, thereby making accurate measurement and avoidance of leakage during the wash cycle critical to obtaining the desired benefits to be provided by the additive during the rinse cycle.
The present invention has further relation to such a method and apparatus wherein the center of gravity of the apparatus and the rinse water additive fluid contained therein is maintained in such position that rinse water is readily able to enter and exit the dispenser during the rinse cycle after the dispensing valve has been opened, thereby ensuring that all of the rinse water additive initially provided in the dispenser is fully utilized during the rinse cycle.
BACKGROUND OF THE INVENTION
Dosing dispensers for the addition of laundering and softening materials during the washing and rinsing cycles in an automatic washing machine are well known in the art.
Dispensers for adding materials during the rinse cycle in an automatic washer are generally more complex than those employed for adding materials during the wash cycle due to the fact that the rinse additive dispenser is normally inserted when the wash cycle begins and must survive the entire wash cycle without dispensing the material contained inside, yet reliably open during the spin cycle at the conclusion of the wash cycle to deliver the rinse water additive at a point in time which will be effective.
One prior art example of such a rinse water additive dispenser is disclosed in commonly assigned U.S. Pat. No. 3,888,391 issued to Merz on Jun. 10, 1975 and hereby incorporated herein by reference.
Another example of such a prior art rinse water additive dispenser is disclosed in U.S. Defensive Publication No. T993,001 to McCarthy, which was published on Apr. 1, 1980, and which is hereby incorporated herein by reference.
Dispensers of the aforementioned type employ a valve means which is automatically opened by centrifugal forces acting upon a counterweight during the spin cycle at the conclusion of the wash operation. After the spin cycle, dispensers of the aforementioned type fall from the wall of the washing machine drum and rinse water floods the dispenser, mixing with and dispensing the additive into the rinse water.
While dispensers of the aforementioned type have functioned adequately for their intended purpose with prior art rinse water additives, recent trends in the development of more effective rinse water additives have been in the direction of more highly concentrated products which deliver comparable performance benefits to the less concentrated products which they are tending to replace. For example, one fluid ounce of a highly concentrated fabric softener, such as Ultra Downy® now being marketed by The Procter & Gamble Company of Cincinnati, Ohio, can deliver benefits comparable to three fluid ounces of a less concentrated fluid softener product of the type which has been on the market for several years.
However, to obtain maximum performance benefits from the newer more highly concentrated products, accuracy of measurement has become much more critical. In addition, it has become much more critical that substantially all of the additive material initially placed in the dispenser be retained within the dispenser during the wash cycle, since any lost additive material will not be available to accomplish its intended objective during the rinse cycle.
Prior art rinse additive dispensers of the type described earlier herein are generally spherical in shape and employ a fill mark to indicate when the desired amount of additive has been poured into the dispenser. While the fill mark approach in a spherical dispenser has worked well for products which are relatively dilute (when compared to the more highly concentrated products being marketed today) when the volume of product to be added is quite small accurate measurement thereof is quite difficult to achieve with prior art style dispensers because even a slight deviation from the fill mark represents a substantial change in product volume, i.e., the cross-section of the sphere increases rapidly in the area of the fill mark so that slight deviations from the fill mark represent substantial deviations in the amount of product actually included within the dispenser, particularly if the user overshoots the fill mark.
In addition, it has been observed that prior art dispensers of the type described earlier herein may tend to lose some of the additive initially placed in the dispenser during the wash cycle due to flexing of the valve member during the wash cycle, even though the valve may remain in a substantially closed condition until the dispenser is subjected to a spin cycle. This loss of product also negatively impacts the benefits provided by highly concentrated rinse additives, since their loss during the wash cycle renders them unavailable to impart benefits to the laundered fabrics during the rinse cycle. Loss of the highly concentrated additive is particularly detrimental, since it results in a greater loss of the active materials when compared to less concentrated fluid product forms.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved method and apparatus which makes accurate measurement of the laundry additive into the dispenser relatively easy for the user.
It is another object of the present invention to provide a dispensing apparatus having an improved valve seal which substantially prevents the loss of any laundry additive from the dispenser during the wash cycle.
It is still another object of the present invention to provide such an improved rinse additive dispenser which will maintain the center of gravity of the dispenser and the additive contained therein in a position that will ensure the ability of the rinse water to enter and exit the dispenser through the filling/dispensing aperture of the dispenser once the valve used to close the filling/dispensing aperture has moved to its open position to effectively utilize all of the rinse additive originally placed within the dispenser.
DISCLOSURE OF THE INVENTION
Briefly, the present invention, in a particularly preferred embodiment provides an improved method of accurately measuring a relatively small amount of fluid additive within the confines of an improved dispenser. The improved method involves adding the liquid additive to a dispenser which is provided with a base having an internal upwardly extending pushup configuration. In a particularly preferred embodiment the pushup configuration extends proximately to the desired fill level of laundry additive in the dispenser. It can, if desired, also extend above the desired fill level. Thus, the laundry additive forms an annular column within the dispenser so that even though a relatively small amount of fluid is involved, the rise of the fluid in the annular column can be readily observed and accurately controlled. This also alleviates the severity of minor errors caused by slightly missing the predetermined fill line or fill point in the dispenser, since the amount of fluid per unit of vertical height within the dispenser is determined only by the volume of the annular column, and not the entire cross-section of the dispenser.
The internal pushup configuration within the dispenser also serves to prevent the counterweight and valve used to close the filling/dispensing aperture from interfering with the fluid measurement process, since the annular column formed by the pushup configuration is preferably sized so as to prevent any portion of the counterweight or valve member from entering into the annular column and displacing any of the fluid being measured during the dispenser filling process.
Finally, the pushup configuration of the base within the dispenser of the present invention can be used to adjust the center of gravity of the dispenser to ensure that the filling/dispensing aperture in the dispenser will be properly oriented when the dispenser is lying in the washer drum as the rinse water is entering. A substantially horizontal orientation of the dispenser's vertical axis allows the rinse water to readily enter and flood the dispenser through the filling/dispensing aperture once the valve is opened. This is preferably accomplished by vertically positioning the uppermost portion of the pushup configuration within the dispenser so that it prevents the counterweight used to open the valve from getting too near the base of the dispenser. In addition, the internal pushup configuration can be thickened, as desired, to provide sufficient ballast at the bottom end of the dispenser so that the vertical axis of the dispenser will normally be oriented in a substantially horizontal position within the rinse water. This further helps to ensure that rinse water may readily enter and exit through the filling/dispensing aperture throughout the rinse cycle when the valve is open. Because it is not necessary to see through the internal base pushup configuration during the filling cycle, the thickened plastic which may be employed as ballast in this portion of the dispenser does not interfere with the user's ability to view the level of liquid additive as it is poured into the dispenser. Thus, in a particularly preferred embodiment of the present invention which employs a translucent, preferably transparent, dispenser body, accurate measurement of small fluid volumes, e.g., on the order of one fluid ounce, is readily feasible. This measurement is made even easier if the laundry additive in question is colored or tinted so that it contrasts with the dispenser body.
In yet another aspect of the present invention, an improved sealing valve is provided in the dispenser to substantially prevent the loss of any rinse additive material during the wash cycle. Unlike prior art dispensers of the type described earlier herein which attempt to form a face seal about the filling and dispensing aperture in the dispenser body, the improved seal valve of the present invention repositions the liquid seal to an internal cylindrical or tubular member which projects from the innermost surface of the dispenser body about the filling/dispensing aperture. The improved seal valve employs a mating flange having a resiliently deformable outermost periphery which forms a piston-type seal with the innermost surface of the cylindrical member. Because the flange can move about its axis and back and forth within the cylindrical member without losing its sealing engagement with the cylindrical member, vibrations imparted to the sealing valve by movement of the counterweight prior to actual opening of the valve do not permit loss of the fluid additive from the dispenser during the wash cycle. Thus, substantially all of the fluid additive material initially placed in the dispenser is available for dispensing into the rinse water once centrifugal forces applied during the spin cycle have caused the valve detent to disengage from the filling/dispensing aperture in the body of the dispenser.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the present invention will be better understood from the following description in conjunction with the accompanying drawings in which:
FIG. 1 is a sectioned front elevation view of a dosing dispenser, taken through the center of the dispenser, showing the dispenser setting upright with valve open and fluid being poured into the annular volume around the pushup configuration.
FIG. 2 is a sectioned front elevation view of a dosing dispenser, taken through the center of the dispenser and through a vertical section of the washing machine drum, showing the dispenser held against the spinning washer drum just before centrifugal force pulls the cantilevered weight toward the drum to open the valve.
FIG. 3 is a sectioned front elevation view of a dosing dispenser, taken through the center of the dispenser, showing the dispenser as it would normally lie on the bottom of the drum after the spin cycle with its valve open, just before rinse water enters the dispenser to flood the dispenser and begin flushing out the product fluid.
DETAILED DESCRIPTION OF THE INVENTION
The Body
Referring now to the Drawings, and more particularly to FIG. 1, there is shown a preferred embodiment of the present invention, generally indicated as 10. A fluid dispenser chamber 12 is constructed with continuous side walls 14, with open finish 16 and closed bottom end 18. Snapped onto finish 16 is valve housing 20. Valve housing 20 has an annular flange or face 22 surrounding filling/dispensing opening 23. Opening 23 is the only fluid communication opening between chamber 12 and the outside of the dispenser. Annular flange or face 22 serves as a detent which holds the valve member in its closed position. Valve housing 20 also has an internally extending cylindrical wall 24, the internal surface of which forms a seal with the resiliently deformable periphery of a flange 46 on the valve member 42.
The Weight and Pull Ring
In FIG. 1 a valve and weight assembly 26 is shown unseated within chamber 12, resting against inside surface 28 of pushed up bottom end 18. Assembly 26 has a preferably rigid weight 30 and rigid stem 32. At the end of stem 32, opposite weight 30, is a tapered portion 34 with hole 36 therethrough. Connected to tapered portion 34 through hole 36 is a chain 38. Connected to the other end of chain 38 is pull ring 40. Pull ring 40 is used to manually seat assembly 26 after chamber 12 is filled to the desired level with product fluid.
Because the chain and pull ring are flexibly connected to one another, they cannot impart opening forces against the valve member during the wash cycle. They can exert forces only in tension. Furthermore, because the valve member, including tapered portion 34, are recessed completely within valve housing 20, they are substantially protected against premature opening during the wash cycle due to contact with articles of clothing being laundered or portions of the washing machine.
Protection against premature opening is extremely important for rinse additive dispensers, since premature opening of the dispenser during the wash cycle will most likely result in complete loss of the additive during the wash cycle.
The Valve Means
Between tapered portion 34 and weight 30 is resilient disk valve 42 connected to stem 32 by means of a groove formed in conjunction with stem 32 which engages a hole in disk 42, preferably by means of an interference fit. Disk valve 42 has an upper flanged portion 44 which seats against annular face 22 and a lower flanged portion 46 which seats the innermost surface of annular face 22 when the valve is manually pulled closed. Flanged portions 44 and 46 serve as a detent with annular flange 22 to hold the valve in a closed position until the spin cycle of the washing machine takes place. The portion of valve 42 between flange 44 and flange 46 closes, but does not completely fill opening 23. It also serves to pull flange 44 against face 22 of housing 20 after the resiliently deformable periphery of flange 46 has formed a movable piston-type seal against the innermost surface of cylindrical or tubular wall 24. The movable piston-type seal thus formed prevents fluid from exiting chamber 12 despite movement of the flange 46 within cylindrical member 24 until such time as the detent formed between flanges 44 and 46 and annular flange 22 becomes disengaged from filling/dispensing aperture 23.
The Filling Problem
When assembly 26 is in the open position, as shown in FIG. 1, and the dispenser 10 is setting upright, either on a horizontal surface or held in one's hand, a product fluid may be poured into dispenser 10 through opening 23. This fluid is preferably highly concentrated in the present invention; therefore, its volume is quite small. However, since it is concentrated, its accuracy of filling to a desired volume is more important than if it were dilute. Dispenser 10 is of a size that is small enough to fit within the washer drum of most clothes washers without being battered by frequent contact with the washer agitator during the wash cycle or interfere with the operation of the washing machine, yet it is preferably large enough that it does not easily become entrapped in clothing, e.g., pockets, pantlegs, etc. Thus, it is preferable that dispenser 10 not be substantially reduced in size relative to prior art dispensers even though a much smaller volume of fluid is normally used in it. This helps to provide the buoyancy needed to keep it near the surface of the water during the wash cycle.
The Filling Solution
With a conventional flat bottom in chamber 12, the desired volume accuracy cannot easily be controlled via pouring to a visual fill-line or mark when a relatively small amount of fluid, e.g., about one fluid ounce, is to be measured. However, with bottom end 18 pushed up to a point where its inner surface 28 is at or above a fill-line 48 to produce a narrow annular column 50 between wall 14 and the pushup configuration wall, the ratio of fill height to volume is substantially increased. It is believed that this higher ratio permits more accurate visual alignment of a fluid level, with fill-line 48, and therefore more accurate filling. While the pushup configuration can go higher than the desired fill line, it is believed that visual acuity will be maximized if the top of the pushup configuration and the fill line approximately coincide with one another.
Other Pushup Advantages
Another advantage of having pushed up bottom end 18 with its inner surface 28 at or above fill-line 48 is that the annular column 50 thus formed substantially prevents the weight and valve assembly 26 from resting in the additive fluid during the measurement process. Importantly, this avoids displacing fluid which could cause an erroneous volume measurement. It is also believed that the proximity of flat surface 28 at or near the level of fill-line 48 helps the user judge whether or not the dispenser is being held level while filling it. This is also important to accurate measurement.
Need for Buoyancy
After filling and closing the valve 42, dispenser 10 is gently placed in the washer prior to starting the wash cycle. When the wash water rises, dispenser 10 floats in the wash water. Buoyancy helps prevent dispenser 10 from becoming entrapped in clothing or being battered by the extended agitator fins of the washer below the water level. Although dispenser 10 employs a flexible chain and pull ring and a completely recessed valve member to minimize the chance of premature opening in the wash cycle, excessive clothing or agitator contact is nonetheless undesirable, since severe collisions tend to cause the dispenser to open prematurely. If this happens, the product fluid is lost with the wash water and is not available for the rinse cycle as desired.
Spin Cycle Orientation
Dispenser 10 is preferably shaped like a barrel and has a length greater than its circular cross-section so that its most stable orientation is at rest on a side 14 rather than on an end. FIG. 2 shows how the dispenser 10 may position itself by resting against the innermost surface of the washer's drum 60 during a spin cycle. A side 14 contacts the drum 60 during the spinning cycle which follows the washing cycle. In this orientation the centrifugal force of the spinning drum acting on cantilevered weight 30 generates a bending moment at valve 42. The bending moment required to open the valve 42 is relatively predictable as a function of drum RPM. If valve housing 20 were resting against the drum during the spin cycle, the centrifugal force would act to hold the valve 42 closed, i.e., it would tend to cause flange 46 to be pushed outward. If bottom end 18 rested against the drum 60, the centrifugal force would act to pull the weight 30 toward the bottom end 18. This would tend to open the valve 42, but would typically require a higher centrifugal force since there is no bending moment of the type presented by a cantilevered beam, as shown in FIG. 2.
Rinse Cycle Orientation
FIG. 3 shows the dispenser 10 after the washer spin cycle has been completed, the centrifugal force of the spin cycle has opened the valve and the rinse water has begun to enter the drum. When rinse water fills the washer drum, it is desirable for the dispenser 10 become substantially flooded. This flooding process is just about to commence in FIG. 3.
If opening 23 were maintained above the water level throughout the rinse cycle so that the dispenser could not become partially flooded, water could not easily enter and exit the dispenser. As a result all of the product fluid may not be flushed out.
Conversely, if the filling/discharge aperture 23 remains completely inverted throughout the rinse cycle, an air pocket would remain within the dispenser and cause it to float. This too could make complete flushing of the interior of the dispenser with rinse water difficult.
For maximum effectiveness, it is believed most desirable for dispenser 10 to remain close to a substantially horizontal condition so it can fill as much as possible with rinse water and so that turbulence of the rinse cycle agitation can pull it under to help to flush the product fluid out of the dispenser 10.
Pushup used to trim Center of Gravity
The valve and weight assembly 26 fall to one side of chamber 12 when pulled out of opening 23 by centrifugal force in the spin cycle. This effectively moves the center of gravity of the dispenser 10 to near its center. Being longer than it is across, the barrel shaped dispenser 10 then has stability for assuming a natural horizontal orientation and for floating substantially on its side 14 during the rinse cycle. To further encourage such orientation or floating, the pushed up bottom end 18 can serve two additional functions. First it can limit the travel of the assembly 26 to maintain the center of gravity of assembly 26 near the center of dispenser 10. Second, it can provide a region to add ballast material in order to trim the center of gravity of the dispenser to an optimum position to ensure complete emptying of the dispenser's contents during the rinse cycle. Because the wall 14 of the dispenser is normally translucent, and preferably transparent, for easily sighting the fill level of the fluid additive with fill-line 48, varying the thickness of external wall 14 is less desirable because greater thickness typically reduces visibility. However, increasing the thickness of the bottom pushup configuration 18 to provide ballast does not adversely affect the user's ability to visually see the product level during filling. Furthermore, increasing the thickness of the bottom end 18 is less expensive than adding separate weights to the dispenser.
Completion of the Dispensing Cycle
After rinse water has flushed product fluid from the dispenser, and the final machine cycle is completed, the dispenser may be removed from the washer drum and drained of water so that it may be refilled, as in FIG. 1, for the next wash load.
Pull Ring connected by Chain
FIG. 2 shows the use of a chain 38 to connect the pull ring 40 with the valve and weight assembly 26. An alternative to the chain is a cable or other flexible linkage. These connectors transmit force only when in tension. Therefore, they are not prone to cause premature opening during the wash cycle. Protection against premature opening is maximized when flexible chain 38 and pull ring 40 are used in conjunction with recessing of the tapered end 34 of the rigid stem 32 inward of the outermost surface of housing 20. This protects tapered end 34 of stem 32 from inadvertent bumping during the wash cycle. If desired, the pull ring 40 may be snapped into a detent (not shown) in the valve housing 20 to further protect valve 42 from being prematurely dislodged from opening 23 during the wash cycle.
Exemplary Embodiment
In an exemplary embodiment of the present invention, the dispenser elements can be designed and made as follows:
Dispenser chamber walls 14 can be approximately 0.03 inches thick and can be made of a material such as clarified polypropylene. They can be shaped generally like a whiskey barrel with a maximum diameter of approximately 3 inches and a maximum height, including valve housing 20, of approximately 3 1/2 inches. Dispenser chamber bottom 18 can be approximately 0.15 inches thick and can be pushed up approximately 5/8 inches with a sloping outer diameter ranging from approximately 1.98 inches, as measured at the top of the pushup configuration, to approximately 2.2 inches, as measured at the bottom of the dispenser, thereby creating an annular column 50 below fill-line 48 of approximately 1.8 cubic inches, which corresponds to a volume of approximately one fluid ounce of liquid. Dispenser chamber 12 can be made by a stretch blow mold process of the type well known in the art.
Valve housing 20 preferably has an annular flange 22 measuring approximately 1 5/8 inches in diameter and including a filling/dispensing opening 23 which measures approximately 1.1 inches in diameter centered on the axis of the barrel-shaped dispenser. Housing 20 also has an internal cylindrical or tubular wall 24 which measures approximately 0.2 inches in length and has an internal diameter of approximately 1.64 inches. Housing 20 can be made of a material such as polypropylene plastic by an injection molding process of the type well known in the art.
Weight 30 and stem 32 may be comprised of a material such as metal, e.g., aluminum, or a substantially rigid plastic, e.g., molded polypropylene. The weight 30, which is preferably molded in an open condition and thereafter closed about the stem, as generally shown in the cross-section of FIG. 2, weighs approximately 0.56 ounces and is positioned so that its center is located approximately 1 1/4 inches from the center of valve 42, such that the centrifugal acceleration typically experienced in a washing machine spin cycle will dislodge valve 42 from aperture 23 in valve housing 20 during the spin cycle which follows the washing cycle.
Valve 42 can be made of Shore A 58 durometer polyisoprene elastomer by an injection molding process of the type well known in the art. Alternatively, natural rubber can be compression molded to form valve 42. Valve 42 is preferably assembled onto stem 32 by forcing the hole in its center over that portion of the stem to which the weight 30 is secured prior to assembly of the weight 30 onto the stem. Flange 44 on valve 42 can be about 0.035 inches thick and about 1 1/4 inches in diameter. Flange 46, which also acts as a piston within cylindrical or tubular member 24, can be about 0.07 inches thick. Flange 46 preferably has a minimum outside diameter of about 1 19/32 inches, as measured at its uppermost edge, tapering to a maximum outside diameter of about 1 11/16 inches, as measured at its lowermost edge. In lieu of a taper, a step-like cross-section could be employed to provide the desired degree of resilient deformability at the outermost periphery of flange 46. The tapered portion of flange 46 is resiliently deformable to form a movable piston-type seal with the innermost surface of cylindrical or tubular member 24.
The ring 40, chain 38 and stem 32, including connecting member 34 are preferably molded as one unit using an acetal resin such as Delrin via an injection molding process of the type well known in the art. The pull ring 40 can have an outside diameter of approximately 1.25 inches, an inside diameter of approximately 0.92 inches and is preferably connected to element 34 on stem 32 by means of three oval links. The first oval link that connects to the pull ring 40 has a major axis of approximately 0.4 inches and a minor axis of approximately 0.23 inches, while the remaining two links have a major axis of approximately 0.34 inches and a minor axis of approximately 0.16 inches.
Dispenser 10 has an overall internal volume of approximately 15.9 cubic inches and a fully assembled weight of approximately 2.33 ounces, not counting the fluid product to be housed within the dispenser. The normal dose of fluid product to be included within the dispenser which is targeted to coincide with fill line 48 is approximately one fluid ounce or approximately 1.8 cubic inches within annular column 50.
While the dispenser 10 is particularly well suited for dispensing relatively small amounts of highly concentrated rinse water additive, it is of course recognized that the dispenser may also be employed to dispense greater volumes of less concentrated rinse water additives. In such applications additional fill level markings can be provided, as appropriate, for less concentrated products.
While particular embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention, and it is intended to cover in the appended claims all such modifications that are within the scope of this invention.
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An improved apparatus for accurately measuring and dispensing a rinse water additive in an automatic washing machine. In a particularly preferred embodiment, an apparatus is provided for accurately measuring a relatively small volume of fluid product by forming an annular column within the dispenser. The annular column extends at least to approximately the desired fill level for the additive so that the relatively small amount of fluid product causes a substantial change in the fluid's vertical position within the dispenser. This is preferably accomplished by providing a dispenser having an internal pushup configuration in its base, the pushup configuration extending at least to approximately the desired fill level within the dispenser. An improved sealing structure is also provided for the valve used to close the filling and dispensing aperture in the dispenser body during the wash cycle. A flexible securement member is used to secure a recessed valve to the dispenser to minimize the chances of premature opening during the wash cycle. Each of these improvements helps to insure that the correct amount of additive will be added to the dispenser and that substantially all of additive initially added to the dispenser will be present when the valve is opened by the centrifugal force of the spin cycle so that all of the material can be effectively utilized during the rinse cycle.
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FIELD OF THE INVENTION
This invention relates generally to plumbing and more particularly to a stopper assembly for sinks, basins and tubs. Most specifically, the invention relates to a stopper assembly having magnetically coupled elements therein.
BACKGROUND OF THE INVENTION
It is common to close the drain openings of sinks, basins, tubs and the like with a stopper. In some instances, the stopper is a simple plug which is inserted into the drain opening. Stoppers of this type tend to become lost and require the user to reach into the tub to insert and remove them. As a consequence, drains are often provided with an automatically actuated stopper. Such prior art automatic stopper assemblies typically comprise an actuator linkage which is disposed in the drain pipe and which is operated by a lever passing through the pipe to raise and lower an attached stopper. Several problems arise with the use of this type of prior art stopper assembly. The linkage disposed in the pipe acts to trap hair, soap particles and the like so as to clog the drain. Such blockages are hard to clear and frequently require disassembly of the drain pipe. Additionally, the lever which passes through the drain pipe can be a source of leaks and makes installation and adjustment of the drain assembly difficult.
It would be highly desirable to have a drain stopper assembly which is readily installed and adjusted and which does not impose any obstructing hardware in the drain line. It is further desirable that any such drain stopper actuator be readily removable from the drain so as to permit easy cleaning of the drain pipe. The present invention provides an automatically actuated drain stopper assembly which includes magnetically coupled elements therein. The assembly of the present invention provides a clear drain path and does not require any levers or other hardware to pass through the drain pipe.
Magnetic actuators have heretofore been employed for purposes of fluid control; however, the use of a magnetic linkage for actuating an automatic drain assembly in the manner set forth hereinbelow has nowhere been shown or suggested in the prior art. U.S. Pat. No. 3,348,543 discloses the magnetic manipulation of a needle valve for purposes of controlling fluid flow in an intravenous solution delivery system. The control assembly of the '543 patent includes a ring-like magnet used for moving a tapered needle into and out of the body of the valve. This assembly cannot be utilized to seal a drain since hydrostatic pressure of water in the basin would tend to open the valve. Additionally, the opening provided thereby is relatively small and the nature of the valve would tend to cause clogging. U.S. Pat. No. 2,576,168 discloses a magnetic cut-off valve wherein movement of a ball by a magnet is employed to open and close a fluid flow path. U.S. Pat. Nos. 2,536,813; 2,346,904; and 2,289,574 all disclose valves including magnetic elements therein; however, none of these valves are adaptable to a sink assembly and none operate in the manner of the present invention.
BRIEF DESCRIPTION OF THE INVENTION
There is disclosed herein a stopper assembly configured to engage a drain pipe attached to a drain orifice of a sink. The stopper assembly is actuatable from a first position which closes the drain orifice to a second position which opens the drain orifice. The stopper assembly includes a closure member having a hollow cylinder configured to pass through the drain orifice and into the drain pipe. The hollow cylinder defines a central passageway therethrough and a first length of the cylinder is made of a first magnetic material. The closure member also includes a stopper which is larger than the drain orifice and which is disposed at one end of the cylinder. The stopper assembly also includes an actuator which has a body of a second magnetic material disposed to surround a portion of the length of the exterior of the drain pipe. At least one of the first magnetic material and the second magnetic material is a permanent magnet and magnetic coupling between the closure member and the actuator is thereby achieved. The hollow cylinder may include an opening therethrough proximate the stopper. In particular embodiments the opening in the cylinder is configured as a plurality of slits which extend therethrough. The slits commence proximate the stopper and run for at least a portion of the length of the cylinder. In one particular embodiment the slits run the entire length of the cylinder.
In another embodiment of the invention, the cylinder includes a second length comprised of a non-magnetic material which is disposed proximate the stopper. In yet another embodiment, the magnetic material of the actuator comprises a neodymium containing permanent magnet. And in particular applications the actuator may include a rod associated therewith for moving the actuator from a first position to a second position for opening and closing the drain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a portion of a sink showing the stopper assembly of the present invention employed therewith;
FIG. 2 is a top plan view of one embodiment of actuator structured in accord with the principles of the present invention;
FIG. 3 is a front elevational view of one embodiment of closure member structured in accord with the principles of the present invention; and
FIG. 4 is a front elevational view of a portion of an actuator illustrating the attachment of an actuator rod thereto.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of stopper assembly structured in accord with the principles of the present invention is illustrated, in cross section, in FIG. 1. Shown is a portion of a sink specifically including two walls 10,12 in spaced apart relationship. The inner wall 10 forms the interior, water-retaining portion of the sink and the outer wall 12, the outside of the sink. The space therebetween 14 is in communication with an overflow drain (not shown). Such construction is well known to those of skill in the art. The sink further includes a drain pipe 16 which typically includes a flange 16a which engages the interior wall 10 of the sink to provide a drain orifice.
The stopper assembly of the present invention includes a closure member 18 which includes a cylindrical portion 20 sized to fit closely into the drain line 16. As will be explained in greater detail hereinbelow, the cylindrical portion includes a first length thereof 20a fabricated from a first magnetic material and a second length 20b fabricated from a non-magnetic material. The closure member includes a stopper 22 disposed at one end of the hollow cylinder 20. The stopper 22 is sized so as to prevent its passage into the drain pipe 16. The stopper further includes a sealing gasket 24 associated therewith for engaging the flange 16a of the drain pipe 16. It will also be noted that the closure member 18 includes an opening 26 therethrough proximate the stopper 22. This opening is, in this embodiment, configured as a slit and when the closure member is in the elevated position, as illustrated in the figure, the opening 26 allows water to pass through the wall of the cylinder 20 and into the drain pipe 16. As noted hereinabove, the sink includes an interior space 14 communicating with the overflow drain, and the slit 26 is sufficiently large so that when the stopper is in the lowered or closed position the slit still establishes communication between the interior space 14 and the drain pipe 26 so as to prevent accidents resultant from overfilling of the sink.
The stopper assembly further includes an actuator 30 which surrounds at least a portion of the length of the cylindrical member contained within the drain pipe 16. The actuator 30 includes a body of a second magnetic material. In the most preferred embodiment, the actuator 30 includes a permanent magnetic material and the first magnetic material which comprises a first length 20a of the hollow cylinder 20 is a ferro magnetic material and in this manner, magnetic coupling between the actuator 3 and the closure member 18 is effected. Although not illustrated in this figure, the actuator 30 includes a rod or similar member associated therewith. The rod projects from the top of the sink and is operative to move the actuator in an upward and downward direction and such motion of the actuator 30 causes a corresponding motion of the closure member 18.
It is to be noted that in the illustrated embodiment, the magnetic body 30 of the actuator is of a greater length than the length of the magnetic portion 20a of the cylinder 20. By employing an arrangement of this type, the magnetic portion 20a of the cylinder will center itself within the magnetic field created by the actuator 30 thereby simplifying adjustment of the assembly. It is also to be noted that the cylinder 20 of the closure member is relatively close in diameter to the diameter of the drain pipe 16 and provides a relatively close clearance. Such close geometry allows the drain pipe 16 to guide the closure member 18 therethrough. In use, the magnet of the actuator 30 will draw the cylinder 20 of the closure member into contact with the drain pipe 16. This frictional contact assists in retaining the closure member 18 in the drain pipe 16. Should the diameter of the cylindrical portion 20 of the closure member 18 be significantly smaller than the diameter of the drain pipe 16, proper seating of the stopper may be prevented since the cylinder portion 20 of the closure member 18 will be drawn against the drain pipe 16 at a rather large angle.
It is further to be noted that the non-magnetic portion 20b of the cylinder 20 is most proximate the stopper portion 22 of the closure member 18. This physical configuration of the magnetic and non-magnetic portions enables the closure member to readily center within the field of the actuator's magnet, thereby permitting smooth and positive motion of the stopper 22 in response to upward and downward motion of the actuator 30.
The magnet of the actuator 30 may comprise a single large cylindrical magnet surrounding the drain pipe 16 or it may be comprised of a plurality of smaller magnets disposed in a matrix.
Referring now to FIG. 2 there is shown a top plan view of another embodiment of actuator 32 which includes a plurality of discrete magnets 34a-34g. It is also noted, the actuator 30 includes an attachment clip 36 for engaging a rod.
There are a variety of configurations in which the components of the present invention may be manufactured. FIG. 3 depicts another embodiment of closure member 40. The closure member 40 of FIG. 3 includes a cylindrical portion 42 which has a first region 42a which is magnetic and a second region 42b which is non-magnetic.
The closure member 40 further includes a stopper 22 as previously described and having a gasket 24 associated therewith. The closure member 40 of FIG. 3 includes a plurality of slits 44 which extend substantially the entire length of the cylindrical portion 42. These slits 44 are open at the bottom and thus eliminate the potential of clogging by fibers or soap residue. Additionally, it has been found that the lengthwise slits act as cutters and mere rotation of the closure member 40 in the drain pipe will serve to clean any residue from either the pipe or the closure member 40. Clearly, other configurations of closure member may be employed in the practice of the present invention.
Referring now to FIG. 4 there is shown a portion of an actuator member 30 having an attachment clip 36 affixed thereto for slidably retaining an actuator rod 50. The clip 36 is fabricated from a resilient material such as spring steel and the illustrated configuration includes two separate tab portions 52,54 which are affixed to the actuator 30 via a central portion 56. Attachment may be through a spot weld, solder, adhesive or a mechanical affixation such as a screw, tab and slot arrangement or the like. The two tabs 52,54 each have a hole therethrough configured to receive the rod 50. Through the use of the clip 36, the rod 50 and actuator 30 may be positionally adjusted relative to one another by simply squeezing the tabs 52 54 together slightly so as to release the grip on the rod 50 and by repositioning the rod and actuator 30 relative to one another. Releasing of the tabs 52,54 causes the clip 36 to grip the rod 50. Clearly, other fixturing arrangements such as a set screw and the like may be similarly employed.
There are a variety of materials which may be employed to fabricate the stopper assembly of the present invention. With reference to FIG. 1, it is to be understand that the first magnetic material 20a of the cylinder 20 is preferably a ferro magnetic material such as an iron-based alloy. One particularly preferred material is magnetic stainless steel of the type which is commercially available under the designation 400 stainless steel. This material combines magnetic attractability with corrosion resistance and is generally preferred for the magnetic portion of the closure member although other magnetically attractable alloys as well as galvanized steel and other coated materials may be similarly employed. The non-magnetic portion of the cylinder is preferably fabricated from a metal such as brass or a non-magnetic alloy such as 300 type stainless steel. In some instances, the non-magnetic portion of the cylinder may be fabricated from polymeric material. In other instances, the nonmagnetic portion may be simply eliminated and the entire length of the cylinder may be magnetic.
The stopper portion of the closure member is most preferably fabricated from the same material as the non-magnetic portion 20b of the cylinder 20 although it is to be understood that various other materials, including magnetically attractable materials, may be employed to fabricate the stopper portion 22 of the closure member 18. The actuator 30 is preferably fabricated from a permanent magnetic material and one particularly preferred magnetic material is a neodymium-based magnetic alloy. Other preferred magnetic alloys comprise samarium-cobalt alloys and the like. In general, any magnet having a high degree of magnetic strength and a high degree of permanence may be employed. In this regard, the commonly available ceramic magnets have also been found to be satisfactory. As noted above, the magnetic portion of the actuator 30 may comprise a single large magnet or may comprise a plurality of individual magnets. Generally, the magnets are encased in a protective material such as body of polymer or a non-magnetic metal such as aluminum. In the vast majority of drain installations the sink drain pipe is fabricated from plated brass or polymeric material and hence will not interfere with the magnetic action of the stopper assembly of the present invention.
It will be appreciated that the stopper assembly of the present invention may be fabricated in configurations other than those precisely shown herein depending upon the particular geometry of the sink or tub and drain involved. Likewise, aesthetic considerations may dictate the shape and finish of the stopper portion. While the assembly has been described primarily in terms of the actuator comprising a permanent magnet and the cylinder as including a ferro magnetic portion it will be appreciated that these materials may be reversed and the permanent magnet may be associated with the cylinder and the magnetically attractable body may comprise the actuator. Similarly, both the actuator and cylinder may have permanent magnets associated therewith. For this reason, the ferro magnetic material and the permanent magnet are both referred to herein as "magnetic materials," this term being understood to include any material which is, or is attracted by, a magnet.
In view of the foregoing it will be appreciated that the present invention may be practiced in a variety of embodiments. The foregoing drawings, discussion and description are meant to illustrate particular embodiments of the present invention but are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.
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A stopper assembly for a drain pipe includes a closure member having a stopper at one end and a cylindrical portion configured to fit into the drain pipe. An actuator disposed outside the drain pipe is magnetically coupled to the closure member and may be manipulated to raise and lower the closure member so as to open and close the drain outlet. The magnetic coupling avoids the need for any levers or other mechanical elements to pass through the wall of the drain pipe.
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This application claims priority to EP Application No. 09425421.6 filed 23 Oct. 2009, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for refilling the filter-holders of a machine for the preparation of espresso coffee with selected doses of ground coffee to order.
An apparatus as mentioned above is widely used as the basic fitting for an espresso coffee preparation station as might be found, for instance, in bars and restaurants.
As is known, moreover, the filter-holders of the machine are filled only at the time of preparation of the beverage by taking the filter-holder from the relative dispensing unit of the machine and positioning it in the appropriate support provided in the metering and grinding device.
The dose of ground coffee to be supplied to the filter-holder is preferably prepared to order by pressing a corresponding key disposed on the metering and grinding device. In this way the coffee is kept in bean form in the hopper and ground only to order, thereby advantageously retaining its flavour.
Apparatus constructed in accordance with the prior art described above has various drawbacks which may lead, among other things, to errors as regards the type of beverage prepared.
As is known, espresso coffee machines are required to supply different kinds of beverages which are influenced by the tastes and traditions of various countries and which therefore require different quantities of ground coffee or doses, which may also be ground to different grain sizes.
For instance, in order to prepare a small espresso coffee of the Mediterranean type of 15 cm 3 , six grams of ground coffee are used on average while, to prepare a beaker of coffee of 120-150 cm 3 as consumed in northern Europe, up to nine grams of coffee may be needed.
The same kind of beverage may be prepared, moreover, from coffee roasted to differing extents or from decaffeinated coffee or even using single or double doses.
As the filter-holders of the machine have, as a result, to be filled in a variety of ways, it is quite possible for the beverages dispensed to differ from those actually ordered, leading to complaints, the need to replace the incorrect beverage and therefore losses of materials with economic repercussions which are particularly substantial in the case of apparatus installed in mass distribution outlets such as, for instance, service stations along motorways.
The object of the present invention is to remedy the drawbacks of the prior art by providing an apparatus which makes it possible to fill a filter-holder of a coffee machine in a highly accurate manner both in relation to the quality of the coffee needed to prepare the beverage requested and in relation to the quantity of the dose, as well as the degree to which the coffee needs to be ground for the beverage requested.
A further object of the present invention is to provide a method for filling the filter-holders of an espresso coffee machine with a desired dose of ground coffee in a highly automated and reliable manner in order to reduce the risk of filling errors.
SUMMARY OF THE INVENTION
The object is achieved by an apparatus for refilling the filter-holders of a machine for the preparation of espresso coffee with selected doses of ground coffee to order, comprising at least one machine for the preparation of espresso coffee the machine being provided with a plurality of dispensing units for the preparation of respective coffee beverages, each dispensing unit comprising a respective detachable filter-holder and a plurality of keys for selecting the beverage to be dispensed by the relative dispensing unit, at least one coffee bean grinder and metering device provided with a hopper for supplying the beans with adjustable grinding adapted to provide a desired grain size for the ground coffee, an outlet on the grinder and metering device for supplying the ground coffee and supporting means for maintaining the filter-holder of the coffee machine with respect to the supply outlet when it is being refilled with the dose of ground coffee, an identification unit on the espresso coffee machine generating information for recognising the filter-holder of a selected relative dispensing unit and information related to the type of dose with which the filter-holder is to be refilled, a detection unit on the coffee bean metering and grinding device for detecting the information generated by the identification unit, the detection unit causing the corresponding dose to be supplied to the filter-holder when the latter is positioned and held by the supporting means of the metering and grinding device, a wireless communicating device on the espresso coffee machine for transmitting the information generated by the identification unit to the detection unit on the coffee bean metering and grinding device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail below with reference to a preferred embodiment thereof shown by way of non-limiting example in the accompanying drawings, in which:
FIG. 1 is a perspective diagrammatic view of a machine for preparing and dispensing espresso coffee provided with a coffee bean metering and grinding device of the invention;
FIG. 2 is a perspective diagrammatic view of a machine for preparing and dispensing espresso coffee provided with a plurality of dispensing units;
FIG. 3 is a perspective diagrammatic view of a filter-holder;
FIG. 4 shows an apparatus Comprising two machines for preparing and dispensing espresso coffee and four coffee bean metering and grinding devices according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A metering and grinding device provided with a hopper 2 is shown overall by 1 in FIG. 1 .
Roasted coffee beans are kept in the hopper 2 in order to be ground to order to fill the filter-holder of a machine for preparing espresso coffee as will be explained in further detail below.
The metering and grinding device 1 is also provided with an outlet 3 discharging the coffee, ground by a conventional grinder (not shown) within the device 1 , which is reached by the coffee beans from the hopper 2 .
The grinder may be adjusted to vary the degree of grinding by means of an adjustment nut 4 and an actuator 5 which causes the nut 4 to move.
The device 1 is provided with a communication interface 6 , preferably but not exclusively in the form of a touch screen which may show virtual electronic keys, by means of which the operating conditions of the device may be adjusted and the current condition of the device may be indicated.
This device 1 is provided with a sensor 7 which detects the presence of a filter-holder of a coffee machine provided with a code, for instance a colour code, as will be described in detail below, when the filter-holder is positioned on the support fork 8 which retains it below the outlet 3 when it is being refilled with the ground coffee.
The metering and grinding device 1 is lastly provided internally with an electronic circuit board, shown overall by 9 , including memory and radio communication devices of the short-range LAN wireless type, which acts as the unit detecting the information received.
By means of the circuit board 9 , as will be explained in detail below, the metering and grinding device 1 is able to exchange information with other apparatus, for instance, a machine for preparing espresso coffee shown overall by 10 in FIG. 2 .
In FIG. 2 , the espresso coffee machine 10 of the invention comprises an electronic circuit board 11 including memory and short-range radio communication devices compatible with the electronic circuit board 9 of the metering and grinding device 1 .
The circuit board 11 is housed inside the machine 10 and acts as a unit identifying the filter-holder of the selected dispensing unit and the type of beverage ordered and selected, as will be described in further detail below.
The machine 10 is further provided with a communication screen 12 showing information on the operation of the machine, with a relative programming keyboard 13 acting as a unit identifying the type of coffee ordered and the relative dose. The keyboard and screen functions may also be performed by a touch screen which is known per se, possibly with virtual electronic keys.
The machine 10 is provided with a plurality of dispensing units, shown respectively by 14 , 15 , 16 and 17 . Each of the dispensing units is provided with respective push buttons shown by 18 , 19 , 20 and 21 which control the selection of corresponding dispensing operations from the respective dispensing units and which are connected to the identification unit formed by the circuit board 11 .
Each dispensing unit is provided with a respective filter-holder shown by 22 , 23 , 24 and 25 , each of which bears a code which can be recognised both by the machine 10 and by a metering and grinding device of the type shown in FIG. 1 .
For this purpose, each dispensing unit of the machine 10 is provided with a respective sensor 26 , 27 , 25 and 29 able to detect the code of each filter-holder and, at the same time, the presence of containers 30 for collecting the beverage disposed below the dispensing nozzles of the filter-holders.
FIG. 3 shows an example of a filter-holder 22 , 23 , 24 or 25 , with its relative code 31 . The code may be in the form of a bar code or in the form of a coloured bar.
The machine 10 may be programmed by means of the screen 12 and the keyboard 13 or by an external programming device in communication with the electronic circuit board 11 . In this latter case, the machine 10 may in turn carry out programming and exchange information with an apparatus which communicates with it via the circuit board 11 , for instance the metering and grinding device 1 of FIG. 1 provided with the electronic circuit board 9 , acting as a detection unit, comprising receiver and transmitter devices or with a plurality of machines as shown in FIG. 4 and described in detail below.
FIG. 4 shows an installation of a plurality of machines for preparing coffee-based beverages, which installation is particularly suited to public premises, for instance service stations along motorways.
The installation, in the embodiment shown, comprises a pair of coffee machines shown by 10 and 10 A, each having the structural and operational features as described with reference to FIG. 2 , and a plurality of metering and grinding devices shown respectively by 32 , 33 , 34 and 35 , each having the structural and operational features as described with reference to the metering and grinding device 1 of FIG. 1 .
In accordance with the invention, the metering and grinding device 32 for instance contains, in its hopper 2 , a mixture of highly roasted coffee beans suited to an Italian espresso coffee; this device is therefore programmed to dispense the quantities of ground coffee needed for one or two small cups of Italian espresso coffee and the nut 4 is set to provide a grain size likely to optimise their delivery in a dispensing time of 25 seconds.
The second metering and grinding device 33 , in accordance with the invention, for instance contains, in its hopper 2 , a mixture of lightly roasted coffee beans suited to a filter coffee of the type consumed in central and northern Europe; the device is thus programmed to dispense the quantities of ground coffee needed for one or two cups of filter coffee and the nut 4 is set to provide a grain size likely to optimise their delivery in a dispensing time of 25 seconds.
The third metering and grinding device 34 , also of the type shown in FIG. 1 , contains, in its hopper 2 , a mixture of highly roasted decaffeinated coffee beans suited to an Italian espresso coffee; the device 34 is therefore programmed to dispense the quantities of ground coffee needed for one or two small cups of Italian decaffeinated espresso coffee and the nut 4 is set to provide a grain size likely to optimise their delivery in a dispensing time of 25 seconds.
Lastly, the fourth metering and grinding device 35 , also of the type shown in FIG. 1 , for instance contains, in its hopper 2 , a mixture of lightly roasted decaffeinated coffee beans suited to a filter coffee of the type consumed in central and northern Europe; the device 35 is thus programmed to dispense the quantities of ground coffee needed for one or two cups of filter coffee and the nut 4 is set to provide a grain size likely to optimise their delivery in a dispensing time of 25 seconds.
Considering the coffee machines which make up the installation of FIG. 4 , it will be appreciated that, for instance, the machine shown by 10 comprises the dispensing unit 14 programmed to dispense the doses for two cups of non-decaffeinated Italian espresso coffee by pressing a key of a relative keyboard 18 or the doses for two cups of decaffeinated Italian espresso coffee by pressing another key on the keyboard 18 ; the dispensing unit 14 is also programmed to recognise the relative filter-holder 22 which bears a filter suited to Italian espresso coffee.
A further dispensing unit shown, for instance, by 15 is programmed to dispense the doses for one cup of non-decaffeinated Italian espresso coffee by pressing a key of its keyboard 19 or the doses for one cup of decaffeinated Italian espresso coffee by pressing another key on the keyboard 19 ; the dispensing unit 15 is also programmed to recognise the relative filter-holder 23 which bears a filter suited to Italian espresso coffee.
Continuing with the description of the installation shown in FIG. 4 , the dispensing unit 16 is for instance programmed to dispense the doses for two cups of non-decaffeinated filter coffee by pressing a key of the keyboard 20 or the doses for two cups of decaffeinated filter coffee by pressing another key on the keyboard 20 ; the dispensing unit 16 is also programmed to recognise the relative filter-holder 24 which bears a filter suited to filter coffee.
Lastly, the dispensing unit 17 is programmed to dispense the doses for one cup of non-decaffeinated filter coffee by pressing a key of the keyboard 21 or the doses for one cup of decaffeinated filter coffee by pressing another key on the keyboard 21 ; the dispensing unit 17 is also programmed to recognise the relative filter-holder 25 which bears a filter suited to filter coffee.
The second machine 10 A, which is structurally and functionally identical to the coffee machine 10 shown in FIG. 2 , may be programmed and arranged in the same way as described for the machine 10 or its dispensing unit 14 may in particular be programmed to dispense doses of black coffee in a quantity of 250 cm 3 in 25 seconds.
In an installation as illustrated in FIG. 4 and described above, various types of coffee-based beverages may be dispensed in accordance with the practical and operational examples described below.
Bar staff working with the apparatus as described and required, for instance, to prepare two small cups of non-decaffeinated Italian espresso coffee will input what is to be dispensed on the keyboard 18 corresponding to the dispensing unit 14 and take the filter-holder 22 from the dispensing unit. As a result of pressing the key, the machine 10 communicates the request to the metering and grinding device 32 which contains non-decaffeinated roasted coffee beans in its hopper 2 .
The screen 6 on the metering device 32 lights up, showing the operator the position from which the ground coffee is to be taken.
The operator places the filter-holder 22 on the fork 8 below the outlet 3 of the metering device in the vicinity of the sensor 7 which, recognising that the filter-holder 22 corresponds to the type of coffee requested by the machine 10 , supplies the necessary quantity of ground coffee.
The operator can then take the filter-holder 22 with the ground coffee and move it to the dispensing unit 14 of the machine 10 which recognises the filter-holder via the sensor 26 .
Once the container 30 has been placed below the dispensing unit 14 , the required coffee can start to be dispensed as the sensor 26 has also detected the presence of the container 30 .
When preparing the other kinds of coffee described above, the operator works in the same way, each time taking the ground coffee from the metering and grinding device corresponding to the beverage to be dispensed.
In accordance with a further example, it is assumed that the dispensing unit 14 on the machine 10 A has been prepared to dispense a beaker of 250 cm 3 of black coffee to be made from the lightly roasted mixture in the hopper of the metering and grinding device 33 .
In this case, as it is necessary during preparation of the beverage to dispense, in 25 seconds, a quantity double that of a filter coffee of 120 cm 3 dispensed by the dispensing unit 16 , use is therefore made of more coarsely ground coffee. When the operator requests a black coffee from the dispensing unit 14 of the machine 10 A, the latter communicates the request for the beverage to the metering and grinding device 33 which is actuated and has its nut 4 adjusted by means of the actuator 5 in order to provide the ground coffee with the adjustment required for this kind of coffee, confirming that what has been requested is available on the screen 6 . When the operator requests a filter coffee, however, the actuator 5 returns the nut 4 to the optimum setting for this latter type of coffee.
If the machines 10 and 10 A are provided with individual systems for regulating the dispensing pressure and temperature of each dispensing unit, it is also possible, by means of the push buttons 18 , 19 , 20 and 21 , to request different types of coffee from the same dispensing unit 14 , 15 , 16 and 17 , in each case requesting a mixture with a specific quantity and type of ground coffee from one of the metering and grinding devices 32 , 33 , 34 and 35 . In the installation shown in FIG. 4 , each metering and grinding device 32 , 33 , 34 and 35 is able to receive the requests from the dispensing units 14 , 15 , 16 and 17 of the machines 10 and 10 A and is adapted to dispense the type of ground coffee requested.
If the machines are arranged such that they produce, in a dedicated manner, only one type of ground coffee from each dispensing unit 14 , 15 , 16 and 17 , operation may also be streamlined. In this case, by taking out one of the filter-holders 22 , 23 , 24 or 25 , the machine 10 or 10 A will directly request the type of coffee corresponding to that particular filter-holder from the metering device and it is sufficient to dispose the filter-holder in question on the fork 8 of the metering device which has been actuated in order automatically to receive the dose in the filter-holder; when the filter-holder is again disposed in the dispensing unit, dispensing of the coffee starts automatically.
The apparatus of the present invention has many advantages. The following may in particular be mentioned.
Signalling of the request directly to the corresponding metering and grinding device prevents errors which could cause, for instance, a decaffeinated coffee to be served to a person who has ordered a normal coffee or, worse, a normal coffee to a person who has ordered a decaffeinated coffee.
If a first bar operator requests a type of coffee from the machine 10 and a second bar operator requests a different type of coffee from the second machine 10 A, two metering and grinding devices are actuated but on each of these the touch screen is lit and indicates the type of coffee that has been requested from it, making it possible to prevent any errors from the point of view of reversing the filter-holders to be refilled. Moreover, as a result of the presence sensor 7 which recognises the code of the filter-holder, the metering and grinding device supplies the ground coffee only if it recognises the filter-holder corresponding to the request received by the machine, in practice ruling out any possibility of error as regards the positioning of the filter-holder.
The fact that the dispensing unit 14 , 15 , 16 and 17 is enabled only if the filter-holder 22 , 23 , 24 and 25 corresponding to the code of the particular unit is applied to it prevents errors such as the provision of an espresso coffee from a dispensing unit calibrated for filter coffee and vice versa; the machine 10 or 10 A is actuated only if the metering and grinding device 32 , 33 , 34 or 35 has confirmed to the dispensing unit that it has carried out the required grinding.
At the end of dispensing, the machine 10 or 10 A can detect and memorize, in an appropriate electronic log, the length of the dispensing time and may compare the progressive mean of the dispensing time by comparing it with the optimum dispensing time programmed for each kind of coffee.
As coffee is a hygroscopic raw material, it is strongly affected by ambient moisture and it is known to operators in the sector that an increase in moisture tends to increase coffee's resistance to the passage of water, the opposite happening in a dry climate. As it is desired to keep a high quality of dispensing by maintaining the dispensing time at an optimum value, the bar operator should undertake frequent adjustments of the extent of grinding. In accordance with the present invention, the machine detects a deviation of the dispensing time from the admissible tolerance, and may directly inform the metering and grinding device that grinding needs to be adjusted, the metering and grinding device then acting on the nut 4 by means of the actuator 5 in order to bring the dispensing time back within the admissible tolerance.
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Apparatus for refilling the filter-holders of a machine for the preparation of espresso coffee with selected doses of ground coffee. The machine has a plurality of dispensing units for the preparation of coffee beverages, each dispensing unit having a detachable filter-holder and a plurality of keys for selecting the beverage to be dispensed and a coffee bean grinder and metering device provided with a hopper for supplying beans of a desired grain size. The grinder and metering device has a hopper for supplying ground coffee and supporting means for the filter-holder. An identification unit generates information for recognizing the filter-holder of a selected dispensing unit and information related to the dose with which the filter-holder is to be refilled. A detection unit detects the information generated by the identification unit. A wireless device transmits the information generated by the identification unit to the detection unit.
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[0001] This application claims priority under 35 U.S.C. §119 to patent application no. EP 12165410.7, filed on Apr. 24, 2012 with the European Patent Office, the disclosure of which is incorporated herein by reference in its entirety.
[0002] The present disclosure relates to a cutter guard for a rotating blade of a lawn mower, particularly for a robotic, self-guided or autonomous lawn mower.
BACKGROUND
[0003] Conventional rotary lawn mowers, in which a motor-driven blade rotates about a generally vertical axis, require a guard around the blade to prevent injury to users or other people in the proximity of the mower during operation. An inevitable consequence of such a guard is the build-up of debris, principally in the form of grass cuttings, on the underside of, and around the cutter guard. Generally, such lawn mowers have large motor which provide a surplus of power, which allows the continued operation of blade in spite of the debris build-up.
[0004] In a battery-operated robotic mower, however, such a build-up of grass cuttings around the inside of the cutter guard is more critical. The use of batteries means that power needs to be conserved as much as possible to maximise the length of time for which the robotic mower can operate. This typically involves the use of smaller, lighter and usually lower-powered motors. A preferred cutting system for such applications (see patent application EP0808096) is one in which the motor drives a solid circular cutter disc of substantially smooth form at the outer edge of which are mounted a number of light weight sharpened thin steel cutter blades. These blades can rotate freely with respect to the cutter disc for minimal drag while still cutting the grass efficiently due to their inertia and sharpness. The lower power supplied to the cutting blades means that any debris build-up is likely to have a considerable detrimental effect on the operation of the mower. It will be appreciated that the practical use of a robotic lawnmower will involve cutting the grass more frequently such that often only a small amount of growth has occurred since the last cut. Such small grass elements are especially prone to sticking to and building up on surfaces with which they may come into contact.
[0005] A robotic mower typically has an outer shell, which acts as or provides support for a collision detector. This shell can also act as a guard for the blade mechanism, to a certain extent. A full guard for the blade is therefore unnecessary to the same degree as for a conventional mower.
SUMMARY
[0006] The current disclosure therefore seeks to provide a guard structure which prevents fingers being put near to the blades whilst allowing grass cuttings to pass through gaps in the structure, thus preventing debris build up. An air stream may be provided to blow across the underside of the cutter guard to assist in the removal of grass cuttings and other debris from the cutter guard and the cutter.
[0007] Accordingly, in its broadest aspect, the present disclosure provides a cutter guard for a rotatable blade of a robotic rotary lawn mower, the guard forming a cutting bowl in which the blade is mounted for rotation about a generally vertical axis; and wherein the guard comprises a generally planar guard section surrounded by an arcuate section, transverse edges of which define an opening in said cutter guard, such as to define an opening, which in operation is pointed to the front of the lawn mower, to allow uncut grass to be accessed by the cutting blades, the arcuate section comprising a plurality of apertures.
[0008] Preferably the arcuate section subtends an angle of between 180° and 270° at the centre of the guard.
[0009] More preferably the arcuate section subtends an angle of about 240° at the centre of the guard.
[0010] Preferably the apertures occupy an area greater than about 40% of the planar area of said arcuate section, preferably said apertures occupy more than about 50% of the area of said arcuate section.
[0011] Preferably the apertures occupy at least 35%, preferably at least about 40% of the area of the first 60° to 90°, preferably 70° to 80° and more preferably about 75° of the arcuate section from a point of meeting of an inner edge of said opening with a side edge of said opening.
[0012] Preferably the cutter guard further comprises a first lip section extending downwardly from the outer edge of the arcuate section to a point substantially aligned with the blade.
[0013] Preferably the cutter guard further comprises a second lip section upwardly extending along the length of opening.
[0014] Preferably the cutter guard further comprises between three and ten apertures;
[0015] More preferably the cutter guard further comprises between four and eight apertures;
[0016] Yet more preferably the cutter guard further comprises between five and seven apertures;
[0017] Optionally the cutter guard further comprises six apertures.
[0018] Preferably the apertures are substantially circular;
[0019] More preferably, the apertures are elliptical.
[0020] Yet more preferably the apertures are annular segment shaped or rectangular.
[0021] Preferably the apertures are of different sizes and subtend angles between 15° and 60° at the centre of the cutter guard.
[0022] Preferably the apertures located adjacent to the grass entry opening are larger than apertures remote the opening.
[0023] Preferably, the cutter guard comprises six apertures, two of size substantially 45° around the circumference of the annular section, two of substantially 28° and two of substantially 24°.
[0024] In a modification, the arcuate section is formed by a plurality of discrete arcuate section elements.
[0025] Optionally one or more apertures is defined by one or more spaces between adjacent arcuate section elements.
[0026] The present disclosure also provides a rotary lawn mower, having a cutting bowl, at least one blade, a motor and a housing for the motor, and further comprises a cutter guard comprising a mount for mounting to the bowl, a generally planar guard section surrounded by an arcuate section, the annulus comprising a plurality of apertures.
[0027] Preferably the rotary lawn mower further comprises a fan located in the housing, the fan being located above and powered by the motor and a channelling means to guide an airstream from the fan radially across the surface of the cutter guard.
[0028] Preferably, the cutting system comprises a cutter disc mounting at least one cutting blade, wherein the cutter guard apertures do not extend over said cutter disc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The above and other aspects of the disclosure will now be described in further detail, by way of example only, with reference to the accompanying drawings in which:
[0030] FIG. 1 illustrates a robotic lawn mower with an outer shell, for which the disclosure is suitable;
[0031] FIG. 2 illustrates a perspective view of the underside of the mower, showing an embodiment of the cutter guard according to the present disclosure;
[0032] FIG. 3 is a perspective view of the underside of the cutter guard of FIG. 2 coupled to a motor housing;
[0033] FIG. 4 is a top perspective view of a motor housing and cutter guard of FIG. 3 ;
[0034] FIG. 5 is a cross-sectional view of the motor housing and cutter guard of FIGS. 3 and 4 ;
[0035] FIG. 6 is a further perspective view of the motor housing and cutter guard as shown in FIGS. 3 to 5 ;
[0036] FIG. 7 is a perspective view of the underside of the arrangements of FIGS. 3 to 6 ;
[0037] FIG. 8 illustrates a cutter guard according to a preferred embodiment of the invention;
[0038] FIG. 9 is a perspective view of a first alternative embodiment of a cutter guard;
[0039] FIG. 10 is a perspective view of a second alternative embodiment of a cutter guard;
[0040] FIG. 11 is a perspective view of a third alternative embodiment of a cutter guard; and
[0041] FIG. 12 is a perspective view of a fourth alternative embodiment of a cutter guard.
DETAILED DESCRIPTION
[0042] A robotic lawn mower 100 is illustrated in FIG. 1 . A lawn mower of this type has an outer shell 101 , which provides an aesthetic cover and provides some protection around the blades of the device and removes the need for a guard to completely cover the blades and driving wheels 102 . FIG. 2 provides a perspective view of the underside of the mower of FIG. 1 . The cutting disc 201 to which are mounted a plurality of replaceable blades 202 mounted within a cutter guard 203 .
[0043] FIG. 3 shows a perspective view of the underside of the cutter guard 203 . In the embodiment shown, there is provided a generally planar guard element in the form of a disc section 301 , through which an aperture 302 is provided to allow a motor output shaft 303 for powering the cutting system (omitted for clarity) to pass. The underside of the cutter guard 203 defines a cutting bowl. An arcuate section 304 , with transverse edges 310 partially surrounds the disc section 301 . An operatively downwardly extending lip 305 is provided around the arcuate section 304 . An opening 306 , having an inner edge 307 and two side edges 308 , coincident with transverse edges 310 of the arcuate section is formed around the section of the disc not surrounded by the arcuate section. In the arcuate section, apertures 311 are provided.
[0044] The cutting system consists of a solid circular cutter disc 201 of substantially smooth form. At its outer edge 3 short, thin sharpened steel blades 202 are mounted to pivot freely so as to cut the grass by their centrifugal loading, but to swing back and limit the maximum electrical power drawn in tougher conditions. In the preferred embodiments, the diameter of disc section 301 of cutter guard 203 corresponds generally with the diameter of the cutter disc so that the cutting itself always takes place outside this diameter and within opening 306 or beneath arcuate section 304 .
[0045] In operation, the cutting disc and blades of the mower rotate within the cavity formed by disc 301 , arcuate section 304 and lip 305 . The apertures in the arcuate section preferably extend over the blades, but do not extend over the cutting disc. The opening 306 is orientated towards substantially the front of the mower. The opening 306 allows the mower to pass over uncut grass without compressing it, thus allowing contact between grass and blades. Cut grass would, in a mower with a conventional cutter guard, build up on the underside of the guard. In a low-power battery operated system such as a robotic mower, this would have a detrimental effect on the operation of the blade. This problem is overcome by the recognition that, with the outer shell 101 of a robot mower, less substantial protection of the blade is required. This recognition allows apertures 311 to be provided in the annular segment sections, which allow an exit route for the grass cuttings from the cavity of the cutting bowl. This exit is facilitated by the blowing of an air stream radially across the underside of the cutting bowl, from air inlet apertures 312 .
[0046] This air stream originates from a fan located in the housing 309 for the mower motor. The air forces any debris/cutting build-up from the surfaces of the blades and cutting disc, and also from the underside of the cutting bowl. The grass cuttings dislodged by the air stream or projected by the action of the cutting blades are expelled from the cutting cavity through the apertures 311 .
[0047] The creation and action of the air stream are further illustrated in FIGS. 4 to 7 . FIG. 4 is a perspective view of the motor housing with the upper section removed, to show a fan 401 . The fan provides a downward air stream, which cools the motor and provides the radial air stream across the under-surface of the cutting bowl. The upper surface of the cutter guard is also shown. There is provided an upwardly extending lip 402 , locate above the grass entry opening, which helps to prevent the build-up of debris on the upper surface of the guard.
[0048] FIG. 5 is a cross sectional view of the housing and cutting bowl illustrated in FIG. 4 . Fan 401 causes an air stream 501 to flow past motor 502 and subsequently through apertures 503 of the motor housing (one illustrated) into channel 504 . The positioning of the apertures 503 and the shaping of channel 504 ensure that the air stream 505 is then blown radially across the underside of the cutter guard and the top of the cutter disc.
[0049] FIG. 6 is a perspective view of the housing and cutting bowl. The upper section 601 of the housing is shown, with apertures 602 provided to allow air intake 603 . FIG. 7 is a perspective view of the underside of the cutting bowl, showing radial airflows 701 .
[0050] The design of the cutter guard is a balance of three desiderata. Firstly, adequate channels must be provided to allow the expulsion of grass cuttings and other debris from the cutter guard. Secondly, the air streams need to be channeled so as to direct debris from the surfaces of the bowl and the cutting blades. Finally, the construction must be sufficiently robust to provide a guard for the blade.
[0051] The preferred embodiment therefore comprises elongate apertures in the form of arcuate slots ranging in size from the length of an arc along the circumference subtending an angle substantially 240 at the centre of the cutter guard to one subtending an angle of substantially 45°. A typical arrangement is illustrated in FIG. 8 . In this embodiment, six elongate slots are provided. In the illustrated embodiment, the slots 801 to 803 are unequal in sizes. These are provided in a range of angular sizes, arranged symmetrically: two of 45° around the circumference ( 801 ), two of 28° ( 802 ) and two of 24° ( 803 ). The angularly larger slots are located adjacent to the grass entry opening, as this is the point at which most of the grass cuttings aggregate. Smaller apertures to the rear allow for a smaller spacing between connecting sections 804 between the outer rim and the main part of the bowl. This arrangement provides a high level of strength to the structure. Cutting disc 201 and blades 202 are also illustrated. The cutter guard comprises a solid disc, above the cutting disc, which cooperates with the cutting disc to form a guide for the air stream.
[0052] It can be seen that this design enables the apertures to occupy more than 40% of the area of arcuate section 304 and more than 50% in a preferred embodiment. More particularly, of the first 60° to 90°, preferably 70° to 80° and more preferably about 75° to at least one side of the front opening 306 , from the point where the inner edge 307 of opening meets the side edge 308 , advantageously, the apertures occupy at least 35% of the section, preferably at least about 40%. Although the design provides this to either side it will be appreciated that cuttings are typically thrown in the direction of cutter rotation and it is the aperture in the first 75° in this direction which contribute the most benefit.
[0053] FIG. 9 illustrates a perspective view of an alternative design for the cutter guard. Here the cutting bowl comprises an outer rim 901 , supported by struts 902 attaching to a small central disc 803 . Thus the apertures for allowing the expulsion of debris are maximized. However, guidance of the air streams is reduced.
[0054] FIG. 10 shows a cutter guard with circular apertures 1001 , all of the same size and a solid central disc 1002 . FIG. 11 shows a guard comprising a rim 1101 suspended by minimal support structures 1102 , extending from a solid central disc 1103 .
[0055] The arrangement in FIG. 10 satisfactorily achieves the three objectives in the cutter guard design. However, the larger apertures achieve better expulsion of grass cuttings and reduce the possibility of longer cuttings being able to lodge across apertures. Elongate holes are also more efficient for this purpose. The embodiment in FIG. 11 provides an excellent performance in terms of the expulsion of cuttings and other debris, delivering almost 100% aperture and with the solid disc surface to guide the air stream as required. However, care is needed to ensure the strength of the construction of this embodiment.
[0056] FIG. 12 illustrates a perspective view of yet another embodiment of the invention, comprising a cutter guard with an arcuate section 304 constructed from arcuate section elements 1201 and 1202 , with a space or gap 1203 between them. In FIG. 12 , two arcuate sections are shown, but the person skilled in the art will appreciate that more than two arcuate sections may be used, with a plurality of gaps between them. Optionally, the gaps may define one or more of the apertures of the arcuate section.
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A cutter guard for a rotating blade of a lawn mower, particularly for a robotic, self-guided or autonomous lawn mower forms a cutting bowl in which the blade is mounted for rotation about a generally vertical axis. The guard comprises a generally planar guard section surrounded by an arcuate section, transverse edges of which define an opening in the cutter guard, which in operation is pointed to the front of the lawn mower, to allow uncut grass to be accessed by the cutting blades. The arcuate section comprises a plurality of apertures.
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BACKGROUND OF THE INVENTION
The present invention relates to the production of microcapsules containing as the core material oily substances or water-insoluble solid particles. More particularly, the present invention relates to a process for producing microcapsules which comprises forming a wall of coacervates on microdroplets of an oily substance of water-insoluble solid particles through reaction between gelatin and an anionic polymer, and allowing an iridoid compound to act on the coacervates so that cross-linking occurs between the polymer molecules of gelatin to harden the microcapsules.
Microcapsules which are tiny particles of a core material surrounded by a coating consisting of a wall material such as gelatin serve to protect the core material from its surroundings by means of the wall membrane, or to control the time, place or rate at which the core material is released. Having these capabilities, microcapsules have been extensively used in pressure-sensitive copy paper, foodstuffs, pharmaceuticals and in many other fields of industry.
One of the common methods for producing microcapsules is "complex coacervation" which is commercially the most common for pressure-sensitive copy paper. In this process, two colloidal substances, such as gelatin and an anionic polymeric substance, having mutually opposite electric charges, are added to a core-containing suspension to form an aqueous sol, which is then pH-adjusted or otherwise treated to form a wall of coacervates on the microdroplets of an oily core material, and after they have gelled the coacervates are hardened with a hardening agent to form microcapsules. Details of this complex coacervation process are disclosed in U.S. Pat. No. 2,800,457, etc. and many methods of improvement have been proposed.
For instance, Japanese Patent Publication No. 39-24782 proposes that the temperature of the system be slowly elevated in the presence of a hardening reagent in order to shorten the duration of the hardening treatment. Japanese Patent Publication Nos. 47-16166, 47-16167 and 47-16168 propose that in order to prevent agglomeration of coacervates, an anti-shock agent be added after the wall membrane of coacervates has been gelled. Japanese Patent Publication Nos. 50-27827, 50-27828 and 50-27829 show that by adding an anti-shock agent such as CMC or an acrylic acid copolymer together with an anionic surfactant, it is possible to prevent any increase in viscosity that would otherwise occur on account of the reaction taking place between gelatin and aldehyde during the pre-hardening step. Japanese Patent Public Disclosure No. 61-4527 discloses a method in which a water-soluble wax derivative is added after gelation and before hardening. Methods employing hardening agents that may be added to foods are disclosed in Japanese Patent Public Disclosure Nos. 59-36540, 60-37934, 61-4527, 61-78351, etc.
As described above, numerous improvements have been developed in the technology of microencapsulation by complex coacervation. However, there still remains much room for improvement in the art of hardening coacervates. For example, no process has yet been developed for producing microcapsules employing a hardening agent which can be safely incorporated in foodstuffs, which is stable, and which allows the hardening treatment to be effected within a short period. Hardening agents that are most commonly employed in the conventional techniques of complex coacervation are aldehydes such as formaldehyde and glutaraldehyde. However, aldehydes are toxic and cannot be used in the production of microcapsules to be incorporated in foodstuffs.
A further problem with the use of aldehydes as hardeners is that the pH of the system has to be adjusted to the alkali side in order to increase the rate of hardening reaction. Unless utmost care is exercised in the pH adjustment, agglomeration of coacervates and other troubles will occur to increase the complexity of process control.
Hardeners that have been employed in the production of microcapsules for incorporation in foodstuffs include glucono delta lactone, tannic acid, potassium alum [KAl (SO 4 ) 2 .12H 2 O] and ammonium alum [NH 4 Al (SO 4 ) 2 .12H 2 O]. Glucono delta lactone and tannic acid harden gelatin by causing acid denaturation of the gelatin protein, and the alum compounds achieve the same result by binding between the molecules of gelatin protein. However, all of these hardeners are slow in their hardening rate because their action is weaker than that of aldehydes. If the reaction temperature is raised in an attempt to increase the hardening rate, the chance of coacervates being broken is increased. Under these circumstances, the hardening reaction must be carried out over a prolonged period (usually several tens of hours) at room temperature. Furthermore, the wall membrane of the resulting capsules is weak and has insufficient heat resistance.
SUMMARY OF THE INVENTION
The present invention has been accomplished in order to solve the aforementioned problems of the prior art and its principal object is to provide a method of hardening coacervates in the production of microcapsules (i) in a pH range that will not cause agglomeration of the coacervates (ii) within a short period of time (iii) without employing any harmful component that cannot be incorporated in foodstuffs and by which (iv) microcapsules having high physical strength and heat resistance can be obtained.
This object of the present invention can be attained by a process for producing microcapsules by complex coacervation of an aqueous solution of gelatin and an anionic polymeric substance having a core material present in an emulsified or dispersed state, which is characterized in that the gelatin in the wall membrane of coacervates formed around the microdroplets of the core material is hardened by a crosslinking reaction with an iridoid compound so as to produce microcapsules.
DETAILED DESCRIPTION OF THE INVENTION
The present inventors found that iridoid compounds, in particular genipin, are a very effective hardeners for use in the production of microcapsules having a gelatin wall membrane.
The present invention provides a process for producing microcapsules by complex coacervation of an aqueous solution of gelatin and an anionic polymeric substance having a core material present in an emulsified or dispersed state, which is characterized in that the gelatin in the wall membrane of coacervates formed around the microdroplets of the core material is hardened by a crosslinking reaction with an iridoid compound so as to produce microcapsules.
The first step of the process of the present invention is to have the core material emulsified or dispersed in an aqueous solution containing gelatin and an anionic polymer. This may be accomplished by mixing an aqueous solution of an anionic polymer with an aqueous gelatin solution that has the core material emulsified or dispersed in it. Alternatively, the core material emulsified or dispersed in the aqueous solution of an anionic polymer may be mixed with the aqueous gelatin solution. Still another approach is to have the core material emulsified or dispersed in an aqueous solution containing gelatin and an anionic polymer. In short, the first step of the process of the present invention is satisfactorily performed if the core material is emulsified or dispersed in an aqueous solution containing gelatin and an anionic polymer.
A suitable core material may be selected from among oily substances such as flavor oils and lecithin, and from water-insoluble solid particles such as stearyl alcohol.
There is no particular limitation on the gelatin that can be used but it is preferable to use gelatin having good physicochemical and chemical properties as typified by good film-forming ability, the nature of an ampholyte, the controllability of the quantity of charges by pH, and the occurrence of the change from sol to gel at a critical temperature. Stated specifically, any gelatin that satisfies the specifications for use in the production of a certain microcapsule may be employed. More preferably, gelatin having an isoelectric point of pH 8-9 and a bloom strength of 280-320 is used.
Any anionic polymer that reacts with gelatin to form complex coacervates may be employed and preferred examples include gum arabic, sodium alginate, agar, carrageenan, carboxymethyl cellulose, sodium polyacrylate, polyphosphoric acid, etc.
The mixture of gelatin and a suitable anionic polymer is diluted with warm water; thereafter, an acidic aqueous solution such as acetic acid is added to reduce the pH of the system to the isoelectric point of gelatin or below, and the mixture is stirred with the temperature elevated at least to the gelling point of gelatin. In this step, coacervates will form. The pH of the reaction system is normally reduced to between 4.0 and 5.0 but this condition need not be satisfied if the pH is no higher than the isoelectric point of the gelatin used. The temperature of the system is usually adjusted to be within the range of 45°-55° C.
The coacervates are then cooled to 20° C. or below to gel and are thereafter subjected to a hardening reaction. What is important to the process of the present invention is that an iridoid compound is used as a hardening agent. Stated more specifically, an iridoid compound is added to a coacervate-containing slurry and the temperature of the system is slowly elevated to effect the hardening reaction. In this step, the gelatin component of the coacervates is hardened to become water-insoluble, thereby completing the production of microcapsules having the core material confined in the shell of coacervates.
Any iridoid compound having a crosslinking ability may be used in the process of the present invention and illustrative examples are the aglycones of geniposide, gardenoside, geniposidic acid, etc. Of these compounds, genipin derived from Gardenia jasminoides Ellis which is the aglycone of geniposide is most preferred. These iridoid compounds may be prepared in accordance with the disclosures in Japanese Patent Publication No. 57-14781, Japanese Patent Public Disclosure No. 61-47167, etc.
The amount of the iridoid compound to be used in the hardening reaction ranges from 0.001 to 1.0 part per part of gelatin on a dry weight basis. In accordance with the process of the present invention, the amount of iridoid compound used may be adjusted to control the physical properties and heat stability of the microcapsules to be obtained, thereby making it possible to produce microcapsules of a desired strength.
The hardening reaction is preferably conducted at a pH of 4-10, more preferably below 7 where agglomeration of coacervates will not easily take place. One of the great advantages of the present invention is that the coacervates can be hardened within this preferred range of pH. The reaction temperature may be within the range of 5°-60° C. Since the iridoid compounds have a comparatively strong cross-linking action, the intended hardening reaction can be accomplished without further elevating the temperature. The reaction time varies with pH and temperature, but a satisfactory hardening treatment can be performed by leaving the system to stand or stirring it for a period of 0.5-24 hours.
It has been reported that the iridoid compounds derived from Gardenia jasminoides Ellis which are used as hardeners in the process of the present invention react with primary amino compounds and are further polymerized under oxidizing conditions to form blue dyes (Japanese Patent Publication No. 57-14781 and Japanese Patent Public Disclosure No. 61-47167). The safety of the blue dyes thus formed has been widely recognized as a result of their extensive use as natural pigments in foods. Therefore, the microcapsules produced in the process of the present invention by crosslinking an iridoid compound with complex coacervates of gelatin and an anionic polymer are also safe and are of particular utility for use in foods, pharmaceuticals and other fields of industry.
The following examples are provided for the purpose of further illustrating the present invention but are in no way to be taken as limiting.
EXAMPLE 1
Peppermint oil (9 g) was dispersed and emulsified, with stirring, in 30 g of a 10% aqueous solution of gelatin (Type A) at 40° C. to form an oil-in-water (O/W) emulsion. To the resulting emulsion, 30 g of a 10% aqueous gum arabic solution preheated to 40° C. was added with stirring. To the liquid mixture, 140 g of warm water (40° C.) was added, followed by addition of acetic acid to adjust the pH of the system to 4.0. The system was quickly quenched to 10° C. with stirring. Thereafter, 3 g of genipin was added to the system while at the same time, its pH was adjusted to 6.0 with sodium hydroxide. Subsequently, a hardening treatment was conducted by raising the temperature of the system to 40° C. at a rate of 1° C./min. The precipitated microcapsules were thoroughly washed with water to remove any uncrosslinked genipin and thereafter centrifuged for 10 minutes at 2,800 rpm to recover the microcapsules as the final product.
EXAMPLE 2
A cold (10° C.) microcapsule solution was prepared as in Example 1. To the system was added 3 g of genipin and the resulting system having a pH of 4.0 was subjected to a hardening treatment for 18 hours at 20° C. under mild stirring. The precipitated microcapsules were washed thoroughly with water to remove any uncrosslinked genipin and thereafter centrifuged for 10 minutes at 2,800 rpm to recover the microcapsules as the final product.
EXAMPLE 3
Microcapsules were produced by the same procedures of microencapsulation as those adapted in Example 2 except that the amount of genipin was reduced to 0.3 g.
EXAMPLE 4
Microcapsules were produced by the same procedures of microencapsulation as those adapted in Example 2 except that the amount of genipin was further reduced to 0.03 g.
The microcapsules produced in Examples 1-4 were suitable for use as peppermint flavors in ready-to-eat foods.
COMPARATIVE EXAMPLE 1
A cold (10° C.) microcapsule solution was prepared as in Example 1. Three grams of glucono delta lactone was added to the solution under stirring and a hardening treatment was then performed by mildly stirring the mixture at 20° C. for 18 hours. The precipitated microcapsules were washed thoroughly with water and centrifuged at 2,800 rpm for 10 minutes to recover the microcapsules as the final product.
COMPARATIVE EXAMPLE 2
Microcapsules were produced as in Comparative Example 1 except that 3 g of potassium alum was used as a hardener.
COMPARATIVE EXAMPLE 3
Microcapsules were produced as in Comparative Example 1 except that 3 g of tannic acid was used as a hardener.
COMPARATIVE TEST
The microcapsules produced in Examples 1-4 and Comparative Examples 1-3 were dried, and 5 g of each sample was added to 100 ml of distilled water. The solutions were heated at a rate of 1° C./min and the temperature at which the wall of microcapsules in each sample thoroughly dissolved was measured. The results are shown in Table 1; the walls of the microcapsules in the samples of Examples 1 and 2 dissolved at 100° C. and those of the microcapsules in the sample of Example 3 dissolved at 80° C.; in contrast, wall dissolution occurred at 45° C. and below in the samples of Example 4 and Comparative Examples 1-3.
These results show that by hardening coacervates with genipin, the heat resistance of microcapsules was improved, the duration of hardening treatment was shortened (see Example 1), and the degree of heat resistance could be controlled by adjusting the amount of genipin added.
Table 1 also shows the amount of agglomeration which occurred in the microcapsules of Examples 1-4 and Comparative Examples 1-3 after centrifugation. No detectable agglomeration occurred in the samples produced in Examples 1-4, but the wall membranes of the capsules prepared in Comparative Examples 1-3 were so weak that they readily formed agglomeration materials. It is therefore clear that the hardening treatment with genipin is also effective in improving the handling properties of microcapsules.
TABLE 1______________________________________Evaluation of the Heat Stability ofMicrocapsules and Their Agglomerationafter Centrifugation Capsule melting Agglomeration ofSample No. temperature °C. microcapsules______________________________________Example1 100 -2 100 -3 80 -4 45 -ComparativeExample1 35 ++2 40 ++3 45 +______________________________________ -: No agglomeration +: Some agglomeration ++: Extensive agglomeration
The present invention provides a process for producing microcapsules by complex coacervation using gelatin as at least one hydrophlic colloid. In this process, an iridoid compound having no human toxicity which can be safely incorporated in foodstuffs is used as a hardener for coacervates. Besides the advantage of rapidity of treatment, the iridoid compound is capable of hardening coacervates with reduced agglomeration, thereby enabling the desired microcapsules to be produced easily and efficiently. If desired, an appropriate degree of heat resistance can be imparted to the microcapsules, so they have potential use in a wide range of applications including the food and pharmaceutical industries.
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A process for producing microcapsules which comprises forming a wall of coacervates on microdroplets of an oily substance of water-insoluble solid particles through reaction between gelatin and an anionic polymer, allowing a ylidoid compound to act on the coacervates so that cross-linking occurs between the polymer molecules of gelatin to harden the microcapsules.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. patent application No. 60/600,661 entitled “Method and System for Automatic Cue Sheet Generation” filed Aug. 11, 2004, now pending, which is incorporated herein by reference.
BACKGROUND
[0002] Companies that use music in productions that are broadcast in any public way, such as television stations, radio stations or advertisers are required to pay royalties for such use. Agreements with performing rights societies (“PRS”) which represent the music owners require these companies to create and file “cue sheets” in order to report the specific music they have used in each of their productions. Example PRS are ASCAP and BMI.
[0003] A “cue sheet” usually lists the name of the track used, how and where the track was used, the writer(s) of the track, the publisher of the track, and the performing rights society to which the track is affiliated. A cue sheet lists, in sequence, all music used in a particular production, duration of use, and form of use (i.e., whether it use as background instrumental music, as a theme, or as a featured performance). This information affects the royalty rate paid by the PRS to the owners of the music.
[0004] Ordinarily, an administrator at the broadcaster production facility complies the cue sheet data from information indicating the music content used in a particular broadcast program. The administrator employs the musical content identification to retrieve data required for the cue sheet. The data is generally retrieved by reference to published indicis available either in print or online.
SUMMARY
[0005] The present invention provides an automated method for generating cue sheets from Edit Decision Lists (EDL) which are generated by production facilities. The present invention recognizes the EDL are generated by production facilities as part of an editing process when employing digital editing tools. The data in the EDL can be used to arrive at information which is required for a cue sheet submission. Accordingly, the present invention parses the EDL data to retrieve information for a cue sheet. The cue sheet information is then entered into corresponding fields of a cue sheet to provide a ready-for-submission cue sheet.
[0006] In one embodiment, the invention provides a method for generating a cue sheet for submission to a PRS. The method includes a computer receiving production piece information and an associated EDL file. The computer parses the EDL file to extract track file names, a duration of use, and a time code in the production piece for each file. The computer searches a database for the track file name to retrieve a composer, publisher, and PRS associated with the track file name. In a final step, the computer stores the extracted information and said retrieval information in a cue sheet template to provide a cue sheet for submission to a PRS.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a contact information screen of the web application of the invention;
[0008] FIG. 2 illustrates a show details screen of the web application;
[0009] FIG. 3 illustrates a web application screen for importing EDL data; and
[0010] FIG. 4 illustrates the EDL presentation screen of the web application.
DESCRIPTION
[0011] An edit decision list (“EDL”) is a list of instructions for all the edit actions taken during the creation of a program. Some of the information provided by an EDL includes cuts, wipes, fades, dissolves, and black edits. The EDL organizes the instructions as a series of chronological edits called events. Each event specifies a timecode for the edit on the source and master. EDLs can display additional types of information such as comments and the different audio and video tracks in the sequence.
[0012] EDLs are created automatically by all forms of digital editing software (Avid, Final Cut Pro, Pro Tools). EDLs can be exported from the editing software as an EDL file or as a text file in a variety of formats. Each provides for different format data and possibly different presentation arrangement. The present application is adapted to operate with any EDL format as long as minimal music identification data is included.
[0013] The Cue Sheet Application automatically generates a cue sheet which contains all meta-data required by performing rights societies and is correctly formatted, by reference to the Edit Decision List created by any digital video/audio editing software.
[0014] The structure and operation of a system in accordance with the invention will now be discussed by reference to screen diagrams for a web based application that receives an EDL file and provides a corresponding output cue sheet. FIG. 1 illustrates a contact information screen 19 of the web application of the invention. The user preferably logs in to the web-application by entering a username and password. In the screen of FIG. 1 , the user submits contact information by entering corresponding text in the name 20 and email 21 fields of the contact information screen 19 .
[0015] The form data is transmitted to the web server by selecting a Submit Data button 23 . The form data is cleared by selecting a Reset Data button. FIG. 2 illustrates a show details screen 30 of the web application. The user enters data specific to the subject production in fields of the screen. These fields include: the network airing the show 31 , the production company 32 , the producer 33 , name of the show 34 (including episode number 35 ), the length of the show 36 , the airing date 37 , and any miscellaneous comments 38 . This information is generally required for a cue sheet since it identifies the manner and form of use. As discussed above, this information is critical to the PRS as it directly affects the royalty calculation.
[0016] FIG. 3 illustrates a web application screen for importing EDL data. As discussed above, the user imports the EDL file corresponding to the production for which the cue sheet is required. The user is first prompted to select an EDL format for a file upload from a selection drop-down box 41 . In another embodiment, the user pastes the text of an EDL file directly into a special web application window (not shown). In the second step, the user either selects an EDL to upload 42 or pastes the EDL text as discussed above.
[0017] FIG. 4 illustrates the EDL presentation screen of the web application. As discussed above, the EDL file is imported to the application web server via the internet by the upload procedure of FIG. 3 . The user selects from available formats 50 , 51 , 52 for the cue sheet information. In the illustrated embodiment, the formats include a Word file 50 , an Excel spreadsheet 51 , or an Email attachment 52 . The web application parses the imported EDL file and extracts the information needed to generate a cue sheet. The cue sheet information is displayed in a cue sheet display area 60 of the web application. The fist section of the cue sheet display provides the show details discussed with reference to FIG. 2 . Additionally, the section includes a field for a producer signature 53 . The second section of the cue sheet provides detail as to the works used in the show as extracted from the input EDL file. The detail information includes the track title 61 duration of use 62 , the timecode in the program during which the music track was used 63 , 64 and form of use 65 . A third section of the cue sheet displays information retrieved from databases which is required for the cue sheet submission. The information is retrieved by the application searching a database which contains additional key data for cue sheet purposes: writer name 66 , publisher 67 , and affiliated PRS 68 . In one embodiment, the database is an internal database maintained by the web application provider. In another embodiment, the database is an external public database. Preferably, the internal database is a database of works compiled from both local and external sources providing musical work information. The application dynamically formats the entire cue sheet, based on built-in templates that fulfill the required PRS formatting. As discussed above, the cue sheet data illustrated in FIG. 4 is preferably displayed to the user in HTML format. As discussed above, the user downloads a copy of the cue sheet from the web based application server to their local computer as either a Microsoft Word or Microsoft Excel document. This feature allows the user to subsequently alter the document to suit the individual user purposes. In some implementations, the user emails copies of the cue sheet in either format to other users directly through the web application without saving a local copy on the user computer by employing the e-mail option.
[0018] Although the present invention was discussed in terms of certain preferred embodiments, the invention is not limited to such embodiments. A person of ordinary skill in the art will appreciate that numerous variations and combinations of the features set forth above can be utilized without departing from the present invention as set forth in the claims. Thus, the scope of the invention should not be limited by the preceding description but should be ascertained by reference to claims that follow.
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A cue sheet generation system is used to compose a cue sheet for submission to PRS from an input EDL. The system parses the EDL to extract data relating to use of musical works associated with a PRS. The system employs both local and remote databases to retrieve information relating to the extracted musical work data. The information is then used to construct a cue sheet in a form appropriate for submission to a PRS.
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BACKGROUND OF THE INVENTION
The present invention relates to an elastic or resilient shaft coupling, such as for a diesel engine drive mechanism.
Various flexible or resilient shaft couplings are known. One such coupling is disclosed in U.S. Pat. No. 4,708,514, Walter et al dated Nov. 24, 1987 and foreign British disclosure 2,164,726 Walter et al which correspond to each other and which belong to the assignee of the present invention.
An essential basis for the construction of a resilient shaft coupling of this type is the torque at rated load that has to be transmitted. A further important characteristic is the resilience that is required, in which connection a specific load capacity in the rubber material of the resilient annular assembly must be ensured. Taking into account the permissible shearing stress of rubber, the necessary shearing surface for a predetermined torque of a rated load can be ascertained. One of the main dimensions of such a resilient shaft coupling is also provided at the same time.
The demand for a desired resilience in the shaft coupling can be fulfilled with known properties of the rubber material that is used by calculating the necessary spring length of the rubber. A further characteristic regarding the main dimensions of the shaft coupling is thereby provided. With this type of procedure in regard to the determination of the rubber body, rotationally symmetrical rubber bodies are produced that have correspondingly larger dimensions for larger torques that are to be transmitted.
In the case of operational stresses on resilient shaft couplings of this type, the shaft coupling apart from the transmission of the mean driving torque, is also acted upon with a dynamic moment that can be attributed to the unavoidable torsional vibrations of the drive mechanism. As the dimensions of the rubber body increase, the ratio of thermal stressability to mechanical stressability becomes more and more disadvantageous. Regarding this, it should be noted that the specific mechanical load remains constant because of the dimensions calculated whereas in contrast, the temperatures in the core area of the rubber body rise sharply due to the poor heat conductivity of rubber when the rubber body is increasingly enlarged. With the measures for dissipating heat that have been customary up to now, a certain level of thermal stressability can be obtained; however, this level is not adequate in numerous applications. To this extent, the question of the obtainable thermal stressability comes more and more into the forefront when assessing the applicability of resilient shaft couplings.
It is therefore an object of the present invention to provide a resilient shaft coupling of the aforementioned general type that, at given mechanical properties, provides considerably greater thermal stressability, especially with rubber bodies having larger dimensions, to avoid unacceptably high heating in the core area of the rubber body.
BRIEF DESCRIPTION OF THE DRAWINGS
This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying drawings, in which:
FIG. 1 is an axial cross-sectional view of one exemplary embodiment of the resilient shaft coupling of the present invention;
FIG. 2 is a side view of segments of a four-part resilient annular assembly of the inventive shaft coupling, as fitted into position; and
FIG. 3 is a cross-sectional view of the resilient annular assembly taken along the line I--I in FIG. 2.
SUMMARY OF THE INVENTION
The present invention provides a resilient shaft coupling in which rigid coupling members on both the driving side and the driven side are interconnected by at least one resilient annular assembly, which has outer metallic annular disks, or plates, each of which is composed of several segments, to the inner surfaces of which is vulcanized an elastomeric body, of rubber or the like, which is composed of an equal number of segments and in an axial plane has a trapezoidal cross-sectional shape with a width that increases radially outwardly, wherein the annular assembly in its entirety being composed of two ring halves that are disposed in axially abutting relationship as mirror images, with the segments of the one ring half being staggered or offset by half of a segment division in relation to the segments of the other ring half, and with the central metallic annular disks or plates of the two ring halves being clamped to each other at their outer adjacently situated peripheral edges, whereby the rubber body of each segment is provided with at least one window, which extends in the circumferential direction along a circular line and also extends over the axial thickness of said rubber body, with the curved walls of said window extending approximately coaxially or concentrically and with the ends of the window terminating in the vicinity of the radial end faces of the associated metallic plate segments, and whereby each of the two segment plates of each segment contain an opening that is congruent or aligned with the contiguous window in the rubber body.
The radial position of the windows is advantageously selected such that during operation of the shaft coupling, approximately equal temperatures prevail in the core areas of the two portions of the rubber body that are adjacent to the window.
The advantage that can be achieved with the present invention is based upon the fact that in the core area of the rubber body, in which the heating is normally greater than the edge regions, the material is eliminated by defining a window. Although a certain reduction in the mechanical stressability of the shaft coupling can be expected, in return a much greater gain in thermal stressability is surprisingly obtained. In comparison to the overall size that has been customary up to now, while the mechanical stressability is not intended to decrease, the shaft coupling merely needs to be enlarged slightly in its outer dimensions. However, as already mentioned, a disproportionately greater gain in thermal stressability of the shaft coupling offsets this enlargement. By the use of this principle, the difficulties present in known shaft couplings, namely the occurrence of unacceptably high heating in the core area of the rubber body, can be alleviated by simple means.
The size of the windows can be determined by the following procedure. To begin with, the trapezoidal full cross-section of the rubber body, with given dimensions and known material characteristics at a certain heat stress, is examined mathematically with regard to heat distribution and the extent of allowable maximum temperatures. By this means, the position and the size of the window can be determined. The center of the high temperatures in the rubber body is not necessary here as far as heat technology is concerned. After this, in a second stage, the radial heights of the resulting portions of the rubber body, which are situated on both sides of the window, are determined in such a way that approximately equal temperatures prevail in the centers of the two portions when there is a certain heat action. In so doing it will be observed that the radial heights of the two portions are not identical, but that the radial height of the outer portion is less than that of the inner portion. The cause of this is essentially the trapezoidal cross-sectional shape of the rubber body, for which reason the outer portion has a greater axial extent than does the inner section.
The present invention also has a further substantial advantage. This can be attributed to the fact that the windows in the rubber bodies extend into the abutting metallic segment plates, so that the entire resilient annular assembly has extending through it axial passages through which cooling air can flow. A better ventilation of that side of the shaft coupling facing the drive motor, which is generally more highly thermally stressed than the opposite free side, can also be achieved at the same time. This will be examined in greater detail in the following part of the specification.
In addition, further specific features of the present invention will be described in detail subsequently.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings in detail, in the resilient shaft coupling embodiment illustrated in the drawings, the resilient annular interconnection or intermediate assembly is composed of two identical annular members or parts 2, 3 that butt against one another, in the manner of a mirror image, at their dividing plane. The primarY rigid coupling member is constructed as a hub 1, which extends beyond the dividing plane of the ring or annular parts 2, 3 of the resilient annular or ring assembly 4 to the inside of the shaft coupling. Formed on the outer front face of the hub 1 is a fastening flange 5, which serves for the non-rotational connection of a drive ring 6. As a connecting link between the hub 1 and the drive ring 6, there is provided a diaphragm ring 7 of spring steel that allows for a certain axial movability between the primary coupling member, namely the hub 1, and the secondary coupling member, namely a flange ring 8.
The diaphragm ring 7 is non-rotatably braced against the hub 1 with the aid of a clamping ring 9; in order to create the axially directed clamping force, several clamping bolts 10 are provided. These bolts 10 are retained in through-holes in the flange 5 and in the clamping ring 9, and are equidistantly distributed over the entire periphery. Disposed on a circle that is smaller than the imaginary circle of the clamping bolts 10, further aligned through-holes are provided in the parts 5 and 9, with known clamping sleeves 11 being frictionally retained in these further holes. These sleeves, together with the clamping bolts 10, produce the non-rotational connection between the parts 5 and 9.
The drive ring 6 contains, on an inner circle, a number of through-holes in which connecting bolts 12 are positively retained. The outer ends of the connecting bolts 12 pass through a bearing element 13 of limited resilience that is provided on the outer periphery of the diaphragm ring 7. This construction makes possible a bending of the diaphragm ring 7 in axially opposite directions without the risk of imposing transverse stresses on the connecting bolts 12 or on the drive ring 6.
In the illustrated embodiment, the two halves 2, 3 of the resilient annular assembly 4 each comprise four sectors or segments, with two sectors or segments 15, and 15a of the rear half 2, a sector or segment 14, and part of a further sector or segment 14a being illustrated in the side view of FIG. 2. The resilient annular assembly 4, in cross-section, has an essentially trapezoidal shape, as can be seen from FIG. 1. Such a shape is known. It serves the purpose of economizing on rubber material and, at the same time, on weight due to the fact that the torsional stress is smaller in those areas of the rubber body that are closer to the axis of rotation than in those areas that are disposed radially outwardly thereof.
The resilient annular assembly 4 is composed of a total of eight identical segments 14 and 15. Each segment is composed of an axially outer sector or segment plate 16, an axially inner sector or segment plate 17, and a rubber body 18 that is vulcanized to the inner surfaces of the plates 16, 17. Integrally formed on the outside of the outer segment plates 16 are circumferential projecting rims 19 that extend along a circular sector. Those surfaces of the rims 19 that extend at right angles to the axis of rotation are disposed parallel to the abutment surfaces on the drive ring 6 on the one hand, and on the flange ring 8 on the other hand. In order to clamp the assembly 4 to the drive ring 6 and to the flange ring 8, fitted bolts or dowels 20 are inserted in aligned bores in the parts that are to be connected; the dowels 20 are equipped with a threaded end and a nut. Radially projecting annular shoulders 21 or 22 are formed on the driver ring 6 and on the flange ring 8 in order to center the segments (see FIG. 1).
The inner segment plates 17 are in contact with one another only at their radially inner and outer edges. Here, annular plane-parallel outer and inner abutment surfaces 23 and 24 are provided (FIG. 2). The reciprocal clamping is effected on only the outer abutment surfaces. Axially parallel holes or through-bores that are successively arranged in the circumferential direction are provided in the area of these abutment surfaces 23, with clamping bolts 26 being secured in these holes 25.
Defined in the wall of each segment plate 17, between the inner abutment surface 24 and the outer abutment surface 23, is a large recess or cavity 27 that extends from one radial end face edge to the opposite radial end face edge of the segment plate 17. In its center, the outer abutment surface 23 is interrupted by a notch or indentation 31, which extends the cavity 27 as far as the peripheral edge.
Formed on the inner peripheral edge of the segment plates 17 are radially projecting lands or ribs 28, the free outer surface on which lie on a common circle that is concentric with the hub 1. By means of these lands 28, the parts 2, 3 of the resilient annular assembly 4 are supported radially against the hub 1. In this connection, disposed between the hub 1 and the lands 28 is a bearing sleeve or bushing 29, that is inserted in a circumferential groove in the hub 1 and therefore cannot move axially. The task of the bearing bushing 29 is to improve the sliding motion of the lands 28 with respect to relative movements between the two rigid coupling members 1 and 8, both in the axial direction and in the direction of rotation.
The segments 14 or 15 of the two halves 2 or 3 of the resilient annular assembly 4 are clamped together in a position in which they are staggered in relation to one another by half a segment division. In this way, a closed rigid ring is formed without any additional back-up or support rings. At the intersections of the segments 14 or 15, a radial end face gap 30 is left clear in each case, through which on the outside, air can penetrate into the passages which extend in the circumferential direction of the segments and are formed by the large cavities 27. During operation of the coupling, this air is driven outwardly, as a result of centrifugal force, through the outlet slots at the notches 31 in the center of the inner segment plates 17, so that a forced flow is produced that brings about good cooling of the inner segment plates 17, and hence of the rubber bodies 18 which are fastened to the latter.
In order to avoid excessive thermal stresses on the rubber bodies 18, a window 32 having the cross-sectional shape illustrated in FIG. 2 is left clear in the rubber body of each part 2, 3. Each individual window 32, which has end walls 34 and curved walls 33 that are essentially concentric to the axis of rotation, extends over the axial thickness of the rubber body 18. The window 32 is extended into the outer and inner segment plate 16 and 17 respectively, which contain congruent or aligned openings 35 and 35a (see FIG. 3).
As FIG. 1 shows, that portion of the rubber body 18 that is on the radially outer side of the window 32 has a smaller radial thickness than does the radially inwardly disposed portion of the rubber body. This is related to the fact that the radial position of the window 32 is selected in such a way that approximately equal temperatures prevail during operation of the shaft coupling in the core areas of the two portions of the rubber body 18 that are adjacent to the window.
Because the rubber bodies 18 of the individual parts contain windows 32, passages are produced that extend in the axial direction from one end face to the other end face of the resilient annular assembly 4; through these passages, cooling air can flow during operation of the shaft coupling. This brings about an additional cooling of the rubber bodies 18 in the areas that adjoin the window 32. As a result of this, better ventilation of the space between the resilient shaft coupling and the adjacent flywheel is also obtained.
This is especially important, particularly if the flywheel is cup-shaped and the shaft coupling closes the inner space completely or partially. As a result of this arrangement, relatively high temperatures prevail in the space between the shaft coupling and the base of the cup. This means that the flywheel side of an elastic shaft coupling is usually more highly thermally stressed than is the opposite exposed side. With such a structural design of the flywheel, the inner space can be effectively ventilated, due to the aforementioned, inventive axially extending passages in the area of the resilient annular assembly, and hence the thermal stress on the flywheel side of the shaft coupling can be reduced at the same time.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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A resilient shaft coupling in which a rigid primary and a rigid secondary coupling member are connected together by at least one resilient annular assembly of a multi-part construction that is composed of a number of ring segments that are identical and run circumferentially in close succession. Each segment is composed of axially outer metallic segment plates and an inner rubber body that has a trapezoidal cross-sectional shape with a radially outwardly increasing width in an axial plane. In order to obtain higher thermal stressability of the shaft coupling, at least one window is provided in the rubber body of each segment. The ends of the window end in the vicinity of the radial end faces of the segment. Openings are also provided in the two segment plates of each segment and are congruent with the window in the rubber body.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/774,782, filed Feb. 17, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a manipulator arm and drive system that can be operated in multiple modes, including an on or off mode, referred to herein as a “rate mode” or a spatially correspondent (“SC”) mode. The multi-mode manipulator arm and drive system of the present invention can be hydraulically operated subsea.
[0004] 2. Description of the Prior Art
[0005] Prior art manipulator arms are available in two alternate primary modes (types), rate mode and spatially correspondent (“SC”) mode manipulators. In rate mode, each of the manipulator degrees-of-freedom (DOF) is controlled by an actuator which in turn is controlled via a directional control valve that is either fully on or fully off. While the term “rate mode” is familiar to those skilled in the manipulator arm art, it does not provide a literal description of the functional capabilities of this mode. In prior art rate mode, the manipulator joint is either moving at full speed or it is completely stopped. In prior art rate mode, the rate of movement of the manipulator arm is not controlled. It would be advantageous to have a single manipulator that could be selectively operated in either of these modes.
[0006] In rate mode operation, the rate mode controller allows simple, on/off control of one or more actuator control channels. This further causes actuation of the appropriate actuator which, in turn causes movement of the appropriate arm joint or segment. The operator may actuate more than one actuator at a time. The operator is not in control of the velocity of the joint or segment since it is simply an “on/off” function. In rate mode, joint position feedback is not present. The operator simply actuates the desired joint or segment until he sees that it is the desired position/orientation.
[0007] A rate mode manipulator arm and drive system suitable for subsea applications is shown in FIG. 1 . The rate mode manipulator shown in FIG. 1 is suitable for use with a manipulator having a single degree of freedom. In rate mode, the operator energizes a directional control valve by depressing individual buttons or button in order to move the directional control valve, and hence the actuator, in the desired direction. Rate mode manipulators operate in an “open-loop” fashion wherein the operator depresses the corresponding button or buttons until the manipulator joint or joints move into the desired position. The operator monitors the position of the manipulator visually. In subsea applications using an ROV, this may be accomplished via a subsea camera. There is no position feedback signal utilized in the manipulator control electronics itself.
[0008] Rate mode provides a more awkward method of controlling a manipulator arm than SC mode; however, rate mode manipulation is simpler and less costly to implement than SC mode manipulation. A rate mode manipulator is also more reliable than an SC mode manipulator because it requires less electronics than an SC mode manipulator.
[0009] In the SC mode (also known as “position controlled mode”), the position of each manipulator arm joint is known and controlled. Typically, an SC manipulator system comprises two parts: a master and a slave. The master is an input device, often embodied in a hand controller that is equipped with a number of joints whose angular position is measured and monitored as the operator moves the controller. Generally, the master has a joint arrangement that mimics the joint arrangement of the slave.
[0010] The slave is the manipulator itself. The manipulator is a tele-robotic arm. The slave will move in proportion to the master hand controller. If a joint on the master is moved slowly, the slave joint will move slowly. If the master is moved quickly, the slave will move quickly. The movement (velocity) of the slave joints and segments “correspond” to the movement of the “master” controller joints and segments. An SC mode manipulator arm and drive system is shown in FIG. 2 .
[0011] Positions or changes-in-position of the master's joints and segments is monitored by a local control computer. The local control computer sends the appropriate signals to the remote control computer in response to master controller inputs. The remote control computer monitors the position of the arm joints and segments and compares those positions with the position information sent from the local control computer. It then performs the necessary calculations to determine the direction and magnitude of the signals required from the actuator control in order to move the actuators, and hence the arm joints and segments, to the right position.
[0012] Prior art SC manipulators operate in “closed-loop” mode, which uses an error signal that represents the position of each and every joint on the slave. This signal is continuously compared to the desired joint position (as indicated by the position of the master's matching joint) and the direction and magnitude of the corresponding control valve is modulated as necessary according to some sort of algorithm which is usually a variant of a proportional, integral, derivative (PID) loop.
[0013] In existing manipulator or robotic arm designs, the angular displacement of one or more joints is monitored with a resolver, potentiometer, or other rotation sensor. These require some sort of mechanical connection, typically a shaft, between the moveable portion of the joint and the sensor. Sensors are typically held stationary by the non-moveable portion of the joint. In a subsea environment, mechanical connection, e.g. a shaft, must be equipped with a mechanical connection seal to prevent seawater intrusion into the sensor. This mechanical connection seal is prone to failure, thus resulting in the subsequent failure of the sensor.
[0014] Existing solutions require discrete wiring for each sensor installed. Arms with large numbers of joint sensors require considerable wiring that can be difficult to install and maintain.
[0015] Existing sensor types often require that some sort of host controller read analog values that are produced by the sensor, e.g. a resolver or potentiometer. This requires that the controller provide processing power to read, filter, and scale the readings of each of the sensors which have had to transmit analog signals over long, noise-prone conductors.
[0016] Prior art SC mode manipulator systems have several problems. Each joint of the slave must be equipped with a position feedback device such as an encoder, resolver, or potentiometer. The control algorithm must have a reliable signal from this device in order for the manipulator to work. If any of the feedback devices fail, then the manipulator is unusable.
[0017] The velocity and acceleration of the slave joints must be variable and, preferably, stepless. Traditionally, this has been achieved by using hydraulic servo valves which suffer four disadvantages, which are high cost, propensity for failure due to lack of fluid cleanliness, high leakage rate, and high pressure drop at high flow rates. In order to increase the longevity of the SC manipulator, an isolated hydraulic power unit (HPU) is often required. This adds to the cost, weight and complexity of the system.
[0018] SC mode manipulators are easier than rate mode manipulators to operate. They also provide the operator with a fluid touch. An SC mode manipulator requires more responsive valves and electronics than a rate mode manipulator. This results in increased complexity and reduced reliability for an SC mode manipulator versus a rate mode manipulator.
DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 depicts a rate mode manipulator and drive system of the prior art.
[0020] FIG. 2 depicts an SC rate mode manipulator and drive system of the prior art.
[0021] FIG. 3 is a system level diagram of a first preferred embodiment of the invention.
[0022] FIG. 4 a is a system level diagram of a second preferred embodiment of the invention selectively operating in the rate mode.
[0023] FIG. 4 b is a system level diagram of a second preferred embodiment of the invention selectively operating in the SC mode.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Preferred embodiments of the invention are directed to a multi-mode manipulator arm and drive system capable of driving and/or controlling a manipulator arm in either a selected rate mode or SC mode, as shown in FIGS. 3, 4 a and 4 b . A preferred embodiment of the invention comprises one or more rate mode selector switches 10 , each of which is configured to output a rate mode signal capable of driving a manipulator arm in a rate mode. In preferred embodiments, each rate mode selector switch is a push button or a toggle switch. In another preferred embodiment, the rate mode selector switch is operable to be placed in an open position or in a closed position by an operator. In a preferred embodiment, there is a rate mode selector switch for each joint of the manipulator arm to be controlled.
[0025] Another embodiment of the invention comprises a digital signal input 16 operatively coupled to the rate mode selector or actuation switch such that the digital signal input registers a change in the digital input signal when the rate mode actuation switch is depressed and registers the opposite digital input signal when the rate mode actuation switch is released, as shown in FIGS. 3, 4 a and 4 b.
[0026] A preferred embodiment of the invention further comprises a spatially correspondent controller 11 comprising a position adjustable master configured to output a spatially correspondent mode signal responsive to the position of the master and capable of driving a manipulator arm in a spatially correspondent mode, as shown in FIG. 3 a . In a preferred embodiment, the spatially correspondent mode controller is a hand controller, such as a joystick. In a preferred embodiment, the master comprises a number of analog sensors equal to the number of degrees of freedom of the slave, minus one. For example the master for a seven degree of freedom manipulator would have six analog sensors. In another preferred embodiment, the master would comprise a single digital input to open and close the manipulator jaws.
[0027] A preferred embodiment of the invention further comprises a mode selector device 13 operatively coupled to selectively receive at least one of the rate mode signal and the spatially correspondent mode signal and to selectively output one of the rate mode signal or the spatially correspondent signal as the selected mode signal. In a preferred embodiment, the mode selector comprises a selector switch configured to select one of at least two inputs. In this embodiment, the selector switch can be positioned by an operator to select between the rate mode signal and the spatially correspondent mode signal. The combination of the rate mode selection switch, spatially correspondent controller, and mode selector device can be used as a multi-mode manipulator drive selection system that can be used to selectively control manipulator operations in the selected mode.
[0028] Another embodiment, the invention further comprises a local control computer 15 operatively connected to receive the selected mode signal and to output a remote control input signal. In a preferred embodiment, the local control computer is capable of transmitting the remote control input signal to a remote control computer via a wire or optical fiber. The term “computer” as used herein, encompasses a microprocessor. In a preferred embodiment, the local control computer is configured to compare the analog control signal received from the spatially correspondent controller with the position signal received from the arm segment position sensor and to produce an error correction signal determined by the magnitude of the difference between the two signals, as shown in FIG. 3 . In one embodiment, this controller comprises a PID loop.
[0029] In a preferred embodiment, the invention further comprises a remote control computer 17 operatively connected to the local control computer to receive the remote control input signal and to output an actuator control input signal. In a preferred embodiment, the remote control computer is capable of receiving the remote control input signal. In another preferred embodiment, where the local control computer is involved in closed-loop control of a tele-robotic arm, it is also capable of receiving an input from the remote control computer. In some preferred embodiments, the invention is operable to control manipulators located subsea, as shown in FIGS. 3, 4 a and 4 b . In subsea applications, the remote control computer comprises subsea telemetry electronics and software, as shown in FIGS. 3, 4 a and 4 b.
[0030] In a preferred embodiment, the invention further comprises an actuator control 19 configured to receive the actuator control input signal and to output an actuator position signal, as shown in FIGS. 4 a and 4 b . In another preferred embodiment, where a tele-robotic arm is to be operated in a closed-loop fashion, the remote control computer is configured to receive inputs from one or more position or velocity feedback sensors. In a preferred embodiment, the actuator control is capable of acting upon desired joint position and/or velocity information, coming from the remote control computer. In an embodiment where a tele-robotic arm is moved by hydraulic actuators, the actuator control is capable of controlling the hydraulic valves which supply hydraulic pressure and flow to the hydraulic actuators.
[0031] In another preferred embodiment, the invention further comprises an actuator 21 configured to receive the actuator position signal and to move the manipulator arm segment or joint, as shown in FIGS. 4 a and 4 b . The term signal, as used herein, encompasses the transmission of data or other quantitative information via an electrical, electromechanical, electromagnetic, electronic, or hydraulic medium. The actuator is configured to move in response to the actuator position signal. The actuator imparts mechanical force to a respective tele-robotic arm segment 23 to change the position and/or velocity of that segment. The tele-robotic arm segment is coupled to the actuator such that it moves in response to the movement of the actuator. In an embodiment where hydraulic actuators are used, the actuator is a hydraulic cylinder or a hydraulic rotary actuator and the actuator position signal is generated in response to a predetermined level of a hydraulic process parameter, such as hydraulic pressure or flow. In another preferred embodiment, the invention comprises an arm segment position sensor 25 , for each arm segment.
[0032] An embodiment of the invention further comprises a moveable manipulator arm 44 and a position sensor 45 operatively coupled to the manipulator arm and configured to output a position signal indicative of the position of the manipulator arm, as shown in FIG. 3 . In another preferred embodiment, the manipulator arm comprises multiple segments, connected by multiple joints.
[0033] Another embodiment of the invention further comprises a hydraulic drive system 30 comprising a first port 32 , a second port 49 , a proportional control solenoid 34 , and a directional control valve 36 operable to be configured in a first direction mode and a second direction mode, as shown in FIG. 3 . In one preferred embodiment, the directional control valve is a 4-way, 3-position proportional valve. This hydraulic drive system is configured to receive the manipulator actuation signal from the digital signal receiver, and to receive the error correction signal from the spatially correspondent mode control system. This hydraulic drive system is further configured to eject hydraulic fluid through the first port in response to the manipulator actuation signal and the error correction signal when the proportional control solenoid is in a first configuration. In this first configuration, the hydraulic drive system receives hydraulic fluid though the second port 49 .
[0034] This embodiment of the invention further comprises a first hydraulic fluid channel 31 comprising a first end 33 connected to the first port 32 and a second end 35 opposite the first end, as shown in FIG. 3 . This embodiment of the invention further comprises a second hydraulic fluid channel 37 comprising a first end 39 connected to the second port 49 and a second end 38 opposite the first end, as shown in FIG. 3 . When the proportional control solenoid is placed in a second configuration, the direction of hydraulic fluid flow through fluid channels 31 and 37 and through ports 32 and 49 is reversed, from the direction of such flow when the control solenoid is in a first configuration.
[0035] This embodiment of the invention further comprises a hydraulic piston 42 comprising a first port 41 connected to the second end of the first hydraulic fluid channel and a second port 43 connected to the second end of the second hydraulic fluid channel such that when the directional control valve is configured in a first direction mode, hydraulic fluid ejected from the drive system flows into the first port and out of the second port, causing the piston to extend, and when the directional control valve is configured in a second direction mode, hydraulic fluid ejected from the drive system flows into the second port and out of the first port, causing the piston to retract, as shown in FIG. 3 . The piston is also connected to the manipulator arm such that extension of the piston causes movement of the manipulator arm in a first direction and retraction of the piston causes movement of the manipulator arm in a second direction.
[0036] The hybrid control scheme employed in preferred embodiments of the invention has the advantages of both the rate and SC modes. Preferred embodiments of the invention have a position feedback device for each joint and a device for modulating the flow to each actuator associated with the joint.
[0037] In a preferred embodiment, the invention uses proportional flow, directional control valves. These are a fraction of the cost of servo valves and have a lower pressure drop across them. The proportional valve is also more tolerant of contaminated oil. A proportional valve has a leakage rate that corresponds to that of simple directional control valve typically used in rate manipulators. This means that the manipulator arm joints do not drift and require continuous monitoring of position.
[0038] By employing proportional valves, specialized software, and electronics, a preferred embodiment of the invention can be switched between SC and rate modes at any time. If, while operating in SC mode, a position feedback sensor should fail, the operator can switch the manipulator from SC mode to rate mode and continue working. Alternatively, the mode can be switched back and forth as a consequence of operator preference.
[0039] There are scenarios where it would be desirable to operate some of the manipulator joints in SC mode while other joints are operated in rate mode. This would be implemented largely in software but would require that the topside control console be equipped with a means for setting operating modes for individual joints. The simplest arrangement would consist of nothing more than a toggle switch and indicator lamp (LED) for each joint.
[0040] The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.
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The present invention relates to a manipulator arm and drive system that can be operated in multiple modes, including an on or off mode, referred to herein as a “rate mode” or a spatially correspondent (“SC”) mode. The multi-mode manipulator arm and drive system of the present invention can be hydraulically operated subsea.
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BACKGROUND OF THE INVENTION
The present invention generally relates to noise reduction circuits for video signals, and more particularly to a noise reduction circuit which can satisfactorily reduce a noise component in a video signal without introducing undesirable effects to a video signal component by using correlations in the video signal such as a correlation within a line, a correlation between lines, and a correlation between fields.
Conventionally, a noise component within a video signal is reduced in noise reduction circuits which use correlations such as a correlation within a line (hereinafter simply referred to as a within-line correlation), a correlation between lines (hereinafter simply referred to as a line correlation), and a correlation between fields (hereinafter simply referred to as a field correlation). The construction of the conventional noise reduction circuits will be described later on in the specification by referring to drawings. However, the conventional noise reduction circuits are constructed independently depending on the kind of correlation which is taken into account to reduce the noise component. Further, especially in the case where the video signal has no within-line correlation, no line correlation, and no field correlation, the pattern of the reproduced picture becomes deteriorated when the video signal is passed through a noise reduction circuit which uses one of the correlations in the video signal to reduce the noise component. For this reason, each of the conventional noise reduction circuits comprises an internal limiter circuit having a limiting level thereof selected to a low value to such an extent that no undesirable effects are introduced to the video signal. Accordingly, the conventional noise reduction circuits had a disadvantage in that a satisfactory noise reducing effect cannot be obtained. On the other hand, when the limiting level is increased to improve the noise reducing effect so that the signal-to-noise (S/N) ratio is improved, there is a problem in that the pattern of the reproduced picture becomes faded in the case where no correlation exists in the information contents of the video signal.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a novel and useful noise reduction circuit for video signal, in which the disadvantages described heretofore are eliminated.
Another and more specific object of the present invention is to provide a noise reduction circuit comprising a plurality of different noise reduction circuits which use different correlations in a video signal and are coupled in series, wherein each interval between upper and lower limiting levels of the different noise reduction circuits is normally set to a small (narrow) value, but when the correlation in the video signal does not exist with respect to one of the different noise reduction circuits, each interval between the upper and lower limiting levels of the remaining different noise reduction circuits is variably controlled to a large (wide) value so that the remaining different noise reduction circuits reduce a noise component which could not be reduced in the one of the noise reduction circuits. According to the noise reduction circuit of the present invention, it is possible to effectively and satisfactorily reduce the noise component even in the case where a kind of correlation does not exist in the video signal, and more over, the pattern of the reproduced picture will not be deteriorated.
Other objects and features of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram for explaining the correlations in the video signal;
FIG. 2 is a system block diagram showing an essential part of a conventional noise reduction circuit;
FIGS. 3(A) through 3(G) are block diagrams respectively showing examples of essential parts of other noise reduction circuits which are coupled to the noise reduction circuit shown in FIG. 2;
FIG. 4 is a system block diagram showing an embodiment of a noise reduction circuit according to the present invention;
FIG. 5 is a system block diagram showing an embodiment of a non-correlated part detecting circuit within the block system shown in FIG. 4;
FIGS. 6(A) through 6(D) show signal waveforms at parts of the block system shown in FIG. 5; and
FIG. 7 is a system circuit diagram showing a concrete circuit of a part of the block system shown in FIG. 4.
DETAILED DESCRIPTION
Generally, correlations exist in the information contents of a video signal, and the correlations can be divided into the following kinds. That is, as shown in FIG. 1, the correlations in the video signal can be divided into (A) the case where a within-line correlation exists in a forward direction (direction in which the time progresses) indicated by an arrow ○1 with respect to a horizontal scanning line (hereinafter simply referred to as a line) L within a picture 10a (one field), (B) the case where a within-line correlation exists in a backward direction (direction opposite to the direction in which the time progresses) indicated by an arrow ○2 with respect to the line L within the picture 10a, (C) the case where a line correlation exists in a forward direction indicated by an arrow ○3 within the picture 10a, (D) the case where a line correlation exists in a backward direction indicated by an arrow ○4 within the picture 10a, (E) the case where a field correlation (or a frame correlation) exists in a forward direction indicated by an arrow ○5 between the picture 10a and a previous picture 10b (or a picture 10c which is previous to the picture 10b), and the case where a field correlation (or a frame correlation) exists in a backward direction indicated by an arrow ○6 between the picture 10a and a next picture (or a picture which is subsequent to the next picture).
The information contents of the video signal generally have one of the kinds of correlations described above, and it is uncommon for the information contents to have no such correlation. On the other hand, the correlation generally does not exist with respect to a noise component. Hence, in a noise reduction circuit which uses the correlation in the video signal in order to reduce the noise component, a subtraction between an input signal and a video signal which is relatively prior to or subsequent to the input video signal by a predetermined time period. As a result of such a subtraction, the video signal components are cancelled because the video signal components have the correlation, and the noise component having no correlation is obtained. A video signal which is eliminated of the noise component, is obtained by subtracting the noise component from the input video signal.
This noise reduction will now be described by referring to FIG. 2. FIG. 2 shows an essential part of the conventional noise reduction circuit. An input video signal a is applied to an input terminal 11a, and a video signal a which will be described later is applied to an input terminal 11b. The video signal a is subtracted from the input video signal a in a subtracting circuit 12. A noise component is obtained from the subtracting circuit 12 and is subjected to an amplitude limitation in a limiter 13. An output signal of the limiter 13 is attenuated by a predetermined quantity in an attenuator 14, and is supplied to a subtracting circuit 15. The subtracting circuit 15 subtracts an output signal of the attenuator 14 from the input video signal a, and a video signal b which is eliminated of the noise component is obtained through an output terminal 16.
When using the within-line correlation in the forward direction described under the case (A) given before, an output terminal 22 of a circuit shown in FIG. 3(A) is coupled to the input terminal 11b. The input video signal a applied to the input terminal 11a is also applied to an input terminal 20. The input video signal a is passed through a lowpass filter 21, and an output signal of the lowpass filter 21 is applied to the input terminal 11b as the video signal a, through an output terminal 22. A noise reduction circuit constituted by the circuits shown in FIGS. 2 and 3(A) is generally referred to as a coring circuit.
When using the within-line correlation in the backward direction described under the case (B), output terminals 22 and 24 of a circuit shown in FIG. 3(B) are, for example, coupled to the input terminals 11b and 11a, respectively. The input video signal a applied to the input terminal 20 is passed through the lowpass filter 21 on one hand, and is passed through a delay circuit 23 on the other. The output signal of the lowpass filter 21 is applied to the input terminal 11b as the video signal a, through the output terminal 22. An output signal of the delay circuit 22 is applied to the input terminal 11a through the output terminal 24. A noise reduction circuit constituted by the circuits shown in FIGS. 2 and 3(B) is generally referred to as a backward type coring circuit.
A circuit shown in FIG. 3(C) is employed in a modification of the backward type coring circuit. The input video signal a applied to the input terminal 20 is supplied to a (1H-Δ) delay circuit 25, where H represents one horizontal scanning period. An output signal of the delay circuit 25 is applied to the input terminal 11b through the output terminal 22.
When using the line correlation in the forward direction described under the case (C), the output terminal 22 of a circuit shown in FIG. 3(D) is coupled to the input terminal 11b. The input video signal a applied to the input terminal 20 is passed through a 1H delay circuit 26 which delays the signal by a time period of 1H, and a delayed output signal of the 1H delay circuit 26 is applied to the input terminal 11b through the output terminal 22. A noise reduction circuit constituted by the circuits shown in FIGS. 2 and 3(D) is generally referred to as a noise canceller using line correlation.
On the other hand, as another example of the use of the line correlation in the forward direction, a circuit shown in FIG. 3(E) is employed. The output signal b of the subtracting circuit 15 shown in FIG. 2 is applied to an input terminal 27, and is passed through the 1H delay circuit 26. The output signal of the 1H delay circuit 26 is passed through the output terminal 22 and is applied to the input terminal 11b. A noise reduction circuit constituted by the circuits shown in FIGS. 2 and 3(E) is generally referred to as a recursive type noise canceller using line correlation.
When using the field (or frame) correlation in the forward direction described under the case (E), a circuit shown in FIG. 3(F) is employed. The output signal of the subtracting circuit 15 shown in FIG. 2 is applied to an input terminal 27, and is passed through a one field (or one frame) memory 28 wherein the signal is delayed by one field (or one frame). An output signal of the one field (or one frame) memory 28 is applied to the input terminal 11b through the output terminal 22. A noise reduction circuit constituted by the circuits shown in FIGS. 2 and 3(F) is generally referred to as a recursive type noise canceller using field (or frame) correlation.
As another example, it is possible to employ a circuit shown in FIG. 3(G), and in this case, the input video signal a applied to the input terminal 20 is passed through the one field (or one frame) memory 28 and the output terminal 22 and is applied to the input terminal 11b.
The conventional noise reduction circuit uses one of the noise reduction circuits described heretofore, independently, and this lead to the disadvantages described before.
The present invention has eliminated the disadvantages of the conventional circuits described before, and an embodiment of the noise reduction circuit according to the present invention will now be described by referring to FIG. 4 and the figures which follow.
In the embodiment shown in FIG. 4, a noise reduction circuit 30 generally comprises a noise reduction circuit part 31A which uses the within-line correlation, a noise reduction circuit part 31B which uses the line correlation, a noise reduction circuit part 31C which uses the field correlation, and a control circuit part 32.
An input video signal which includes a noise component which is to be eliminated, is applied to an input terminal 33. The input video signal is supplied to a lowpass filter 34 and subtracting circuits 35A and 38A within the noise reduction circuit part 31A. An output signal of the lowpass filter 34 is supplied to the subtracting circuit 35A and is subtracted from the input video signal from the input terminal 33. Hence, the noise component is obtained from the subtracting circuit 35A. An output signal of the subtracting circuit 35A is supplied to a non-correlated part detecting circuit 42A within the control circuit part 32 which will be described later and a limiter circuit 36A which will be described later. A signal which is amplitude-limited in the limiter circuit 36A is passed through an attenuator 37A and is supplied to the subtracting circuit 38A wherein an output signal of the attenuator 37A is subtracted from the input video signal from the input terminal 33. Accordingly, a video signal which is eliminated of the noise component to a certain extent is obtained from the subtracting circuit 38A.
The output signal of the subtracting circuit 38A is supplied to a 1H delay circuit 39 and subtracting circuits 35B and 38B within the noise reduction circuit part 31B. The signal which is delayed by one horizontal scanning period (1H) in the 1H delay circuit 39 is subtracted from the output signal of the subtracting circuit 38A in the subtracting circuit 35B. An output signal of the subtracting circuit 35B is supplied to a non-correlated part detecting circuit 42B within the control circuit part 32 and a limiter circuit 36B. Because the operations of the subtracting circuits 35B and 38B, the limiter circuit 36B, and an attenuator 37B are the same as those of the subtracting circuits 35A and 38A, the limiter circuit 36A, and the attenuator 37A, these circuit elements are designated by the same reference numerals as those of the corresponding circuit elements of the noise reduction circuit part 31A with a subscript "B" instead of "A" and description thereof will be omitted.
The output signal of the subtracting circuit 38B is supplied to a one field delay circuit 40 and subtracting circuits 35C and 38C within the noise reduction circuit part 31C. The signal which is delayed by one field in the one field delay circuit 40 is subtracted from the output signal of the subtracting circuit 38B in the subtracting circuit 35C. An output signal of the subtracting circuit 35C is supplied to a non-correlated part detecting circuit 42C within the control circuit part 32 and a limiter circuit 36C. Because the operations of the subtracting circuits 35C and 38C, the limiter circuit 36C, and an attenuator 37C are the same as those of the subtracting circuits 35A and 38A, the limiter circuit 36A, and the attenuator 37A, these circuit elements are designated by the same reference numerals as those of the corresponding circuit elements of the noise reduction circuit part 31A with a subscript "C" instead of "A" and description thereof will be omitted. An output video signal of the subtracting circuit 38C, which is eliminated of the noise component, is obtained through an output terminal 41.
In the case where the noise reduction circuit part 31C is to be constituted by a noise reduction circuit part using the frame correlation, a one frame delay circuit is used instead of the one field delay circuit 40. In addition, a noise reduction circuit which uses the frame correlation and is constructed in this manner, may be coupled in series with the noise reduction circuit part 31C. Further, the circuit shown in FIG. 3(B) or FIG. 3(C) may be used instead of the lowpass filter 34 within the noise reduction circuit part 31A, the circuit shown in FIG. 3(E) may be used instead of the 1H delay circuit 39 within the noise reduction circuit part 31B, and the circuit shown in FIG. 3(F) may be used instead of the one field delay circuit 40 within the noise reduction circuit part 31C.
FIG. 5 shows an embodiment of a concrete circuit construction of the non-correlated part detecting circuit 42A. Because the constructions of the non-correlated part detecting circuits 42B and 42C are the same as that of the non-correlated part detecting circuit 42A, description and illustration thereof will be omitted. An output signal c of the subtracting circuit 35A is applied to a terminal 50 and is supplied to an upper part slicing circuit 51 and a lower part slicing circuit 52. In the case where the within-line correlation exists in the two signals supplied to the subtracting circuit 35A, the video signal components in the two signals cancel each other, but the noise components in the two signals are not cancelled since the within-line correlation does not exist with respect to the noise component. Thus, a noise component c1 shown in FIG. 6(A) is obtained from the subtracting circuit 35A. On the other hand, even with respect to the video signal component, the within-line correlation does not exist at parts where the information content changes from black to white or white to black in the horizontal scanning direction. As a result, large amplitude signal components c2 and c3 shown in FIG. 6(A) are also obtained from the subtracting circuit 35A in correspondence with the parts of the video signal component having no within-line correlation. In the case where the information content of the video signal component gradually changes from black to white (or white to black), for example, the correlation does not exist during the change, and a large amplitude signal component having a large width is produced although the amplitude thereof is slightly smaller than those of the components c2 and c3.
The signal c comprising the signal components c1, c2, and c3 is supplied to the upper part slicing circuit 51 wherein a signal part over a predetermined slicing level L1 is sliced. In other words, the upper part slicing circuit 51 removes the signal part over the level L1 of the large amplitude signal component c2. Accordingly, a signal d shown in FIG. 6(B) is obtained from the upper part slicing circuit 51 and is supplied to an adding circuit 54. The signal c is also supplied to a lower part slicing circuit 52 wherein a signal part under a predetermined slicing level L2 is sliced. That is, the lower part slicing circuit 52 removes the signal part under the level L2 of the large amplitude signal component c3. Thus, a signal e shown in FIG. 6(C) is obtained from the lower part slicing circuit 52 and is supplied to an inverting circuit 53 wherein the signal e is inverted. An output signal of the inverting circuit 53 is supplied to the adding circuit 53 and is added with the signal d. As a result, a signal f shown in FIG. 6(D) is produced from the adding circuit 54 and is obtained through a terminal 55. The signal f obtained through the terminal 55 is produced from the non-correlated part detecting circuit 42A as a detection signal f1. The detection signal f1 is supplied to an adding circuit 44a through an attenuator 43a on one hand, and is supplied to an adding circuit 44b through an attenuator 43b on the other.
Similarly, a detection signal f2 is obtained from the non-correlated part detecting circuit 42B in correspondence with a part of the video signal having no line correlation. The detection signal f2 is supplied to the adding circuit 44a through an attenuator 43c on one hand, and is supplied to an adding circuit 44c through an attenuator 43d. Similarly, a detection signal f3 is obtained from the non-correlated part detecting circuit 42C in correspondence with a part of the video signal having no field correlation. The detection signal f3 is supplied to the adding circuit 44b through an attenuator 43e on one hand, and is supplied to the adding circuit 44c through an attenuator 43f.
When each interval between the upper and lower limiting levels of the respective limiter circuits 36A through 36C of the respective noise reduction circuit parts 31A through 31C is wide (that is, when each interval between upper and lower limiting levels of the respective amplitude limitations is large), the output noise components of the subtracting circuits 35A through 35C are all supplied to the subtracting circuits 38A through 38C, and the noise reducing effect is large. However, when the large amplitude signal components c2 and c3 shown in FIG. 6(A) are also supplied to the subtracting circuits 38A through 38C, the video signals obtained from the subtracting circuits 38A through 38C are subjected to unnecessary subtractions, and the pattern of the reproduced picture becomes greatly deteriorated in that the contours of the images become faded. On the other hand, when the large amplitude signal components c2 and c3 are eliminated in the limiter circuits 36A through 36C, the noise components included in the large amplitude signal components c2 and c3 are also eliminated, and there is a problem in that the noise components in the corresponding signal parts cannot be eliminated in the subtracting circuits 38A through 38C.
Accordingly, in the noise reduction circuit of the present invention, each interval between the upper and lower limiting levels of the respective limiter circuits 36A through 36C is selected to a value which is narrow (small) to such an extent that there is constantly no deterioration in the pattern of the reproduced picture. Thus, in the case where the within-line correlation, the line correlation, and the field correlation exist in the information contents of the video signal, the noise reduction can be carried out effectively without deteriorating the pattern of the reproduced picture.
However, in the case where the within-line correlation does not exist in the information contents of the video signal, the pattern of the reproduced picture will not be deteriorated because of the narrow interval between the upper and lower limiting levels of the limiter circuit 36A, but the noise component cannot be sufficiently eliminated in the noise reduction circuit part 31A. In this case, the detection signal f1 described before is produced from the non-correlated part detecting circuit 42A in the noise reduction circuit of the present invention. This detection signal f1 is passed through the attenuator 43a and the adding circuit 44a, and is supplied to the limiter circuit 36C of the noise reduction circuit part 31C as a control signal. On the other hand, the detection signal f1 is passed through the attenuator 43b and the adding circuit 44b, and is supplied to the limiter circuit 36B of the noise reduction circuit part 31B as a control signal. When the limiter circuits 36C and 36B are supplied with the control signals from the respective adding circuits 44a and 44b, the interval between the upper and lower limiting levels of each of the limiter circuits 36C and 36B is slightly widened (enlarged) during the time period in which the corresponding control signal exists. Generally, even when the information contents of the video signal have no within-line correlation, at least one of the line correlation and the field correlation exists. In other words, it is uncommon for the information contents of the video signal to have none of the within-line correlation, the line correlation, and the field correlation. Accordingly, even in the case described above where the within-line correlation does not exist and the noise component cannot be sufficiently reduced in the noise reduction circuit part 31A, the remaining noise component is effectively reduced in the noise reduction circuit parts 31B and 31C respectively comprising the limiter circuits 36B and 36C each having the widened interval between the upper and lower limiting levels, without fading the pattern of the reproduced picture.
Similarly, in the case where the line correlation does not exist in the information contents of the video signal, the detection signal f2 is produced from the non-correlated part detecting circuit 42B. This detection signal f2 is passed through the attenuator 43c and the adding circuit 44a, and is supplied to the limiter circuit 36C of the noise reduction circuit part 31C as a control signal. On the other hand, the detection signal f2 is passed through the attenuator 43d and the adding circuit 44c, and is supplied to the limiter circuit 36A of the noise reduction circuit part 31A as a control signal. When the limiter circuits 36C and 36A are supplied with the control signals from the respective adding circuits 44a and 44c, the interval between the upper and lower limiting levels of each of the limiter circuits 36C and 36A is slightly widened (enlarged) during the time period in which the corresponding control signal exists.
Next, a description will be given with respect to an embodiment of a concrete circuit construction of the limiter circuit 36C by referring to FIG. 7. Because the circuit constructions of the limiter circuits 36A and 36B are similar to that of the limiter circuit 36C, description and illustration thereof will be omitted. The signal from the subtracting circuit 35A is applied to a terminal 60 and is supplied to the non-correlated part detecting circuit 42A. The signal from the subtracting circuit 35B is applied to a terminal 61 and is supplied to a non-correlated part detecting circuit 42B. The output detection signals f1 and f2 of the non-correlated part detecting circuits 42A and 42B are passed through the respective attenuators 43a and 43c, and are added in the adding circuit 44a. The output signal of the adding circuit 44a is applied to the base of a transistor Q6 of an upper part limiter circuit part 64 within the limiter circuit 36C. The upper part limiter circuit part 64 comprises transistors Q5 through Q9 and a variable resistor VR2. The variable resistor VR2 is provided for the setting of the upper limiting level, and a slider of the variable resistor VR2 is coupled to the base of the transistor Q6.
On the other hand, the output signal of the adding circuit 44a is inverted in an inverting circuit 62 and is applied to the base of a transistor Q4 of a lower part limiter circuit part 63. The lower part limiter circuit part 63 comprises transistors Q1 through Q4 and a variable resistor VR1. The variable resistor VR1 is provided for the setting of the lower limiting level, and a slider of the variable resistor VR1 is coupled to the base of the transistor Q4. The output signal of the subtracting circuit 35C is applied to an input terminal 65, and a signal obtained through an output terminal 66 is supplied to the subtracting circuit 38C through the attenuator 37C.
When no output signal is obtained from the adding circuit 44a, the upper part limiter circuit part 64 limits the upper part of the amplitude of the signal passing through the circuit part 64 with the upper limiting level set by the variable resistor VR2. On the other hand, lower part limiter circuit part 63 limits the lower part of the amplitude of the signal passing through the circuit part 63 with the lower limiting level set by the variable resistor VR1.
In the case where an output signal of the adding circuit 44a exists, a positive polarity signal thereof is applied to the base of the transistor Q6, and the upper limiting level of the upper part limiter circuit part 64 rises in the upper part. At the same time, a negative polarity signal from the inverting circuit 62 is applied to the base of the transistor Q4, and the lower limiting level of the lower part limiter circuit part 63 falls in the lower part. Accordingly, when the output signal of the adding circuit 44a exists, the interval between the upper and lower limiting levels of the limiter circuit 36C comprising the upper and lower part limiter circuit parts 64 and 63 is widened.
Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
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A noise reduction circuit for a video signal comprises a plurality of circuit parts coupled in series and a control circuit. Each of the circuit parts comprises a delay circuit for delaying an input video signal supplied thereto, a first subtracting circuit for subtracting an output signal of the delay circuit from the input video signal, a limiter circuit for limiting the amplitude of an output signal of the first subtracting circuit, and a second subtracting circuit for subtracting an output signal of the limiter circuit from the input video signal and for producing a signal which is reduced of a noise component within the input video signal. The delay circuit in each of the circuit parts has a different delay time in accordance with a kind of correlation existing in information contents of the input video signal. The control circuit comprises a plurality of detecting circuits provided in correspondence with the circuit parts and a control signal supplying circuit. Each of the detecting circuits is supplied with the output signal of the first subtracting circuit of a corresponding circuit part and detects large amplitude signal components thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. application Ser. No. 11/820,345, filed Jun. 18, 2007, which claims priority to U.S. Provisional Patent Application No. 60/814,176, filed Jun. 16, 2006, the entire disclosures of which are incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates generally to mobile radio systems.
BACKGROUND
[0003] In the spectrum of motor vehicle passenger safety, motorcycles are some of the most dangerous vehicles on the road. This danger only increases when a motorcycle rider takes his/her hands off of the handlebars to use a communications device. When you apply this to the job of a law enforcement motorcycle officer, the risk of injury only increases because officers are constantly using communication devices while riding. Enabling riders to keep their hands on the handlebars while riding is an important safety requirement. Moreover, most jurisdictions require by law that motorcyclists keep both hands on the handlebars.
[0004] Law enforcement motorcycles have a number of different radio configurations which can include a combination of portable radios and mobile radios.
[0005] Portable Radio. This type of two-way radio is typically worn on the officer's belt and is typically low power with its transceiver being able to have between 3 and 5 watts of power. Portable radios work well in situations where the patrol area is limited and the geographical features of the area are fairly flat.
[0006] Mobile Radio. This type of two-way radio is mounted on the motorcycle in the radio box that is on the back of the bike. This radio has more range than a portable radio because it has greater power. The typical wattage of a motorcycle mobile radio is 15 watts. Mobile radios typically cost 3×-5× as much as a portable radio and work well when the patrol area is over a large area and/or the terrain is hilly or has significant obstructions.
[0007] In addition to the radios, often a public address (PA) system is installed on the motorcycle. Through a loudspeaker, this system is used to audibly broadcast instructions or information to violators or the general public in a limited area.
[0008] Since 1970, there have been a number of offerings in the marketplace to allow motorcycle officers the ability to operate their radios and public address systems without having to take their hands off the handlebars.
[0009] These offerings typically include additional equipment on a motorcycle, such as a radio push-to-talk (PTT) button mounted on the handlebar. Pressing the PTT keys the radio and allows the officer to transmit communication. For the PA system, an additional button is also mounted on the handlebar which when pressed, broadcasts the officer's speech over the PA system.
[0010] On the officer, these offerings typically include a boom microphone and speakers that are mounted on/in the helmet.
[0011] In between the motorcycle and officer, historically, a wire with a quick release connector has been used to connect the officer worn equipment to bike mounted equipment. This wire carries the inbound and outbound transmissions over the mobile radio and also allows for the keying of the radio.
[0012] Others have invented wireless interfaces between communication devices and riders. In general, however, these systems have lacked features. The following are some examples of desirable features: (a) Allowing the rider to both receive and transmit over the mobile radio while on the motorcycle. (b) Operating solely off of the motorcycle battery and the portable radio battery. No additional charging of batteries is required. (c) Having the ability to remotely and wirelessly operate the PA system while a significant distance (e.g., 50 feet) from the motorcycle. (d) Not requiring a rider to pair or sync his on-person equipment with the equipment on the motorcycle. (e) Not requiring locking connectors, which greatly increases rider safety. (f) Having the ability to operate in a wired mode if the wireless connection should fail. (g) Having side tone, which increases the ease of communication for the rider.
SUMMARY OF THE INVENTION
[0013] This invention relates to a radio accessory system, specifically to a system that is on a vehicle and worn on a person and interfaces radios, speakers, microphones, and public address systems. The interface between the part of the system that is on the vehicle and the other part that is worn on a person is wireless. The intent of the invention is to reduce the distraction of operating communications devices while operating a vehicle thus increasing the safety of a vehicle's users while also enabling the use of communication devices.
[0014] In an embodiment of the invention, a communications system for a vehicle user is provided. The system comprises a portable transceiver which the vehicle user can easily carry on his or her person and a vehicle-mounted transceiver. The portable transceiver is capable of communicating with the vehicle-mounted transceiver. Audio information contained in a transmission from the portable transceiver may be retransmitted by the vehicle-mounted transceiver either to a public address system or a second vehicle mounted transceiver.
[0015] In a further embodiment of the invention, a method of communicating for a vehicle user is provided. By means of a first transceiver mounted on a vehicle used by the user, a first radio signal containing audio information is received. The first radio signal is transformed to produce a second radio signal containing substantially the same audio information. By means of a portable transceiver mounted on the user's person, the second radio signal is received and demodulated it to produce an audio signal. At least one speaker is energized with the audio signal so that the user perceives audio information contained in the first radio signal. By means of a microphone additional audio information resulting from words said by the user is captured. By means of the portable transceiver, a third radio signal containing the audio information resulting from words said by the user is generated. In response to the third radio signal, either playing the audio information in the third radio signal on a public address system, or transmitting that audio information in a fourth radio signal.
FIGURES
[0016] FIG. 1 is a representation of an operator on a vehicle using the system.
[0017] FIG. 2 is a representation of an operator off and away from the vehicle using the system and the remote PA feature.
[0018] FIG. 3 is a representation of the system without it being on a vehicle and the operator.
[0019] FIG. 4 is a system schematic of the vehicle module assembly.
[0020] FIG. 5 is a system schematic of the operator module assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Before describing the present invention in detail, it is to be understood that this invention is not limited to specific embodiments, materials, or device structures, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
[0022] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include both singular and plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an active ingredient” includes a plurality of active ingredients as well as a single active ingredient, reference to “a temperature” includes a plurality of temperatures as well as single temperature, and the like.
[0023] In the following a preferred embodiment of the invention is described.
[0024] FIG. 1 shows a radio system comprised of the equipment permanently affixed to the vehicle 20 (vehicle module assembly 21 ) and removable equipment worn and controlled by the operator 22 (operator module assembly 23 ). This system allows the operator 22 to communicate to a distant radio through the vehicle mobile radio 24 by pressing the steering bar 26 mounted switch 28 to the radio push-to-talk (PTT) position 30 and speaking into the microphone 32 . When the operator 22 releases the PTT switch 28 , the operator 22 will receive any inbound communications from the mobile radio 24 thought the speaker(s) 34 . If the operator 22 exits the vehicle 20 , the operator 22 can communicate to a distant radio using the portable radio 36 attached to his person by pressing the PTT switch 38 on the speaker-microphone 40 . When the operator 22 releases the PTT switch 38 , the operator 22 will receive any inbound communications from the portable radio 36 through the speaker(s) 34 .
[0025] By pressing either the steering bar switch 28 to the PTT position 30 , or the speaker-microphone PTT switch 38 , the operator 22 automatically selects which radio system with which he wishes communicate. By pressing the steering bar switch 28 to the PTT position 30 , all inbound and outbound communications will be established via the mobile radio 24 . The mobile radio 24 is connected to the vehicle module assembly 21 through a mobile radio connector assembly 41 which varies in design depending on the type of mobile radio 24 . Alternately, by pressing the speaker-microphone PTT switch 38 , the operator 22 will switch all inbound and outbound communications to the portable radio 36 . The portable radio 36 is connected to the operator module assembly 23 through a portable radio adaptor 42 which varies in design depending on the type of portable radio 36 .
[0026] Pressing the steering bar 26 mounted switch 28 to the radio push-to-talk (PTT) position 30 enables a mobile mode signaling command from the vehicle module 21 to the speaker-microphone 40 . This sets an internal flip-flop 43 that switches internal circuitry within the speaker microphone 40 into the mobile mode. When the system is in the mobile mode, the mobile radio's 24 inbound and outbound transmissions are routed to the headset 44 . The headset is comprised of the speaker(s) 34 and microphone 32 . When the headset 44 is connected to the speaker-microphone 40 , a sidetone feature is enabled sending a small amount of the microphone signal back into the speaker(s) 34 so the operator 22 hears a little bit of his speech for enhanced aural feedback. The operator 22 has the option to disconnect the headset 44 from the speaker-microphone 40 and in doing so the headset 44 functions are automatically switched to a self-contained internal microphone 46 and speaker 48 within the speaker-microphone 40 . The sidetone feature is only functional with the headset 44 connected to the speaker-microphone 40 .
[0027] When operating in the mobile wireless mode, the operator 22 has a transmit and receive audio link established from the speaker-microphone 40 to the vehicle module assembly 21 . This wireless communication path is radiated from an antenna 50 within the speaker-microphone 40 , to an antenna 51 affixed to the vehicle 20 . The vehicle antenna 51 is connected to the vehicle control module 52 located within the vehicle 20 . The steering bar switch 28 , public address (PA) cable assembly 54 , wired-backup cable assembly 56 , and vehicle power cable 58 , are additional cables routing power and control signals to the vehicle control module 52 .
[0028] When the operator 22 momentarily presses or locks the steering bar switch 28 to the PA position 60 , the wireless signal from the headset microphone 32 is transmitted to the vehicle control module 52 and is rebroadcast to the vehicle public address system 62 . When in remote PA mode, the remote PA feature is operational at considerable distance away from the vehicle 20 . The PA mute button 63 when pressed, mutes the PA system until the PA mute button 63 is released. This PA mute button 63 can be a momentary or locking switch.
[0029] The speaker-microphone 40 has three optional audio interfaces. First, the operator 22 can plug in an ear bud speaker 64 and privately monitor incoming radio transmissions. When inserted into the port 66 in the speaker-microphone 40 , the ear bud speaker 64 would mute the speaker-microphone's speaker 48 . Second, the operator 22 can plug into the personal entertainment device port 67 a device 68 such as a CD player or transistor radio that is summed with incoming radio transmissions. Third, the operator 22 can plug into the cellular telephone port 69 a cellular telephone 70 that is summed with incoming radio transmissions and outbound cellular telephone conversation can be accomplished through the headset microphone 32 .
[0030] Internal within the vehicle control module 52 are voltage regulators 72 that step down the vehicle's volt system to voltage levels appropriate for internal circuitry. In the speaker-microphone 40 are voltage regulators 74 that step down the portable radio's 36 power source to voltage levels appropriate for the speaker-microphone's 40 internal circuitry.
[0031] Within both the vehicle control module 52 and the speaker-microphone 40 are binary switches 76 , 78 that allow the manual selection of numerous discrete RF frequencies for dedicated individual wireless links so operators with similar equipment will not interfere with each other. The operator 22 also has the ability to automatically increment though discrete RF frequencies to establish a clear channel.
[0032] The operator 22 has the option to connect his headset 44 to the vehicle control module's 52 wired-backup cable assembly 56 thus allowing a conventional wired signal path from the headset 44 directly to the mobile radio 24 . This feature could be used in the event the wireless system should fail. Within the vehicle control module 52 , is a detection circuit 80 (shown in FIG. 4 ) that senses that the wired-backup cable assembly 56 is connected to the headset 44 . This connection activates a relay 82 within the vehicle control module 52 that directly routes the headset's 44 speaker(s) 34 and microphone 32 to the mobile radio 24 . Also, the detection circuit 80 disables the vehicle control module transceiver 84 transmit function to prevent superfluous wireless transmissions. In this wired mode, the vehicle steering bar PTT and PA switch 28 still activate the mobile radio 24 and vehicle public address system 62 , respectively.
[0033] When the operator 22 exits the vehicle 20 and wishes to have inbound and outbound communications established via the portable radio 36 , the operator 22 only needs to press the PTT switch 38 on the speaker microphone 40 . When this PTT button 38 is pressed an internal flip flop 42 within the speaker microphone 40 is reset which switches internal circuitry into the portable radio mode. When operating in the portable radio mode, the PTT switch 38 , speaker microphone 40 , or headset 44 , will be directly connected to the portable radio 36 . The sidetone feature is functional when the headset 44 is connected to the speaker microphone 40 .
[0034] In certain embodiments of the invention, the operator is able to simultaneously hear the audio streams from the portable radio 36 as well as the mobile radio 24 in the vehicle operator's 22 headset speaker(s) 34 or speaker-microphone speaker 48 . The operator module assembly 23 takes the multiple audio streams and sums them such that both audio streams are simultaneously sent to the headset speakers 34 . By adjusting the volume of either radio, the operator can hear one stream more loudly or softly or the at the same volume level as the other radio. Transmitting over either radio is accomplished as described above. No different technique is required to transmit.
[0035] The operation of an embodiment of the invention is now described:
[0036] A. On/In Vehicle
[0037] While operating the vehicle 20 , the operator 22 receives from and transmits to the mobile radio 24 . Keying the mobile radio 24 is accomplished by pressing the switch 28 mounted on the steering bar 26 of the vehicle 20 to the radio push-to-talk (PTT) position 30 . Once the switch 28 is pressed to the PTT position 30 , the operator 22 speaks into the headset microphone 32 . When speaking, the operator 22 hears sidetone through the speaker(s) 34 . Sidetone is when the operator can hear his own voice through the speaker(s) 34 when he transmits. This helps the brain process speech when communicating, particularly in high noise environments. The operator's speech is transmitted from the mobile radio 24 .
[0038] To use the vehicle PA system 62 , the operator 22 presses the switch 28 to the PA position 60 . The operator speaks into ‘the headset microphone 32 . When speaking, the operator 22 hears sidetone through the headset speaker(s) 34 . The operator's speech is transmitted through the PA system 62 .
[0039] When the operator 22 is not transmitting, inbound transmissions on the mobile radio 24 are heard by the operator 22 through the headset speaker(s) 34 .
[0040] If the operator 22 prefers to have a wired connection to the system instead of the wireless connection, the operator 22 takes the wired-backup cable assembly 56 and plugs it directly into the headset 44 . In the wired mode, the system works the same as described above except that there is a physical wired connection between the operator module assembly 23 and vehicle module assembly 21 .
[0041] B. Out/Off of Vehicle
[0042] When the operator 22 exits the vehicle 20 , the operator 22 will continue to hear inbound transmissions from the mobile radio 24 until the operator 22 is out of range or the operator 22 presses PTT button 38 on the speaker-microphone 40 . Pressing the speaker-microphone PTT switch 38 switches the system from transmitting and receiving on the mobile radio 24 to transmitting and receiving on the portable radio 36 . To go back to transmitting and receiving over the mobile radio 24 , the operator 22 must press the switch 28 mounted on the steering bar 26 of the vehicle 20 to the PTT position 30 . From this point, until the PTT switch 28 on the speaker-microphone 40 is pressed again, the system will be in mobile radio mode and all transmissions will be transmitted to and received from the mobile radio 24 .
[0043] When pressing the speaker-microphone PTT button 38 and the headset 44 is connected to the speaker-microphone 40 , the operator 22 speaks into the headset microphone 32 and the operator's speech is transmitted through the portable radio 36 . When transmitting, the operator 22 hears sidetone through the speaker(s) 34 . When not transmitting and the headset 44 is connected to the speaker-microphone 40 , all transmissions received by the portable radio 36 are heard through the speaker(s) 34 and the speaker 48 in the speaker-microphone 40 is muted. This is called the auto mute function.
[0044] When the headset 44 is not connected to the speaker-microphone 40 , the speaker-microphone auto mute function is turned off and transmissions from the portable radio 36 are broadcast through the speaker-microphone's speaker 48 . When the headset 44 is not connected to the speaker-microphone 40 and the operator 22 pushes the PTT button 38 on the speaker-microphone, the operator 22 speaks into the speaker-microphone microphone 46 . The operator's speech is transmitted through the portable radio 36 .
[0045] To operate the vehicle PA system 62 remotely, the operator 22 presses the switch 28 on the vehicle steering bar 26 to the PA position 60 and locks it down to this position. Now whenever the operator 22 speaks into the microphone 32 and the headset 44 is connected to the speaker-microphone 40 , the operator's speech is broadcast through the PA system 62 . If the headset 44 is disconnected from the speaker-microphone 40 , the speaker-microphone 40 auto-mute function is disabled and the speech spoken into the speaker-microphone microphone 46 is broadcast through the PA system 62 . While in the remote PA mode, if an inbound radio transmission should come in from the portable radio 36 or mobile radio 24 , depending on which radio is selected, the inbound transmission is heard by the operator 22 through the either the headset speaker(s) 34 or the speaker-microphone speaker 48 , depending on whether or not the headset 44 is connected. While in PA mode, if the operator 22 would like to momentarily mute either the headset microphone 32 or the speaker-microphone microphone 46 , the operator 22 presses the mute button 63 on the speaker-microphone 40 . As long as the mute button 63 is held down, the microphone that is currently being used is muted. When in PA mode, if the operator 22 would like to transmit over the portable radio 36 , the operator 22 presses the PTT switch 38 on the speaker-microphone 40 and speaks into the headset microphone 32 or the speaker-microphone microphone 46 depending on whether the headset 44 is connected to the speaker-microphone 40 or not. Pressing the speaker-microphone PTT switch 38 overrides the PA mode functionality, so that no broadcasts are made through the PA system 62 , and the operator's speech is transmitted through the portable radio 36 .
[0046] C. Maintenance
[0047] No regular maintenance of the system is required. The system may run off of the vehicle's battery 86 and the portable radio's battery 88 so there is no requirement to charge an internal battery in the speaker-microphone 40 from an external power source in order to power the operator module assembly 23 .
[0048] D. Frequency Selection
[0049] In order to avoid operators of different vehicles from interfering with each other, each system can be set to different operating frequencies. This ability to have different frequencies allows for numerous operators to use their communications devices in close proximity without any interference. The frequency selection is made by selecting a particular frequency on a switch. The vehicle control module frequency switch 90 and the speaker-microphone frequency switch 92 both must be set to the same frequency setting in order for the system to operate properly. Exemplary frequencies include, for example, the 902 to 928 MHz frequency range and the 2.4 GHz frequency band (as used, for example, by the Bluetooth communications standards).
[0050] E. Accessories
[0051] Attaching an ear bud speaker 64 simply requires plugging in the ear bud speaker 64 to the ear bud speaker port 66 on the speaker-microphone 40 . This mutes the speaker-microphone speaker 48 . The same procedure is used to connect a cellular telephone 70 or personal entertainment device 68 to the system except that they would be plugged into the cellular telephone port 69 and entertainment audio port 67 , respectively.
[0052] The following briefly describes some features of alternative embodiments of the invention.
[0053] Mobile and Portable Radios without Public Address System Interface. Similar system as described above except that the PA mode functionality is not included.
[0054] Portable Radio Only with Public Address System Interface. Similar system as described above except that there is no interface to a mobile radio. All inbound and outbound radios transmissions are through the portable radio whether the operator in or out of the vehicle. PA mode functionality is the same as described above.
[0055] Mobile-only with PA. Similar system as described above except that there is no interface or usage of a portable radio. An alternate power source for the on-person components of the system would be supplied. In addition, all communications would be through the mobile radio whether the operator is in or out of the vehicle.
[0056] Mobile-only. Similar system as “Mobile-only with PA” above, except that there is no interface to the PA.
[0057] Remotely Turn on the PA System. Instead of turning the remote PA functionality on at the vehicle, the system would have ability to remotely activate the PA within the range of the wireless system.
[0058] Automatic Frequency Selection. Instead of having to manually select the frequency, the system would automatically select a frequency from which to work in order to avoid interference with other systems being used within range of the system.
[0059] Interface to Multiple Mobile Radios. Similar system as described above except that there could be more than one mobile radio which the system interfaces to. Similarly, the system could interface to multiple portable radios.
[0060] Superposition of Audio Streams. The user may wish to listen simultaneously to multiple audio streams. One audio stream may come, for example, from a portable radio and the other from a mobile radio. Alternatively, if the system of the invention interfaces to multiple mobile radios, two audio streams may for example come from mobile radios.
[0061] The superposition of the audio streams is easily implemented by standard techniques of electronics. For example, analog summation of the audio streams using an analog adder circuit may be employed. Alternatively, the two audio streams may be digitized in the form of samples and may be added digitally.
[0062] The ability to interface to multiple audio streams may be useful in particular circumstances. An example is a police motorcycle officer who wants to hear a dispatch channel over the mobile radio and also have the ability to hear a tactical channel over the portable radio at the same time.
[0063] It is to be understood that while the invention has been described in conjunction with the preferred specific embodiments thereof, the foregoing description is intended to illustrate and not limit the scope of the invention. Other aspects, advantages, and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
[0064] All patents, patent applications, and publications mentioned herein are hereby incorporated by reference in their entireties. However, where a patent, patent application, or publication containing express definitions is incorporated by reference, those express definitions should be understood to apply to the incorporated patent, patent application, or publication in which they are found, and not to the remainder of the text of this application, in particular the claims of this application.
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A communications system for a vehicle user is provided. The system comprises a portable transceiver which the vehicle user can easily carry on his or her person and a vehicle-mounted transceiver. The portable transceiver is capable of communicating with the vehicle-mounted transceiver. Audio information contained in a transmission from the portable transceiver may be retransmitted by the vehicle-mounted transceiver either to a public address system or a second vehicle-mounted transceiver.
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BACKGROUND OF THE INVENTION
The present invention relates to a technique of driving a flat type image display device used in a display for the like of a television receiver or a computer.
As one of the prior arts is known an image display device described by U.S. Pat. No. 4,227,117 assigned to the assignee of the present application. FIG. 12 is a view showing the construction of a flat type cathode-ray tube which has an internal structure slightly different from that of the display device of the U.S. Pat. No. 4,227,117 but displays an image in accordance with substantially the same principle as the display device of U.S. Pat. No. 4,227,117. The display device shown in FIG. 12A or FIG. 12B includes line-like thermionic cathodes 1 (hereinafter referred to as line cathodes) as electron beam emitting sources, a back face electrode 2 which is disposed opposing the line cathodes 1 and on a side reverse to an image display plane, and a plate-like electron beam extracting electrode 3, an electron beam modulating electrode 4, a vertical focusing electrode 5, a horizontal focusing electrode 6, horizontal deflection electrodes 7, 7', vertical deflection electrodes 8, 8' and a phosphor-coated screen 9 which are successively disposed opposing the line cathodes 1 and on the same side as the image display plane. Here, FIG. 12B is a structural drawing showing a practical structure of conventional flat type cathode-ray tube corresponding to the cathode-ray tube shown in FIG. 12A. These components are accommodated in a flat vacuum glass vessel (not shown).
Each line cathode 1 functioning as the beam source is stretched in a horizontal direction and a plurality of such line cathodes (L in the explanation and four in the illustration in FIG. 12A or FIG. 12B) are disposed at proper intervals along a vertical direction. The line cathode 1 has a structure in which an oxide cathode material is applied on the surface of a tungsten filament of, for example, 20 to 30 μmφ.
The back face electrode 2 made of a conductive plate which may be planar, has a function of suppressing the generation of an electron beam or pushing the generated electron beam toward the display plane side.
The electron beam extracting electrode 3 is a plate-like electrode having M beam transmissive apertures which are provided at each of locations opposite to the line cathodes 1-1 to 1-L and at proper intervals in the horizontal direction. A part of an electron beam extracted from the heated line cathode 1 toward the display plane side by the electron beam extracting electrode 3 is passed through the apertures of the electron beam extracting electrode 3. When passed through the apertures, the beam is divided into M beams in the horizontal direction.
The electron beam modulating electrode 4 provided next to the electron beam extracting electrode 3 is divided into M segments in the horizontal direction so as to permit independent and simultaneous control of the quantities of transmission of the M divisional electron beams from the beam transmissive apertures of the electron beam extracting electrode 3. Only four segments of the electron beam modulating electrode 4 are shown.
The vertical focusing electrode 5 or the horizontal focusing electrode 6 has slits elongated in the vertical direction or the horizontal direction or apertures elongated in the vertical direction or the horizontal direction and serves to focus each beam in the vertical direction or the horizontal direction.
The horizontal deflection electrode includes M pairs of electrodes 7 and 7' with each of the divisional electron beams being sandwiched between the one pair of electrodes 7 and 7' on opposite sides in the horizontal direction. The beam is deflected in the horizontal direction by virtue of a potential difference applied between the paired electrodes 7 and 7'. Since the electrodes 7 in the M pairs and the electrodes 7' in the M pairs are connected by respective common buses or frames 12, the deflection is made for M beams for each line all at once.
The vertical deflection electrode includes L pairs of electrodes 8 and 8' with all of the beams for one line being sandwiched between one pair of electrodes 8 and 8' on opposite sides in the vertical direction. Each beam is deflected in the vertical direction by virtue of a potential difference applied between the paired electrodes 8 and 8'. The electrodes 8 in the L pairs and the electrodes 8' in the L pairs are connected by respective common buses or frames 12 so as to drive the beams such that the directions of vertical deflection of the beams corresponding to adjacent line cathodes 1 are reversed to each other.
Electron beams subjected to the focusing, modulation and deflection mentioned above are accelerated by a high voltage applied to the screen 9 so that the electron beams impinge upon phosphors on the screen 9 to excite the phosphors into luminescence. The screen 9 is formed by applying three-color (R, G and B) phosphors in stripe shapes with blacks therebetween on a glass plate and depositing a metal back layer on the phosphor stripes. The phosphor stripe is formed, for example, so that one pair of R, G and B (or one triplet) correspond to each of the beam transmissive apertures of the electron beam modulating electrode 4. Each of image display sections 10 shown by broken lines in FIG. 12 represents a region where an image is displayed by one beam which is passed through the modulating electrode 4 and is deflected in the vertical and horizontal directions. The plurality of image display sections 10 are connected on the screen 9 to display one image as a whole.
Next, a method of driving the conventional display device will be explained by use of FIG. 13 which shows a block diagram of the basic driving circuit and FIG. 14 which shows the waveforms of driving signals for the respective electrodes.
Reference signals for driving are a vertical synchronizing signal V.D, a horizontal synchronizing signal H.D which are separated from a television video signal 21 at a sync separator circuit 22 and a clock signal generated at a system clock generating circuit 32. The explanation will be made supposing a video signal in an NTSC system. Now, assume that the number of the line cathodes 1 is L. Then, in an effective vertical scanning period of a vertical scanning period IV excepting a vertical blanking interval (or a period of 240H corresponding to 240 horizontal scanning periods), L pulses k 1 to k L having different phases and each having a low potential during only a period of time corresponding to the width of (240/L)H are generated and are successively applied to the line cathodes 1-1 to 1-L. The cathode driving pulses are generated in such a manner that a pulse having a pulse width of (240/L)H is sequentially shifted in a line cathode driving circuit 24 by virtue of trigger pulses p 1 to p L each of which is generated by a vertical driving pulse generating circuit 23 each time it counts 240/L horizontal synchronizing signals H.D.. The back face electrode 2 is applied with a DC potential V 2 which is slightly lower than the low potential level of the pulse applied to the line cathode, and the beam extracting electrode 3 is applied with a DC potential V 3 which is sufficiently higher than the low potential level of the pulse applied to the line cathode. V 2 and V 3 are supplied from a power source circuit 20. During a period of time when the potential of the line cathode 1 is high, the cathode is heated but no electrons are extracted from the cathode. Only in periods of time when the potentials of the line cathodes 1-1 to 1-L are made low by the pulses k 1 to k L , electron beams are successively extracted from the line cathodes 1-1 to 1-L.
The extracted electron beam is modulated in accordance with a video signal voltage including image information. In order to display a color image, it is necessary to excite three R, G and B phosphors into luminescence for R, G and B video signals, respectively. In the illustrated example, there is employed a method in which R, G and B video signals are successively applied to the modulating electrodes 4-1 to 4-M on the time-sequential basis in synchronism with the horizontal deflection. A video signal 21 is demodulated by a color demodulation circuit 34 into R, G and B signals which in turn are digitized by A/D converters 25-1 to 25-M at each timing triggered by pulses S 1 to S M generated at a sampling pulse generating circuit 33 and are then held in video memories 26-1 to 26-M for a period of time 1H. The held data are sent to modulating circuits 27-1 to 27-M in a period of time for change-over of 1H in accordance with a read-out pulse f. In the modulating circuits, the digital data are converted into analog signals having pulse widths proportional to the values of data or analog signals having pulse amplitudes proportional to the values of data. The analog signals are applied to the beam modulating electrodes 4-1 to 4-M in the form of a serial signal of R, G and B by switching pulses S R , S G and S B which are generated at a switching pulse generating circuit 28 synchronizing horizontal driving pulses r, g and b which are generated at a horizontal driving pulse generating circuit 29. An example of the modulation signal is shown in FIG. 14, as w. The timings of application of the R, G and B pulses are matched to periods of time when the beam is resting on R, G and B phosphors at three steps synchronizing the horizontal driving pulses r, g and b in one horizontal deflection period 1H. Since (M) video signals for one line in the horizontal direction can be simultaneously applied to the modulating electrode 4, there is provided a line-sequential or line-by-line display system in which an image for one line can be displayed at a time.
The modulated electron beam is focused in the vertical and horizontal directions by DC potentials V 5 and V 6 , which are generated at the power circuit 20, applied to the vertical focusing electrode 5 and the horizontal focusing electrode 6 and is thereafter electrostatically deflected by the horizontal deflection electrodes 7 and 7'. The deflection is effected by stepped deflection waveforms h and h' shown in FIG. 14 which are generated at a horizontal deflection driving circuit 30. Provided that the deflection width is selected to be equal to one triplet of R, G and B, the deflection waveform h or h' synchnous with the horizontal synchronizing signal H.D takes a stepped waveform in which the voltage is step-wise raised or lowered at every H/3 period synchronizing the horizontal driving pulses r, g and b. Accordingly, the electron beam rests on the R, G and B phosphors for H/3 periods, respectively.
On the other hand, the deflection in the vertical direction is effected by stepped deflection waveforms v and v' which are generated at a vertical deflection driving circuit 31. Since a period of time when the beam is extracted from each cathode is (240/L)H, each beam is deflected with (240/L) steps (in the shown example, 240/80=3 steps on the assumption that L=80) in the vertical direction or the deflection over the whole of the screen is made with 240 steps in total in one vertical scanning period (or one field) to depict 240 rasters. In the next field, the voltage value of the vertical deflection waveform is shifted so that beams land between the rasters depicted in the preceding field. Namely, an interlace scanning is performed.
The horizontal deflection and the vertical deflection are made in the above manner so that one image display section 10 is formed by 3 (in the vertical direction)×3 (in the horizontal direction) spots excited into luminescence by one electron beam accelerated by a high voltage V 9 applied to the screen 9, and such image display sections 10 are regularly arranged on the screen 9 to provide one image.
In the above flat type cathode-ray tube described as the prior art or another display device with a deflection of a plurality of electron beams, the uniformity of image quality is deteriorated unless the landing state of the electron beam on the screen 9 is uniform at any point.
Because the non-uniformity of beam landing positions and luminous spot shapes in the vertical direction appears as stepped brightness differences at the boundary portions between adjacent image display sections and the non-uniformity of landing positions and luminous spot shapes in the horizontal direction appears as stepped brightness differences or color differences at the boundary portions. The non-uniformity of beam landing positions is caused from the precision of work and the precision of assemblage of electrodes which contribute to vertical deflection or horizontal deflection in the flat type cathode-ray tube. However, as an area where an image is to be displayed is enlarged, it becomes difficult in view of technique and cost to enhance each of the precision of work and the precision of assemblage up to a level at which the image is not affected. Therefore, attempts to control the beam landing by use of electrical means have been proposed by, for example, U.S. Pat. No. 4,451,852. However, since it is not possible to drive deflection electrodes separately for individual beams, it was not possible to eliminate localized non-uniformity of landing.
The non-uniformity is shape of luminous spots is caused from a change in focusing characteristic of a beam depending on the degree of deflection of the beam which change is produced since the screen plane is planar of flat. This may be prevented by making the deflection angle as small as possible. For accomplishment of that purpose in a large-area display device may be considered, for example, a measure in which the deflection angle in the vertical direction is reduced by increasing the number of line cathodes and the deflection angle in the horizontal direction is reduced by increasing the number of electron beams into which an electron beam from one line cathode is to be divided. However, this measure is not proper since there results in an increase of a power consumption required for heating and an increase in cost or the precision of work electrodes in cost or the precision of work electrodes must be further enhanced. Also, there was not a method of coping with localized non-uniformity in shape of spots.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above problems of the prior art.
According to a first aspect of the present invention, there is provided a method of driving an image display device comprising at least a plurality of electron beam generating means, electron beam quantity controlling electron beam deflecting means, and luminous means excited into luminescence by impingement of an electron beam thereupon, in which deflection means for making an electron beam roughly land onto a predetermined position on the luminous means, deflection means for displacing the beam landing position within a munute range including the predetermined position, and means for controlling the instant of time of application of a driving signal for the electron beam quantity controlling means in a form temporally related to the driving of the electron beam deflecting means are provided to control the luminescence of the luminous means.
According to a second aspect of the present invention, there is provided a method of driving an image display device comprising at least a plurality of electron beam generating means, electron beam quantity controlling means, electron beam deflecting means, and luminous means excited into luminescence by impingement of an electron beam thereupon, in which deflection means for making an electron beam roughly land onto a predetermined position on the luminous means, deflection means for displacing the beam landing position within a minute range including the predetermined position, and means for controlling the duration of a driving pulse signal for the electron beam quantity controlling means in a form temporally related to the driving of the electron beam deflecting means are provided to control the luminescence of the luminous means.
According to a third aspect of the present invention, there is provided a method of driving an image display element in which the means mentioned in conjunction with the first or second invention are provided, the driving signal for the electron beam quantity controlling means is a pulse signal the pulse width of which is modulated by a video signal, and there is provided means for changing the pulse width of the driving pulse signal in accordance with the level of the video signal and equally in positive and negative directions around an instant of time when a pulse having the minimum width necessary for representation as an image is to be generated.
The first, second and third aspects of the present invention provide the following functions.
With the construction according to the first aspect of the present invention, each electron beam roughly lands on the predetermined position on a screen by a stepped vertical or horizontal deflection component to form a luminous spot and an unstepped deflection component such as sawtooth wave deflects the electron beam around the predetermined position from up to down or from down to up on the screen or from left to right or from right to left on the screen to the extent of about a half of a distance to a spot which is excited into luminescence by an electron beam adjacent to the electron beam under consideration in the vertical or horizontal direction. If the instant of time of application of the driving pulse to the electron beam quantity controlling means or a modulating electrode is controlled in positive and negative directions in synchronism with the deflection of the electron beam, a position where the electron beam lands on the screen or a spot position where a phosphor is excited into luminescence can be changed upward or downward or leftward or rightward within a range of the distance by which the electron beam is deflected in the vertical or horizontal direction by the sawtooth deflection component.
With the construction according to the second aspect of the present invention, each electron beam roughly lands on the predetermined position on a screen by a stepped vertical or horizontal deflection component to form a luminous spot and an unstepped deflection component such as sawtooth wave deflects the electron beam around the predetermined position from up to down or from down to up on the screen or from left to right of from right to left on the screen to the extent of about a half of a distance to a spot which is excited into luminescence by an electron beam adjacent to the electron beam under consideration in the vertical or horizontal direction. If the pulse width of the driving pulse signal to the electron beam quantity controlling means or a modulating electrode is controlled in synchronism with the deflection of the electron beam so that it is widened or narrowed in conformity with the angle of deflection, a range of positions where the electron beam lands on the screen or the diameter of a spot where a phosphor is excited into luminescence can be increased or reduced within a range of the distance by which the electron beam is deflected in the vertical or horizontal direction by the sawtooth deflection component.
With the construction according to the third aspect of the present invention, the pulse width of the driving signal for the electron beam quantity controlling means or the pulse signal pulse width-modulated by the video signal is changed in accordance with the level of the video signal and equally in positive and negative directions around the instant of time of generation of the pulse having the minimum width necessary for representation as an image when the above-mentioned function provided by the construction according to the first or second aspect of the present invention is effected, it is possible to change the center position of the luminous spot in accordance with the level of the video signal without an inconvenience that a range of beam landing positions on the screen from is one-sided to either one of upward and downward directions or either one of rightward and leftward directions on the screen when the pulse duration changes from its minimum value to the maximum value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view for explaining the operation of a first embodiment of the present invention;
FIG. 2 is a time chart showing variations of deflection waveforms;
FIGS. 3a and 3b are views showing the directions of movement of beam spots by the deflection waveforms;
FIGS. 4 and 5 are circuit diagrams of circuits for generating the deflection waveforms;
FIG. 6 is a circuit diagram of a circuit for controlling the instant of time of application of a beam modulating signal;
FIG. 7 is a view for explaining the operation of a second embodiment of the present invention;
FIG. 8 is a circuit diagram of a circuit for controlling the pulse width of a beam modulating signal in accordance with a pulse width modulation system;
FIG. 9 is a circuit diagram of a circuit for controlling the pulse width of a beam modulating signal in accordance with a pulse amplitude modulation system;
FIG. 10 is a circuit diagram of a third embodiment of the present invention;
FIG. 11 is a time chart of signal waveforms in operation of the third embodiment;
FIG. 12A is a view showing the internal structure of the conventional flat type cathode-ray tune and FIG. 12B is a structural view showing a practical structure of a prior art cathode-ray tube corresponding to the cathode-ray tube of FIG. 12A;
FIG. 13 is a circuit diagram of a circuit for driving the conventional flat type cathode-ray tube; and
FIG. 14 is a time chart of driving waveforms used in the conventional flat type cathode-ray tube.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the present invention will now be explained in reference to FIGS. 1 to 6. The explanation will be made limited to the beam landing in a vertical direction in order to avoid complexity.
First, explanation will be made of voltage waveforms used for the deflection and modulation of an electron beam and the principle of change in position of a luminous spot on a screen in association with the voltage waveforms. The upper portion of FIG. 1 shows a phosphor stripe 41 formed on the screen and a beam spot 43 in a form in which the vertical direction and the horizontal direction are interchanged as a matter of convenience. The lower portion of FIG. 1 shows a pair of vertical deflection voltage waveforms v and v' and an electron beam modulating signal waveform w.
As shown in (a) or (b) of FIG. 2, each of the vertical deflection waveforms v and v' has a waveform in which a sawtooth wave, a triangular wave or another continuously changing voltage waveform having a period of H/3 is superimposed on the conventional stepped voltage waveform (shown by one-dotted chain line in the figure) ascending or descending at every 1H. The polarities of change of the deflection voltages v and v' are made reverse to each other. The period of the sawtooth wave is determined by the number of phosphor stripes excited into luminescence through the stepped horizontal deflection of an electron beam during the period of 1H, and the period of H/3 for the sawtooth wave is selected on the assumption that three stripes of R, G and B are excited into luminescence. If the number of horizontal deflection steps is changed, it is necessary to correspondingly change the period of the sawtooth wave.
Due to the use of the above vertical deflection waveforms v and v', an electron beam oscillates at a period of H/3 in the vertical direction without resting on the same position during the period of 1H as in the conventional device. The oscillations of respective beam spots take directions of arrow shown in FIG. 3A or FIG. 3B. The amplitude of the sawtooth wave is set such that the amplitude of the oscillation falls within about a half of a distance between beam spots 43 and 44 adjacent to each other in the vertical direction on the screen in FIG. 1. The reason is that the deterioration of a resolution due to the overlapping of beam spots 43 and 44 is prevented.
For the above vertical deflection waveform v and v', a beam modulating signal w having a pulse width within the period of H/3 is applied to the electron beam modulating electrode 4. If a pulse waveform shown by solid line in FIG. 1 is employed as the beam modulating signal w, the electron beam excites the phosphor 41 into luminescence while moving in the vertical direction in accordance with the vertical deflection voltage waveforms from the instant of time t 1 of rise of the pulse w until the instant of time t 2 of fall of the pulse w. Namely, the beam spot 43 moves from a position y 1 on the phosphor corresponding to the voltage values v 1 and v 1 ' of the deflection waveforms v and v' to a position y 2 corresponding to the voltage values v 2 and v 2 '. In this time, the beam spot takes a shape shown by solid line in FIG. 1 and the center position of luminescence thereof is represented by (y 1 +y 2 )/2.
For example, assume that the center position is deviated from a normal landing position by -Δy. Then, if the instant of time of application of the modulating signal pulse w is shifted by a small time Δt to provide a pulse having a pulse width from the instant of time t 1 +Δt to the instant of time t 2 +Δt, the beam spot 43 moves from a position y 1 +Δy on the phosphor corresponding to the voltage values v 1 +Δv and v 1 '+Δv of the deflection waveforms v and v' to a position y 2 +Δy corresponding to the voltage values v 2 -Δv and v 2 '-Δv to provide a spot shape shown by broken line in FIG. 1. Accordingly, the center position of luminescence of the beam spot takes a position of (y 1 +y 2 )/2+Δy or the center position of luminescence is moved by a distance Δy, which provides an effect equivalent to the case where a resting spot is excited into luminescence at the normal landing position.
If the center position of luminescence is deviated from the normal position by Δy, the modulating signal pulse is shifted by a time Δt in a direction reverse to that in the above case to move the center of luminescence by -y, thereby bringing it into the normal landing position.
Next, the construction of a driving circuit for realizing the control method in the present embodiment will be explained in reference to an example shown in FIG. 4. Stepped vertical deflection voltage waveforms v and v' used in the conventional method are generated by a known vertical deflection driving block 31 (shown in FIG. 13) in which digital data stored in a memory is D/A converted. A sawtooth wave necessary for the present invention is generated by the combination of a counter 50 and a D/A converter 51. The counter 50 receives at its CK input terminal, system reference clocks from a system clock generating circuit 32 which have a sufficiently high frequency, and is reset by pulses z synchronous with signals r, q and b which are used for change-over of R, G and B video signals at every H/3 period. The output value of the counter 50 is incremented for each clock and is returned to zero simultaneously with resetting of the counter. This digital output value of the counter 50 is converted into an analog voltage value by the D/A converter 51, thereby obtaining a sawtooth wave in which a monotonic increase is repeated at a period of H/3. A sawtooth wave including a repetitive monotonic decrease can be readily obtained by polarity-inverting the output of the D/A converter 52 by an inverting amplifier 52.
On the other hand, a triangular waveform can be generated by the combination of an up/down counter 54, a D/A converter 55 and a flip-flop 56 shown in FIG. 5. The counter 54 is reset by a horizontal synchronizing signal H.D. The flip-flop 56 is reset by the horizontal synchronizing signal H.D and takes an output value q which has high and low levels alternated each time the above-mentioned pulse z is inputted. The output signal q of the flip-flop 56 is used for change-over of count-up and count-down of the counter 54. If the construction is designed such that the count-up is made when the signal q is high and the count-down is made when it is low, the output value of the counter 54 monotonically increases in the first H/3 period, monotonically decreases in the next H/3 period and monotonically increases at the further next H/3 period. The output value of the counter 55 is converted into an analog value by the D/A converter 55, thereby obtaining a desired waveform. A waveform having an inverted polarity is obtained by porality-inverting the output of the D/A converter 55 by an inverting amplifier 57.
The thus obtained sawtooth waves or triangular waves and the conventional stepped waves are added in analog adders 53 or 58, and the outputs of the adders 53 or 58 are voltage-amplified to obtain vertical deflection waveforms v and v' necessary for the present invention.
A control memory 60 shown in FIG. 6 for storing digital data for control is prepared for controlling the instant of time of application of a beam modulating signal to a modulating electrode. In a 1H period immediately preceding a 1H period when an image is to be displayed, control data corresponding to respective electron beams are successively read from the memory 60 by a trigger signal d having M pulses synchronous with the horizontal synchronizing signal H.D. and are preset into control counters 61-1 to 61-M. Upon start of the 1H period when the image is to be displayed, the counters 61-1 to 61-M start the counting of the system reference clocks from the system clock generating circuit 32 by the signal z synchronous with the horizontal driving pulses r, g and b. Each counter generates a carry pulse at a point of time when the preset data value has been counted. The carry pulses from the counters 61-1 to 61-M are supplied to video signal memories 26-1 to 26-M so that R, G and B video data are read from the memories. The video data read from the memory 26 are supplied to a pulse width modulating circuit 62 for conversion into analog signals having pulse widths corresponding to the data values. The analog signals are applied as a serial signal w of R, G and B to the electron beam modulating electrode 4. As a result, the instant of time of application of the modulating signal is changed by the control data. In the case where a pulse amplitude modulation is employed for the modulation method, it suffices that the pulse width modulating circuits 62-1 to 62-M arc replaced by D/A converters.
It does not necessarily follow that one control data is allotted to one electron beam. If one control data is allotted to a plurality of electron beams in accordance with the degree of non-uniformity in landing of beam spots on the screen 9, the saving of the capacity of the control memory is possible. The writing of the control data into the control memory 60 can be made by an external personal computer 64 through an interface circuit 63 separately prepared, thereby making it possible to perform adjustment while visually confirming a change of the position of a beam spot on the screen.
Next, the second embodiment of the present invention will be explained in reference to FIGS. 7 to 9. The explanation will be made limited to the beam landing in the vertical direction in order to avoid complexity.
First, explanation will be made of voltage waveforms used for the deflection and modulation of an electron beam and the principle of change in diameter of a luminous spot on a screen in association with the voltage waveforms. The upper portion of FIG. 7 shows a phosphor stripe 41 formed on the screen and beam spots 45 and 46 in a form in which the vertical direction and the horizontal direction are interchanged as a matter of convenience. The lower portion of FIG. 7 shows a pair of vertical deflection voltage waveforms v and v' and an electron beam modulating waveform w.
The vertical deflection waveforms v and v' may be the same as those explained in conjunction with the embodiment of the first invention and the process of deflection of an electron beam by the vertical deflection waveforms are also the same as that in the first embodiment of the present invention. Therefore, further explanation thereof will be omitted.
for the above vertical deflection waveforms v and v', a beam modualting signal w having a pulse width within the period of H/3 is applied to the electron beam modulating electrode 4. If a pulse waveform shown by solid line in FIG. 7 is employed as the beam modulating signal w, the electron beam excites the phosphor 41 into luminescence while moving in the vertical direction in accordance with the vertical deflection voltage waveforms from the instant of time t 1 of the pulse w to the instant of time t 2 of fall of the pulse w. Namely, the beam spot 45 moves from a position y 1 on the phosphor corresponding to the voltage values v 1 and v 1 ' of the deflection waveforms v and v' to a position y 2 corresponding to the voltage values v 2 and v 2 '. In this time, the beam spot has a diameter shown by solid line in FIG. 7 and represented by R s +(y 2 -y 1 ) wherein R s is the diameter of a spot excited into luminescence in the case where the team rests on the phosphor.
Now, assume that the spot diameter is smaller than a desired spot diameter by Δy. Then, if the pulse width of the modulating signal is increased by a minute time Δt to provide a pulse width (shown by broken lines) from the instant of time t 1 -Δt/2 to the instant of time t 2 +Δt/2, the beam spot 45 moves from a position y 1 -Δy/2 corresponding to the voltage values v 1 -Δv/2 and v 1 '+Δv/2 of the reflection waveforms v and v' to a position y 2 +Δy/2 corresponding to the voltage values v 2 +Δv/2 and v 2 -Δv/2. Accordingly, the beam spot diameter takes a value of R s +(y 2 -y 1 +Δy) or the spot diameter is increased to Δy as shown by broken lines, thereby obtaining the desired spot diameter. On the other hand, if the spot diameter is larger than the desired spot diameter by Δy, the pulse width of the modulating signal is decreased by Δt in contrary to the above case to decrease the spot diameter by Δy, thereby providing the desired value.
Next, the construction of a driving circuit for realizing the control method in the present embodiment will be explained in reference to an example shown in FIG. 8. Since a circuit construction for generating the vertical deflection voltage waveforms (v and v' is the same as that in the embodiment of the first invention, explanation thereof will be omitted. In order to control the pulse width of the beam modulating signal, there is prepared a control memory 60 for storing digital data for control. In the case of a pulse width modulation system, in an 1H period immediately preceding an 1H period when an image is to be displayed, control data corresponding to respective electron beams are successively read from the memory 60 by a trigger signal d having M pulses synchronous with the horizontal synchronizing signal H.D, are added to R, G and B video data in adders 65-1 to 65-M, and are stored into video memories 26-1 to 26-M. Accordingly, the widths of pulses converted into analog signals in pulse width modulating circuits 62-1 to 62-M are widened corresponding to the addition of the control data.
In the case of a pulse amplitude modulation system, a beam modulating signal the pulse width of which is determined by the control data can be obtained by a circuit construction shown in FIG. 9 or in such a manner that the pulse width modulating circuits 62-1 to 62-M are replaced by D/A converters 66-1 to 66-M, data of the control memory 60 are preset into pulse width control counters 67-1 to 67-M, and RS flip-flops 68-1 to 68-M are set by the trigger signal d having M pulses synchronous with the horizontal synchronizing signal H.D and reset by carry output pulses c of the pulse width control counters 67-1 to 67-M. An operation of changing the value of the control data in conformity with the degree of vertical deflection can be performed by an external personal computer 64 through an interface circuit 63 separately prepared, thereby making it possible to perform adjustment while visually confirming a change of the diameter of a beam spot on the screen.
Next, as the third embodiment of the present invention will be explained a method in which in the case of making the beam modulation in accordance with the pulse width modulation system in the first embodiments and second embodiment of the present invention, the pulse width is changed in accordance with the level of a video signal and equally in positive and negative directions around the instant of time when a pulse having the minimum width necessary for representation as an image is to be generated.
FIG. 10 shows a circuit diagram of a pulse width modulating circuit in the present embodiment and FIG. 11 shows a time chart of the operation of this circuit. M circuits are required but only one circuit is shown for simplification, R, G and B video digital data, after having been stored into a video memory 26 in a 1H period preceding an 1H period when an image is to be displayed, are respectively read from the memory by a trigger signal f synchronous with the horizontal vertical pulses r, g and b and the read data values R v , G v and B v are shifted by one bit toward the lower bit direction in data shift circuits 70 to be reduced to R v /2, G v /2 and B v /2, respectively. On the other hand, control data R c , G c and B c are read by the trigger signal f from a control memory 60 in which data determining the center position of a beam modulating pulse is stored, and the shifted video signal data R v /2, G v /2 and B v /2 are subtracted from the control data R c , G c and B c in subtracters 71. Next, data R c -R v /2, G c -G v /2 and B c -B v /2 obtained by the operation of subtraction are respectively preset into set counters 72 and at the same time the video data R v , G v and B v are respectively preset into reset counters 73.
At a point of time entering the 1H period when the image is to be displayed, the set counters 72 successively start their counting operations in response to the horizontal deflection pulses r, g and b and generate carry pulses after having counted the preset data. The carry pulses are used as set signals for RS flip-flops 74 as well as count start signals for the reset counters 73. After having made the counting corresponding to the video data R v , G v and B v , the reset counters 73 generate carry pulses to reset the RS flip-flops 74. Through this operation, the outputs of the flip-flops 74 produce pulse width-modulated signals w 1 ', w 2' and w 3 ' (see FIG. 11) which in turn are converted into a serial signal or a beam modulating signal w by an OR circuit 75.
With such a construction, it is possible to change the pulse width of the modulating signal in accordance with the level of the video signal and equally in positive and negative directions around the instant of time of supply of the control data, that is, the instant of time of generation of the pulse having the minimum width necessary for representation of an image.
Both the first and second embodiments have been explained in conjunction with only the beam landing and spot diameter control in the vertical direction. It is obvious that the present invention is also applicable to the horizontal direction if the vertical deflection in the explanation is replaced by the horizontal deflection.
Effects provided by the first, second and third embodiments of the present invention are as follows.
According to the first embodiment, since the positions of spots on the screen for exciting phosphor into luminescence can be individually controlled for a plurality of electron beams, respectively, it is possible to eliminate brightness differences resulting from localized non-uniformity of beam landing positions caused from the precision of work and/or the precision of assemblage of electrodes contributing to the vertical deflection and horizontal deflection in a flat type cathode-ray tube and to eliminate unevenness in brightness even at the boundary portions between image display sections, thereby greatly improving the uniformity of image quality.
According to the second embodiment, since the diameters of spots on the screen for exciting phosphor into luminescence can be individually controlled for a plurality of electron beams, respectively, it is possible to eliminate brightness differences and/or color differences resulting from localized non-uniformity of beam spot diameters produced by the vertical deflection and horizontal deflection in a flat type cathode-ray tube and to eliminate unevenness in brightness and/or unevenness in color even at the boundary portions between image display sections, thereby greatly improving the uniformity of image quality.
According to the third embodiment, even if a beam modulating signal is pulse width-modulated in controlling the position or diameter of a spot on the screen for exciting phosphor into luminescence, this modulation is made without an inconvenience that the position of the beam spot is one-sided to either one of upward and downward directions or either one of rightward and leftward directions on the screen, and there is not a fear that the uniformity of image quality may change between high-light images and low-light images.
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A method of driving an image display device is disclosed in which electron beams from line cathodes are impinged upon a display screen through beam modulating and deflecting electrodes to display an image. Each beam roughly lands onto a predetermined position on the screen by a stepped deflection voltage waveform to form a spot on the screen while the beam is deflected around the predetermined position by an unstepped deflection voltage waveform. The timing of application or the pulse width of a driving pulse signal for the beam modulating electrode is controlled in a form temporally related to the driving of the beam deflecting electrode to control the landing position or diameter of the spot on the screen. In the case where the driving pulse signal is a signal the pulse width of which is modulated by a video signal, the pulse width is changed in accordance with the level of the video signal and equally in positive and negative directions around the instant of time when a signal pulse having the minimum width necessary for representation as an image is to be generated.
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FIELD OF THE INVENTION
The present invention relates to a method and associated system for managing multiple identities.
BACKGROUND OF THE INVENTION
Protecting information typically comprises an inefficient process with little flexibility. Accordingly, there exists a need in the art to overcome the deficiencies and limitations described herein above.
SUMMARY OF THE INVENTION
The present invention provides a An identity management method comprising: registering, by a computer processor of a computing system, identity context management (ICM) clients of said computing system with an ICM server of said computing system; monitoring for a user, by an ICM client of said ICM clients, access to a first Internet resource; transmitting, by said ICM client to said ICM server, a notification indicating said access to said first Internet resource; transmitting, by said ICM server to said user, a first request for an ID associated with said first Internet resource; receiving, by said ICM server from said user in response to said first request, a first ID associated with said first Internet resource; recording, by said ICM server, an association describing said first ID associated with said first Internet resource; generating, by said ICM server in response to said receiving said first ID, a first virtual machine (VM) within said computing system; enabling, by said ICM server, said first VM; registering, by said first VM, said ICM client with said ICM server; enabling, by said ICM client in response to a command from said ICM server, access to said first Internet resource; and presenting, by said first VM to said user in response to said enabling said first Internet resource, first Webpages and first Internet contents associated with said first Internet resource.
The present invention provides a computer program product, comprising a computer readable storage medium having a computer readable program code embodied therein, said computer readable program code comprising an algorithm that when executed by a computer processor of a computing system implements a method comprising: registering, by said computer processor, identity context management (ICM) clients of said computing system with an ICM server of said computing system; monitoring for a user, by an ICM client of said ICM clients, access to a first Internet resource; transmitting, by said ICM client to said ICM server, a notification indicating said access to said first Internet resource; transmitting, by said ICM server to said user, a first request for an ID associated with said first Internet resource; receiving, by said ICM server from said user in response to said first request, a first ID associated with said first Internet resource; recording, by said ICM server, an association describing said first ID associated with said first Internet resource; generating, by said ICM server in response to said receiving said first ID, a first virtual machine (VM) within said computing system; enabling, by said ICM server, said first VM; registering, by said first VM, said ICM client with said ICM server; enabling, by said ICM client in response to a command from said ICM server, access to said first Internet resource; and presenting, by said first VM to said user in response to said enabling said first Internet resource, first Webpages and first Internet contents associated with said first Internet resource.
The present invention provides a computing system comprising a computer processor coupled to a computer-readable memory unit, said memory unit comprising instructions that when executed by the computer processor implements a method comprising: registering, by said computer processor, identity context management (ICM) clients of said computing system with an ICM server of said computing system; monitoring for a user, by an ICM client of said ICM clients, access to a first Internet resource; transmitting, by said ICM client to said ICM server, a notification indicating said access to said first Internet resource; transmitting, by said ICM server to said user, a first request for an ID associated with said first Internet resource; receiving, by said ICM server from said user in response to said first request, a first ID associated with said first Internet resource; recording, by said ICM server, an association describing said first ID associated with said first Internet resource; generating, by said ICM server in response to said receiving said first ID, a first virtual machine (VM) within said computing system; enabling, by said ICM server, said first VM; registering, by said first VM, said ICM client with said ICM server; enabling, by said ICM client in response to a command from said ICM server, access to said first Internet resource; and presenting, by said first VM to said user in response to said enabling said first Internet resource, first Webpages and first Internet contents associated with said first Internet resource.
The present invention advantageously provides a simple method and associated system capable of protecting information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system for managing multiple identities, in accordance with embodiments of the present invention.
FIG. 2A illustrates an algorithm used by the system of FIG. 1 for implementing a process for allowing a user to retrieve information, in accordance with embodiments of the present invention.
FIG. 2B illustrates an algorithm used by the system of FIG. 1 for implementing a process for allowing a user to manage identity contexts, in accordance with embodiments of the present invention.
FIG. 3A illustrates an algorithm used by one of the ICM clients of FIG. 1 , in accordance with embodiments of the present invention.
FIG. 3B illustrates an algorithm associated with a user action with respect to one of the ICM servers of FIG. 1 , in accordance with embodiments of the present invention.
FIG. 3C illustrates an algorithm used by an administration enabled ICM server of FIG. 1 , in accordance with embodiments of the present invention.
FIGS. 4A-4E illustrate implementation example sequence charts implemented by the system of FIG. 1 , in accordance with embodiments of the present invention.
FIG. 5 illustrates a computer apparatus used for managing multiple identities, in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a system 5 for managing multiple identities, in accordance with embodiments of the present invention. System 5 allows for the use of virtual machines (VMs) for executing Internet access means such as, inter alia, browsers or email clients for isolation/partitioning of user identities associated with users accessing information on the Internet. Additionally, system 5 enables a differential feature of VMs for managing a hierarchy of user identities.
System 5 of FIG. 1 comprises Internet resources 12 (e.g., mail servers, content Web servers, news servers, etc) connected to devices 9 a . . . 9 n through a network 7 such as the Internet. Device 9 a illustrates an internal block diagram view of devices 9 b . . . 9 n . Network 7 may comprise any type of network including, inter alia, a telephone network, a local area network, (LAN), a wide area network (WAN), the Internet, a wireless network, etc. Devices 9 a . . . 9 n may comprise any type of computing device capable of connecting to the Internet such as, inter alia, a computer (PC), a server computer, a database computer, etc. Devices 9 a . . . 9 n each comprise a memory system 14 . Memory system 14 may comprise a single memory system. Alternatively, memory system 14 may comprise a plurality of memory systems. Memory system 14 comprises a software system 23 and a (context and identities) data store 14 a (e.g., a database). Software system 23 comprises an identity context management component 24 and an identity context execution engine 26 comprising virtual machines 26 a (VMs).
Identity context management component 24 comprises:
1. Identity context management (ICM) clients 24 a for monitoring clicks or actions in Web browsers, email systems, etc. ICM clients 24 a may run on main system (e.g., computing system 20 ) or on VMs 26 a.
2. ICM servers 24 b that receive client notifications and execute decisions associated with identities and locations for executing requests. ICM clients 24 a and ICM servers 24 b isolate VMs 26 a such that ICM clients 24 a notify ICM servers 24 b regarding captured actions and receive/execute commands from ICM servers 24 b in order to enable Internet browsing/Internet resource access.
Identity context execution engine 26 executing each identity context as a VM of VMs 26 a . Each of VMs 26 a comprises:
1. A virtual central processing unit (CPU) for executing functions. 2. Allocated virtual memory isolated from all other of VMs 26 a. 3. Allocated file system (space) on a disk isolated from all other of VMs 26 a . The allocated file system space represents a VM state and includes operating execution and data files, navigation means execution and data files, additional files, etc. (data file may include, inter alia, configuration data, Internet navigation means context, etc). The allocated file system includes an applied differential feature including a capability to store a VM state (i.e., file system) as a delta (i.e., a differential feature) of another VM state. The file system of a VM includes a sum of all components of a chain of deltas from a first root VM (i.e., comprising an order from a root VM to a current VM). An executing VM is represented by its own delta file compared to its last stored VM state. Any stored VM state may comprise a full file system image or a delta compared to another VM state.
User identities may comprise a hierarchal relationship. A hierarchal relationship between two user identities is defined by a unidirectional relation between two identities whereby at creation time, a second identity context is copied from a first identity (i.e., with a different name and a 0-size VM delta file compared to a last stored state of the first identity VM. The two identities are independent from each other by a VM delta to a reference which may become fixed. Each of the two identities may comprise a parent of any number of hierarchal relationships. Each identity may only comprise a lower ordered entity of one hierarchal relationship and may be represented by a delta file representing a lower ordered entity VM file system as compared to a file system of a non executing portion of an associated parent VM. A delta (or differential) file therefore comprises: added data blocks, modified data blocks, and suppressed data blocks compared to a stored state (of a non executing portion) of a parent file system. When an executing VM is deactivated, a capability to replace a last stored VM state is augmented with a delta as a new state.
When an augmented state for a VM is stored (i.e., if a parent VM against which a lower ordered VM has been created), the augmented state is stored as delta compared to a last stored state and is additionally used as reference for a lower ordered VM state. If there is no sibling, a last stored state file is replaced by an augmented concatenation result.
Data store 14 a is used to:
1. Store identity names and URL/Internet context associated with an identity storing a VM state 2. Store relationships (hierarchal) between identities and match relationships between VM states.
FIG. 2A illustrates an algorithm used by system 5 of FIG. 1 for implementing a process for allowing a user to retrieve information, in accordance with embodiments of the present invention. In step 200 , a computer processor (i.e., of a computing system such as, inter alia, computing system 20 of FIG. 1 ) executing an ICM client (e.g., one of ICM clients 24 a of FIG. 1 within a VM) captures a user action (e.g., enabling an Internet resource, activating email, etc) and notifies an ICM server (e.g., one of ICM servers 24 b of FIG. 1 ) of the user action. In step 204 , the ICM server receives (i.e., from the ICM client) the notification (of step 200 ). In step 205 , the ICM server generates or retrieves an identity and an associated VM (execution content). The identity and an associated VM is associated and stored with the user action of step 200 . In step 210 , the ICM server activates the VM. In step 214 , the ICM server transmits a command (i.e., within the VM) to execute the user action and present a related result (i.e., from the executed user action) to the user.
FIG. 2B illustrates an algorithm used by system 5 of FIG. 1 for implementing a process for allowing a user to manage identity contexts, in accordance with embodiments of the present invention. In step 224 , a computer processor (i.e., of a computing system such as, inter alia, computing system 20 of FIG. 1 ) executing an ICM server retrieves an administrative action and names associated with identity contexts for managing. In step 228 , the ICM server generates or retrieves an associated identity (i.e., associated with the administrative action) and associated VM from a data store (e.g., data store 14 a of FIG. 1 ). In step 230 , the ICM server executes the administrative action on the associated identity (and associated context). In step 234 , the ICM server applies a modification (based on results of step 230 ) to the data store.
FIG. 3A illustrates an algorithm used by one of ICM clients 24 a of FIG. 1 , in accordance with embodiments of the present invention. In step 300 , an ICM client connects to an ICM server. In step 304 , the ICM client monitors actions associated with URLs and Internet actions. Additionally, the ICM client receives commands from the ICM server. In step 308 , the ICM client captures an event and notifies the ICM server (i.e., of the event) and step 304 is repeated. Alternatively, one of the commands from the ICM server is executed and step 304 is repeated.
FIG. 3B illustrates an algorithm associated with a user action with respect to one of ICM servers 24 b of FIG. 1 , in accordance with embodiments of the present invention. In step 310 , an ICM server monitors ICM clients. In step 312 , it is determined if any of the ICM clients is accessing the Internet.
If in step 312 , it is determined that none of the ICM clients is accessing the Internet then in step 314 , the ICM server retrieves a configuration parameter (i.e., if a last state for an associated VM will be saved or reset (with an associated identity) to a previous state). If the associated identity comprises a hierarchal relationship then the associated VM is saved within the hierarchal relationship and step 310 is repeated.
If in step 312 , it is determined that an ICM client of the ICM clients is accessing the Internet then in step 316 , the ICM server retrieves an identity associated with a description for an Internet resource associated with the Internet access. In step 318 , the ICM server provides a list of identities for user selection, receives a user selected identity (from the list), and retrieves associated Internet content. Alternatively, the ICM server may create a new identity and retrieve associated Internet content. In step 320 , it is determined if an associated VM (i.e., associated with the identity from step 318 ) is enabled and running. If in step 320 , it is determined that the associated VM is enabled and running then in step 326 , a command within an ICM client (associated with the VM) executes an associated action and step 310 is repeated. If in step 320 , it is determined that the associated VM is not enabled and running then in step 322 , it is determined if the associated VM exists. If in step 322 , it is determined that the associated VM exists then in step 328 , the associated VM is enabled and step 326 is repeated. If in step 322 , it is determined that the associated VM does not exist then in step 324 , the associated VM is generated (e.g., as a delta) and step 328 is repeated.
FIG. 3C illustrates an algorithm used by an administration enabled ICM server of FIG. 1 , in accordance with embodiments of the present invention. In step 332 , an ICM server attempt to retrieve context from a database. In step 334 , it is determined if the associated context exists. If in step 334 , it is determined that the associated context does not exist then in step 364 , the associated context and associated VM are created (e.g., the VM may be created by a delta (differential feature) from a parent VM) and in step 362 the associated VM is enabled and step 332 is repeated. If in step 334 , it is determined that the associated context does exist then in steps 338 , 340 , 342 , and 344 associated actions are determined. If in step 338 , the action comprises a start action then step 362 is repeated. If in step 338 , the action does not comprise a start action then step 340 is executed. If in step 340 , the action comprises a reset action then in step 358 the VM is deactivated and step 332 is repeated. If in step 340 , the action does not comprise a reset action then step 342 is executed. If in step 342 , the action comprises a delete action then in step 354 the VM is deactivated (and lower ordered VM states are merged with differential states) and step 332 is repeated. If in step 342 , the action does not comprise a delete action then step 344 is executed. If in step 344 , the action comprises a confirm action then in step 352 a current executing state is saved as a reference point and step 332 is repeated. If in step 342 , the action does not comprise a confirm action then in step 348 an ICM client is commanded to save in a shared location and in step 350 identities are shared in the shared location and step 332 is repeated.
FIGS. 4A-4E illustrate implementation example sequence charts implemented by system 5 (of FIG. 1 ) for managing multiple identities, in accordance with embodiments of the present invention.
FIG. 4A illustrates the following sequence:
1. Identity context management (ICM) clients of a computing system (e.g., computing system 20 of FIG. 1 ) are registered with an ICM server of the computing system. 2. An ICM client monitors (for a user) access to a first Internet resource. 3. The ICM client transmits a notification (to the ICM server) indicating the access to the first Internet resource. 4. The ICM server transmits (to the user) a first request for an ID associated with the first Internet resource. 5. The ICM server receives (from the user in response to the first request) a first ID associated with the first Internet resource. 6. The ICM server records an association describing the first ID associated with the first Internet resource. 7. The ICM server generates (in response to receiving the first ID, a first virtual machine (VM) within said computing system. 8. The ICM server enables the first VM. 9. The first VM registers the ICM client with the ICM server. 10. The ICM client enables (in response to a command from the ICM server) access to the first Internet resource. 11. The first VM presents (to the user in response to enabling the first Internet resource) first Webpages and first Internet contents associated with the first Internet resource. 12. Any ICM client of the ICM clients monitors access to a second Internet resource associated with the first VM. The second Internet resource differs from the first Internet resource. 13. Any ICM client of the ICM clients transmits (to the ICM server) a notification indicating the access to the second Internet resource. 14. The ICM server transmits (to the user) a second request for an ID associated with the second Internet resource. 15. The ICM server receives (from the user in response to the second request) a second ID associated with the second Internet resource. 16. The ICM server records an association describing the second ID associated with the second Internet resource. 17. The ICM server generates (in response to receiving the second ID) a second VM within the computing system. 18. The ICM server enables the second VM. 19. The second VM registers an ICM client with the ICM server. 20. The ICM client enables (in response to a command from the ICM server) access to the second Internet resource. 21. The second VM presents (to the user in response to enabling the second Internet resource) second Webpages and second Internet contents associated with the second Internet resource.
FIG. 4B illustrates the following sequence continued from the sequence of FIG. 4A :
1. Any ICM client monitors access to a third Internet resource. The third Internet resource is associated with the first ID and the second ID or is not associated with any IDs. The third Internet resource differs from the first Internet resource and the second Internet resource. 2. The ICM client transmits (to the ICM server) a notification indicating access to the third Internet resource. 3. The ICM server transmits (to the user) a third request for an ID associated with the third Internet resource. 4. The ICM server receives (from the user in response to the third request) the first ID or the second ID. 5. The ICM server records an association describing the existing ID associated with the third Internet resource. 6. The ICM client enables (within the first VM or the second VM in response to a command from the ICM server) access to the third Internet resource. 7. The first VM or the second VM presents (to the user in response to the enabling of step 6) the third Internet resource, the third Webpages, and the third Internet contents associated with the third Internet resource. 8. The ICM client monitors (for the user) access to a fourth Internet resource associated with the first VM or the second VM. The fourth Internet resource differs from the first Internet resource, the second Internet resource, and the third Internet resource. 9. The ICM client transmits (to the ICM server) a notification indicating access to the fourth Internet resource. 10. The ICM server determines that the first ID or the second ID is associated with the fourth Internet resource. 11. The ICM client (within the first VM or the second VM) enables (in response to a command from the ICM server) access to the fourth Internet resource. 12. The first VM or the second VM presents (to the user in response to enabling the fourth Internet resource) fourth Webpages and fourth Internet contents associated with the fourth Internet resource. 13. The ICM client monitors (for the user) access to a fifth Internet resource associated with the first VM. The fifth Internet resource is associated with the first ID and the second ID or is not associated with any IDs. The fifth Internet resource differs from the first Internet resource, the second Internet resource, the third Internet resource, and the fourth Internet resource. 14. The ICM client transmits (to the ICM server) a notification indicating access to the fifth Internet resource. 15. The ICM server transmits (to the user) a fourth request for an ID associated with the fifth Internet resource. 16. The ICM server receives (from the user in response to the fourth request) a third ID associated with the fifth Internet resource. The third ID is a lower ordered ID of the first ID. 17. The ICM server records an association describing the third ID associated with the fifth Internet resource. 18. The ICM server saves a first state of the first VM as a first reference thereby confirming the first ID. 19. The ICM server generates (in response to receiving the third ID and the saving the first state of the first VM) a third VM within the computing system. The third VM comprises a first differential with respect to the first state of the first VM as the first reference. 20. The ICM server enables the third VM. 21. The second VM registers a third copy of the ICM client within the third VM with the ICM server. 22. The third copy of the ICM client within the third VM enables (in response to a command from the ICM server) access to the fifth Internet resource. 23. The third VM presents (to the user in response to enabling the fifth Internet resource) fifth Webpages and fifth Internet contents associated with the fifth Internet resource.
FIG. 4C illustrates the following sequence continued from the sequence of FIG. 4B :
1. The ICM server receives (from the user) a command for resetting the first VM, the second VM, or the third VM to a last stored state or a start state. The user operates as an administrator. 2. The ICM server disables (in response to the command for resetting the first VM, the second VM, or the third VM) the first VM, the second VM, or the third VM. 3. The first VM, the second VM, or the third VM receives (from the user) a command for exiting the first VM, the second VM, or the third VM. 4. The ICM server receives (from any the ICM client in response to the command for exiting the first VM, the second VM, or the third VM) a notification indicating that the first VM, the second VM, or the third VM will be closed. 5. The ICM server transmits (to the user) a request for saving or resetting a state (i.e., to a last starting point) of the first VM, the second VM, or the third VM that has been closed. 6. The ICM server receives (from the user in response to the request for saving or resetting the state) a decision for saving. 7. The ICM server saves a state of the first VM, the second VM, or the third VM upon being exited. 8. The ICM server receives a delete command. 9. The ICM server deletes the first VM, the second VM, the third VM, or the saved state. 10. The ICM client monitors (for the user) any additional access to an Internet resource associated with an existing deactivated VM. 11. The ICM client transmits (to the ICM server) a notification indicating the additional access to the Internet resource. 12. The ICM server determines that the Internet resource is associated with the first ID, the second ID, or the third ID associated with the first VM, the second VM, or the third VM currently in a deactivated state. 13. The ICM server enables the first VM, the second VM, or the third VM from a reference state. 14. An enabled VM (of the first VM, the second VM, or the third VM) registers a new ICM client within the enabled VM. 15. The new ICM client (within the enabled VM) enables (in response to a command from the ICM server) access to the Internet resource. 16. The enabled VM presents (to the user in response to the enabling of step 15 ) the Internet resource, Webpages, and Internet contents associated with the Internet resource.
FIG. 4D illustrates the following sequence continued from the sequence of FIG. 4C :
1. The ICM server receives (from the user) a command for confirming the first ID, the second ID, or the third ID. 2. The ICM server saves a first state of a VM of the first ID, the second ID, or the third ID to confirm as a second reference. 3. The ICM server receives (from the user) a command for generating a fourth ID as a lower ordered entity and a differential with respect to an existing confirmed ID. 4. The ICM client monitors (for the user) access to a sixth Internet resource. 5. The ICM client transmits (to the ICM server) a notification indicating access to the sixth Internet resource. 6. The ICM client transmits (to the ICM server) a request for an ID. 7. The ICM server receives (from the user in response to the request for the ID) the fourth ID. 8. The ICM server records an association describing the fourth ID. 9. The fourth VM registers a fifth copy of the ICM client within the fourth VM. 10. The fourth VM enables (in response to a command from the ICM server) access to the sixth Internet resource. 11. The fourth VM presents (to the user in response to the enabling of step 10 ) the sixth Internet resource, sixth Webpages, and sixth Internet contents associated with the sixth Internet resource. 12. The ICM server receives (from the user) a command for sharing identified content from the first VM, the second VM, the third VM, or the fourth VM with the first VM, the second VM, the third VM, or the fourth VM. 13. The ICM client copies (in response to the command for sharing the identified content) the shared content to a shared zone. 14. The first VM, the second VM, the third VM, or the fourth VM copies the shared content from the shared zone to a protected zone.
FIG. 4E illustrates the following sequence continued from the sequence of FIG. 4D :
1. The ICM server receives (from the user) a command for deleting a selected ID selected from the first ID, the second ID, the third ID, or the fourth ID. The selected ID is a lower ordered ID of another ID and comprises a lower ordered ID.
2. The ICM server disables the selected ID and associated VM.
3. The ICM server merges a differential with a reference state.
4. The ICM server deletes a selected ID and VM.
FIG. 5 illustrates a computer apparatus 90 (e.g., computing system 20 of FIG. 1 ) used for managing multiple identities, in accordance with embodiments of the present invention. The computer system 90 comprises a processor 91 , an input device 92 coupled to the processor 91 , an output device 93 coupled to the processor 91 , and memory devices 94 and 95 each coupled to the processor 91 . The input device 92 may be, inter alia, a keyboard, a software application, a mouse, etc. The output device 93 may be, inter alia, a printer, a plotter, a computer screen, a magnetic tape, a removable hard disk, a floppy disk, a software application, etc. The memory devices 94 and 95 may be, inter alia, a hard disk, a floppy disk, a magnetic tape, an optical storage such as a compact disc (CD) or a digital video disc (DVD), a dynamic random access memory (DRAM), a read-only memory (ROM), etc. The memory device 95 includes a computer code 97 . The computer code 97 includes algorithms (e.g., the algorithms of FIGS. 2-4E ) for managing multiple identities. The processor 91 executes the computer code 97 . The memory device 94 includes input data 96 . The input data 96 includes input required by the computer code 97 . The output device 93 displays output from the computer code 97 . Either or both memory devices 94 and 95 (or one or more additional memory devices not shown in FIG. 5 ) may comprise the algorithms of FIGS. 2-4E and may be used as a computer usable medium (or a computer readable medium or a program storage device) having a computer readable program code embodied therein and/or having other data stored therein, wherein the computer readable program code comprises the computer code 97 . Generally, a computer program product (or, alternatively, an article of manufacture) of the computer system 90 may comprise the computer usable medium (or said program storage device).
Still yet, any of the components of the present invention could be created, integrated, hosted, maintained, deployed, managed, serviced, etc. by a service provider who offers to manage multiple identities. Thus the present invention discloses a process for deploying, creating, integrating, hosting, maintaining, and/or integrating computing infrastructure, comprising integrating computer-readable code into the computer system 90 , wherein the code in combination with the computer system 90 is capable of performing a method for locating specified information associated with a Webpage(s). In another embodiment, the invention provides a method that performs the process steps of the invention on a subscription, advertising, and/or fee basis. That is, a service provider, such as a Solution Integrator, could offer to manage multiple identities. In this case, the service provider can create, maintain, support, etc. a computer infrastructure that performs the process steps of the invention for one or more customers. In return, the service provider can receive payment from the customer(s) under a subscription and/or fee agreement and/or the service provider can receive payment from the sale of advertising content to one or more third parties.
While FIG. 5 shows the computer system 90 as a particular configuration of hardware and software, any configuration of hardware and software, as would be known to a person of ordinary skill in the art, may be utilized for the purposes stated supra in conjunction with the particular computer system 90 of FIG. 5 . For example, the memory devices 94 and 95 may be portions of a single memory device rather than separate memory devices.
While embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.
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An identity management method and system is disclosed. The method includes identity context management (ICM) clients monitoring access to Internet resources using dedicated Virtual Machines (VM). An ICM server monitors associations between Internet resource identifiers (IDs) and the Internet resources accessed by the VMs. The VMs register context for the ICM clients with the ICM server. An ICM client enables access to Internet resources and presentation of Webpages and Internet contents associated with the Internet resources within the associated Virtual Machine context.
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