description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
[0001] This application claims the benefit of Prov. App. 60/995,759, filed on Sep. 28, 2007 (Docket BI8053PR), Prov. App. 60/994,891, filed on Sep. 21, 2007 (Docket BI8052PR), Prov. App. 60/994,723, filed on Sep. 20, 2007 (Docket BI8051PR), and Prov. App. 60/994,571, filed on Sep. 19, 2007 (Docket BI8050PR), the contents of all which are expressly incorporated herein by reference. This application is related to U.S. application Ser. No. 12/142,656, filed on Jun. 19, 2008 (Docket BI8087P), U.S. application Ser. No. 11/800,184, filed on May 3, 2007 (Docket BI9827CIP2), Prov. App. 12/020,455, filed on Jan. 25, 2008 (Docket BI9827CIP), and U.S. application Ser. No. 11/033,441, filed on Jan. 10, 2005 (Docket BI9827P), the entire contents of all which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to electromagnetic radiation procedural devices and, more particularly, to the use of electromagnetic radiation devices in medical applications.
[0004] 2. Description of Related Art
[0005] A primary causative agent in pulpal and periapical pathosis is inadequate bacteria control. Research has shown that the absence of infection before obturation of a tooth undergoing endodontic treatment can result in a higher success rate, thus indicating the control or elimination of such intracanal pathogens to be advantageous to the generation of a favorable outcome for a given procedure.
[0006] The prior art has encompassed various endodontic treatments directed to the attenuation of bacterial counts and adverse symptoms from the root canal system, many being implemented in a relatively nonsurgical or low impact fashion. Typically, clinical endodontic procedures have relied on mechanical instrumentation, mechanical intracanal irrigants, and medicaments to disinfect the root canal system.
[0007] Prior-art instrumentation techniques involving hand and/or rotary instruments, as well as ultrasonic and sonic devices, have brought about some success in reducing bacterial loads in infected canals. While such instrumentation techniques of the prior art have not been altogether ineffective, they do tend to fall short of the goal of total or near total disinfection of the root canal system.
[0008] In the category of irrigants, agents such as sodium hypochlorite and chlorhexidine have been implemented in root canal disinfecting treatments with some degree of success. Such agents have been found to be capable, for example, of providing relatively useful antimicrobial effects in certain instances. Here, too, infection of the root canal and adjacent dentin may persist, however, following such applications, owing perhaps to an inability of these agents to reach all the infecting microorganisms.
[0009] Regarding the third mentioned category, of medicaments, the use of intracanal medications, such as calcium hydroxide, has typically been ineffective in the context of short-term applications. That is, longer term applications have frequently been indicated as a consequence, for example, of such agents failing to adequately address and eliminate endodontic infections by way of only a few applications. Consequently, such applications in the prior-art have typically required multiple applications, which in turn have required multiple patient visits. These multiple visits, while potentially increasing a rate of effective treatments in connection with medicaments such as calcium hydroxide, can increase treatment time and reduce patient compliance, thus increasing the risk of treatment failure.
[0010] Lasers, such as mid-infrared lasers including the Erbium, chromium:yttrium-scandiumgallium-garnet (Er,Cr:YSGG) laser, have been used in root canal procedures involving cleaning, shaping and enlarging of the root canal, as well as in osseous, apical and periodontal surgical procedures. The Er,Cr:YSGG laser is known to be capable of removing calcified hard tissues by emitting a beam of infrared energy at 2.78 μm in combination with an emitted water spray.
SUMMARY OF THE INVENTION
[0011] A laser having a high absorption for one or more predetermined fluids, which are disposed either around or adjacent to a target tissue or disposed within the target tissue, is implemented to achieve intra-passage or intracanal disinfection. The fluid can comprise water in typical applications, and the target tissue can comprise soft tissue such as that of a root canal wall in exemplary implementations of the invention. The laser can be operated to clean or disinfect tissue within the root canal in one mode in which an external source applies fluid to or in a vicinity of the target tissue or in another mode in which external fluid is not applied, the latter mode being capable of potentiating an effect of absorption of the laser energy or greater absorption of the laser energy by fluids within bacteria on or in the target tissue. In accordance with another feature of the present invention, radially emitting laser tips are used in the implementation of cleaning and disinfecting procedures of root canals. The radially emitting or side firing effects provided by these laser tips can facilitate, among other things, better coverage of the root canal walls in certain instances as compared, for example, to conventional, forward firing tips. Consequently, a probability that the emitted laser energy will enter dentinal tubules of the root canal can be augmented, thus increasing a disinfecting potential or efficacy of the system, whereby disinfection or cleaning of portions of dentinal tubules disposed at relatively large distances from the canal can be achieved or achieved more efficiently (e.g., during a smaller time window) or more reliably (e.g., yielding results with greater reproducibility).
[0012] According to one aspect of the present invention, an endodontic probe is used to perform disinfection of target tissues within root canal passages and tubules. The endodontic probe can comprise an electromagnetic radiation emitting fiber optic tip having a distal end and a radiation emitting region disposed proximally of the distal end, and can further comprise a porous structure which encompasses a region of the fiber optic tip excluding the radiation emitting region and/or which comprises a material that is transparent to a wavelength of energy carried by the electromagnetic radiation emitting fiber optic tip. The porous structure can be loaded with biologically-active particles, cleaning particles, biologically-active agents, and/or cleaning agents that are structured to be delivered from the porous structure onto the target tissues.
[0013] Another feature of the present invention includes an endodontic probe for performing disinfection of target tissues within root canal passages and tubules, the endodontic probe comprising (a) an electromagnetic radiation emitting fiber optic tip having a distal end and a radiation emitting region disposed proximally of the distal end and (b) an adjustable channel-depth indicator encompassing a region of the fiber optic tip besides the radiation emitting region. The adjustable channel-depth indicator can be configured to be movable in proximal and distal directions along a surface of the fiber optic tip to provide, for example, depth-of-insertion information to a user of the endodontic probe.
[0014] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112.
[0015] Any feature or combination of features described or referenced herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one skilled in the art. In addition, any feature or combination of features may be specifically excluded from any embodiment of the present invention. For purposes of summarizing the present invention, certain aspects, advantages and novel features of the present invention are described. Of course, it is to be understood that not necessarily all such aspects, advantages or features will be embodied in any particular implementation of the present invention. Additional advantages and aspects of the present invention are apparent in the following detailed description and claims that follow.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIGS. 1A-1E are side-elevational and perspective views depicting various features of a first embodiment of the present invention;
[0017] FIGS. 2A-2E are side-elevational and perspective views of various features of a second embodiment of the present invention;
[0018] FIGS. 3A-3D provides cross-sectional views of sponges, sheaths, cannulas, and tips in accordance with implementations of the present invention; and
[0019] FIGS. 4A-4D depict disposable prophy angle implementations in accordance with the present invention, in which a light source is located within (e.g., centrally within) the flexible cup.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference is made to Prov. App. 60/961,113, which contains an article entitled The antimicrobial efficacy of the erbium, chromium:yttrium-scandium-gallium-garnet laser with radial emitting tips on root canal dentin walls infected with Enterococcus faecalis . The devices and methods disclosed and referenced herein are intended to relate to and build upon devices and methods disclosed, and referenced, in that article, in part or in whole, in any combination or permutation, with or without modification, as would be understood by one skilled in the art to be possible in view of this disclosure to be feasible or modifiable to be feasible.
[0021] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers are used in the drawings and the description to refer to the same or like parts. It should be noted that the drawings are in simplified form and are not presumed, automatically, to be to precise scale in all embodiments. That is, they are intended to be examples of implementations of various aspects of the present invention and, according to certain but not all embodiments, to be to-scale. While, according to certain implementations, the structures depicted in these figures are to be interpreted to be to scale, in other implementations the same structures should not. In certain aspects of the invention, use of the same reference designator numbers in the drawings and the following description is intended to refer to similar or analogous, but not necessarily the same, components and elements. According to other aspects, use of the same reference designator numbers in these drawings and the following description is intended to be interpreted as referring to the same or substantially the same, and/or functionally the same, components and elements. In reference to the disclosure herein, for purposes of convenience and clarity only, directional terms, such as, top, bottom, left, right, up, down, over, above, below, beneath, rear, and front, are used with respect to the accompanying drawings. Such directional terms should not be construed to limit the scope of the invention in any manner.
[0022] Although the disclosure herein refers to certain illustrated embodiments, it is to be understood that these embodiments are presented by way of example and not by way of limitation. The intent accompanying this disclosure is to discuss exemplary embodiments with the following detailed description being construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the spirit and scope of the invention as defined by the appended claims. It is to be understood and appreciated that the process steps and structures described herein do not cover a complete architecture or process, and only so much of the commonly practiced features and steps are included herein as are necessary to provide an understanding of the present invention. The present invention has applicability in the field of laser devices in general. For illustrative purposes, however, the following description pertains to a medical laser device and a method of operating the medical laser device to perform surgical functions.
[0023] The invention disclosed and referenced herein relates to electromagnetic energy and/or sound wave emitting devices, such as fiber optic and ultrasonic probes, for treating tissue (e.g., necrotic and/or inflamed tissue) and removing deposits (e.g. plaque and/or calculus) and stains, from surfaces (e.g., hard and soft tissue surfaces). The fiber optic devices and probes may additionally and/or alternatively be used to treat tissues (e.g., hard tissues) and, in certain implementations, to treat surfaces that have lost connective tissue and/or bone responsible for attachment or that have been affected by bacteria, decalcified and/or that require fluoride uptake.
[0024] The tissues may comprise, for example, tooth root surfaces, which, for example, may be covered with calculus deposits, plaque and/or various types of stains. Furthermore, the tissues may comprise, for example, surfaces which have been decalcified and/or which require fluoride uptake. Other examples include channels, openings or tissues that have been affected by deposits of plaque, and calcified tissues. The following disclosure elucidates exemplary embodiments that relate to fiber optic and sound emitting probes and devices in accordance with the present invention and that are operative to remove and treat tissue such as surfaces of soft tissue, teeth and tooth roots covered by calcified deposits (e.g., calculus) and plaque or various types of stains as well as surfaces that lack attachment or have been decalcified or require fluoride uptake.
[0025] The energy source may comprise, for example, (1) a laser with or without a water spray or (2) a laser with or without a water spray in combination with a sonic and/or ultrasonic energy emitting source. In typical embodiments, source specifications may be implemented, as follows: sonic/ultrasonic frequencies or frequency ranges can be within, range, or contain ranges of or within, for example, 10 kHz-50 kHz and 20 kHz-25 kHz; and laser wavelengths or wavelength ranges can be, range, or range within, for example, about 2.789 μm, about 2.94 μm, about 2.69 μm, and/or can be within or range from or within about 2.1 μm to about 3 μm. Fiber lasers can be in the near IR region and Q-switched at kHz frequencies of operation.
[0026] Laser wavelengths for photo-biostimulation can take any one or more values or ranges within the following exemplary limits: about 630 nm-700 nm, about 700 nm-850 nm and about 900-980 nm. Photo-biostimulation implementations may include steps and structures, in whole or in part, in any permutation or combination, as will occur, to the extent not mutually exclusive to those skilled in the art upon consideration of the included and referenced disclosures, including those of application Ser. No. 12/204,638, filed on Sep. 4, 2008 (Docket BI8047P) and application Ser. No. 11/447,605, filed on Jun. 5, 2006 (Docket BI9846P), the entire contents of both which are hereby incorporated by reference.
[0027] The laser source or sources can also comprise a wavelength that can be run at KHz frequencies to generate vibrations which may help to dislocate, for example, calcified deposits and/or plaque.
[0028] Applications can include removal of calculus deposits, plaque and stains from tooth enamel, tooth root surfaces and tooth cementum; preparation of a smoother enamel or root surface after the removal of calculus deposits; and treatment of a root surface to facilitate precipitation of an amelogenics hydrophobic constituent such as an enamel matrix derivative (e.g., an EMD having a clinical concentration of about 5 mg/ml-50 mg/ml) with or without propylene glycol alginate (PGA). The EMD can be implemented to dissolve in PGA at an acidic pH (with the laser thus being used to dehydrate the tissue surface in order to facilitate deposition of the EMD product). With photo-biostimulation, a source (e.g., a laser or a laser and an ultrasonic source) can be used to induce tissue regeneration for formation of a new attachment comprising new cementum, periodontal ligament (fibroblasts) and/or bone, and to facilitate reduction of bacterial endotoxins.
[0029] Energy densities or energy density ranges can be within, contain ranges within, or comprise ranges of about 0.014 J/cm 2 -250 J/cm 2 , about 10-50 J/cm 2 and/or about 75-120 J/cm 2 (e.g., for mid IR laser+water spray implementations). Frequencies of operation for the laser can be or vary between 5-500 Hz or 5-100 Hz, as well as combination frequencies. Pulse durations, having one or more values or ranges from or within 30-300 μs, or combinations of pulses having such durations, may be implemented.
[0030] Tips or bundles of tips with or without a dispenser for bio-fluid (e.g. in gel and/or liquid form, with different viscosities) may be implemented. Exemplary viscosities may range, for example, from about 70,000 centipoise to about 120,000 centipoise. Components or agents of the biofluids, powder, gel or liquid may comprise any part of the items described or referenced in (a) U.S. Pat. No. 5,785,521, and/or (b) document or application that references U.S. Pat. No. 5,785,521.
[0031] When a bio-fluid or bio-fluids are implemented, the bio-fluid or bio-fluids may be characterized as follows: the fluid(s) may comprise one or more medicated fluids and/or gels (e.g., EDTA ethylenediaminetetracetic acid (EDTA) 0.01-0.1%, or 0.05%, EMD+PGA 5-50 mg/ml, fluoride (sodium fluoride, etc) X %, potassium nitrate Y %) or an aqueous type fluid that can be used to supplement or replace the water spray.
[0032] The currently described embodiments are provided by way of examples, and the present invention is not limited to these examples. Multiple variations and modification to the disclosed embodiments will occur, to the extent not mutually exclusive, to those skilled in the art upon consideration of the included disclosure. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of that described and referenced herein (and/or described or referenced in any of the referenced items).
[0033] Any feature or combination of features described and referenced herein (and/or described or referenced in any of the referenced items) are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. For example, any of the herein described and/or referenced (e.g., described or referenced herein and/or described or referenced in any of the referenced items) lasers and laser components, including handpiece apparatus (e.g., tips and/or target surface contacting structures and/or methods, and/or items used with, on, inside or in conjunction with the tips and target contacting structures), and any particulars or features thereof, or other features, including method steps and techniques, may be used with any other structure and/or process described or referenced herein (and/or described or referenced in any of the referenced items), in whole or in part, in any combination or permutation.
[0034] In addition, any feature or combination of features may be specifically excluded from any embodiment of the present invention. For purposes of summarizing the present invention, certain aspects, advantages and novel features of the present invention are described. Of course, it is to be understood that not necessarily all such aspects, advantages or features will be embodied in any particular implementation of the present invention. The intent of this disclosure, while discussing exemplary embodiments, is that the included and/or referenced (e.g., described or referenced herein and/or described or referenced in any of the referenced items) structures and/or steps be construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the spirit and scope of the invention.
[0035] The following illustrations represent conceptual prototypes of sponge/sheath dispensing mechanisms according to the present invention, which mechanisms can be used to hold and position components (e.g., fluids), or components/agents as defined below, in proximity to an output fiber optic tip, or a probe, for dispensing, for example, of the components (e.g., biofluids or biopowders, as disclosed herein) or components/agents during a procedure such as a treatment procedure on tissue. The sponges and sheaths can be formed, for example, in a compact (e.g., low profile) fashion for providing minimally invasive access to the surgical site of tissue (e.g., a canal, pocket, such as a periodontal pocket, or other formation of tissue).
[0036] The sponges can be formed, for example, according to process steps and/or structures as implemented, in whole or in part, in products elucidated and/or referenced in connection with the “K-Sponge” name or brand, such as owned by Katena Products, Inc., of Denville, N.J., the entire set of products and relevant contents of which is incorporated herein by reference.
[0037] Components, such as one or more of the fluids, biofluids and biopowders disclosed herein, and/or any sub-components or agents thereof (“components/agents”), may be applied to the sponge in one or more of a powder, liquid and/or intermediate (e.g., gel or part powder/liquid) state, for subsequent release on or near a treatment site. The components/agents may be added in liquid or semi-liquid form before the sponge is formed into a compressed or low-profile shape (using, for example, any one or more parts of the above-referenced K-Sponge technology), followed by, for example, drying (e.g., dehydrating) and compressing of the sponge.
[0038] Alternatively, and/or additionally, components/agents may be added in a powder, solid, semi-solid, suspended solid, dissolved or distributed solid, gel and/or powder/liquid form before, during and/or after the sponge is formed into a compressed or low-profile shape (using, for example, any one or more parts of the above-referenced K-Sponge technology). In an implementation wherein one or more components/agents are added after the sponge has been formed into a compressed or low-profile shape, the sponge may be contacted with the component(s)/agent(s) by way of (1) dipping of the sponge into a component/agent containing solution, (2) dripping of a liquid containing the component/agent onto the sponge, or touching of the sponge with a powder of or containing the component/agent so that the component/agent attaches to a surface of and/or an interior of the sponge.
[0039] The sponges may take various shapes to be effective. These shapes can be, but are not limited to rectangular, point-end, and round-end shapes. Once placed into contact with, for example, fluid in the mouth, the sponge can be configured to expand and allow the release of biofluids or biopowders to the target site to aid the procedure.
[0040] The sheaths can be formed, for example, of a silicon type sheet of material. In other embodiments, the sheaths may be formed, in whole or in part, of, for example, gelatin and/or cellulose (e.g., alpha-cellulose). Moreover, the sheaths of the present invention may alternatively or additionally be formed, in whole or in part, of any one or more of the materials, structures, compositions or distributions of compositions, shapes, components/agents and/or steps used to make/use the sponges as described or referenced herein.
[0041] The architecture of each sheath may comprise, for example: (a) a construction with one or more pores or perforations disposed anywhere along a length thereof and/or (b) a construction without pores and an opening at a distal end thereof. Either or both of the (a) and (b) constructions can be configured for dispensing the components/agents (e.g., biofluids, biopowders and/or other material) as, for example, described and depicted herein. Once pressed into contact with, for example, tissue, the sheath may release biofluids or biopowders to the target site to aid the procedure.
[0042] Furthermore, components/agents may be disposed (e.g., selectively disposed) on or in only parts of the sponge or sheath, such as on and/or in one or more of: selected (e.g., partial) area(s), selected volume(s), a single side, selected pores, other surface features or indentations, all pores or other surface features or indentations, and combinations thereof.
[0043] Combination embodiments comprising hybrid sponge/sheath implementations, such as a sheath made of a sponge-like material, may also be implemented. As another example of a modification, rather than or in addition to a sponge or a sheath of sponge-like material, and/or in any embodiment described herein, an external surface of the sponge and/or sheath can be formed with surface irregularities (e.g., features) to hold components/agents (e.g., bioflulids or biopowders), such as, for example, bristles.
[0044] Another application for the same sponge and/or sheath (without biofluids or biopowders) is the use of removing material from the tissue site. The sponge and/or sheath can absorb and collect dislodged materials (e.g., calculus deposits and/or removed tissue, dislodged or removed by way of, for example, the probe, fiber, other implement to which the sponge is affixed) from the site instead of using suction or other methods of removing the debris from the target.
[0045] Any of the implementations described or referenced herein may be loaded with a component/agent (e.g., biofluid or biopowder) that, for example, (1) softens a component or agent on a surface of the target (e.g., a calculus deposit, and/or with such softening agent being, e.g., propylene glycol alginate (PGA)—whereby, for example, EMD dissolves in PGA at acidic pH (and/or, for example, a laser may be used to dehydrate tissue surface in order to facilitate the deposition of the EMD product)); (2) cleans the target (e.g., root) surface (e.g., an acidic component and/or etching agent, e.g., EDTA); and/or (3) medicaments such as anesthetizing agents, growth promoters, etc.
[0046] With reference to FIGS. 4A-4D , other embodiments can be fiber bundles with non cylindrical (e.g., non truncated) distal ends (e.g., angled, beveled, double-beveled, etc. distal ends) to provide different energy outputs with varying characteristics. For such bundled embodiments one or more components/agents (e.g., a viscous component(s)) may be disposed in one or more of a central area or lumen and a peripheral area(s) of the optical fibers, and/or may be disposed or dispersed between two or more of the optical fibers. While the cross-section an one or more of FIGS. 4A-4D shows a circular cross-sectional area wherein the body of each fiber bundle resemble an envelope (i.e., shape) of a cylinder, other cross-sectional shapes are also possible, such as rectangular shape or other shapes.
[0047] In other embodiments, the cross-sections may correspond to flat or blade configurations of fiber bundles. Thus, as an example of a “thin blade” fiber bundle configuration, a cross section may comprise a single, straight (or, alternatively, arched) row formed by five circles (i.e., “ooooo”) corresponding to a fiber bundle formed of five fiber optics and having a flat (or, alternatively, arched) cross-sectional shape (rather than the illustrated circular cross-sectional shape). As another example, which may be used as an alternative to the mentioned “thin blade” fiber bundle, a “double-thickness blade” construction may include a fiber bundle configuration, a cross section of which comprises a single, straight (or, alternatively, arched) row formed by two rows of five circles (i.e., “ooooo”) each corresponding to a fiber bundle formed to be five fiber optics wide and two fiber optics thick and having a flat (or, alternatively, arched) cross-sectional shape (rather than the illustrated circular cross-sectional shape). As another example, a “triple-thickness blade” construction may include a fiber bundle configuration, a cross section of which comprises a single, straight (or, alternatively, arched) row formed by three rows of five circles (i.e., “ooooo”) each corresponding to a fiber bundle formed to be five fiber optics wide and three fiber optics thick and having a flat (or, alternatively, arched) cross-sectional shape.
[0048] Rather than the number of “five” (or other number of) fiber optics, other implementations may comprise other numbers such as ten, fifteen, twenty, or more fiber optics. Additionally, as another alternative to the number of “five” (or other number of) fiber optics, other implementations may comprise a continuous compartment such as that symbolized, for example, by “====” (c.f., FIG. 3A ) rather than “ooooo” (e.g., the equivalent of an infinite number of fiber optics, or an interior formed between two planar, e.g., straight or arched, surfaces). The light transmitting centers or compartments (e.g., of the fiber optic or continuous compartment) may be hollow or solid, and may be bordered by one or more of a skin, jacket or outer wall (e.g., reflective or, alternatively, transmissive to a wavelength or the wavelength of radiation).
[0049] In still other embodiments, the cross-sections may correspond to oval or circular (e.g., with cross-sectional areas that do not change in the distal direction, or that decrease in the distal direction such as in FIGS. 3A and 3D , or that increase in the distal direction such as in FIGS. 4A , 4 B and 4 C) configurations of fiber bundles. As an example, a cross section may comprise a single, closed row formed by about six circles (i.e., “oooooo”) corresponding to a fiber bundle formed of six fiber optics and having an oval or circular cross-sectional shape. Other examples may comprise any fewer or, typically, greater number of circles, such as ten, twenty, or more. Other examples, which may be used as an alternative to any mentioned single-row implementation of an oval or circular shape, can comprise, for example, a double-row or triple-row of fiber optics (“oooooo”) each corresponding to a fiber bundle formed to be six fiber optics wide and two, or three, fiber optics thick.
[0050] Additionally, as an alternative to the mentioned “six” (or other number of) fiber optics, other implementations may comprise a continuous compartment such as that symbolized, for example, by “====” rather than “oooooo” (e.g., the equivalent of an infinite number of fiber optics, or an interior formed between two planar, e.g., straight or arched, surfaces). The light transmitting centers or compartments (e.g., of the fiber optic or continuous compartment) may be hollow or solid, and may be bordered by one or more of a skin, jacket or outer wall (e.g., reflective or, alternatively, transmissive to a wavelength or the wavelength of radiation). For instance, the structure defining the prophy cup of FIG. 4A may be transparent to a wavelength(s) of radiation (e.g., laser or LLLT energy) emitted from the device. The light transmitting centers or compartments may be hollow or solid.
[0051] According to certain implementations, the skin, jacket or outer wall may comprise a construction as elucidated in FIG. 3B and/or may comprise (e.g., consist of) a sponge or sheath as described herein. In one implementation, the light-transmitting center is bordered with a sponge or sheath (e.g., a wall or a membrane that is: flexible, rigid, fabric, removable, permanently attached, porous, perforated e.g. as in FIG. 3B , nonporous, nonperforated, and/or of the same or different material as the tip) over one of its two planar/arched boundaries.
[0052] In another implementation, the light-transmitting center is bordered with a sponge or sheath (e.g., a wall or a membrane that is: flexible, rigid, fabric, removable, permanently attached, porous, perforated e.g. as in FIG. 3B , nonporous, nonperforated, and/or of the same or different material as the tip) over both of its planar/arched boundaries. In yet another implementation, all or substantially all of the light-transmitting center is surrounded with sponge or sheath (e.g., a wall or membrane that is: flexible, rigid, fabric, removable, permanently attached, porous, perforated e.g. as in FIG. 3B , nonporous, nonperforated, and/or of the same or different material as the tip). The wall(s) or membrane(s) may correspond to a shape encompassing part or all of any fiber optic described or referenced herein (e.g., cf. FIGS. 3A-3D ). Furthermore, the wall(s) or membrane(s) may comprise, take the form, resemble, or serve as a prophy cup as depicted in FIGS. 4A-4D .
[0053] Additionally, any of the compartments may comprise structure for carrying any type of fluid described or referenced herein as an alternative to or in addition to a gel or paste as described, for example, in FIGS. 3A and 3B . The “dispensing cannula” language of FIG. 3A is intended to encompass, or be defined by, one or more of the above mentioned sponges or sheaths, so that, for example, the interior of the cannula may correspond to the above mentioned transmitting centers or compartments. Furthermore, the structures of FIGS. 3C and 3D in any number, permutation, or combination, can be interpreted, or formed as, as any one or more of the herein described or referenced optics, tips, fibers, fiber optics, fiber bundles; and/or may have transmitting centers or compartments.
[0054] Any one or more of the herein described or referenced optics, tips, fibers, fiber optics, and/or fiber bundles may comprise shapes, surfaces, structures and/or functions as described or referenced in one or more of the documents referenced herein, including, application Ser. No. 11/033,043 filed Jan. 10, 2005 (Docket BI9830P); application Ser. No. 09/714,497 filed Nov. 15, 2000 (Docket BI9100CIP); application Ser. No. 11/800,184 (Docket BI9827CIP2), Int. App. PCT/US08/52106 (Docket BI9827CIPPCT); and application Ser. No. 11/033,441 (Docket BI9827P).
[0055] Lumens of any of the structures herein described or referenced may be provided with any one or more of the structures and/or arrangements as disclosed, referenced, or taught by any one or more of the documents referenced herein, including, application Ser. No. 11/033,043 filed Jan. 10, 2005 (Docket BI9830P); application Ser. No. 09/714,497 filed Nov. 15, 2000 (Docket BI9100CIP); application Ser. No. 11/800,184 (Docket BI9827CIP2), Int. App. PCT/US08/52106 (Docket BI9827CIPPCT); and application Ser. No. 11/033,441 (Docket BI9827P). For instance, the area inside of the prophy cup of FIG. 4A may correspond to the distal end of, for example, any of FIGS. 9 b , 10 b , 11 b or 11 c of application Ser. No. 11/033,043; or the area inside of the prophy cup of FIG. 4A may correspond to the distal end of, for example, any of FIG. 4 or 5 of U.S. Pat. No. 5,741,247.
[0056] Furthermore, any embodiment described or referenced may comprise one or more of the fiber optics (e.g., of a give fiber bundle) having a shape other than that of a regular, conventional, cylindrically-shaped fiber optic end (i.e., a truncated fiber end corresponding or identical to the shape of a cylinder). For example, one or more of the fiber optics may comprise a planar, beveled output end of any orientation and/or may comprise an output end that may be wholly or partially spherical, rounded, jagged, chiseled or otherwise shaped for altering a light-intensity output distribution thereof, as compared to a truncated fiber end.
[0057] Use of side-firing tips can increase the probability that the emitted laser radiation will enter dentinal tubules and have an effect on bacteria (e.g., to attenuate or eliminate endodontic infection) that are some distance from the canal. Distal ends or regions of the fiber output tips (e.g., side-firing tips and/or tips formed of sapphire or quartz) can be formed with jackets or without jackets such as disclosed, for example, in the herein referenced patents and patent applications.
[0058] In another implementation, a user can dip the fiber or bundled fiber construction into a component or medicament (e.g., any bioflulid or biopowder as described herein), before use thereof. Any of such constructions may be implemented as a single fiber, as well, as distinguished from a fiber bundle. Also, the “sheath” may be embodied, in addition and/or as an alternative to any of the implementations described herein, as a side cannula as elucidated in the bottom center cross-sectional schematic provided in one or more of FIGS. 4C and 4D (e.g., for holding/dispensing components (e.g., biofluids or biopowders) along length thereof); thus, a single or an additional cannula or cannulas can be provided on the side each with a single output at its distal end and/or with one or more output apertures along a length thereof, alone or in addition to, for example, a central cannula-type (e.g., lumen) structure for holding/dispensing components (e.g., biofluids or biopowders) along length thereof.
[0059] According to certain implementations, laser radiation is output from a power or treatment fiber (e.g., forming or within a probe), and is directed, for example, into fluid (e.g., an air and/or water spray or an atomized distribution of fluid particles from a water connection and/or a spray connection near an output end of the handpiece) that is emitted from a fluid output of a handpiece above a target surface (e.g., one or more of tooth, bone, cartilage and soft tissue). The fluid output may comprise a plurality of fluid outputs, concentrically arranged around a power fiber, as described in, for example, application Ser. No. 11/042,824 and Prov. App. 60/601,415. The power or treatment fiber may be coupled to an electromagnetic radiation source comprising, for example, one or more of a wavelength within a range from about 2.69 to about 2.80 microns and a wavelength of about 2.94 microns. In certain implementations the power fiber may be coupled to one or more of a diode, an Er:YAG laser, an Er:YSGG laser, an Er, Cr:YSGG laser and a CTE:YAG laser, and in particular instances may be coupled to one of an Er, Cr:YSGG solid state laser having a wavelength of about 2.789 microns and an Er:YAG solid state laser having a wavelength of about 2.940 microns. An apparatus including corresponding structure for directing electromagnetic radiation into an atomized distribution of fluid particles above a target surface is disclosed, for example, in the below-referenced U.S. Pat. No. 5,741,247, which describes the impartation of laser radiation into fluid particles to thereby apply disruptive forces to the target surface.
[0060] According to exemplary embodiments, operation in one or more of a gaseous and a liquid environment (e.g., within a channel or canal) can comprise a laser (e.g., an Er, Cr:YSGG solid state laser) having: a repetition rate of about 10 or 20 Hz or, in other implementations (e.g., for one or more of a relatively larger channel and a more calcified or stubborn target) about 30 to 50 Hz; and an energy per pulse from about 2 to 60 mJ, or in other embodiments (e.g., for one or more of a relatively larger channel and a more calcified or stubborn target) greater than 60 mJ such as levels up to about 150 mJ or 200 mJ. The higher frequencies are believed potentially to enhance an efficiency or efficacy of one or more of enlargement and shaping, root canal debridement and cleaning, pulp extirpation, pulpotomy for root canal therapy, sulcular debridement, and others. For exemplary channel transverse-widths (e.g., diameters) greater than 25 microns, such as those ranging from about 250 to 450, or 600, microns, probe or fiber diameters may range from about 10 to 450 microns, or from about 25 to 300 microns.
[0061] For channels comprising one or more of a relatively large diameter (e.g., about 400 or 450 to about 600, or more, microns) and a more calcified or stubborn target, probe or fiber diameters may range from about 300 to 400, or 500, or 600, or more, microns. An example may comprise a 200 to 300 micron fiber, outputting radiation at about 60 mJ/pulse and 50 Hz, in a 250 to 600 micron wide canal. Probe or fiber output regions may comprise, for example, one or more of the structures and functions as disclosed in, for example, any of Prov. App. 61/012,446 (Docket BI8063PR), Prov. App. 60/995,759 (Docket BI8053PR), Prov. App. 60/961,113 (Docket BI8038PR), application Ser. No. 11/800,184 (Docket BI9827CIP2), Int. App. PCT/US08/52106 (Docket BI9827CIPPCT), application Ser. No. 11/330,388 (Docket BI9914P), application Ser. No. 11/033,441 (Docket BI9827P), and U.S. Pat. No. 7,270,657 (Docket BI9546P). As an example, the outputting distal end of a probe or fiber may comprise a conical shape having a full angle of about 45 to 60 degrees and/or may comprise one or more beveled surfaces.
[0062] By way of the disclosure herein, a laser has been described that can output electromagnetic radiation useful to diagnose, monitor and/or affect a target surface. In the case of procedures using fiber optic tip radiation, a probe can include one or more power or treatment fibers for transmitting treatment radiation to a target surface for treating (e.g., ablating) a dental structure, such as within a canal. In any of the embodiments described herein, the light for illumination and/or diagnostics may be transmitted simultaneously with, or intermittently with or separate from, transmission of the treatment radiation and/or of the fluid from the fluid output or outputs.
[0063] Corresponding or related structure and methods described in the following patents assigned to BIOLASE Technology, Inc., are incorporated herein by reference in their entireties, wherein such incorporation includes corresponding or related structure (and modifications thereof) in the following patents which may be, in whole or in part, (i) operable with, (ii) modified by one skilled in the art to be operable with, and/or (iii) implemented/used with or in combination with, any part(s) of the present invention according to this disclosure, that of the patents or below applications, and the knowledge and judgment of one skilled in the art.
[0064] Such patents include, but are not limited to, U.S. Pat. No. 7,356,208 entitled Fiber detector apparatus and related methods; U.S. Pat. No. 7,320,594 entitled Fluid and laser system; U.S. Pat. No. 7,303,397 entitled Caries detection using timing differentials between excitation and return pulses; U.S. Pat. No. 7,292,759 entitled Contra-angle rotating handpiece having tactile-feedback tip ferrule; U.S. Pat. No. 7,290,940 entitled Fiber tip detector apparatus and related methods; U.S. Pat. No. 7,288,086 entitled High-efficiency, side-pumped diode laser system; U.S. Pat. No. 7,270,657 entitled Radiation emitting apparatus with spatially controllable output energy distributions; U.S. Pat. No. 7,261,558 entitled Electromagnetic radiation emitting toothbrush and dentifrice system; U.S. Pat. No. 7,194,180 entitled Fiber detector apparatus and related methods; U.S. Pat. No. 7,187,822 entitled Fiber tip fluid output device; U.S. Pat. No. 7,144,249 entitled Device for dental care and whitening; U.S. Pat. No. 7,108,693 entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting; U.S. Pat. No. 7,068,912 entitled Fiber detector apparatus and related methods; U.S. Pat. No. 6,942,658 entitled Radiation emitting apparatus with spatially controllable output energy distributions; U.S. Pat. No. 6,829,427 entitled Fiber detector apparatus and related methods; U.S. Pat. No. 6,821,272 entitled Electromagnetic energy distributions for electromagnetically induced cutting; U.S. Pat. No. 6,744,790 entitled Device for reduction of thermal lensing; U.S. Pat. No. 6,669,685 entitled Tissue remover and method; U.S. Pat. No. 6,616,451 entitled Electromagnetic radiation emitting toothbrush and dentifrice system; U.S. Pat. No. 6,616,447 entitled Device for dental care and whitening; U.S. Pat. No. 6,610,053 entitled Methods of using atomized particles for electromagnetically induced cutting; U.S. Pat. No. 6,567,582 entitled Fiber tip fluid output device; U.S. Pat. No. 6,561,803 entitled Fluid conditioning system; U.S. Pat. No. 6,544,256 entitled Electromagnetically induced cutting with atomized fluid particles for dermatological applications; U.S. Pat. No. 6,533,775 entitled Light-activated hair treatment and removal device; U.S. Pat. No. 6,389,193 entitled Rotating handpiece; U.S. Pat. No. 6,350,123 entitled Fluid conditioning system; U.S. Pat. No. 6,288,499 entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting; U.S. Pat. No. 6,254,597 entitled Tissue remover and method; U.S. Pat. No. 6,231,567 entitled Material remover and method; U.S. Pat. No. 6,086,367 entitled Dental and medical procedures employing laser radiation; U.S. Pat. No. 5,968,037 entitled User programmable combination of atomized particles for electromagnetically induced cutting; U.S. Pat. No. 5,785,521 entitled Fluid conditioning system; and U.S. Pat. No. 5,741,247 entitled Atomized fluid particles for electromagnetically induced cutting.
[0065] Also, the above disclosure and referenced items, and that described on the referenced pages, are intended to be operable or modifiable to be operable, in whole or in part, with corresponding or related structure and methods, in whole or in part, described in the following published applications and items referenced therein, which applications are listed as follows: App. Pub. 20080125677 entitled Methods for treating hyperopia and presbyopia via laser tunneling; App. Pub. 20080125676 entitled Methods for treating hyperopia and presbyopia via laser tunneling; App. Pub. 20080097418 entitled Methods for treating eye conditions; App. Pub. 20080097417 entitled Methods for treating eye conditions; App. Pub. 20080097416 entitled Methods for treating eye conditions; App. Pub. 20080070185 entitled Caries detection using timing differentials between excitation and return pulses; App. Pub. 20080065057 entitled High-efficiency, side-pumped diode laser system; App. Pub. 20080065055 entitled Methods for treating eye conditions; App. Pub. 20080065054 entitled Methods for treating hyperopia and presbyopia via laser tunneling; App. Pub. 20080065053 entitled Methods for treating eye conditions; App. Pub. 20080033411 entitled High efficiency electromagnetic laser energy cutting device; App. Pub. 20080033409 entitled Methods for treating eye conditions; App. Pub. 20080033407 entitled Methods for treating eye conditions; App. Pub. 20080025675 entitled Fiber tip detector apparatus and related methods; App. Pub. 20080025672 entitled Contra-angle rotating handpiece having tactile-feedback tip ferrule; App. Pub. 20080025671 entitled Contra-angle rotating handpiece having tactile-feedback tip ferrule; App. Pub. 20070298369 entitled Electromagnetic radiation emitting toothbrush and dentifrice system; App. Pub. 20070263975 entitled Modified-output fiber optic tips; App. Pub. 20070258693 entitled Fiber detector apparatus and related methods; App. Pub. 20070208404 entitled Tissue treatment device and method; App. Pub. 20070208328 entitled Contra-angel rotating handpiece having tactile-feedback tip ferrule; App. Pub. 20070190482 entitled Fluid conditioning system; App. Pub. 20070184402 entitled Caries detection using real-time imaging and multiple excitation frequencies; App. Pub. 20070104419 entitled Fiber tip fluid output device; App. Pub. 20070060917 entitled High-efficiency, side-pumped diode laser system; App. Pub. 20070059660 entitled Device for dental care and whitening; App. Pub. 20070054236 entitled Device for dental care and whitening; App. Pub. 20070054235 entitled Device for dental care and whitening; App. Pub. 20070054233 entitled Device for dental care and whitening; App. Pub. 20070042315 entitled Visual feedback implements for electromagnetic energy output devices; App. Pub. 20070014517 entitled Electromagnetic energy emitting device with increased spot size; App. Pub. 20070014322 entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting; App. Pub. 20070009856 entitled Device having activated textured surfaces for treating oral tissue; App. Pub. 20070003604 entitled Tissue coverings bearing customized tissue images; App. Pub. 20060281042 entitled Electromagnetic radiation emitting toothbrush and dentifrice system; App. Pub. 20060275016 entitled Contra-angle rotating handpiece having tactile-feedback tip ferrule; App. Pub. 20060241574 entitled Electromagnetic energy distributions for electromagnetically induced disruptive cutting; App. Pub. 20060240381 entitled Fluid conditioning system; App. Pub. 20060210228 entitled Fiber detector apparatus and related methods; App. Pub. 20060204203 entitled Radiation emitting apparatus with spatially controllable output energy distributions; App. Pub. 20060142743 entitled Medical laser having controlled-temperature and sterilized fluid output; App. Pub. 20060099548 entitled Caries detection using timing differentials between excitation and return pulses; App. Pub. 20060043903 entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting; App. Pub. 20050283143 entitled Tissue remover and method; App. Pub. 20050281887 entitled Fluid conditioning system; App. Pub. 20050281530 entitled Modified-output fiber optic tips; App. Pub. 20040106082 entitled Device for dental care and whitening; App. Pub. 20040092925 entitled Methods of using atomized particles for electromagnetically induced cutting; App. Pub. 20040091834 entitled Electromagnetic radiation emitting toothbrush and dentifrice system; App. Pub. 20040068256 entitled Tissue remover and method; App. Pub. 20030228094 entitled Fiber tip fluid output device; App. Pub. 20020149324 entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting; and App. Pub. 20020014855 entitled entitled Electromagnetic energy distributions for electromagnetically induced mechanical cutting.
[0066] All of the contents of the preceding published applications are incorporated herein by reference in their entireties.
[0067] The above-described embodiments have been provided by way of example, and the present invention is not limited to these examples. Multiple variations and modifications to the disclosed embodiments will occur, to the extent not mutually exclusive, to those skilled in the art upon consideration of the foregoing description. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein. As iterated above, any feature or combination of features described and referenced herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. For example, any of the radiation outputs (e.g., lasers), any of the fluid outputs (e.g., water outputs), and any conditioning agents, particles, agents, etc., and particulars or features thereof, or other features, including method steps and techniques, may be used with any other structure(s) and process described or referenced herein, in whole or in part, in any combination or permutation as a non-equivalent, separate, non-interchangeable aspect of this invention. Accordingly, the present invention is not intended to be limited by the disclosed embodiments, but is to be defined by such embodiments and by reference to the following claims.
|
An endodontic probe is used to perform disinfection procedures on target tissues within root canal passages and tubules. The endodontic probe can include an electromagnetic radiation emitting fiber optic tip having a distal end and a radiation emitting region disposed proximally of the distal end. According to one aspect, the endodontic probe can include a porous structure that encompasses a region of the fiber optic tip excluding the radiation emitting region and that is loaded with biologically-active particles, cleaning particles, biologically-active agents, or cleaning agents for delivery from the porous structure onto the target tissues. Another aspect can include provision of the endodontic probe with an adjustable channel-depth indicator, which encompasses a region of the fiber optic tip besides the radiation emitting region and which is movable in proximal and distal directions along a surface of the fiber optic tip to facilitate the provision of depth-of-insertion information to users of the endodontic probe.
| 0
|
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to novel amide derivatives and antiallergic agents containing the same. The amide derivatives provided by the invention inhibit the passive cutaneous anaphylaxis reaction (PCA reaction, Naohiko Watanabe, Akio Kobayashi; Int. Archs Allergy Appl. Immun. 72, pp 53-58, S. Karger AG, Basel, 1983) in rats which is associated with the onset of allergy. The amide derivatives of the invention, therefore, are useful as an antiallergic agent.
(2) Description of the Prior Arts
A variety of compounds are known as possessing antiallergic activities, but there are no surely effective therapeutic agents, and development of drugs with improved efficacy is desired.
SUMMARY OF THE INVENTION
As a result of extensive studies on the synthesis of a variety of amide derivatives and their PCA reaction-inhibitory activities in rats, we have found that the amide derivatives according to the present invention have potent inhibitory activities of the PCA reaction in rats. The invention has been completed on the basis of the above finding.
It is an object of the invention to provide novel amide derivatives and antiallergic agents containing the same.
According to the invention, there are provided amide derivatives represented by the general formula (I) ##STR1## wherein R 1 and R 2 may be the same or different and each represents a lower alkyl group, a benzyl group, a tetrahydrofuranyl group, a lower alkoxy (lower)alkyl group or a lower alkoxycarbonyl group, R 3 represents a hydrogen atom or a lower alkoxy group, m represents an integer of 1 or 2 and Y represents a group of the formula (II), (III) or (IV), ##STR2## wherein X 1 and X 2 may be the same or different and each represents a hydrogen atom, a halogen atom or a lower alkoxy group, n, p and q each represents an integer of 1 to 4, provided that when R 1 and R 2 may be the same or different and each represents a lower alkyl group or a lower alkoxycaronyl group, Y does not represent a group of the above formula (II) or (III).
Further, according to the invention there are provided antiallergic agents containing an amide derivative represented by the above-mentioned formula (I).
Further, according to the invention there is provided a therapeutic method of allergic conditions which comprises administering animals with an effective dose of an amide derivative represented by the above-mentioned formula (I).
DETAILED DESCRIPTION OF THE INVENTION
In the above definition for the substituents R 1 -R 3 , X 1 and X 2 in the formula (I), the term "lower alkyl group" means a straight or branched chain alkyl group having from 1 to 4 carbon atoms, which is preferably methyl, ethyl, n-propyl or isopropyl, and the term "lower alkoxy group" means a straight or branched chain alkoxyl group having from 1 to 4 carbon atoms, which is preferably methoxy, ethyoxy, n-propoxy or isopropoxy. As the halogen atom is preferred fluorine, chlorine or bromine.
The amide derivatives represented by the abovementioned formula (I) are produced by reacting a reactive derivative of a carboxylic acid represented by the formula (V), ##STR3## wherein R 1 , R 2 , R 3 and m have the same meanings as defined above with an amine derivative represented by the formula (VI)
H.sub.2 N--Y (VI)
wherein Y has the same meaning as defined above.
As the reactive derivative of the above-mentioned carboxylic acids (V) is preferably employed an acid halide, for example, the chloride or bromide, an anhydride or a mixed acid anhydride, for example, the mixed acid anhydride with ethylcarbonic acid.
The above-described reaction is carried out by a method known per se. For example, to a solution of a reactive derivative of the carboxylic acid (V) dissolved in an appropriate organic solvent such as, for example, dichloromethane or chloroform is added the amine derivative (VI), and the mixture is reacted at room temperature for several hours. The desired product (I) is isolated from the reaction mixture by conventional procedures and purified by such means as recrystallization or column chromatography.
The amide derivatives of the invention are used as an antiallergic agent. The dosage, which may be variable depending upon conditions of the disease, is generally 1-1000 mg and preferably 10-500 mg per day in adults, divided into one to three doses as required for the conditions. The administration may be in any suitable form, oral administration being particularly preferred but intravenous administration also being acceptable.
The compound of the invention may be administered as the active component or one of the active components either alone or in admixture with pharmaceutical carriers or excipients formulated by a conventional process into tablets, sugar-coated tablets, powders, capsules, granules, suspension, emulsion, injectable solution or the like. As examples of the carrier or excipient are mentioned calcium carbonate, calcium phosphate, starch, glucose, lactose, dextrin, alginic acid, mannitol, talc, and magnesium stearate.
Examples and a test example will be given below to describe in more details, but they are not intended to limit the invention in any way.
EXAMPLE 1
To a solution of 2.0 g (9.08 mmol) of 5-(3-methoxy-4-hydroxyphenyl)-2,4-pentadienoic acid in 90 ml of acetone was added 2.76 g (19.97 mmol) of anhydrous potassium carbonate and 2.30 ml (19.99 mmol) of benzyl chloride, successively, followed by heating under reflux for 15 hours. The mixture was concentrated under reduced pressure, diluted with water and extracted with chloroform. The organic layer obtained was dried over anhydrous sodium sulfate and concentrated under reduced pressure to give 4.01 g of a residue.
To a solution of the residue in 55 ml of a 10:1 mixture of methanol and water was added 1.82 g (45.5 mmol) of sodium hydroxide and the mixture was heated under reflux for 16 hours. The mixture was concentrated under reduced pressure, diluted with water and ice-cooled. The mixture was adjusted to pH 1 with a 6N hydrochloric acid aqueous solution and precipitated crystals were collected on a filter and dried in a vacuum desiccator to afford 2.62 g (8.44 mmol) of 5-[3-methoxy-4-(benzyloxy)phenyl]-2,4-pentadienoic acid.
To a solution of 3.50 g (7.94 mmol) of 1-β-(N-phthaloyl)aminoethyl-4-diphenylmethoxypiperidine in 70 ml of ethanol was added 0.52 g (8.31 mmol) of 80% hydrazine hydrate, followed by heating under reflux for 2 hours and concentrating under reduced pressure to give 4.10 g of a residue.
To a solution of the residue suspended in 90 ml of ethanol were added 2.46 g (7.93 mmol) of 5-(3-methoxy-4-benzyloxyphenyl)-2,4-pentadienoic acid, 1.80 g (8.72 mmol) of N,N'-dicyclohexylcarbodiimide and 0.10 g (0.82 mmol) of 4-dimethylaminopyridine, successively, followed by stirring at room temperature for 20 hours. The reaction mixture was filtered and the resulting organic layer was concentrated under reduced pressure. 5.5 g of the residue was subjected to silica gel column chromatography to give 2.53 g (4.20 mmol) of 1-[2-(5-(3-methoxy-4-benzyloxyphenyl)-2,4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine from an eluate of chloroform-methanol (100:1). Spectrophotometric data of the product support the following structural formula (VII). ##STR4##
H - NMR(CDCl 3 ) δ: 6.4-7.6(21H, m), 6.10(1H, t, J=5 Hz), 5.89(1H, d, J=16 Hz), 5.49(1H, s), 5.12 (2H, s), 3.89(3H, s), 1.3-3.6(13H, m)
IR: ν (cm -1 KBr): 3270, 1665, 1645, 1610, 1595, 1565, 1510
EXAMPLE 2
To a solution of 2.0 g (9.08 mmol) of 5-(3-methoxy-4-hydroxyphenyl)-2,4-pentadienoic acid in 90 ml of dry methylene chloride was added 1.51 ml (19.98 mmol) of 2.3-dihydrofuran and 229 mg (0.91 mmol) of pyridinium p-toluenesulphonic acid, successively, followed by stirring at room temperature for 16 hours. The mixture was washed successively with a saturated aqueous sodium hydroxide solution and water, and the resulting organic layer was dried over anhydrous sodium sulfate and concentrated under reduced pressure to give 4.07 g of a residue.
To a solution of the residue in 55 ml of a 10:1 mixture of tetrahydrofuran and water was added 1.63 g (40.8 mmol) of sodium hydroxide and the mixture was heated under reflux for 14 hours. The mixture was concentrated under reduced pressure, diluted with water and ice-cooled. The mixture was adjusted to pH 6.5 with a 1N hydrochloric acid aqueous solution and precipitated crystals were collected on a filter and dried in a vacuum desiccator to afford 2.56 g (8.82 mmol) of 5-[3-methoxy-4-(2-tetrahydrofuranyl)oxyphenyl]-2,4-pentadienoic acid.
To a solution of 4.55 g (10.33 mmol) of 1-β-(N-phthaloyl)aminoethyl-4-diphenylmethoxypiperidine in 75 ml of ethanol was added 0.71 g (11.36 mmol) of 80% hydrazine hydrate, followed by heating under reflux for 2 hours and concentrating under reduced pressure to give 5.26 g of a residue.
To a solution of the residue suspended in 100 ml of methylene chloride were added successively 2.50 g (8.61 mmol) of 5-(3-methoxy-4-(2-tetrahydrofuranyl)oxyphenyl)-2,4-pentadienoic acid, 1.95 g (9.47 mmol) of N,N'-dicyclohexylcarbodiimide and 0.11 g (0.90 mmol) of 4-dimethylaminopyridine, followed by stirring at room temperature for 19 hours. The reaction mixture was filtered and the resulting organic layer was concentrated under reduced pressure. 6.0 g of the residue was subjected to silica gel column chromatography to give 2.68 g (4.60 mmol) of 1-[2-(5-(3-methoxy-4-(2-tetrahydrofuranyl)oxyphenyl)-2,4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine from an eluate of chloroform-methanol (100:1). Spectrophotometric data of the product support the following structural formula (VIII). ##STR5##
H - NMR(CDCl 3 ) δ: 6.4-7.6(16H,m), 6.17(1H, t, J=5 Hz), 5.89(1H, d, J=16 Hz), 5.76(1H, bs), 5.43(1H, s), 3.77(3H, s), 3.1-4.3(5H, m), 1.2-3.0(14H, m)
IR: ν (cm -1 CHCl 3 ): 3400, 1660, 1620, 1600, 1510
EXAMPLE 3
In 100 ml of dry ethylene chloride were dissolved 5.00 g (22.7 mmol) of 5-(3-methoxy-4-hydroxyphenyl)-2,4-pentadienoic acid and 11.87 ml of diisopropylethylamine in an argon atmosphere. To the solution was added dropwise 6.25 ml of chloromethyl ethyl ether at room temperature over 15 minutes. The mixture was left to stand at room temperature overnight, diluted with water and extracted three times with methylene chloride. The organic extract layer was washed with water and dried over anhydrous sodium sulfate. The solvent was distilled off under reduced pressure to give 8.66 g of a residue. The residue was subjected to silica gel column chromatography to afford 6.89 g (20.5 mmol) of ethoxymethyl 5-(3-methoxy-4-ethoxymethoxyphenyl)-2,4-pentadienoate from a fraction with chloroform.
6.00 g (17.8 mmol) of the ester was dissolved in 120 ml of methanol. To the resulting solution was added 30 ml of an aqueous solution containing 3.60 g of sodium hydroxide at room temperature. The mixture was left to stand at room temperature overnight. Methanol was distilled off from the reaction mixture under reduced pressure and the residue was made acidic with hydrochloric acid under ice cooling. The mixture was extracted three times with chloroform. The extract organic layer was washed with water and subsequently dried over anhydrous sodium sulfate. The solvent was distilled off from the extract under reduced pressure to afford 4.320 g (15.5 mmol) of 5-(3-methoxy-4-ethoxymethoxyphenyl)-2,4-pentadienoic acid.
4.260 g (15.3 mmol) of the carboxylic acid was subjected to a reaction similar to the reaction of 5-(3-methoxy-4-benzyloxyphenyl)-2,4-pentadienoic acid in Example 1 to obtain 5.53 g (9.7 mmol) of 1-[2-(5-(3-methoxy-4-ethoxymethoxyphenyl)-2,4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine. The spectrophotometric data of the product support the following structural formula (IX).
H - NMR(CDCl 3 ) δ (ppm): 1.20(3H, t, J=7.5 Hz). 3.73(2H, q, J=7.5 Hz), 3.85(3H, s), 5.23(2H, s), 5.47(1H, s), 5.92(1H, d, J=14 Hz)
IN: ν (cm -1 , CHCl 3 ) 3400, 1660, 1620, 1600 ##STR6##
TEST EXAMPLE
DNP-ascaris (1 mg) prepared by combining a swine ascaris extract with 2,4-dinitrophenyl sulfate was mixe with 20 mg of aluminum hydroxide gel. The mixture was administered to rats subcutaneously on the back, and at the same time the animals were intraperitoneally given 2×10 10 dead Bordetella pertussis respectively. The same procedures were repeated after 14 days, and blood sample was obtained after 21 days to produce antisera.
Female Sprague-Dawley strain rats (8 weeks old) were sensitized by subcutaneously administering 0.1 ml of 1:256 diluted antisera (titer=1024) respectively on the grained back. After 48 hours, groups of four rats were orally given the amide derivatives produced in the examples above at various concentrations. After one hour, the rats were challenged by intravenously administering a 0.5% physiological saline solution of Evans Blue containing 1 mg of the NDP-ascaris from the tail. After 30 minutes, the animal was sacrificed by bleeding and the portion of the skin with the dye exuded was cut off. The cut skin was treated with 1N-KOH solution, and the dye was extracted by adding 9 ml of 0.6N-phosphoric acid-acetone (5:13) mixture. The supernatant from centrifugal separation was measured for absorbancy at 620 nm to determine amount of the dye. Percent inhibition at each of the concentrations of the amide derivatives was calculated in comparison with amount of the dye for control group. Results are shown in Table-I. Percent inhibition of tranilast, an antiallergic agent commercially available from Kissei Pharmaceutical Co., Ltd. under the trade name of Rizaben against PCA reaction was also shown in Table-I. As shown in Table-I, the amide derivatives of the invention produced high PCA reaction-inhibitory effects.
Table I______________________________________PCA reaction-inhibitory effects in ratsTest compound Concentration Inhibition (%)Example No. (mg/kg) mean ± SE______________________________________1 30 0 ± 20 100 50 ± 142 10 51 ± 18 30 71 ± 63 30 55 ± 9 100 78 ± 8Control 100 37 ± 8(Tranilast) 200 40 ± 10 300 42 ± 5______________________________________
It has been confirmed that amide derivatives of the invention not shown in Table-I also possess PCA reaction-inhibitory effects in rats. Acute Toxicity
An acute toxicity test was conducted using male ICR mice (5 weeks old) by oral administration. LD 50 was 1000 mg/kg or higher with every compound of the invention to demonstrate high safety margin as compared with the effective dose.
|
Novel amide derivatives are disclosed. As examples of said amide derivatives are mentioned 1-[2-(5-(3-methoxy-4-benzyloxyphenyl)-2,4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine, 1-[2-(5-(3-methoxy-4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine and 1-[2-(5-(3-methoxy-4-ethoxymethoxyphenyl)-2,4-pentadienoyl)aminoethyl]-4-diphenylmethoxypiperidine. These amide derivatives are useful as antiallergic agents.
| 2
|
NOTICE OF COPYRIGHT
[0001] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to any reproduction by anyone of the patent disclosure, as it appears in the United States Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE PRESENT INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to an air-water punching bag structure, in particularly, a bag structure which weight and firmness can be adjusted and which has multi-training functions.
[0004] 2. Description of Related Arts
[0005] Conventional punching bag for combat training is a closed bladder using solid (such as sand), liquid (such as water), or gas (such as air) as filler and is placed inside of an external bag.
[0006] It is easy and cheap to obtain the fillers, but the ideal weight of a punching bag, which may impact the training effect, is about half of its user's weight. Also, when solid is used as filler in inner bladder, the weight of the punching bag becomes too heavy to be easily moved or stored. When liquid is solely used as the filler of the inner bladder, the heavy weight of punching bag will result in poor training effect. When gas is used as filler of the inner bladder, the punching bag is usually too light and requires other material to fix it in place. Thus, all of the above can result in poor training effect.
[0007] In addition, for conventional punching bag structure which adopts solid, liquid, or gas as filler, there is only one tactile feel. When filling with solids, punching bag gives a firm texture while liquids add a little softness and resilience. When filling with gas, punching bag is even more resilient. However, none of the foregoing fillers can be adjusted in the same structure to create different texture to satisfy different training techniques and users.
[0008] In addition, the conventional punching bag structure cannot integrate different training functions simultaneously (such as croissant move training, push-up training, sit-up training, Judo training, boxing training, upper cut training, tackle training, suppression training, and weight training). More training equipments need to be purchased in order to provide different training functions when using punching bag for different technique training, which further increases the training cost. Thus, the drawbacks of conventional punching bag need to be improved.
SUMMARY OF THE PRESENT INVENTION
[0009] To overcome the existing problems of prior art, the present invention provides an air-water punching bag structure that uses liquids or colloid as the major weight source for the inner bladder structure and fills up the extra space with air. The external bag structure can integrate suspenders or handles to lower training cost and the weight and softness-hardness can be adjusted to meet the user's demand with different training functions for obtaining the training effect.
[0010] The present invention discloses an air-water punching bag structure that comprises an inner bladder, an external bag, at least one set of handles, at least two sets of first suspenders, and at least one set of second suspenders.
[0011] The inner bladder is a hollow bladder that further comprises one gas container and one liquid container. The gas container is a bladder for containing gas and is housed in the inner layer of the inner bladder. The gas container even comprises at least one air valve. The air valve is located on one side of the gas container and can be connected to the interior of the gas container to adjust the pressure and volume of the gas container and adjust the location of the liquid and colloid inside the liquid container. Therefore, the weight of the inner bladder can be adjusted to satisfy user's demand and accomplish better combat training effect. The liquid container is a bladder for containing liquid or colloid and is housed in the outer layer of the gas container. The liquid container even comprises at least one water inlet set and one air valve. The water inlet set is located on top of the liquid container and can be connected to the interior of the liquid container to adjust the weight of the liquid or colloid of the liquid container. The air valve of the liquid container is located on top of the liquid container or on top of the water inlet set and can be connected to the inside of the liquid container to adjust the hardness of the inner bladder through inflating or exhausting with the air valve of the liquid container, and thus to obtain the function of adjusting punching texture.
[0012] The external bag covers the outer layer of the inner bladder and further comprises a body, protection cover, plural hidden suspenders, and at least two connection straps. The body is a hollow bag that has a first connecting part. The connecting part is located at the edge of the opening of the body. An end of the protection cover can be connected to the body and the side protection edge can be folded inside out to cover the opening and the first connecting part of the body and even comprises plural lacing holes and one second connecting part. The lacing holes are located on the circular surface of the protection cover. The second connecting part is located at the edge of bottom of the protection cover and can be connected to the first connecting part of the body. One end of the hidden suspenders is fixed at the inner layer of the opening of the body and the other end can go through the corresponding lacing holes of the protection cover or can be fixed at the bottom of the protection cover. Each of the connection strap is respectively located on each side of the body with a connecting part. The connecting part is located at the connecting area, but not fixed on the body, while the other areas of the connecting strap are fixed on the body.
[0013] The handle set is removable and has multiple handles at different locations and a connecting part. The connecting part is located on one end of the handle set and can be fixed on the connecting part of the connecting strap. The first suspender set is removable and one end of each the first suspender set can go through the connecting part of each the connecting strap and between the external bag of the body. The second suspender set is removable and one end can be fixed on the out layer of the body of the external bag.
[0014] Preferably, the air valve of the gas container and the air valve of the liquid container are those for inflating balls or air beds.
[0015] Preferably, the external bag comprises one waterproof layer housed between the body of the external bag and the inner bladder. The opening of the waterproof layer can open and close.
[0016] Preferably, the second suspender set can adjust its length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a three-dimensional view of the inner bladder of a first preferred embodiment of present invention.
[0018] FIG. 2 is another use of three-dimensional view of the inner bladder of the above first preferred embodiment of present invention.
[0019] FIG. 3 is a three-dimensional view of the external bag of the above first preferred embodiment of present invention.
[0020] FIG. 4 is a three-dimensional view of the integration of external bag and inner bladder of the above first preferred embodiment of the present invention.
[0021] FIG. 5 is a three-dimensional view of a second preferred embodiment of present invention.
[0022] FIG. 6 is a three-dimensional view of a third preferred embodiment of present invention.
[0023] FIG. 7 is a three-dimensional view of a forth preferred embodiment of present invention.
[0024] FIG. 8 is a three-dimensional view of a fifth preferred embodiment of present invention.
[0025] FIG. 9 is a three-dimensional view of a sixth preferred embodiment of present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The presently preferred embodiment and related aspects of the invention will now be described with reference to the accompanied drawings.
[0027] Please refer to FIGS. 1 and 2 for the different three-dimensional views of the inner bladder of preferred embodiment of present invention. Please refer to FIGS. 3 and 4 for the three-dimensional view of the external bog of the first preferred embodiment of present invention and the three-dimensional view of the integration of external bag and inner bladder, respectively. Please refer to FIGS. 5 , 6 , 7 , 8 , and 9 for the three-dimensional views of different embodiments of the present invention. The present invention is a multi-training function air-water punching bag structure; wherein the structure comprises one inner bladder 10 , one external bag 20 , at least one set of handles 30 , at least two sets of first suspenders 40 , and at least one set of second suspender 50 .
[0028] The inner bladder 10 is a hollow bladder that further comprises one gas container 11 and one liquid container 12 , as shown in FIG. 1 . The gas container 11 is a bladder for holding gas and is located in the inner layer of the inner bladder 10 . The gas container 11 further comprises at least one air valve 111 , which is located at one end of the gas container and can be connected to the interior of the gas container. The liquid container 12 is a bladder for holding liquid or colloid and is located in the outer layer of the gas container 11 . The liquid container 12 further comprises at least one water inlet set 121 and at least one air valve 122 . The water inlet set 121 is located on top of the liquid container 12 (as shown in FIGS. 1 and 2 ) and can be connected to the interior of the liquid container 12 . The air valve 122 is located on top of the liquid container 12 and can be connected to the interior of the liquid container 12 .
[0029] As shown in FIG. 3 , the external bag 20 covers the outer layer of the inner bladder 10 and further comprises one body 21 , one water proof layer 22 , one protection cover 23 , plural hidden suspenders 24 , and at least two connection straps 25 . The body 21 is a hollow bag that has one first connecting part 211 and the connecting part 211 is located at the edge of the opening of the body 21 . The waterproof layer 22 is located between the external bag 20 body 21 and the inner bladder 10 . One end of the protection cover 23 can be folded inside out to cover the opening of the body 21 and even comprises plural lacing holes 231 and one second connecting part 232 . The lacing holes 231 are located on the circular surface of the protection cover 23 . The second connecting part 232 is located at the edge of bottom of the protection cover 23 and can be connected to the first connecting part 211 of the body 21 . One end of the hidden suspenders 24 is fixed at the inner layer of the opening of the body 21 and the other end can go through the corresponding lacing holes 231 of the protection cover 23 or can be fixed at the bottom of the protection cover 23 . Each of the connection straps 25 is respectively located on each side of the body 21 with one connecting part 251 . The connecting part 251 is located in one area of the connecting strap 25 , but not fixed on the body 21 , while the other areas of the connecting strap 25 are fixed on the body 21 .
[0030] The handle set 30 is removable and has multiple handles at different locations and one connecting part 31 . The connecting part 31 is located on one end of the handle set 30 and can be fixed on the connecting part 251 of the connecting strap 25 . The first suspender set 40 is removable and one end of each the first suspender set 40 can go through the connecting part 251 of each the connecting strap 25 and between the external bag 20 body 21 . The second suspender set 50 is removable and the length thereof is adjustable and one end thereof can be fixed on the out layer of the external bag 20 body 21 .
[0031] First, the inner bladder 10 was put into the external bag 20 and the inner bladder 10 of the gas container 11 was injected with air via the air valve 111 on the gas container 11 . The volume of the gas container 11 will increase due to the pressure increase inside the gas container 11 and then the volume of the inner bladder 10 of the liquid container 12 will be reduced.
[0032] Then the water inlet set 121 on the liquid container 12 is opened to allow the user to add certain amount of liquid or colloid into the inner bladder 10 of the liquid container 12 via the water inlet set 121 on the liquid container 12 . Meanwhile, the top of liquid or colloid inside the inner bladder 10 of the liquid container 12 is filled with air.
[0033] Finally the water inlet set 121 on the liquid container 12 is closed and the air valve 122 on the liquid container 12 is opened for injecting air into the inner bladder 10 of the gas container 11 via the air valve 111 of the gas container 11 . The volume increases due to the pressure increases inside the inner bladder 10 of the gas container 11 and thus decreases the volume of the inner bladder 10 of the liquid container 12 . Meanwhile, the level of liquid or colloid inside the inner bladder 10 of the liquid container 12 will rise due to compression and the air inside the inner bladder 10 of the liquid container 12 will be exhausted via the air valve 122 until the liquid or colloid inside the inner bladder 10 of the liquid container 12 is drained via air valve 122 , meaning the air inside the inner bladder 10 of the liquid container 12 is completely exhausted. Meanwhile, the air injection into gas container 11 via the air valve 111 of the gas container 12 is stopped and the air valve 122 of the liquid container 12 is closed to completely seal the inner bladder 10 of the liquid container 12 .
[0034] The inner bladder 10 of the liquid container 12 is completely filled with demanded amount of liquid or colloid in accordance with user's training need to obtain desired texture of punching at practice and change the texture of punching via changing the pressure of the gas container 11 , and thus result in better training effect. The liquid or colloid and air inside the inner bladder 10 all can be respectively exhausted via the water inlet set 121 on the liquid container 12 and the air valve 111 on the gas container 11 , thus the air-water punching bag structure is easier to be stored and moved.
[0035] If the firmness of the air-water punching bag structure is desired to be increased, air can be injected into the inner bladder 10 of the liquid container 12 via the air valve 122 on the liquid container 12 .
[0036] In addition, if the liquid of colloid inside the liquid container 12 is not filled all the way up, the liquid or colloid inside the liquid container 12 will jiggle when the air-water punching bag structure is punched with external force; therefore, the center of the air-water punching bag structure will be shifting. A user will have to additionally use his/her muscles in different parts of the body to obtain balance, and thus further train more small groups of muscles.
[0037] As shown in FIGS. 4 and 5 , the side of the protection cover 23 of the external bag 20 is folded up, so one end of the hidden suspenders 24 of the external bag 20 goes through the corresponding lacing holes 231 on the protection cover 23 and the second connecting part 232 on the protection cover 23 integrates the first connecting part 211 of the body 21 . Further the side of the protection cover 23 of the external bag 20 can be folded down to cover the opening of the body 21 . Then the other end of each hidden suspender 24 of the external bag 20 is hung on the boxing suspending device (not shown in the drawings), so as to be used as boxing training sandbag.
[0038] As shown in FIG. 6 , the side of the protection cover 23 of the external bag 20 is folded up and one end of the hidden suspenders 24 of the external bag 20 is fixed on the bottom of the protection cover 23 and the second connecting part 232 on the protection cover 23 integrates the first connecting part 211 of the body 21 . Further the side of the protection cover 23 of the external bag 20 is folded down to cover the opening of the body 21 . If the air-water punching bag structure is vertical, it can produce different throwing, tossing, and tackling training effects when the center shifts. If the air-water punching bag structure is horizontal and is used as the force pivot point, it can produce different push-up and sit-up training effects when the center shifts.
[0039] As shown in FIG. 7 , the side of the protection cover 23 of the external bag 20 is folded up and one end of the hidden suspenders 24 of the external bag 20 is fixed on the bottom of the protection cover 23 and the second connecting part 232 on the protection cover 23 integrates the first connecting part 211 of the body 21 . Further the side of the protection cover 23 of the external bag 20 is folded down to cover the opening of the body 21 . One end of each of the first set of suspenders 40 goes through the connecting strap 25 of the connecting part 251 between the external bag 25 and the body 21 . The second set of suspenders 50 is housed in the outer layer of the external bag 20 and the body 21 . The length of the other end of the second set of suspenders 50 can be adjusted to make the external bag 20 not to be distorted easily while taking external force. Then each end of the each first set of suspenders and the second set of suspenders are hung on the boxing suspending device (not shown in the drawings) to create the sandbag training effect of upper cut.
[0040] As shown in FIG. 8 , the side of the protection cover 23 of the external bag 20 is folded up and one end of the hidden suspenders 24 of the external bag 20 is fixed on the bottom of the protection cover 23 and the second connecting part 232 on the protection cover 23 integrates the first connecting part 211 of the body 21 . Further, the side of the protection cover 23 of the external bag 20 is folded down to cover the opening of the body 21 . The connecting part 31 of the handle set 30 is fixed on top of the connecting part 251 on one side of the connecting strap 25 of the external bag 20 . If a user conducts suppression training on the air-water punching bag structure, the air-water punching bag structure can produce jiggles; meanwhile, trainer holds the handle set 30 to pull and swing to simulate the struggling of a real person to achieve different suppression training effects. If both hands of the user respectively hold on different spots of the handle set 30 to conduct Judo suplex moves training, he can achieve different Judo suplex training effects when the center shifts.
[0041] As shown in FIG. 9 , the side of the protection cover 23 of the external bag 20 is folded up and one end of the hidden suspenders 24 of the external bag 20 is fixed on the bottom of the protection cover 23 and the second connecting part 232 on the protection cover 23 integrates the first connecting part 211 of the body 21 . Further, the side of the protection cover 23 of the external bag 20 is folded down to cover the opening of the body 21 . The connecting part 31 of each the handle set 30 is fixed on the top of the connecting part 251 of each the connecting strap 25 . Both hands of the user can respectively hold on each the handle set 30 to produce different croissant moves, arm weight, and leg weight training effects when the center shifts.
|
The present invention discloses a multi-training function air-water punching bag structure that comprises one inner bladder, one external bag, at least one set of handles, at least two sets of first suspenders, and at least one set of second suspenders. The inner bladder respectively contains liquid and air simultaneously. Users can adjust the volume of the liquid and air according to the needs of training and the tactile feel of the punches. The external bag integrates the handle set or the first set of suspenders and the second set of suspenders to reach the effect of multi-training functions.
| 0
|
This national stage application is a submission under 35 U.S.C. 371 of PCT International Patent Application No. PCT/US2012/034391, filed on 20 Apr. 2012, and claims the priority benefit of U.S. Provisional Application No. 61/477,336, filed on Apr. 20, 2011, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE DISCLOSURE
This disclosure relates to an apparatus and method of forming reclosable containers, and more particularly reclosable thin-walled metal containers.
It is known in the art to form thin-walled reclosable metal containers in a press, and typically a press modified with multiple tooling stations. For example, there is a substantial cost associated with the purchase of a press and tooling for manufacturing reclosable metal containers. This includes related equipment for feeding and transferring blank material, partially completed components, and final components, along with the cost of related controls. As a result, a significant expenditure is incurred with regard to the equipment for forming metal cans having reclosable caps.
It is also known to use air or other pneumatic or hydraulic processes to form metal articles. For example, U.S. Pat. No. 7,191,032 generally describes such an arrangement. However, these arrangements use air or nitrogen pressure. The air and/or nitrogen gas must be pressurized or amplified to a high pressure in order to complete the desired metal forming. Accordingly, there is a cost for pressurizing and handling the gas required to accomplish such forming. Further, the air and nitrogen must be subsequently disposed of during cycling of the article formation. In still other instances, it has been suggested to elevate the temperature of the can body in an effort to assist in such formation.
Thus, a continued need exists for a new apparatus and method that is cost efficient and effective in forming reclosable metal cans.
SUMMARY OF THE DISCLOSURE
An apparatus for forming a reclosable metal can includes a flexible bladder that receives pressure from at least one end. The bladder is received in movable dies that selectively open and close about the bladder, and more particularly about a metal body received between the bladder and die.
An associated hydraulic system provides high pressure to an interior of the bladder to urge the bladder against the metal body and urge the metal body against the die.
The die preferably includes thread or lug profile cavities for forming circumferentially spaced thread lugs in the can body.
Subsequently, the body is removed from between the die and bladder for one or more curling steps.
A preferred method of forming a can body with integrated thread lugs includes pressurizing a bladder against a wall surface of a metal body, and deforming select regions of the metal body into die cavities.
In one exemplary embodiment, the metal body is radially positioned between a body on an inner surface of the wall, and movable die portions on the outer surface. Pressurized fluid is then introduced into the bladder and the bladder radially expands the metal body into the cavities of the die.
The method further includes sealing first and second ends of the bladder and introducing pressurized fluid from at least one end.
A primary benefit relates to the decreased cost associated with manufacture of a metal can having integrated thread lugs.
Still another benefit is the reduced number of manufacturing steps associated with the manufacture of a metal can having integrated thread lugs.
Still other benefits and advantages of the present disclosure will become more apparent to those skilled in the art upon reading and understanding the following, detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a metal can with integrated thread lugs and a resealable cap.
FIG. 2 is a plan view of the resealable cap.
FIG. 3 is across-sectional view through an apparatus for forming the can body.
FIG. 4 is a perspective view of one die portion that includes integrated thread portions.
FIG. 5 is a perspective view of a center post mounting plate.
FIG. 6 is a perspective view of a center post.
FIG. 7 is a perspective view of the bladder that is received over the center post with plural dies with integrated thread portions disposed therearound and a workpiece received therebetween.
FIG. 8 is a perspective view of a clamp plate.
FIG. 9 is a perspective view of the bottom plug.
FIG. 10 is a perspective view of the lower ring.
FIG. 11 is a perspective view of the lower base plate.
FIG. 12 is a perspective view of one of the clamp rings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Commonly-owned published application WO 2005/021388 generally shows and describes forming a metal can body having integrated thread lugs that cooperate with a resealable cap. FIG. 1 is representative of these two individual components of the can assembly, i.e., the body 100 and the cap 102 . In an upper or neck region 104 of the body, there are provided circumferentially spaced thread lugs 106 that cooperate with inwardly extending flanges 108 ( FIG. 2 ) of the cap 102 to seal the cap to an outwardly curled end portion 110 of the body. Preferably flange 108 of the cap cooperates with a corresponding thread lug on the body so that a reclosable pressurized can body is provided. More particular details of such can bodies and associated caps may be found in the noted international application, as well as commonly-owned U.S. Pat. Nos. 6,015,062; 6,082,944; 7,069,763; 7,370,507; 7,841,222; and 7,861,874, the disclosures of which are expressly incorporated herein by reference.
FIG. 3 is a view partially in cross-section of an assembly for simplifying formation of such a can body 100 . The forming assembly includes a die 118 , preferably formed by cooperating die portions 120 (one of which is shown in FIG. 4 ) that cooperate to form a cavity 122 . In the exemplary embodiment, each of four die portions 122 are identical or substantially identical in structure, although one skilled in the art will appreciate that differences may be provided in one or more of the die portions if desired. Each die portion is dimensioned to form, for example, one-fourth of the total die surface and abuttingly engage one another along faces 120 a , 120 b for sealing engagement with a similar face of an adjacent die portion. More particularly, die portion 122 has a generally arcuate or curvilinear inner die cavity surface 122 c that forms a major portion of the can body. At one end, namely a first or upper end, die cavities 124 are formed in spaced relation along the arcuate surface 122 c to, in turn, form the integrated thread lugs 106 in a manner to be described below. A first or lower recess 126 and similarly a second or upper recess 128 are formed in the die portion.
Each die portion 122 is preferably formed of a material that is sufficiently hard (tool steel) to deform a workpiece such as a metal body (aluminum or steel) when the metal body is forced against the die under the influence of pressure or force imposed thereon. In this particular system, the metal body is either a hollow cylinder or cup-shaped member having a bottom wall and a sidewall formed as one piece. Typically, the sidewall includes a seam that extends along a length thereof and therefore the seam is preferably located so as not to be received in one of the thread cavities 124 of the die portion. Without limiting the present disclosure, an aluminum body may have a wall thickness on the order of 0.003-0.006 or a steel body will have a wall thickness of approximately 0.006-0.010.
Each die portion 122 is preferably mounted on a slide or rail (not shown) for generally radial movement as represented by reference numeral 130 . The die portions are preferably actuated by a first hydraulic circuit (not shown) so that the individual die portions 122 can be moved away from one another for loading the metal body in the die (or removing a completed metal body) and likewise moved toward one another in abutting, sealing engagement along the mating surfaces 124 a , 124 b during the forming process.
With continued reference to FIGS. 3 and 4 , and additional reference to FIGS. 5-12 , selected components of the forming assembly will be shown and described in greater detail. Particularly, a center post mounting plate 140 ( FIG. 5 ) and center post 150 ( FIG. 6 ) are received in the die cavity ( FIG. 3 ). In a simple form, the center post mounting plate 140 has a square perimeter 142 (although this conformation is not a necessity) and a central recess 144 that is dimensioned to receive enlarged end 152 of the center post 150 . Fasteners (not shown) interconnect the mounting plate 140 and the center post 150 , and likewise to a base plate through fastener receiving openings 146 , 156 , respectively, in a manner to be described further below. Further, the mounting plate and the center post include respective fluid openings 148 , 158 that operatively communicate with a second hydraulic circuit (not shown). The second hydraulic circuit selectively introduces and removes hydraulic fluid for the purpose of deforming the metal body against the die surface. As will be appreciated, the center post has a central opening along its length that communicates with the fluid openings 148 , 158 , and has a central longitudinal axis that extends in generally co-linear relation with a longitudinal axis of the die when the individual die portions are brought together.
Received around the center post 150 is a flexible bladder 170 ( FIG. 7 ) which in the preferred embodiment adopts a hollow cylindrical sleeve configuration. The hollow sleeve 170 is preferably a urethane construction in the exemplary arrangement having a wall thickness of approximately 0.50″, although the wall thickness may vary depending on the particular details of the metal body and the required deformation. Pressurized fluid, e.g., hydraulic fluid, is introduced into the interior 172 of the bladder and the flexible sleeve defining the bladder is expanded outward into engagement with the metal body B. The pressure level is pre-selected and is sufficient to expand the sleeve 170 outwardly and deform the metal body B beyond its elastic limit such that the metal body conforms to the contour of the die cavity preferably defined by multiple die portions 122 . The die portions when closed abut one another and define a continuous inner surface forming a die cavity having a slightly greater diameter dimension than the metal body B. In this arrangement, any seam in the metal body is oriented so as not to overlie one of the thread cavities 124 . It will also be appreciated that functional features are formed in the metal such as the thread lugs or a neck that tapers from a large diameter to a small diameter adjacent the opening in the top of the container. Likewise, decorative or aesthetic features can be embossed in the metal body by forming a mirror-image of such features in the die surface. By detecting a location of the seam or some other indicia on the metal body, the body can be oriented in a desired position so that functional and aesthetic features can be precisely located.
The clamp plate 180 ( FIG. 8 ), bottom plug 190 ( FIG. 9 ), lower ring 200 ( FIG. 10 ), lower base plate 210 ( FIG. 11 ), and clamp rings 220 ( FIG. 12 ) are assembled together to hold the center post, bladder, and metal body in position, and to seal the upper and lower ends during the forming operation. Of course, the die portions 120 are free to move a limited dimension in a radial direction in order to separate from the formed can body and receive a new metal body in the die cavity and around the hollow sleeve (i.e., move radially outward) and to abut the die portions together along surfaces 124 a , 124 b (i.e., move radially inward) in order to seal the die cavity, sleeve, and metal body during the forming operation.
The first hydraulic circuit is preferably used to advance and retract the die portions toward and away from one another. For example, each die portion is mounted on a slide or rail and a hydraulic piston/cylinder assembly (not shown for ease of illustration) is selectively pressurized to advance and retract the die portions. Further, once the die portions 122 are brought into abutting engagement, the hydraulic cylinder will apply a holding force that resists the outward deforming force applied by the expanding hollow sleeve against the metal body during the forming operation. Once the metal body is formed, the holding force is released, and the die portions retracted to allow the formed metal body to be removed from die cavity and a new metal body inserted. Of course, operation of the second hydraulic circuit that pressurizes the bladder is coordinated with the first hydraulic circuit in order to facilitate automated, repeatable forming of the metal bodies.
The formation of the integrated thread 106 in the can body is one step in the reclosable metal can. After the metal body with integrated thread is removed from the forming apparatus of FIG. 3 , a subsequent curling operation is preferably performed on the open, upper end of the metal body. Details of the curling operation are generally known in the art; however, formation of the outward curl is preferably after formation of the thread lugs in order to maintain the desired dimensional precision of the thread, curl, and cap. Particularly, the dimension between the curl surface and the thread lugs is precise by forming the lug based on the location of the previously formed thread lugs. This assures that the proper closing and sealing force is applied between the cap (and the seal typically provided on an underside of the cap) and the can body.
By using the flexible bladder, the interior of the metal body (and likewise the resultant can body) is not potentially contaminated by the hydraulic fluid. The metal bodies can be easily expanded into desired internal volumes. Further, the elimination of presses, feeder, and transfer equipment, and the reduced costs of replacement tooling since tool wear on the die cavity and bladder will not be as severe, result in a significant reduction in equipment and capital costs. The new process will have a significantly reduced number of steps also, from eight or more steps in the current forming process to perhaps two or three steps. Providing aesthetic features that are embossed in the can not only adds unique designs and shapes to the final article, but also can be used to either reduce or eliminate print material applied to a can body.
The disclosure has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon reading and understanding this specification. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
|
An apparatus for forming a reclosable metal can includes a flexible bladder that receives pressure from at least one end. The bladder is received in movable dies that selectively open and close about the bladder, and more particularly about a metal body received between the bladder and die. The die preferably includes thread or lug profile cavities for forming circumferentially spaced thread lugs in the can body.
| 8
|
TECHNICAL FIELD
[0001] The present invention relates to a pesticidal composition and its use.
BACKGROUND ART
[0002] Many compounds have been developed for controlling pests and actually used (see, for example, PTL 1 and PTL 2).
CITATION LIST
Patent Literature
[0000]
[PTL 1]: WO86/02641
[PTL 2]: WO92/12970
SUMMARY OF INVENTION
Technical Problem
[0005] An object of the present invention is to provide a composition having an excellent pesticidal effect.
Solution to Problem
[0006] The inventor of the present invention studied for seeking a composition having an excellent pesticidal effect and found that a composition comprising a carboxamide compound represented by following formula (I) and one or more phenylpyrazole compounds selected from following group (A) has an excellent pesticidal effect and then completed the present invention.
[0007] The present invention provides the following [1] to [7].
[0008] [1] A pesticidal composition comprising a carboxamide compound represented by formula (I):
[0000]
[0009] wherein
[0010] R 1 represents a hydrogen atom or a methyl group, and
[0011] R 2 represents a methyl group, a difluoromethyl group or a trifluoromethyl group,
[0012] and one or more phenylpyrazole compounds selected from group (A) consisting of fipronil and ethiprole.
[0013] [2] The pesticidal composition according to above [1], wherein the weight ratio of the carboxamide compound to the phenylpyrazole compound(s) is from 0.01/1 to 4/1 of the carboxamide compound/the phenylpyrazole compound(s).
[0014] [3] The pesticidal composition according to above [1] or [2], wherein the phenylpyrazole compound is fipronil.
[0015] [4] A method of controlling pest which comprises a step of treating a plant or the soil where a plant grows with an effective amount of a carboxamide compound represented by formula (I):
[0000]
[0000] wherein
R 1 represents a hydrogen atom or a methyl group, and
R 2 represents a methyl group, a difluoromethyl group or a trifluoromethyl group, and one or more phenylpyrazole compounds selected from group (A) consisting of fipronil and ethiprole.
[0016] [5] The method of controlling pest according to above [4], wherein the weight ratio of the carboxamide compound to the phenylpyrazole compound(s) is from 0.01/1 to 4/1 of the carboxamide compound/the phenylpyrazole compound(s).
[0017] [6] The method of controlling pest according to above [4] or [5], wherein the phenylpyrazole compound is fipronil.
[0018] [7] The method of controlling pest according to any one of above [4] to [6], wherein the plant or the soil where a plant grows is soybean or the soil where soybean grows, respectively.
Advantageous Effect of Invention
[0019] According to the present invention, various pests can be controlled.
DESCRIPTION OF EMBODIMENTS
[0020] The pesticidal composition of the present invention (hereinafter referred to as “composition”) comprises a carboxamide compound represented by formula (I):
[0000]
[0000] wherein
R 1 and R 2 represent the same meanings as defined in the above (hereinafter referred to as “carboxamide compound”),
and one or more phenylpyrazole compounds selected from group (A) consisting of fipronil and ethiprole (hereinafter referred to as “phenylpyrazole compound”).
[0021] The “carboxamide compounds” are those as described in, for example, WO86/02641 or WO92/12970, and can be prepared by the method described therein.
[0022] Particular examples of the “carboxamide compound” are as follows:
[0023] carboxamide compound represented by formula (1):
[0000]
[0024] (hereinafter referred to as “carboxamide compound (1)”);
[0025] carboxamide compound represented by formula (2):
[0000]
[0026] (hereinafter referred to as “carboxamide compound (2)”);
[0027] carboxamide compound represented by formula (3):
[0000]
[0028] (hereinafter referred to as “carboxamide compound (3)”):
[0029] carboxamide compound represented by formula (4):
[0000]
[0030] (hereinafter referred to as “carboxamide compound (4)”);
[0031] carboxamide compound represented by formula (5):
[0000]
[0032] (hereinafter referred to as “carboxamide compound (5)”).
[0033] The “phenylpyrazole compounds” are known compounds and described in, for example, “THE PESTICIDE MANUAL—14 th EDITION (published by BCPC) ISBN 1901396142. These compounds can be obtained from the products containing said “phenylpyrazole compound” in the market or can be synthesized by publicly known methods.
[0034] The weight ratio of the “carboxamide compound” to the “phenylpyrazole compound(s)” in the “composition” is usually from 0.01/1 to 500/1, and preferably from 0.01/1 to 4/1 of “carboxamide compound”/“phenylpyrazole compound(s)”
[0035] Although the “composition” may be a mixture itself of a “carboxamide compound” and “phenylpyrazole compound(s)”, the “composition” is usually prepared by mixing a “carboxamide compound”, “phenylpyrazole compound(s)” and an inert carrier, and if necessary, by adding a surfactant and/or another auxiliary for formulation and by formulating the mixture into oil formulation, emulsifiable concentrate, flowable formulation, wettable powder, water dispersible granules, powder, granules, or the like. The formulation, which is used alone or by adding another inert component, can be used as a pesticide.
[0036] The total content of a “carboxamide compound” and “phenylpyrazole compound(s)” in a “composition” is usually from 0.1 to 99% by weight, preferably from 0.2 to 90% by weight, and more preferably from 1 to 80% by weight.
[0037] Examples of the solid carriers used for the formulation include fine powder or granules of, for example, mineral materials such as kaolin clay, attapulgite, bentonite, montmorillonite, acid clay, pyrophillite, talc, diatomaceous earth and calcite; natural organic materials such as corncob powder and walnut powder; synthesized organic materials such as urea; salts such as potassium carbonate and ammonium sulfate; synthetic inorganic materials such as synthesized hydrous silicon oxide. Examples of the liquid carriers include aromatic hydrocarbons such as xylene, alkylbenzene and methylnaphthalene; alcohols such as 2-propanol, ethylene glycol, propylene glycol and ethylene glycol mono-ethyl ether; ketones such as acetone, cyclohexanone and isophorone; vegetable oils such as soybean oil and cotton seed oil; petrolic aliphatic hydrocarbons; esters; dimethylsulfoxide; acetonitrile; and water. Examples of the surfactants include anionic surfactants such as alkyl sulfate ester salts, alkylarylsulfonate salts, dialkylsulfosuccinate salts, polyoxyethylene alkylaryl ether phosphoric acid ester salts, lignin sulfonate and naphthalene sulfonate formaldehyde polycondensed products; non-ionic surfactants such as polyoxyethylene alkyl aryl ethers, polyoxyethylene alkyl polyoxypropylene block copolymers and sorbitan fatty acid esters; and cationic surfactants such as alkyl trimethyl ammonium salts. Examples of the other auxiliaries for formulation include water-soluble polymers such as polyvinyl alcohol and polyvinylpyrrolidone; polysaccharides such as gum arabic, alginic acid and its salt, CMC (carboxymethylcellulose) and xanthan gum; inorganic materials such as aluminum magnesium silicate and alumina sol; preservatives; coloring agents; and stabilizers such as PAP (acidic isopropyl phosphate) and BHT.
[0038] The “composition” can be also prepared by formulating a “carboxamide compound” and “phenylpyrazole compound(s)” according to the method as described in the above, and then making the formulations or their diluents.
[0039] The “composition” can be used for protecting plants from damage by pest (for example, arthropod pest such as insect pest and acarine pest, nematode pests such as Nematoda, as well as plant disease) which gives damage to the plant by feeding, sucking, or the like.
[0040] Examples of arthropod pest and nematode pests which can be controlled by the “composition” include the followings.
[0041] Hemiptera: Planthoppers (Delphacidae) such as small brown planthopper ( Laodelphax striatellus ), brown rice planthopper ( Nilaparvata lugens ) and white-backed rice planthopper ( Sogatella furcifera ); leafhoppers (Deltocephalidae) such as green rice leafhopper ( Nephotettix cincticeps ), green rice leafhopper ( Nephotettix virescens ); aphids (Aphididae) such as cotton aphid ( Aphis gossypii ), green peach aphid ( Myzus persicae ), cabbage aphid ( Brevicoryne brassicae ), potato aphid ( Macrosiphum euphorbiae ), foxglove aphid ( Aulacorthum solani ), oat bird-cherry aphid ( Rhopalosiphum padi ), tropical citrus aphid ( Toxoptera citricidus ); stink bugs (Pentatomidae) such as green stink bug ( Nezara antennata ), bean bug ( Riptortus clavetus ), rice bug ( Leptocorisa chinensis ), white spotted spined bug ( Eysarcoris parvus ) and brown marmorated stink bug ( Halyomorpha mista ), tarnished plant bug ( Lygus lineolaris ); whiteflies (Aleyrodidae) such as greenhouse whitefly ( Trialeurodes vaporariorum ), silverleaf whitefly ( Bemisia argentifolii ); scales (Coccidae) such as Calfornia red scale ( Aonidiella aurantii ), San Jose scale ( Comstockaspis perniciosa ), citrus north scale ( Unaspis citri ), red wax scale ( Ceroplastes rubens ), cottonycushion scale ( Icerya purchasi ); Tingidae family; Psyllidae family; and the like.
[0000] Lepidoptera: Pyralid moths (Pyralidae) such as rice stem borer ( Chilo suppressalis ), yellow rice borer ( Tryporyza incertulas ), rice leafroller ( Cnaphalocrocis medinalis ), cotton leafroller ( Notarcha derogate ), Indian meal moth ( Plodia interpunctella ), oriental corn borer ( Ostrinia furnacalis ), cabbage webworm ( Hellula undalis ) and bluegrass webworm ( Pediasia teterrellus ); owlet moths (Noctuidae) such as common cutworm ( Spodoptera litura ), beet armyworm ( Spodoptera exigua ), armyworm ( Pseudaletia separate ), cabbage armyworm ( Mamestra brassicae ), black cutworm ( Agrotis ipsilon ), beet semi-looper ( Plusia nigrisigna ), Thoricoplusia spp., Heliothis spp., and Helicoverpa spp.; white butterflies (Pieridae) such as common white ( Pieris rapae ); tortricid moths (Tortricidae) such as Adoxophyes spp., oriental fruit moth ( Grapholita molesta ), soybean pod borer ( Leguminivora glycinivorella ), azuki bean podworm ( Matsumuraeses azukivora ), summer fruit tortrix ( Adoxophyes orana fasciata), smaller tea tortrix ( Adoxophyes honmai .), oriental tea tortrix ( Homona magnanima ), apple tortrix ( Archips fuscocupreanus ) and codling moth ( Cydia pomonella ); leafblotch miners (Gracillariidae) such as tea leafroller ( Caloptilia theivora ) and apple leafminer ( Phyllonorycter ringoneella ); Carposinidae such as peach fruit moth ( Carposina niponensis ); lyonetiid moths (Lyonetiidae) such as Lyonetia spp.; tussock moths (Lymantriidae) such as Lymantria spp. and Euproctis spp.; yponomeutid moths (Yponomeutidae) such as diamondback moth ( Plutella xylostella ); gelechiid moths (Gelechiidae) such as pink bollworm ( Pectinophora gossypiella ) and potato tuberworm ( Phthorimaea operculella ); tiger moths and allies (Arctiidae) such as fall webworm ( Hyphantria cunea ); tineid moths (Tineidae) such as casemaking clothes moth ( Tinea translucens ) and webbing clothes moth ( Tineola bisselliella ); and the like, Thysanoptera: Thrips (Thripidae) such as western flower thrips ( Frankliniella occidentalis ), melon thrips ( Thrips parmi ), yellow tea thrips ( Scirtothrips dorsalis ), onion thrips ( Thrips tabaci ), flower thrips ( Frankliniella intonsa ), tobacco thrips ( Frankliniella fusca );
Diptera: housefly ( Musca domestica ), common mosquito ( Culex pipiens pallens), Tabanus ( Tabanus trigonus ), onion fly ( Hylemya antiqua ), seed-corn fly ( Hylemya platura ), Chinese anopheles ( Anopheles sinensis ), Japanese leaf miner ( Agromyza oryzae ), rice leafminer ( Hydrellia griseola ), rice stem maggot ( Chlorops oryzae ), melon fly ( Dacus cucurbitae ), mediterranean fruit fly ( Ceratitis capitata ) and Liriomyza tritrifolii;
Coleoptera: 28-spotted ladybird ( Epilachna vigintioctopunctata ), cucurbit leaf beetle ( Aulacophora femoralis ), Phyllotreta striolata , rice leaf beetle ( Oulema oryzae ), rice plant weevil ( Echinocnemus squameus ), rice water weevil ( Lissorhoptrus oryzophilus ), boll weevil ( Anthonomus grandis ), adzuki bean weevil ( Callosobruchus chinensis ), zoysia billbug ( Sphenophorus venatus ), Japanese beetle ( Popillia japonica ), cupreous chafer ( Anomala cuprea ), corn rootworm families ( Diabrotica spp.), Colorado potato beetle ( Letinotarsa decemlineata ), beetle of family Elateridae ( Agriotes spp.), tobacco beetle ( Lasioderma serricorne ), Anthrenus ( Anthrenus verbasci ), rust-red flour beetle ( Tribolium castaneum ), power post beetle ( Lyctus brunneus ), white-spotted longicorn beetle ( Anoplophora malasiaca ), common pine shoot beetle ( Tomicus piniperda ), and the like;
Orthoptera: grasshoppers ( Locusta migratoria ), mole cricket ( Gryllotalpa Africana ), Oxya yezoensis, Oxya japonica , and the like;
Hymenoptera: turnip sawfly ( Athalia rosae ), leafcutter ant ( Acromyrmex spp.), fire ants ( Solenopsis spp.), and the like;
Blattaria: German cockroach ( Blattella germanica ), smokybrown cockroach ( Periplaneta fuliginosa ), American cockroach ( Periplaneta americana ), black Mississippi cockroach ( Periplaneta brunnea ), Oriental cockroach ( Blatta orientalis ); Acarina: Tetranychidae such as twospotted spider mite ( Tetranychus urticae ), citrus red mite ( Panonychus citri ) and Oligonychus spp., Eriophyidae such as Aculops pelekassi , Tarsonemidae such as Polyphagotarsonemus latus ; Tenuipalpidae; Tuckerellidae; Acaridae such as Tyrophagus putrescentiae , Epidermoptidae such as Dermatophagoides farinae, Dermatophagoides ptrenyssnus , Cheyletidae such as Cheyletus eruditus, Cheyletus malaccensis, Cheyletus moorei , and the like.
[0042] Nematoda: Pratylenchus coffeae, Pratylenchus fallax, Heterodera glycines, Globodera rostochiensis, Meloidogyne hapla, Meloidogyne incognita, Aphelenchoides besseyi, Nothotylenchus acris , and the like.
[0043] Examples of the plant diseases which can be controlled by the “composition” include the followings.
[0044] Rice diseases: Magnaporthe grisea, Cochliobolus miyabeanus, Rhizoctonia solani, Gibberella fujikuroi;
[0045] Wheat diseases: Erysiphe graminis, Fusarium graminearum, F. avenaceum, F. culmorum, Microdochium nivale, Puccinia striiformis, P. graminis, P. recondita, Micronectriella nivale, Typhula sp., Ustilago tritici, Tilletia caries, Pseudocercosporella herpotrichoides, Mycosphaerella graminicola, Stagonospora nodorum, Pyrenophora tritici - repentis;
[0046] Barley diseases: Erysiphe graminis, Fusarium graminearum, F. avenaceum, F. culmorum, Microdochium nivale, Puccinia striiformis, P. graminis, P. hordei, Ustilago nuda, Rhynchosporium secalis, Pyrenophora teres, Cochliobolus sativus, Pyrenophora graminea, Rhizoctonia solani;
[0047] Maize diseases: Ustilago maydis, Cochliobolus heterostrophus, Gloeocercospora sorghi, Puccinia polysora, Cercospora zeae - maydis, Rhizoctonia solani;
[0048] Citrus diseases: Diaporthe citri, Elsinoe fawcetti, Penicillium digitatum, P. italicum, Phytophthora parasitica, Phytophthora citrophthora;
[0049] Apple diseases: Monilinia mali, Valsa ceratosperma, Podosphaera leucotricha, Alternaria alternata apple pathotype, Venturia inaequalis, Colletotrichum acutatum, Phytophtora cactorum;
[0050] Pear diseases: Venturia nashicola, V. pirina, Alternaria alternata Japanese pear pathotype, Gymnosporangium haraeanum, Phytophtora cactorum;
[0051] Peach diseases: Monilinia fructicola, Cladosporium carpophilum, Phomopsis sp.;
[0052] Grape diseases: Elsinoe ampelina, Glomerella cingulata, Uninula necator, Phakopsora ampelopsidis, Guignardia bidwellii, Plasmopara viticola;
[0053] Persimmon diseases: Gloesporium kaki, Cercospora kaki, Mycosphaerela nawae;
[0054] Gourd diseases: Colletotrichum lagenarium, Sphaerotheca fuliginea, Mycosphaerella melonis, Fusarium oxysporum, Pseudoperonospora cubensis, Phytophthora sp., Pythium sp.;
[0055] Tomato diseases: Alternaria solani, Cladosporium fulvum, Phytophthora infestans;
[0056] Eggplant diseases: Phomopsis vexans, Erysiphe cichoracearum;
[0057] Brassicaceous vegetable diseases: Alternaria japonica, Cercosporella brassicae, Plasmodiophora brassicae, Peronospora parasitica;
[0058] Welsh onion diseases: Puccinia allii, Peronospora destructor;
[0059] Soybean diseases: Cercospora kikuchii, Elsinoe glycines, Diaporthe phaseolorum var. sojae, Septoria glycines, Cercospora sojina, Phakopsora pachyrhizi, Phytophthora sojae, Rhizoctonia solani, Corynespora casiicola, Sclerotinia sclerotiorum;
[0060] Kidney bean diseases: Colletrichum lindemthianum;
[0061] Peanut diseases: Cercospora personata, Cercospora arachidicola, Sclerotium rolfsii;
[0062] Pea diseases: Erysiphe pisi;
[0063] Potato diseases: Alternaria solani, Phytophthora infestans, Phytophthora erythroseptica, Spongospora subterranean , f. sp. Subterranean;
[0064] Strawberry diseases: Sphaerotheca humuli, Glomerella cingulata;
[0065] Tea diseases: Exobasidium reticulatum, Elsinoe leucospila, Pestalotiopsis sp., Colletotrichum theae - sinensis;
[0066] Tobacco diseases: Alternaria longipes, Erysiphe cichoracearum, Colletotrichum tabacum, Peronospora tabacina, Phytophthora nicotianae;
[0000] Rapeseed diseases: Sclerotinia sclerotiorum, Rhizoctonia solani;
Cotton diseases: Rhizoctonia solani;
Beet diseases: Cercospora beticola, Thanatephorus cucumeris, Thanatephorus cucumeris, Aphanomyces cochlioides;
Rose diseases: Diplocarpon rosae, Sphaerotheca pannosa, Peronospora sparsa;
Diseases of chrysanthemum andasteraceae: Bremia lactuca, Septoria chrysanthemiindici, Puccinia horiana;
Diseases of various plants: Pythium aphanidermatum, Pythium debarianum, Pythium graminicola, Pythium irregulare, Pythium ultimum, Botrytis cinerea, Sclerotinia sclerotiorum;
Radish diseases: Alternaria brassicicola;
Zoysia diseases: Sclerotinia homeocarpa, Rhizoctonia solani;
Banana diseases: Mycosphaerella fijiensis, Mycosphaerella musicola;
Sunflower diseases: Plasmopara halstedii;
Seed diseases or diseases in the initial stage of growth of various plants caused by Aspergillus spp., Penicillium spp., Fusarium spp., Gibberella spp., Tricoderma spp., Thielaviopsis spp., Rhizopus spp., Mucor spp., Corticium spp., Rhoma spp., Rhizoctonia spp., Diplodia spp., or the like;
Virus diseases of various plants mediated by Polymixa spp., Olpidium spp. or the like.
[0067] Examples of the plants for which the “composition” can be used are as follows:
[0068] Agricultural crops: maize, rice, wheat, barley, rye, oat, sorghum, cotton, soybean, peanut, buckwheat, sugar beet, rapeseed, sunflower, sugar cane, tobacco, and the like;
[0069] Vegetables: Solanaceous vegetables (eggplant, tomato, green pepper, hot pepper, potato, etc.), Cucurbitaceous vegetables (cucumber, pumpkin, zucchini, watermelon, melon, squash, etc.); Cruciferous vegetables (radish, turnip, horseradish, kohlrabi, Chinese cabbage, cabbage, brown mustard, broccoli, cauliflower, etc.), Asteraceous vegetables (burdock, garland chrysanthemum, artichoke, lettuce, etc.), Liliaceous vegetables (Welsh onion, onion, garlic, asparagus, etc.), Umbelliferous vegetables (carrot, parsley, celery, parsnip, etc.), Chenopodiaceous vegetables (spinach, chard, etc.), Lamiaceous vegetables (Japanese basil, mint, basil, etc.), strawberry, sweet potato, yam, aroid, and the like;
[0070] Flowering plants;
[0071] Ornamental foliage plants;
[0072] Turf;
[0073] Fruit trees: pome fruits (apple, common pear, Japanese pear, Chinese quince, quince, etc.), stone fruits (peach, plum, nectarine, Japanese plum, cherry, apricot, prune, etc.), citrus (mandarin, orange, lemon, lime, grapefruit, etc.), nuts (chestnut, walnut, hazel nut, almond, pistachio, cashew nut, macadamia nut, etc.), berry fruits (blueberry, cranberry, blackberry, raspberry, etc.), grape, persimmon, olive, loquat, banana, coffee, date, coconut palm, and the like;
[0074] Trees other than fruit trees: tea, mulberry, flowering trees, street trees (ash tree, birch, dogwood, eucalyptus, ginkgo, lilac, maple tree, oak, poplar, cercis, Chinese sweet gum, plane tree, zelkova, Japanese arborvitae, fir tree, Japanese hemlock, needle juniper, pine, spruce, yew), and the like.
[0075] The above-described plants may be those having resistance imparted by genetic engineering technique.
[0076] Among the above plants, the “composition” is expected to have excellent controlling effect particularly to plant disease caused in soybean.
[0077] Among the above plant diseases, soybean diseases to which especially excellent effect of the “composition” can be expected are Rhizoctonia solani, Cercospora kikuchii, Septoria glycines, Corynespora casiicola, Phakopsora pachyrizi, Sclerotinia sclerotiorum, Cercospora sojina , and the like.
[0078] Following compositions exemplify an embodiment of the “composition”:
[0079] a composition comprising “carboxamide compound (1)” and fipronil;
[0080] a composition comprising “carboxamide compound (1)” and ethiprole;
[0081] a composition comprising “carboxamide compound (2)” and fipronil;
[0082] a composition comprising “carboxamide compound (2)” and ethiprole;
[0083] a composition comprising “carboxamide compound (3)” and fipronil;
[0084] a composition comprising “carboxamide compound (3)” and ethiprole;
[0085] a composition comprising “carboxamide compound (4)” and fipronil;
[0086] a composition comprising “carboxamide compound (4)” and ethiprole;
[0087] a composition comprising “carboxamide compound (5)” and fipronil;
[0088] a composition comprising “carboxamide compound (5)” and ethiprole;
[0089] a composition comprising “carboxamide compound (1)” and fipronil in which the weight ratio of “carboxamide compound (1)” to fipronil is 0.01/1 to 4/1;
[0090] a composition comprising “carboxamide compound (1)” and ethiprole in which the weight ratio of “carboxamide compound (1)” to ethiprole is 0.01/1 to 4/1;
[0091] a composition comprising “carboxamide compound (2)” and fipronil in which the weight ratio of “carboxamide compound (2)” to fipronil is 0.01/1 to 4/1;
[0092] a composition comprising “carboxamide compound (2)” and ethiprole in which the weight ratio of “carboxamide compound (2)” to ethiprole is 0.01/1 to 4/1;
[0093] a composition comprising “carboxamide compound (3)” and fipronil in which the weight ratio of “carboxamide compound (3)” to fipronil is 0.01/1 to 4/1;
[0094] a composition comprising “carboxamide compound (3)” and ethiprole in which the weight ratio of “carboxamide compound (3)” to ethiprole is 0.01/1 to 4/1;
[0095] a composition comprising “carboxamide compound (4)” and fipronil in which the weight ratio of “carboxamide compound (4)” to fipronil is 0.01/1 to 4/1;
[0096] a composition comprising “carboxamide compound (4)” and ethiprole in which the weight ratio of “carboxamide compound (4)” to ethiprole is 0.01/1 to 4/1;
[0097] a composition comprising “carboxamide compound (5)” and fipronil in which the weight ratio of “carboxamide compound (5)” to fipronil is 0.01/1 to 4/1;
[0098] a composition comprising “carboxamide compound (5)” and ethiprole in which the weight ratio of “carboxamide compound (5)” to ethiprole is 0.01/1 to 4/1;
[0099] The method of controlling pest (hereinafter referred to as “controlling method”) can be carried out by treating a plant or the soil where a plant grows with an effective amount of a “carboxamide compound” and “phenylpyrazole compound(s)”.
[0100] The part of plant to be treated is stem and leaf of a plant, seed or bulb of a plant, and the bulb means bulb, corm, rootstock, tuber, tuberous root and rhizophore.
[0101] In the “controlling method”, the treatment of a plant or the soil where a plant grows with a “carboxamide compound” and “phenylpyrazole compound(s)” can be carried out separately at the same timing, but the treatment is usually carried out by using a “composition” in light of convenience.
[0102] In the “controlling method”, the treatment with a carboxamide compound” and “phenylpyrazole compound(s)” is, for example, stems and leaves application, soil application, roots application or seeds application.
[0103] Examples of the stems and leaves application include a treatment for surface of cultivated plant by a stem and leaves spray or a stem and tree spray.
[0104] Examples of the root application include a method of dipping a whole plant or the root of a plant into a liquid containing a “carboxamide compound” and “phenylpyrazole compound(s)” and a method of sticking a solid preparation comprising a “carboxamide compound”, “phenylpyrazole compound(s)” and a solid carrier onto the root of a plant.
[0105] Examples of the soil application include a method of spraying a “composition” onto a soil, a method of mixing a “composition” with a soil and a method of irrigating a “composition” into the soil.
[0106] Examples of the seed application include a method of treating seeds or bulbs of a plant to be protected from a plant disease with a “composition”. Particularly, the application can be carried out by spraying a suspension of a “composition” to the surface of seeds or bulbs, or by spreading wettable powder, emulsifiable concentrate or flowable formulation itself or a mixture thereof with a small amount of water on the seeds or the bulbs, or by dipping the seeds into a solution of a “composition” for a prescribed time, by film coating application or pellet coating application.
[0107] The amount of a “carboxamide compound” and “phenylpyrazole compound(s)” used in the “controlling method” is different depending on the kind of a plant to be treated, the kind of a plant disease to be controlled and its frequency, the kind of a formulation, timing of treatment, method of treatment, place of treatment, weather condition, and the like.
[0000] When a “composition” is applied to stems and/or leaves of a plant or to the soil where a plant grows, the total amount of a “carboxamide compound” and “phenylpyrazole compound(s)” is usually from 1 g to 500 g/1000 m 2 , preferably from 2 g to 200 g/1000 m 2 and more preferably from 10 g to 100 g/1000 m 2 .
When a “composition” is applied to seeds of a plant, the total amount of a “carboxamide compound” and “phenylpyrazole compound(s)” is usually from 0.001 g to 10 g/1 kg of the seeds, and preferably from 0.01 g to 1 g/1 kg of the seeds.
An emulsifiable concentrate, wettable powder or flowable formulation is usually used by diluting the formulation with a small amount of water and spraying the diluted formulation. In this case, the concentration of a “carboxamide compound” and “phenylpyrazole compound(s)” in total of the diluted formulation is usually from 0.0005% to 2% by weight and preferably from 0.005% to 1% by weight.
A powder formulation or granule formulation and the like is usually used without dilution.
EXAMPLE
[0108] The present invention is further explained in detail with Formulation Examples and Test Examples. However, the present invention is not limited by the following Examples.
[0109] In the following Examples, “part” means “part by weight” unless otherwise provided.
Formulation Example 1
[0110] One of the “carboxamide compound” (1) to (5) (2.5 parts), fipronil (1.25 parts), polyoxyethylene styryl phenyl ether (14 parts), calcium dodecylbenzene sulfonate (6 parts) and xylene (76.25 parts) are thoroughly mixed to give each of formulations, respectively.
Formulation Example 2
[0111] One of the “carboxamide compound” (1) to (5) (2 parts), fipronil (8 parts), a mixture of white carbon and polyoxyethylene alkyl ether sulfate ammonium salt (weight ratio 1:1) (35 parts) and water (55 parts) are mixed and the mixture is milled by wet-milling method to give each of formulations, respectively.
Formulation Example 3
[0112] One of the “carboxamide compound” (1) to (5) (5 parts), fipronil (10 parts), sorbitan trioleate (1.5 parts), and an aqueous solution (28.5 parts) containing polyvinyl alcohol (2 parts) are mixed and the mixture is milled by wet-milling method. An aqueous solution (45 parts) containing xanthan gum (0.05 part) and aluminum magnesium silicate (0.1 part) is added to the milled mixture. To the mixture is added propylene glycol (10 parts) and the resultant mixture is mixed by stirring to give each of formulations, respectively.
Formulation Example 4
[0113] One of the “carboxamide compound” (1) to (5) (1 part), fipronil (4 parts), synthesized hydrous silicon oxide (1 part), calcium lignin sulfonate (2 parts), bentonite (30 parts) and kaolin clay (62 parts) are thoroughly mixed and milled. Water is added to the mixture and the mixture is sufficiently kneaded, granulated and then dried to give each of formulations, respectively.
Formulation Example 5
[0114] One of the “carboxamide compound” (1) to (5) (12.5 parts), fipronil (37.5 parts), calcium lignin sulfonate (3 parts), sodium lauryl sulfate (2 parts) and synthesized hydrous silicon oxide (45 parts) are thoroughly mixed and milled to give each of formulations, respectively.
Formulation Example 6
[0115] One of the “carboxamide compound” (1) to (5) (3 parts), fipronil (2 parts), kaolin clay (85 parts) and talc (10 parts) are thoroughly mixed and milled to give each of formulations, respectively.
Formulation Example 7
[0116] One of the “carboxamide compound” (1) to (5) (2.5 parts), ethiprole (1.25 parts), polyoxyethylene styryl phenyl ether (14 parts), calcium dodecylbenzene sulfonate (6 parts) and xylene (76.25 parts) are thoroughly mixed to give each of formulations, respectively.
Formulation Example 8
[0117] One of the “carboxamide compound” (1) to (5) (2 parts), ethiprole (8 parts), a mixture of white carbon and polyoxyethylene alkyl ether sulfate ammonium salt (weight ratio 1:1) (35 parts) and water (55 parts) are mixed and the mixture is milled by wet-milling method to give each of formulations, respectively.
Formulation Example 9
[0118] One of the “carboxamide compound” (1) to (5) (5 parts), ethiprole (10 parts), sorbitan trioleate (1.5 parts), and an aqueous solution (28.5 parts) containing polyvinyl alcohol (2 parts) are mixed and the mixture is milled by wet-milling method. An aqueous solution (45 parts) containing xanthan gum (0.05 part) and aluminum magnesium silicate (0.1 part) is added to the milled mixture. To the mixture is added propylene glycol (10 parts) and the resultant mixture is mixed by stirring to give each of formulations, respectively.
Formulation Example 10
[0119] One of the “carboxamide compound” (1) to (5) (1 part), ethiprole (4 parts), synthesized hydrous silicon oxide (1 part), calcium lignin sulfonate (3 parts), bentonite (30 parts) and kaolin clay (62 parts) are thoroughly mixed and milled. Water is added to the mixture and the mixture is sufficiently kneaded, granulated and then dried to give each of formulations, respectively.
Formulation Example 11
[0120] One of the “carboxamide compound” (1) to (5) (12.5 parts), ethiprole (37.5 parts), calcium lignin sulfonate (3 parts), sodium lauryl sulfate (2 parts) and synthesized hydrous silicon oxide (45 parts) are thoroughly mixed and milled to give each of formulations, respectively.
Formulation Example 12
[0121] One of the “carboxamide compound” (1) to (5) (3 parts), ethiprole (2 parts), kaolin clay (85 parts) and talc (10 parts) are thoroughly mixed and milled to give each of formulations, respectively.
[0122] Test Examples using each of the “compositions” are shown in the following.
Test Example
[0123] A cyclohexanone solution (100 microL) containing prescribed amount (weight) of a test compound was applied on seeds of soybean (variety: Natto shoryu) (10 g) by using a rotary apparatus for seed treatment (Seed dresser, manufactured by Hans-Ulrich Hege GmbH).
[0124] One day after the treatment, plastic pot was filled with soil contaminated by Rhizoctonia solani , and the seeds treated with the test compounds were seeded in the soil and cultivated in a glass-greenhouse for 20 days (hereinafter referred to as “treated plot”).
[0125] Thereafter, the presence of disease caused by Rhizoctonia solani in the young plants which germinated from each seed was observed and disease severity was calculated according to the following calculation formula (1).
[0126] On the other hand, seeds of soybean which were not treated as above were cultivated in the same way as above (hereinafter referred to as “non-treated plot”) and the disease severity in “non-treated plot” was calculated in the same way as above “treated plot”. On the basis of the above disease severity in “treated plot” and the “non-treated plot”, efficacy in “treated plot” was evaluated according to the following calculation formula (2).
[0127] The results are shown in Table 1 and Table 2.
[0000] Disease severity(%)=(number of infected young plants/total number of young plants)×100 Calculation formula (1)
[0000] Efficacy(%)=[1−(disease severity in “treated plot”/disease severity in “non-treated plot”)]×100 Calculation formula (2)
[0000]
TABLE 1
“carboxamide
fipronil
compound (1)”
[g/100 kg
efficacy
[g/100 kg of seeds]
of seeds]
(%)
0.2
5
68.4
0.2
—
42.1
[0000]
TABLE 2
“carboxamide
fipronil
compound (5)”
[g/100 kg
efficacy
[g/100 kg of seeds]
of seeds]
(%)
0.2
5
52.6
0.2
—
21.1
INDUSTRIAL APPLICABILITY
[0128] A pesticidal composition comprising a “carboxamide compound” represented by formula (I) and one or more phenylpyrazole compounds selected from group (A) is useful for controlling pests.
|
A composition comprising a carboxamide compound represented by following formula (I), wherein R 1 represents a hydrogen atom or a methyl group, and R 2 represents a methyl group, a difluoromethyl group or a trifluoromethyl group, and one or more phenylpyrazole compounds selected from group (A) consisting of fipronil and ethiprole is provided by the present invention, and this composition has an excellent pesticidal effect.
| 0
|
INTRODUCTION
The invention relates to a monolithic combination of two complementary bipolar transistors, of which the one is formed as a lateral transistor, the other as a vertical transistor next to one another on the surface of a semiconductor monocrystal and in which both are designed in such a manner that the base zone of the vertical transistor coincides with the collector zone of the lateral transistor and the base zone of the lateral transistor coincides with the emitter zone of the vertical transistor; in which, moreover, at least one collector zone of monocrystalline semiconductor material is provided, which collector zone belongs to the vertical transistor and is marked off from the base zone of this transistor by means of a pn-junction; and in which a Schottky contact is provided as the collector electrode.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to integrated injection logic (I 2 L) which is a digital circuit technique in which base drive is injected into the base of the switching transistor from an adjacent pn diode. This technique permitted higher functional density and improved power delay efficiency which made it attractive for large scale integration (LSI).
2. Description of the Prior Art
The monolithic combination of two complementary bipolar transistors in which one is formed as a lateral transistor and the other as a vertical transistor next to each other on the surface of a semiconductor monocrystal is known in the art. It is further known in the art that this structure may be further improved by making the collector contacts Schottky contacts. See, for example, the article by Frank W. Hewlett entitled "Schottky I 2 L" in the Journal of Solid State Circuits, October, 1975, Volume SC-10, pages 343-348.
More specifically, this structure is a monolithic combination of complementary transistors of which one is formed as a lateral transistor, and the other is a vertical transistor on the surface of a semiconductor monocrystal, and in which both are designed in such a manner that the base zone of the vertical transistor coincides with the emitter zone of the lateral transistor, and that the base zone of the lateral transistor coincides with the emitter zone of the vertical transistor, and is marked off from the base zone of this transistor by means of a pn junction.
In the monolithic transistor combination described above, the Schottky collector electrodes are formed directly on the monocrystalline material of the collector zone. See also the prior art disclosure, 1975 IEEE International Solid State Circuits Conference, Feb. 14, 1975, pages 172-173.
SUMMARY OF THE INVENTION
Instead of the I 2 L arrangement above referred to, in accordance with the present invention, it is proposed to design the monolithic combination defined above in such a manner that the monocrystalline collector zone of the vertical transistor is enlarged by a layer of polycrystalline semiconductor material of the conduction type of the monocrystalline collector zone and the collector electrode designed as a Schottky contact is formed on the surface of the polycrystalline semiconductor layer.
Thereby, the following advantages over the known monolithic combinations of the type initially referred to can be achieved:
(a) The monolithic combination can be more simply produced than in the known arrangements of this type, since, by contrast to the production of known arrangements, no 600 KeV implantation is necessary;
(b) The polycrystalline silicon layer can assume the function of a second metallisation layer
(c) A higher component density can be attained than in the utilization of the known construction;
(d) Upon use of a common monocrystalline collector area for a plurality of collector connections, the monocrystalline collector area and, thus, also the base zone of the vertical transistor can be significantly reduced with respect to their lateral extent in comparison to the corresponding collector area of the known arrangements, which means a corresponding reduction of the diffusion and depletion layer capacitances. Moreover, the size of the vertical transistor can be reduced to the size of a minimum transistor.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details of the invention, as well as the presentation of the relevant prior art and the substantiation of the indicated advantages are provided on the basis of the circuit diagrams and the diagrammatic views, partly in section appearing in FIGS. 1 through 7. Thereby, FIGS. 1 through 4 refer to known arrangements, FIG. 6 refers partially to known arrangements and partially to the invention, and the remaining Figures refer exclusively to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The equivalent circuit of a monolithic combination of two complementary bipolar transistors corresponding with a single exception of the definition initially given is shown in FIG. 1. The exception consists therein that the collector electrodes are designed as ohmic contacts in the manner usual in I 2 L-gates and not as Schottky contacts. According to the equivalent circuit illustrated in FIG. 1, the collector of a pnp-transistor T 1 is applied to the base of an npn-transistor T 2 which exhibits a plurality of collector outputs A, whereas the emitter of the transistor T 2 and the base of the transistor T 1 have identical potential. This is the result of the identity of the base zone of the lateral transistor T 1 with the emitter zone of the vertical transistor T 2 and the identity of the collector zone of the lateral transistor T 1 with the base zone of the vertical transistor T 2 . The connection E can serve as the input of the gate, whereas the collector outputs A of the vertical transistor T 2 can form the outputs of the logical gate.
The use of a Schottky contact electrode SD as the connection to the collector zone of the vertical transistor T 2 causes the change of the equivalent circuit to be seen in FIG. 2, in that, for each Schottky contact provided as a collector electrode, a respective Schottky diode SD appears in the equivalent circuit.
The realization of the circuit illustrated in FIG. 2 by means of a known monolithic combination can occur in the manner to be seen in FIG. 3 or in FIG. 4, whereby one usually provides not only one but a plurality (in the illustrated sample case, 3) of Schottky contact collector electrodes SD. Thereby, the possibility exists for providing a respective monocrystalline collector zone for each Schottky contact electrode SD, or the possibility for providing a common monocrystalline collector zone of the vertical transistor T 2 for all Schottky contact electrodes SD. The first case is illustrated in FIG. 3, the second in FIG. 4.
In the production of monolithic transistor combinations of the type initially described, one usually forms these in a monocrystalline semiconductor layer of weak doping, particularly with n-doping, which is epitaxially deposited on a semiconductor crystal of the same semiconductor material which at least on its surface exhibits a conduction type corresponding to the conduction type of the epitaxial monocrystalline semiconductor layer of weak doping, whereby, however, the doping concentration on the surface of the substrate is adjusted significantly higher than that in the epitaxial layer. This circumstance is accounted for in FIGS. 3 and 4, as well as in the following Figures by the n+ doped zone 2, in which the combination of the two transistors T 1 and T 2 is more or less embedded. The weakly doped area 3 exhibiting the same conduction type as the zone 2 forms the base zone of the lateral transistor T 1 and the emitter zone of the vertical transistor T 2 . In the example of FIG. 3, the p+ doped emitter zone 4 and the p+ doped collector zone 5 of the lateral transistor T 1 is let into the surface of the area 3, whereas in the example of FIG. 4, the weakly doped area 3 (the actual base of the lateral transistor T 1 ) lies exclusively between the emitter 4 and the collector 5 of T 1 .
The base zone of the vertical transistor T 2 and the collector zone of the lateral transistor T 2 from a coherent area of the same conduction type, whereby, however, the doping of the base zone 5a of T 2 is adjusted lower than the doping of the collector zone 5 of T 1 . In the example of FIG. 3, each Schottky contact collector electrode SD has a respective monocrystalline collector zone 6 allocated to it; in the example of FIG. 4, the totality of the Schottky contact collector electrodes SD of the transistor combination has only a single monocrystalline collector zone 6 allocated to it. The arrangements according to both FIGS. 3 and 4 are completed by an insulating protective layer 8, consisting preferably of SiO 2 , and the depletion-free connections 9 for the emitter and the collector of the lateral transistor T 1 . The bias voltage for the emitter of the vertical transistor T 2 or for the base of the lateral transistor T 1 , respectively, is delivered via the area 2.
The surface of the collector zones of the vertical transistor T 2 must be weakly doped (about 10 16 cm -3 ), so that the collector electrode can be worked out as a Schottky contact SD. The resulting effect is that the active area of the base of the vertical transistor must be p - doped and, therefore, can only be produced by means of ion implantation technology. Because of the required penetration depth, acceleration energies in the magnitude of 600 keV are required for this. (The measure of generating the emitter zone 4 and the collector zone 5 of the lateral transistor T 1 in temporal succession is not to be recommended for technical reasons of adjustment.)
If, on the other hand, the doping of collector zone 6 of the vertical transistor T 2 is increased, i.e., to the n+ type, then the necessary doping of the collector zone 6, which requires a two-time re-doping of the epitaxial layer which accepts the transistor combination and exhibits the doping of the area 3, can ensue in a conventional manner, thus, for example, by means of diffusion.
This is the case in the embodiment illustrated in FIG. 5, and corresponding to the invention. Its realization ensues expediently with the use of silicon as the semiconductor material.
The doner-doped zone of the silicon monocrystal 1 which assumes the function of the emitter zone of the vertical transistor T 2 as well as the function of the base zone of the lateral transistor T 1 consists of an n+ doped part 2 (i.e., exhibiting a donor concentration of about 10 18 or 10 19 cm -3 , respectively), and a weakly doped part 3 (with about 10 16 cm -6 ).
In production, one proceeds in the usual manner as follows: proceeding from a p-doped disk-shaped silicon monocrystal 1, first a highly doped n+ zone 2 is formed at the place where the transistor combination is to be created which zone 2 is then in turn covered with a weakly n doped monocrystalline silicon layer by means of precipitation from the gaseous phase, whose doping corresponds to the doping desired for the area 3.
In this epitaxial zone, the p doped emitter zone 4, the p doped collector zone 5 of the lateral transistor T 1 and the p doped base zone of the vertical transistor T 2 are now produced by means of localized redoping. The production of an arrangement corresponding to the invention, in contrast to the production of the known arrangements according to FIGS. 3 and 4, requires no weakly doped base zone for the vertical transistor, since the collector zone 6 of T 2 to be generated in the area of the base zone of the vertical transistor T 2 , in contrast to the known arrangements according to FIGS. 3 and 4, can be highly doped, i.e., can be n+ doped. For this reason, the acceptor-doped zone representing the collector zone of the lateral transistor T 1 as well as the base of the vertical transistor T 2 can be produced in a single process step, for example, by means of diffusion, whereas in the production of the known arrangements, a special base area 5a must be created for the vertical transistor T 2 . By means of a further redoping of a part of the zone 5, an n+ doped collector zone 6 for the vertical transistor T 2 arises.
The insulating protective layer 8 consisting particularly of SiO 2 provided on the surface of the epitaxial silicon layer is formed by the doping mask used in the production of the collector zone 6 of the vertical transistor T 2 .
Of significance is the layer 7 of doped polycrystalline silicon which is to be provided in an arrangement according to the invention, whose conduction type corresponds to that of the monocrystalline collector zone 6 of the vertical transistor T 2 . The doping concentration of the polysilicon layer 7 is adjusted so low that the application of Schottky contacts SD on it is possible. Thus, it is adjusted to a maximum of circa 10 16 cm -3 .
The production of the polycrystalline silicon layer 7 occurs in the usual manner, for example, by means of gas discharge atomizing or by means of vaporization using electron beam guns or by means of precipitation from a suitable reaction gas, for example, by means of heating in a SiH 4 atmosphere diluted with argon or hydrogen. The Schottky contacts SD, i.e., the collector electrodes of the vertical transistor T 2 , are applied in the same manner as though the polysilicon layer 7 were monocrystalline.
After generating the electrodes SD and the electrodes 9, the arrangement illustrated in cross section in FIG. 5 can be covered with a further insulating layer, which in turn can be made into the carrier for the tracks required for the external contacting.
As the metal for the Schottky collector electrodes SD in the example, aluminum or a PtSi-TiW-Al-layer series can be used, which is also applicable for the electrodes 9. If, in addition, a Schottky-contact-free connection is to be generated on the polycrystalline silicon layer 7, then the donor concentration of the location of the polycrystalline silicon layer 7 provided for the location for the connection in question must be locally increased, so that the occurrence of a Schottky contact at the location of layer 7 concerned is no longer possible. If, deviating from the sample embodiments, the collector zone 6 is p-conductive, then the Schottky contacts SD can be generated on the appertaining polycrystalline silicon layer by using hafnium or zircon as the contact metal.
Significant additions are:
1. As can be seen from FIG. 5, a polycrystalline silicon layer 7 with a plurality of Schottky collector electrodes SD can belong to a collector zone 6. The other case, namely that each monocrystalline collector zone 6 is provided with one respective polycrystalline layer 7 and this, in turn, is provided with one respective Schottky collector electrode SD, is shown in FIG. 7.
2. For the purpose of reducing its lateral resistance, the polycrystalline silicon layer 7 can exhibit an increased doping to the side of the Schottky contact SD. For example, a lower layer part can be doped more highly than the upper layer part forming the Schottky contact. Instead of that, under certain conditions, an after-treatment that does not influence the quality of the Schottky contact SD can be applied in doping atmosphere or by means of ion implantation after the generation of the Schottky contact electrodes SD.
A comparison of FIGS. 3 and 5 shows particularly clearly that the dimensions of the base of the vertical transistor T 2 , and, thus, the dimensions of the layout of the I 2 L gate can be markedly reduced. In order to show this even more clearly, in FIG. 6, the layout of an arrangement according to FIG. 3 (FIG. 6a) is compared with the layout of an arrangement according to FIG. 5 (FIG. 6b or 6c, respectively). Whereas an arrangement according to FIG. 3 has the surface need of monocrystalline semiconductor material illustrated in FIG. 6a by the rectangular border for the transistor T 2 , the analogous need of an arrangement according to FIG. 5 is shown by the left hand rectangular border of FIGS. 6b and 6c and can be reduced in comparison to an arrangement according to FIG. 3 to at least one-third. Thereby, the depletion layer and the diffusion capacitances are also reduced, whereby the arrangement functioning, for example, as a NAND-gate receives noticeably smaller switching times. It should also be pointed out that the monocrystalline silicon area located under the polysilicon layer 7 and no longer required for the two transistors T 1 and T 2 is available for other purposes, for example, for the assumption of other functions of the monolithic combination.
It will be apparent to those skilled in the art that many modifications and variations may be effected without departing from the spirit and scope of the novel concepts of the present invention.
|
In the production of integrated I 2 L-circuits, a lateral transistor and a vertical transistor are generated next to one another on the surface of a monocrystalline semiconductor body. Thereby, it is seen to that the base zone of the vertical transistor coincides with the collector zone of the lateral transistor and the base zone of the lateral transistor coincides with the emitter zone of the vertical transistor. Further, it is known to provide at least one collector zone of monocrystalline semiconductor material belonging to the vertical transistor and marked off from the base zone of this transistor by a pn-junction and to provide a Schottky contact as collector electrode.
The invention makes provisions for applying a polycrystalline layer of the same semiconductor material and the doping of the collector zone on the surface of the monocrystalline collector zone and then making this the carrier of the collector electrode or collector electrodes, respectively.
In addition to reducing the effort otherwise required, an increase of the component density as well as a series of structural improvements can be attained.
| 7
|
BACKGROUND OF THE INVENTION
The present invention is directed generally to a handsaw formed from a frame and a removable main saw blade, where the main saw blade may be stored in the frame and the frame may support an auxiliary saw blade extending forward from the frame.
Numerous handsaw frames have been proposed and used through time. One typical saw frame structure is commonly referred to as a hacksaw frame. Hacksaw frames are generally U-shaped, with the relevant hacksaw blade operatively supported between forward and back downwardly extending frame portions. Examples of hacksaws of this general design can be found in U.S. Pat. Nos. 2,658,541; 2,767,751; and 3,636,997; and more recently in U.S. Pat. Nos. 5,471,752 and 6,230,412. While such hacksaws have been found useful in a variety of situations, there remains a need for alternative handsaw designs.
SUMMARY OF THE INVENTION
The present invention is directed to a saw and/or saw frame comprising: an elongate substantially rigid back member, a handle portion, and a swing arm pivotally connected to the back member distal from the handle portion so as to be rotatable between an extended position generally transverse to the back member and a storage position generally parallel and aligned with the back member; the handle portion comprising at least a first blade mount; the swing arm comprising at least a second blade mount; the back member comprising at least a third blade mount disposed proximate to the swing arm; each of the first, second, and third blade mounts being constructed to engage one end of a removably mounted saw blade of a first type; wherein the first, second, and third blade mounts are disposed with the swing arm in the extended position such that a first distance between the first and second blade mounts substantially equals a second distance between the first and third blade mounts; the back member further comprising an auxiliary blade mount mechanism adapted to removably mount an auxiliary saw blade of a second type operatively extending forward from the frame; the back member further comprising a blade storage cavity adapted to store at least one of the saw blades.
The auxiliary blade mount mechanism may comprise an auxiliary blade mount, a bearing surface disposed forward and above the auxiliary blade mount, and an auxiliary blade holder disposed forward and below the auxiliary blade mount. The auxiliary blade mount, bearing surface, and auxiliary blade holder may all be disposed on a side opposite the third blade mount. The saw may further comprise a quick-release blade tensioning mechanism operative to releasably apply a selectable amount of tension to the first blade mount; and wherein the frame allows conversion from a first configuration with a removably mounted saw blade connected between the first and second blade mounts and a second configuration with the saw blade connected between the first and third blade mounts without adjustment to the selected amount of tension. The saw frame may further comprise a fourth blade mount; wherein the swing arm further comprises a fifth blade mount; wherein the fourth and fifth blade mounts are non-coplanar with the first, second, and third blade mounts, but are spaced a third distance from each other substantially equal to the first distance with the swing arm in the extended position. The saw frame may further comprise at least one magnet, preferably at least two magnets spaced from each other, associated with the blade storage cavity. The blade mounts may comprise a tapered pin. The back member may further comprise an upwardly opening channel in which the swing arm is disposed in the storage position. The back member may further comprise a downwardly extending lobe proximate the swing arm, the third blade mount disposed on the lobe, and the lobe may comprise a bearing surface that limits the rotational movement of the swing arm. A first theoretical line between the first and second blade mounts may be disposed substantially parallel to the back member and a second theoretical line between the first and third blade mounts may be disposed angled with respect to the back member. The saw may further comprise at least one saw blade. The handle portion may comprise a grip portion integrally formed with the back member. The handle portion may further comprise a quick-release blade tensioning mechanism operative to releasably apply tension to the first blade mount. The quick-release blade tensioning mechanism may comprise an operating lever pivotally mounted in an upper portion of the handle portion. The blade storage cavity may be elongate and accessible from above the blade storage cavity may be adapted to store more or more of the blades of the first or second types, optionally at least one of each type simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a handsaw constructed in accordance with one embodiment of the present invention, with the main saw blade in the horizontal configuration (with vertical cant) and the swing arm in the extended position.
FIG. 2 shows a side view of the handsaw of FIG. 1 with the main saw blade in the reduced space configuration and the swing arm in the storage position.
FIG. 3 shows a perspective view of the handsaw of FIG. 1 from above and behind, showing the blade storage cavity.
FIG. 4 shows a side view from the opposite side of the handsaw of FIG. 2 with the main blade removed and the auxiliary blade operatively mounted.
FIG. 5 shows a front view of the handsaw of FIG. 1 with the main blade removed and the swing arm in the storage position.
FIG. 6 shows one embodiment of an auxiliary blade.
FIG. 7 shows a bottom view of the handsaw of FIG. 1 with the main blade removed to show one possible arrangement of blade mounts.
DETAILED DESCRIPTION OF THE INVENTION
The handsaw according to the present invention allows the user to easily change the orientation of the longitudinal axis of a main saw blade between two different configurations each supported on both ends by the saw's frame, to store at least one of such saw blades in the frame of the handsaw, and to attach an auxiliary saw blade to the frame that extends forward from the frame. For clarity of discussion, and without limiting the scope of the attached claims, the main saw blade (which when operatively mounted is supported on both ends) be may be referred to as a hacksaw blade, while the auxiliary saw blade (which when operatively mounted is not supported on both ends) may be referred to as a jabsaw blade.
As illustrated in the Figures, a handsaw according to one embodiment of the present invention, generally designated 5 , includes a frame 10 for supporting a hacksaw blade 2 . The frame 10 includes a spine (or back member) 20 that is generally elongate so as to separate a handle portion 100 from a swing arm 70 . While the spine 20 shown in FIG. 1 is generally rectilinear along longitudinal axis 21 , the spine 20 may alternatively be sinuous, curved, or take any other shape known in the art. The spine 20 includes a pivot 30 and a swing arm storage cavity 32 toward its front (see FIG. 3 ) for pivotally mounting and storing the swing arm 70 as discussed further below. The spine 20 further includes a downwardly extending lobe 22 on its lower side, proximate the swing arm 70 . The lobe 22 provides a location for a hacksaw blade mount 24 on the spine 20 , as discussed further below. In addition, the lobe 22 may advantageously provide a stop face 28 as a rotational positive stop for the swing arm 70 .
The swing arm 70 is pivotally mounted to the spine 20 so as to be rotatable between an extended position ( FIG. 1 ) and a storage position ( FIG. 2 ). In the extended position, the swing arm 70 extends downwardly with respect to the spine 20 , while in the storage position, the swing arm 70 is generally parallel and aligned with the spine 20 , and advantageously disposed in the swing arm storage cavity 32 . The swing arm 70 includes an upper portion 72 , a grip portion 80 , and a lower portion 90 . The upper portion 72 is rotatably coupled to the spine 20 via pivot 30 , which may be of any known type. Advantageously, the pivot 30 takes the form of a simple pin extending through two forwardly extending flanges on the spine 20 and a corresponding pin passage (not shown) through the upper portion 72 of the swing arm 70 . The upper portion 72 may further include a stop face 74 for abutting the lobe 22 in order to provide a positive stop for rotation of the swing arm 70 . Alternative means of limiting the amount of rotation of the swing arm 70 may alternatively be used. The grip portion 80 of the swing arm 70 advantageously includes a plurality of contoured finger indentations 84 and is advantageously covered by a suitable cushion material 82 such as a thermoplastic elastomer. The lower portion 90 of the swing arm 70 provides a location for operatively mounting the main hacksaw blade 2 . The lower portion 90 may include a notched area forming a main blade support face 92 with a main blade mount 94 disposed thereon. The lower portion 90 may advantageously also include a secondary blade supporting face 96 and secondary blade mount 98 for supporting the hacksaw blade 2 in a 45° orientation.
The handle 100 is connected to, or integrally formed with, the rear portion of the spine 20 . The handle 100 may include a grip area 102 , hand guard 106 , at least one blade mount 134 , and a blade tensioning mechanism 110 . The grip area 102 is intended to be gripped by the user's hand and may include a suitable cushion 104 if desired. The hand guard 106 is positioned in front of the grip area 102 , with an opening therebetween, and advantageously provides protection for the user's hand and additional rigidity for the frame 10 . The blade tensioning mechanism 110 includes a lever 112 , a pivot body 120 , and a connecting rod 114 running therebetween. The lever 112 is pivotally mounted at the upper portion of the handle 100 for movement between a closed/tension position generally parallel to the longitudinal axis 21 and an open/released position extending upward from the handle 100 . The rear portion of the lever 112 couples to the connecting rod 114 , which runs interiorly of the grip area 102 to the lower portion of the handle 100 . The connecting rod 114 operatively connects the lever 112 to the pivot body 120 (see FIG. 4 ). The pivot body 120 is pivotally mounted to the middle area of the hand guard 106 and extends from that pivot point 122 down along the hand guard 106 (mostly interiorly) and back toward the grip 102 . The lower forward portion of the pivot body 120 includes a blade mounting area 130 that includes a main blade support face 132 with a main blade mount 134 thereon, and optionally a secondary blade support face 136 and secondary blade mount 138 . The rear portion of the pivot body 120 includes a hole through which the connecting rod 114 extends to engage a tension adjusting knob 116 . By changing the setting of the tension adjusting knob 116 , the “locked” position of the main blade mount 134 (and the optional secondary blade mount 138 ) may be adjusted, thereby adjusting the tension setting for the hacksaw blade 2 . This blade tension mechanism 110 is advantageously of the “over-center locking” type.
With the swing arm 70 down in the extended position, the distance L 1 between blade mount 134 and blade mount 94 on the swing arm 70 is substantially equal to distance L 2 between blade mount 134 and blade mount 24 on the lobe 22 of the spine 20 . This arrangement allows the hacksaw blade 2 to be easily changed from a normal horizontal mounting basically parallel to the spine 20 ( FIG. 1 ) to a reduced space mounting where the mounted hacksaw blade 2 is angled at angle α relative to the spine 20 ( FIG. 2 ) so as to reduce the front profile of the saw 5 , all without requiring an adjustment to the tension setting of the blade tension mechanism 110 via knob 116 . To achieve this, the user simply pulls up on the lever 112 , which releases tension on the blade 2 , decouples the forward end of the blade 2 from blade mount 94 , rotates the swing arm 70 to its storage position in swing arm storage cavity 32 , couples the forward end of the blade 2 to blade mount 24 on the lobe 22 of the spine 20 , and returns the lever 112 to the locked position. A reverse process can also be used to change from the reduced space mounting to the normal horizontal mounting when desired. This type of two-position frame 10 conversion is generally described in U.S. Pat. No. 6,606,795, the disclosure of which is incorporated herein by reference.
It is intended that blade mounts 24 , 94 , 134 will be disposed so as to all lie in one plane that advantageously includes the longitudinal axis 21 of the spine 20 ; these blade mounts 24 , 94 , 134 are intended for a “vertical” mounting of a hacksaw blade 2 . Likewise, the secondary blade mounts 98 , 138 are intended to all lie in another plane that is angled 45° with respect thereto; these blade mounts 98 , 138 are intended for a “45°” mounting of a hacksaw blade 2 . Further, while not required for all embodiments, the distance between blade mounts 98 , 138 may advantageously also be substantially equal to L 1 with the swing arm 70 in the down position. Note that due to the presence of the auxiliary blade mounting mechanism 50 , discussed below, there may or may not be a blade mount on the spine 20 corresponding to the 45° blade mounting orientation, meaning that there may or may not be the ability to quickly change from the horizontal blade orientation to the angled orientation (i.e., front end of blade mounted to spine 20 , not swing arm 70 ) with the blade at a 45° cant in both orientations.
The spine 20 further includes a blade storage cavity 40 for storing extra hacksaw blades 2 or jabsaw blades 6 . The blade storage cavity 40 typically takes the form of a relatively deep slot formed in the upper surface of the spine 20 , that may or may not be connected to the swing arm storage cavity 32 . One or more magnets 44 may be mounted in the spine 20 so as to face the blade storage cavity 40 ; advantageously, there are two or more such magnets 44 at locations spaced from one another. In addition, an access aperture 42 on the side of the spine 20 may connect to the blade storage cavity 40 ; this access aperture 42 allows the user to visually see if a blade 2 is in the blade storage cavity 40 and to contact the blade 2 to urge the same out of the blade storage cavity 40 . It is believed advantageous if the blade storage cavity 40 has a relatively narrow cross section proximate the access aperture 42 so as to provide a resistance surface when the user is urging the blade 2 out of the blade storage cavity 40 with a finger. The rear portion of the blade storage cavity 40 may be enlarged if desired to aesthetically balance the swing arm cavity 32 and to provide additional access to any saw blades 2 stored in the blade storage cavity 40 . It should be noted that having an open top blade storage cavity 40 as shown in FIG. 3 allows for one or more blades 2 , 6 to be stored in the blade storage cavity 40 and to be added and/or removed from above. While not required for all embodiments, the blade storage cavity may advantageously be sized to allow the simultaneous storage of at least one hacksaw blade 2 and at least one jabsaw blade 6 .
The spine 20 further includes an auxiliary blade mounting mechanism 50 for supporting an auxiliary blade 6 that forwardly extends from the frame 10 . This auxiliary blade 6 may be used as a “jab saw” blade, and is therefore sometimes referred to herein as a jabsaw blade 6 , as indicated above. The auxiliary blade mounting mechanism 50 may include an auxiliary blade mount 68 , an auxiliary blade holder 60 , and a bearing surface 54 . The auxiliary blade mount 68 may be disposed on the lobe 22 in a position spaced rearwardly from the frontmost portion of the spine 20 . The blade holder 60 may be disposed forward of, and lower than, the auxiliary blade mount 68 . In some embodiments, the blade holder 60 may take the form of a simple screw arrangement that helps hold the auxiliary blade 6 against the side of the lobe 22 . The screw 62 may pass through a corresponding hole (not shown) in the lobe 22 to engage a nut 64 . This nut 64 may be fitted in a corresponding recess 26 in the lobe 22 and may advantageously be secured to the lobe 22 ; alternatively, the hole in the lobe 22 may be threaded. If desired, a washer or pressing plate 66 may also be used to aid in pressing the auxiliary blade 6 against the lobe 22 . Other forms of blade holders 60 , such as spring clips, quarter-turn fasteners, magnets, or the like may alternatively be used with the understanding that a primary purpose of the blade holder 60 is to aid in keeping the auxiliary blade 6 engaged with the auxiliary blade mount 68 during use. The bearing surface 54 is disposed forward and upward of the auxiliary blade mount 68 . The bearing surface 54 may advantageously be formed as the upper wall of a downwardly open longitudinally extending slot 52 on spine 20 . When operatively mounted, the auxiliary blade 6 juts forward from the frame 10 and is supported from above by the bearing surface 54 and from below by the blade holder 60 . The auxiliary blade mount 68 keeps the auxiliary blade 6 from moving longitudinally with respect to the frame 10 during use. It should be noted that the various portions of the auxiliary blade mounting mechanism 50 may advantageously be on the side of the spine 20 opposite that of the hacksaw blade mount 24 on the lobe 22 to avoid interfering with the main hacksaw blade mounting functions.
The jabsaw blade 6 may take the form shown in FIG. 6 . Because this jabsaw blade 6 is expected to be subjected to significant loads and is supported in a cantilever fashion, the jabsaw blade 6 is typically much thicker and shorter than a conventional hacksaw blade 2 . With this in mind, the blade storage cavity 40 may advantageously be sized to accommodate the jabsaw blade 6 when not mounted to the frame 10 via the auxiliary blade mounting mechanism 50 .
While the disclosure above has been in terms of one embodiment of a lever-actuated blade tensioning mechanism 110 , this particular mechanism is not required in all embodiments. Indeed, any one of a variety of blade tensioning mechanisms may be used, such as one operating according to any of the principles described in U.S. Pat. Nos. 1,187,460; 1,517,827; 3,636,997; 3,822,731; 4,349,059; 4,367,779; 4,466,471; 5,673,488; or 6,134,791. Additionally, the disclosures of U.S. patent applications Ser. Nos. 29/203,985 (filed 22 Apr. 2004) and 29/204,512 (filed 29 Apr. 2004) are incorporated herein by reference.
The various blade mounts 24 , 94 , 134 , 98 , 138 , 68 discussed herein may advantageously take the form of a short slightly tapered, but otherwise cylindrical, pin that is press fitted into the corresponding location. Alternatively, the blade mounts 24 , 94 , 134 , 98 , 138 , 68 may be integrally formed with the corresponding components or take other forms known in the art.
The majority of various parts of the frame 10 may be formed of aluminum, steel, various plastics, or other suitable rigid materials. As mentioned above, some or all of the grip surfaces 82 , 102 may optionally be coated with a suitable cushioning material known in the art.
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
|
A saw and/or saw frame including: an elongate substantially rigid back member and a swing arm pivotally connected to the back member so as to be rotatable between an extended position and a storage position; a handle with a first blade mount; the swing arm includes a second blade mount; the back includes a third blade mount disposed proximate to the swing arm; each of the first, second, and third blade mounts being constructed to engage one end of a removably mounted saw blade, with the first, second, and third blade mounts disposed to allow quick changes in blade configuration. The back member also has an elongate blade storage cavity accessible from above adapted to store at least one of the removably mounted saw blades and an auxiliary blade mounting mechanism configured to operatively mount an auxiliary blade extending forward from the frame.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to piperazinylalkylpyrazole derivatives, the preparation method thereof and the selective T-type calcium channel blocking activity thereof.
[0003] 2. Background of the Related Art
[0004] Depending on the response to membrane depolarization, calcium channels are classified into two main classes, high voltage activated (HVA) Ca 2+ channel and low voltage activated channel (LVA), and particularly, LVA Ca 2+ channel is also called as T-type Ca 2+ channel. Ca 2+ channels exist in neurons, heart, vascular smooth muscle and endocrine cells. The rise of concentration of Ca 2+ causes cell death or damage. Therefore, Ca 2+ channels are known to be involved in the contractions of atrium and smooth muscle, secretion of cortisol and dI-aldosterone in adrenal cortex, nerve stimulation and tissue development, etc. Inhibition of T-type Ca 2+ channel has been reported to have a treatment effect on neuropathic pain, high blood pressure and epilepsy.
[0005] Some well-known T-type Ca 2+ channel blockers are mibefradil (Ro 40-5967, WO 98/49149), flunarizine (Poauwels, P. J. et al. J. Life. Sci. 1991, 48, 18981), nicardipine (Richard, S. et al. J. Neurosci. Lett. 1991, 132(2), 229) and a number of derivatives thereof. However, these drugs showed some undesirable side effects due to its pharmacokinetic interactions with other drugs metabolized by cytochromes P-450 3A4 and 2D6. Therefore, they are no longer in use. So it is very likely that the selective T-type channel blockers will be developed as an effective therapeutic agent for illnesses of neuropathic nerve and heart-related diseases, such as pain, epilepsy and high blood pressure.
[0006] T-type Ca 2+ channel antagonists such as piperazinylalkylisoxazole group (A. N. Pae et al. Bioorganic. Med. Chem. Lett. 2004, 12, 3965-3970) and 3,4-dihydroquinazoline derivatives have been recently reported. (Lee et al. Bioorganic. Med. Chem. Lett. 2004, 14, 3379-3384)
[0007] Therefore, an object of the present invention is to provide novel piperazinylalkylpyrazole derivatives or pharmaceutically acceptable salts thereof which have the possibility of being developed into a therapeutic agent for pain, high blood pressure, and epilepsy as a selective T-type Ca 2+ channel inhibitor, and the preparation methods thereof.
BRIEF DESCRIPTION OF THE INVENTION
[0008] An object of the present invention is to provide a piperazinylalkylpyrazole derivative or its pharmaceutically acceptable salt, and the preparation method thereof. Particularly, it is to provide the piperazinylalkylpyrazole derivative as represented by Formula 1 as set forth below or its pharmaceutically acceptable salt, and its preparation method thereof.
wherein, R 1 represents phenyl, X-substituted phenyl (X include nitro, methyl, chloro, methoxy, etc.; the substitution positions are ortho, meta, and para positions; and can be mono-, di-, tri-, tetra- or entirely-substituted), 1,1-diphenylmethyl, X-substituted diphenylmethyl (X represents chloro, methyl; the substitution position can be ortho, meta, and para positions; and mono, di, tri, tetra or all thereof can be substituted);
R 2 represents hydrogen, methyl or ethyl groups;
R 3 represents methyl, propyl, isobutyl, phenyl, cyclohexyl, substituted phenyl (wherein, the substituents are methyl, chloro, methoxy, etc.), naphthyl, piperidinyl groups;
R 4 represents hydrogen or C 1-6 lower alkyl, preferably methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tertiary butyl, 2-furyl, phenyl, X-substituted phenyl(X represents chloro, methyl, cyclohexyl, piperidinyl, chloro groups, the substitution positions can be ortho, meta, and para positions and mono, di, tri, tetra or all thereof can be substituted); and
n represents an integer from 0 to 3.
[0009] The compound of Formula 1 is a novel piperazinylalkylpyrazole derivative, which particularly has T-type Ca 2+ channel blocking effect and thus can be useful as a therapeutic agent for nerve and muscle pain. As the compound is believed have a treatment effect for epilepsy and high blood pressure, it is expected to replace the addictive pain killers such as morphine. The compound of Formula (I) (R 2 ═H), as represented in Reaction Scheme 1 below, can be produced by reaction between aldehyde compound as represented by Formula 3 and amine compound as represented by Formula 2 with presence of a suitable reducing agent.
[0010] The reducing agents that can be used in the reaction represented by Reaction Scheme 1 are metal hydrides such as NaBH 4 , NaBH(OAc) 3 , NaBH 2 (OAc) 2 , NaBH 3 OAc, KBH 4 , KBH(OAc) 3 , or NaBH 3 CN, and it is preferable to use NaBH(OAc) 3 .
[0011] As reaction solvents, various types of alcohol such as methanol, ethanol or propanol, tetrahydrofuran, chloroform, or alkyl halides such as methylene chloride can be used.
[0012] The amine represented in Formula 2 is 1-R 1 substituted-4-(2-aminoethyl)piperazine, and R 1 is the same as defined in Formula 1. These compounds were prepared from 1-R 1 substituted piperazine and N-1-bromoalkylimide, using a standard amine synthetic method called the Gabriel Synthesis (Gibson, M. S.; Bradshaw, R. W. Angew. Chem. Int. Ed. Engl. 1968, 7, 919).
[0013] The aldehyde as represented by Formula 3 was prepared by reducing the corresponding esters or oxidizing the corresponding alcohols. In Formula 3, R 3 and R 4 are defined the same as those in Formula 1.
[0014] In addition, the compound (R 2 =methyl, ethyl) of Formula 1, as shown below in Reaction Scheme 2, can be prepared by using the aldehydes corresponding to the compound of Formula 1 (R 2 ═H) and reducing agents thereof, wherein NaBH(OAc) 3 is the most preferable metal hydride to be used as the reducing agent.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The preparation method and effects of the compound of the present invention is explained more in detail using the following examples. However, these examples only exemplifies the present invention, and therefore, the scope of the present invention is not limited to the following examples. In addition, the preparation methods of each corresponding piperazinylalkylamine and pyrazole-5-aldehyde are specifically described in the following References of the representative compounds.
[0000] Reference 1
Preparation of 2-[2-(4-phenylpiperazin-1-yl)ethyl]isoindole-1,3-dione
[0016] 4-phenylpiperazine (4.50 g, 27.74 mmol) was dissolved in 30 ml DMF, then K 2 CO 3 (11.50 g, 83.21 mmol) and N-(2-bromoethyl)phthalimide (8.46 g, 33.28 mmol) were added thereto and stirred at about 80° C. The reaction progress and completion were confirmed using TLC (hexane:EtOAc=1:1). Upon completion of the reaction, water was added to the reaction mixture and then was extracted with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , filtered and concentrated under reduced pressure. The concentrate was separated by column chromatography (hexane:EtOAc:CH 2 Cl 2 =3:1:2) to obtain the titled compound.
[0017] Yield: 55.6%
[0018] 1 H NMR (300 MHz, CDCl 3 ) δ 7.81 (m, 2H), 7.68 (m, 2H), 7.22 (m, 2H), 6.89 (d, J=7.41 Hz, 2H), 6.81 (t, J=7.23 Hz, 1H), 3.84 (t, J=6.84 Hz, 2H), 3.11 (t, J=4.71 Hz, 4H), 2.67 (m, 6H)
[0000] Reference 2
Preparation of 2-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propyl}isoindole-1,3-dione
[0019] Using the same method as in Reference 1, the above-mentioned compound was prepared by reacting 2-{2-[4-(2,3-dimethylphenyl)piperazine and N-(2-bromopropyl)phthalimide.
[0020] Yield: 93.7%
[0021] 1 H NMR (300 MHz, CDCl 3 ) δ 7.86 (m, 2H), 7.72 (m, 2H), 7.06 (m, 1H), 6.88 (d, J=6.4 Hz, 1H), 6.76 (d, J=7.9 Hz, 1H), 3.81 (t, J=6.9 Hz, 2H), 2.73 (m, 4H), 2.51 (t, J=6.9 Hz, 4H), 2.29 (m, 2H), 2.25 (s, 3H), 2.18 (s, 3H), 1.92 (m, 2H)
[0000] Reference 3
Preparation of 2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propylamine
[0022] 2-{2-[4-(2,3-dimethylpropyl)piperazin-1-yl]propyl}isoindole-1,3-dione (3.0 g, 7.95 mmol) prepared in Reference 2 was dissolved in 50 ml EtOH, then H 2 NNH 2 .H 2 O (1.54 ml, 31.80 mmol) was added and stirred at about 70° C. The reaction progress and completion were confirmed using TLC (hexane:EtOAc=1:1). Upon completion of the reaction, while the temperature was kept at room temperature, the resulting solution was filtered to remove insolubles. The solvent was removed by distilling it under reduced pressure, followed by adding water and extracting the aqueous layer with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , filtered and concentrated under reduced pressure to obtain the title compound.
[0023] Yield: 44.7%
[0024] 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (t, J=7.8 Hz, 1H), 6.91 (m, 2H), 3.61 (brs, 2H), 2.89 (m, 6H), 2.52 (m, 4H), 2.28 (m, 2H), 2.25 (s, 3H), 2.19 (s, 3H), 1.84 (m, 2H)
[0000] Reference 4
Preparation of 3-formyl-5-methylpyrazole
[0025] Under nitrogen environment, 3-ethoxycarbonyl-5-methylpyrazole (1.0 g, 4.34 mmol) was dissolved in 15 ml of purified toluene, and DIBAL (8.68 ml, 8.62 mmol) was slowly added and stirred at −78° C. The reaction progress and completion were confirmed using TLC (hexane:EtOAc=6:1). Upon completion of the reaction, MeOH and water were slowly added to the reaction mixture and the resulting mixture was filtered through a celite bed, and the aqueous layer was extracted with EtOAc. The organic layer was dried over anhydrous MgSO 4 , filtered and concentrated under reduced pressure. The concentrate was separated by column chromatography (hexane:EtOAc:CH 2 Cl 2 =3:1:1) to obtain the title compound.
[0026] Yield: 82.4%
[0027] 1 H NMR (300 MHz, CDCl 3 ) δ 9.92 (s, 1H), 6.68 (s, 1H), 2.82 (s, 3H)
[0000] Reference 5
Preparation of 1-tert-butyl-5-iso-butyl-3-formylpyrazole
[0028] PCC (0.67 g, 3.12 mmol) and silica gel (0.50 g) were grinded together and dispersed in 10 ml of purified CH 2 Cl 2 followed by treatment with ultrasound at 20° C. for 30 minutes. 1-tert-butyl-5-iso-butyl-3-hydroxymethylpyrazole (0.50 g, 2.08 mmol) was dissolved in 10 ml of purified CH 2 Cl 2 and the solution was added thereto and treated with ultrasound for 15 minutes. The reaction progress and completion were confirmed using TLC (hexane:EtOAc=6:1). Upon completion of the reaction, ether was added to the reaction mixture and then the resulting mixture was filtered through a celite bed, and concentrated under reduced pressure. The concentrate was separated by column chromatography (hexane:EtOAc:CH 2 Cl 2 =3:1:1) to obtain the compound of the present invention.
[0029] Yield: 88.8%
[0030] 1 H NMR (300 MHz, CDCl 3 ) δ 9.86 (s, 1H), 6.79 (s, 1H), 2.51 (d, J=6.6 Hz, 2H), 1.94 (m, 1H), 1.68 (s, 9H), 0.95 (d, J=6.6 Hz, 6H)
EXAMPLE 1
Preparation of 5-methyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole[Compound 1]
[0031] 4-phenylpiperazin-1-ylethylamine (50 mg, 0.208 mmol) and 5-methylpyrazole-3-carbaldehyde (25.24 mg, 0.104 mmol) were dissolved in 5 ml of purified CH 2 Cl 2 , and then 4 Å Molecular sieve (5 beads) was added thereto and was stirred for 12 hours at room temperature. Then, NaBH(OAc) 3 (66.28 mg, 0.313 mmol) was added thereto and was stirred for 1 hour at room temperature. The reaction progress and completion were confirmed using TLC (CH 2 Cl 2 :MeOH=5:1). Upon completion of the reaction, water was added to the reaction mixture and the aqueous layer was extracted with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , filtered and concentrated under reduced pressure. The concentrate was separated by column chromatography (CH 2 Cl 2 :MeOH=10:1) to obtain the titled compound.
[0032] Yield: 52.2%.
[0033] 1 H NMR (300 MHz, CDCl 3 ) δ 7.27 (m, 2H), 6.82-6.95 (m, 3H), 6.17 (s, 1H), 4.56 (brs, 1H), 4.01 (s, 2H), 3.17 (t, J=4.8 Hz, 4H), 3.03 (t, J=5.8 Hz, 2H), 2.53-2.57 (m, 5H), 2.61 (t, J=4.8 Hz, 4H).
[0034] The compounds of the following examples were prepared using the same method as in Example 1 from the corresponding piperazinylamines and pyrazolealdehydes. The following Table 1 illustrates the corresponding piperazinylamines and pyrazolealdehydes used in Examples 2 to 106.
TABLE 1 Example piperazinylamine pyrazole carbaldehyde 1 4-phenylpiperazin-1- 5-methylpyrazole-3-carbaldehyde ylethylamine 2 same as above 5-methyl-1-phenylpyrazole-3-carbaldehyde 3 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 4 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 5 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 6 same as above 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 7 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 8 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 9 same as above 1,5-diphenylpyrazole-3-carbaldehyde 10 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 11 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 12 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 13 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 14 4-(2,3- 5-methyl-1-phenylpyrazole-3-carbaldehyde dimethylphenyl)piperazin- 1-ylethylamine 15 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 16 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 17 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 18 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 19 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 20 same as above 1,5-diphenylpyrazole-3-carbaldehyde 21 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 22 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 23 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 24 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 25 4-(2,4- 5-methyl-1-phenylpyrazole-3-carbaldehyde dimethylphenyl)piperazin- 1-ylethylamine 26 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 27 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 28 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 29 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 30 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 31 same as above 1,5-diphenylpyrazole-3-carbaldehyde 32 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 33 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 34 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 35 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 36 4-(4- 5-methylpyrazole-3-carbaldehyde methoxyphenyl)piperazin- 1-ylethylamine 37 same as above 5-methyl-1-phenylpyrazole-3-carbaldehyde 38 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 39 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 40 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 41 same as above 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 42 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 43 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 44 same as above 1,5-diphenylpyrazole-3-carbaldehyde 45 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 46 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 47 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 48 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 49 4-(4-nitrophenyl)piperazin- 5-methyl-1-phenylpyrazole-3-carbaldehyde 1-yl ethylamine 50 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 51 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 52 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 53 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 54 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 55 same as above 1,5-diphenylpyrazole-3-carbaldehyde 56 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 57 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 58 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 59 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 60 4-(2- 5-methylpyrazole-3-carbaldehyde fluorophenyl)piperazin-1- ylethylamine 61 same as above 5-methyl-1-phenylpyrazole-3-carbaldehyde 62 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 63 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 64 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 65 same as above 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 66 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 67 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 68 same as above 1,5-diphenylpyrazole-3-carbaldehyde 69 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 70 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 71 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 72 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 73 4-(3- 5-methylpyrazole-3-carbaldehyde chlorophenyl)piperazin-1- ylethylamine 74 same as above 5-methyl-1-phenylpyrazole-3-carbaldehyde 75 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 76 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 77 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 78 same as above 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 79 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 80 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 81 4- 5-methyl-1-phenylpyrazole-3-carbaldehyde diphenylmethylpiperazin- 1-ylethylamine 82 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 83 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 84 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 85 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 86 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 87 same as above 1,5-diphenylpyrazole-3-carbaldehyde 88 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 89 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 90 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 91 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 92 4-(4- 5-methyl-1-phenylpyrazole-3-carbaldehyde chlorobenzhydril)piperazin- 1-ylethylamine 93 same as above 5-propyl-1-t-butylpyrazole-3-carbaldehyde 94 same as above 5-propyl-1-phenylpyrazole-3-carbaldehyde 95 same as above 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde 96 same as above 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde 97 same as above 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde 98 same as above 1,5-diphenylpyrazole-3-carbaldehyde 99 same as above 1-t-butyl-5-(4-methylphenyl)pyrazole-3- carbaldehyde 100 same as above 5-(4-chlorophenyl)-1-t-butylpyrazole-3- carbaldehyde 101 same as above 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3- carbaldehyde 102 same as above 1-phenyl-5-(4-(piperidin-1- yl)phenyl)pyrazole-3-carbaldehyde 103 4-(2,3- 5-methyl-1-phenylpyrazole-3-carbaldehyde dimethylphenyl)piperazin- 1-ylpropylamine 104 ? 1,5-diphenylpyrazole-3-carbaldehyde 105 4- 5-methyl-1-phenylpyrazole-3-carbaldehyde diphenylmethylpiperazin- 1-ylpropylamine 106 same as above 1,5-diphenylpyrazole-3-carbaldehyde
EXAMPLE 2
Synthesis of 5-methyl-1-phenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 2]
[0035] Compound 2 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0036] Yield: 46.9%
[0037] 1 H NMR (300 MHz, CDCl 3 ) δ 7.36-7.56 (m, 5H), 7.25 (m, 2H), 6.78-6.89 (m, 3H), 6.30 (s, 1H), 4.30 (brs, 1H), 4.10 (s, 2H), 2.91-3.23 (m, 12H), 2.74 (m, 3H)
EXAMPLE 3
Synthesis of 1-t-butyl-5-propyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 3]
[0038] Compound 3 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0039] Yield: 64.2%
[0040] 1 H NMR (300 MHz, CDCl 3 ) δ 7.27 (t, J=7.7 Hz, 2H), 6.93 (d, J=8.1 Hz, 2H), 6.86 (t, J=7.2 Hz, 1H), 6.04 (s, 1H), 3.98 (s, 2H), 3.20 (m, 4H), 2.84 (t, J=5.7 Hz, 2H), 2.58-2.70 (m, 6H), 2.54 (t, J=7.7 Hz, 2H), 1.56-1.77 (m, 11H), 0.96 (t, J=7.2 Hz, 3H)
EXAMPLE 4
Synthesis of 5-propyl-1-phenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 4]
[0041] Compound 4 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0042] Yield: 55.6%
[0043] 1 H NMR (300 MHz, CDCl 3 ) δ 7.33-7.52 (m, 6H), 7.26 (m, 2H), 6.88 (m, 2H), 6.35 (s, 1H), 3.91 (s, 2H), 3.20 (m, 4H), 2.87 (m, 2H), 2.71 (m, 4H), 2.54-2.67 (m, 4H), 1.62 (m, 2H), 0.93 (t, J=7.3 Hz, 3H)
EXAMPLE 5
Synthesis of 1-t-butyl-5-iso-butyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 5]
[0044] Compound 5 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0045] Yield: 25.8%
[0046] 1 H NMR (300 MHz, CDCl 3 ) δ 7.27 (t, J=8.0 Hz, 2H), 6.93 (m, 2H), 6.86 (t, J=7.2 Hz, 1H), 6.00 (s, 1H), 3.95 (s, 2H), 3.19 (m, 4H), 2.81 (t, J=5.7 Hz, 2H), 2.54-2.69 (m, 6H), 2.42 (m, 2H), 1.88 (m, 1H), 1.62 (s, 9H), 0.92 (d, J=6.6 Hz, 6H)
EXAMPLE 6
Synthesis of 2-t-butyl-5-isobutyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 6]
[0047] Compound 6 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0048] Yield: 50.1%
[0049] 1 H NMR (300 MHz, CDCl 3 ) δ 7.28 (t, J=7.6 Hz, 2H), 6.93 (m, 2H), 6.87 (t, J=7.1 Hz, 1H), 6.01 (s, 1H), 3.96 (s, 2H), 3.20 (m, 4H), 2.81 (t, J=5.6 Hz, 2H), 2.55-2.69 (m, 6H), 2.44 (d, J=7.1 Hz, 2H), 1.90 (m, 1H), 1.63 (s, 9H), 0.94 (d, J=6.5 Hz, 6H)
EXAMPLE 7
Synthesis of 5-iso-butyl-1-phenyl-3-[2-(4-phenyl piperazin-1-yl)ethyl]aminomethylpyrazole [Compound 7]
[0050] Compound 7 was prepared using the same method as used in Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0051] Yield: 56.2%
[0052] 1 H NMR (300 MHz, CDCl 3 ) δ 7.24-7.44 (m, 5H), 7.16 (m, 2H), 6.79 (m, 3H), 6.10 (s, 1H), 3.81 (s, 2H), 3.09 (m, 4H), 2.77 (t, J=5.6 Hz, 2H), 2.46-2.64 (m, 6H), 2.43 (d, J=7.0 Hz, 2H), 1.75 (m, 1H), 0.79 (d, J=6.3 Hz, 6H)
EXAMPLE 8
Synthesis of 5-(furan-2-yl)-1-phenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 8]
[0053] Compound 8 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0054] Yield: 69.2%
[0055] 1 H NMR (300 MHz, CDCl 3 ) δ 7.34-7.59 (m, 6H), 7.23 (m, 2H), 6.78-6.97 (m, 3H), 6.75 (m, 1H), 6.32 (s, 1H), 6.98 (s, 1H), 3.96 (s, 2H), 3.27 (m, 4H), 3.06 (m, 2H), 2.91 (m, 4H), 2.82 (m, 2H)
EXAMPLE 9
Synthesis of 1,5-diphenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 9]
[0056] Compound 9 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0057] Yield: 78.8%
[0058] 1 H NMR (300 MHz, CDCl 3 ) δ 7.28-7.38 (m, 9H), 7.18-7.26 (m, 3H), 6.81-6.91 (m, 3H), 6.60 (s, 1H), 4.23 (brs, 1H), 4.08 (s, 2H), 3.15 (t, J=4.6 Hz, 4H), 3.01 (t, J=5.9 Hz, 2H), 2.70 (t, J=5.9 Hz, 2H), 2.63 (t, J=4.6 Hz, 4H)
EXAMPLE 10
Synthesis of 1-t-butyl-5-(4-methylphenyl)-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 10]
[0059] Compound 10 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0060] Yield: 80.0%
[0061] 1 H NMR (300 MHz, CDCl 3 ) δ 7.13-7.33 (m, 6H), 6.87 (m, 3H), 6.30 and 6.15 (s, 1H), 4.98 (brs, 1H), 4.24 and 3.95 (s, 2H), 3.27 (m, 2H), 3.17 (m, 4H), 2.91 (m, 4H), 2.66 (m, 2H), 2.39 (s, 3H), 1.41 (s, 9H)
EXAMPLE 11
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 11]
[0062] Compound 11 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0063] Yield: 69.1%
[0064] 1 H NMR (300 MHz, CDCl 3 ) δ 7.15-7.47 (m, 6H), 6.85 (m, 3H), 6.40 and 6.17 (s, 1H), 4.90 (brs, 1H), 4.24 and 3.99 (s, 2H), 2.51-3.38 (m, 12H), 1.41 (s, 9H)
EXAMPLE 12
Synthesis of 5-(4-cyclohexylphenyl)-1-phenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethylpyrazole [Compound 12]
[0065] Compound 12 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3-carbaldehyde were used.
[0066] Yield: 71.2%
[0067] 1 H NMR (300 MHz, CDCl 3 ) δ 7.19-7.40 (m, 7H), 7.06-7.19 (m, 4H), 6.81-7.13 (m, 3H), 6.63 and 6.52 (s, 1H), 4.60 (brs, 1H), 4.17 and 3.91 (s, 2H), 3.04-3.24 (m, 6H), 2.54-2.87 (m, 6H), 2.48 (m, 1H), 1.78 (m, 4H), 1.14-1.49(m, 6H)
EXAMPLE 13
Synthesis of 1-phenyl-3-[2-(4-phenylpiperazin-1-yl)ethyl]aminomethyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 13]
[0068] Compound 13 was prepared using the same method as that of Example 1 except that 4-phenylpiperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidine-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0069] Yield: 58.4%
[0070] 1 H NMR (300 MHz, CDCl 3 ) δ 7.16-7.39 (m, 7H), 7.07 (t, J=7.3 Hz, 2H), 6.74-6.91 (m, 5H), 6.53 and 6.42 (s, 1H), 3.69 and 3.57 (s, 2H), 3.04-3.33 (m, 10H), 2.85 (m, 4H), 2.65 (m, 2H), 1.68 (m, 4H), 1.60 (m, 2H)
EXAMPLE 14
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 14]
[0071] Compound 14 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0072] Yield: 85.6%
[0073] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.53 (m, 5H), 7.06 (t, J=7.6 Hz, 1H), 6.90 (d, J=7.2 Hz, 1H), 6.84 (d, J=7.9 Hz, 1H), 6.35 and 6.32 (s, 1H), 4.06 (s, 1H), 3.00 (t, J=5.9 Hz, 2H), 2.89-2.95 (m, 6H), 2.73 (t, J=6.0 Hz, 4H), 2.64 (m, 3H), 2.41 (s, 3H), 2.20 (s, 3H)
EXAMPLE 15
Synthesis of 1-t-butyl-3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-5-propylpyrazole [Compound 15]
[0074] Compound 15 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0075] Yield: 90.7%
[0076] 1 H NMR (300 MHz, CDCl 3 ) δ 7.10 (t, J=7.7 Hz, 1H), 6.93 (m, 2H), 6.07 (s, 1H), 3.97 (s, 1H), 2.91 (m, 4H), 2.84 (t, J=5.8 Hz, 2H), 2.58-2.71 (m, 6H), 2.56 (t, J=7.8 Hz, 2H), 2.29 (s, 3H), 2.24 (s, 3H), 1.56-1.72 (m, 11H), 0.99 (t, J=7.3 Hz, 3H)
EXAMPLE 16
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 16]
[0077] Compound 16 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0078] Yield: 69.2%
[0079] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.54 (m, 5H), 7.05 (t, J=7.6 Hz, 1H), 6.89 (d, J=7.2 Hz, 1H), 6.81 (d, J=7.9 Hz, 1H), 6.36 (s, 1H), 4.46 (brs, 1H), 4.08 (s, 2H), 3.02 (t, J=5.9 Hz, 2H), 2.83 (m, 4H), 2.74 (t, J=5.9 Hz, 4H), 2.48-2.69 (m, 6H), 2.26 (s, 3H), 2.22 (s, 3H), 1.62 (m, 2H), 0.92 (t, J=7.3 Hz, 3H)
EXAMPLE 17
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 17]
[0080] Compound 17 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0081] Yield: 90.8%
[0082] 1 H NMR (300 MHz, CDCl 3 ) δ 7.10 (t, J=7.7 Hz, 1H), 6.92 (m, 2H), 6.03 (s, 1H), 3.97 (s, 2H), 2.92 (t, J=4.6 Hz, 4H), 2.83 (t, J=5.9 Hz, 2H), 2.56-2.72 (m, 6H), 2.45 (d, J=7.1 Hz, 2H), 2.29 (s, 3H), 2.24 (s, 3H), 1.89 (m, 1H), 1.65 (s, 9H), 0.95 (d, J=6.6 Hz, 6H)
EXAMPLE 18
Synthesis of 5-iso-butyl-3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 18]
[0083] Compound 18 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0084] Yield: 96.5%
[0085] 1 H NMR (300 MHz, CDCl 3 ) δ 7.33-7.52 (m, 5H), 7.06 (t, J=7.7 Hz, 1H), 6.90 (d, J=7.3 Hz, 1H), 6.85 (d, J=7.9 Hz, 1H), 6.28 (s, 1H), 4.01 (s, 2H), 2.95 (t, J=6.0 Hz, 2H), 2.86 (t, J=4.5 Hz, 4H), 2.69 (t, J=6.0 Hz, 2H), 2.62 (m, 4H), 2.51 (d, J=7.1 Hz, 2H), 2.27 (s, 3H), 2.22 (s, 3H), 1.83 (m, 1H), 0.87 (d, J=6.6 Hz, 6H)
EXAMPLE 19
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-5-(furan-2-yl)-1-phenylpyrazole [Compound 19]
[0086] Compound 19 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0087] Yield: 77.9%
[0088] 1 H NMR (300 MHz, CDCl 3 ) δ 7.36-7.52 (m, 6H), 7.07 (t, J=7.7 Hz, 1H), 6.88 (m, 2H), 6.72 and 6.65 (s, 1H), 6.33 (m, 1H), 5.97 (d, J=3.2 Hz, 1H), 3.94 and 3.82 (s, 2H) 3.38 (brs, 1H), 2.95 (t, J=6.1 Hz, 2H), 2.87 (t, J=4.3 Hz, 4H), 2.53-2.75 (m, 6H), 2.27 (s, 3H), 2.21 (s, 3H)
EXAMPLE 20
Synthesis of 3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-1,5-diphenylpyrazole [Compound 20]
[0089] Compound 20 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0090] Yield: 72.9%
[0091] 1 H NMR (300 MHz, CDCl 3 ) δ 7.19-7.37 (m, 10H), 7.05 (t, J=7.7 Hz, 1H), 6.90 (d, J=7.3 Hz, 1H), 6.80 (d, J=7.9 Hz, 1H), 6.68 (s, 1H), 4.16 (s, 2H), 3.08 (t, J=5.9 Hz, 2H), 2.85 (t, J=4.3 Hz, 4H), 2.77 (t, J=5.9 Hz, 2H), 2.66 (m, 4H)
EXAMPLE 21
Synthesis of 1-t-butyl-3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-5-(4-methyl)phenylpyrazole [Compound 21]
[0092] Compound 21 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0093] Yield: 71.1%
[0094] 1 H NMR (300 MHz, CDCl 3 ) δ 7.14-7.25 (m, 5H), 7.07 (t, J=7.8 Hz, 1H), 6.90 (m, 2H), 6.18 and 6.06 (s, 1H), 4.59 (brs, 1H), 4.06 and 3.76 (s, 2H), 3.07 (t, J=5.8 Hz, 2H), 2.89 (m, 4H), 2.77 (t, J=5.8 Hz, 2H), 2.66 (m, 4H), 2.41 (s, 3H), 2.27 (s, 3H), 2.22 (s, 3H), 1.44 (s, 9H)
EXAMPLE 22
Synthesis of 1-t-butyl-3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-5-(4-chlorophenyl)pyrazole [Compound 22]
[0095] Compound 22 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0096] Yield: 77.8%
[0097] 1 H NMR (300 MHz, CDCl 3 ) δ 7.35 (m, 2H), 7.27 (m, 2H), 7.08 (t, J=7.7 Hz, 1H), 6.89 (m, 2H), 6.36 (brs, 1H), 6.23 (s, 1H), 4.12 (s, 2H), 3.11 (m, 2H), 2.89 (m, 4H), 2.81 (m, 2H), 2.67 (m, 4H), 2.27(s, 3H), 2.21 (s, 3H), 1.43 (s, 9H)
EXAMPLE 23
Synthesis of 5-(4-cyclohexyl)phenyl-3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 23]
[0098] Compound 23 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 5-(4-cyclohexyl phenyl)-1-phenylpyrazole-3-carbaldehyde were used.
[0099] Yield: 92.1%
[0100] 1 H NMR (300 MHz, CDCl 3 ) δ 7.26-7.38 (m, 5H), 7.02-7.17 (m, 4H), 6.91 (m, 2H), 6.83 (d, J=7.9 Hz, 1H), 6.55 and 6.34 (s, 1H), 5.04 (brs, 2H), 4.07 and 3.97 (s, 2H), 2.94 (t, J=4.6 Hz, 2H), 2.85 (t, J=4.3 Hz, 2H), 2.55-2.82 (m, 8H), 2.49 (m, 1H), 2.27 (m, 3H), 2.20 (m, 3H), 1.68-1.95 (m, 6H), 1.40 (m, 4H)
EXAMPLE 24
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 24]
[0101] Compound 24 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0102] Yield: 65.2%
[0103] 1 H NMR (300 MHz, CDCl 3 ) δ 7.29-7.38 (m, 5H), 7.01-7.13 (m, 4H), 6.91 (t, J=8.1 Hz, 1H), 6.81 (m, 2H), 6.51 (s, 1H), 4.08 (s, 2H), 3.19 (t, J=5.2 Hz, 4H), 3.03 (t, J=5.9 Hz, 2H), 2.83 (m, 4H), 2.73 (t, J=5.9 Hz, 2H), 2.64 (m, 4H), 2.26 (s, 3H), 2.19 (s, 3H), 1.65-1.77 (m, 6H)
EXAMPLE 25
Synthesis of 3-{2-[4-(2,4-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 25]
[0104] Compound 25 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0105] Yield: 39.3%
[0106] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.58 (m, 5H), 6.91-7.04 (m, 3H), 6.21 (s, 1H), 3.85 (s, 2H), 2.89 (m, 4H), 2.74 (t, J=5.6 Hz, 2H), 2.48-2.66 (m, 6H), 2.34 (s, 3H), 2.27 (s, 6H)
EXAMPLE 26
Synthesis of 1-t-butyl-3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-5-propylpyrazole [Compound 26]
[0107] Compound 26 was obtained using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0108] Yield: 79.4%
[0109] 1 H NMR (300 MHz, CDCl 3 ) δ 6.89-7.05 (m, 3H), 6.06 (s, 1H), 3.97 (s, 2H), 2.91 (t, J=4.2 Hz, 4H), 2.83 (t, J=5.9 Hz, 2H), 2.48-2.67 (m, 6H), 2.28 (s, 6H), 1.64 (s, 9H), 0.98 (t, J=7.3 Hz, 3H)
EXAMPLE 27
Synthesis of 3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 27]
[0110] Compound 27 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0111] Yield: 73.6%
[0112] 1 H NMR (300 MHz, CDCl 3 ) δ 7.33-7.52 (m, 5H), 6.82-7.02 (m, 3H), 6.40 and 6.29 (s, 1H), 4.27 (brs, 1H), 4.18 and 3.89 (s, 2H), 2.64-3.15 (m, 12H), 2.59 (m, 2H), 2.26 (s, 3H), 2.22 (s, 3H), 1.61 (m, 1H), 0.91 (m, 3H)
EXAMPLE 28
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 28]
[0113] Compound 28 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0114] Yield: 98.7%
[0115] 1 H NMR (300 MHz, CDCl 3 ) δ 6.91-7.04 (m, 3H), 6.03 (s, 1H), 3.97 (s, 2H), 2.91 (m, 4H), 2.83 (t, J=5.8 Hz, 2H), 2.55-2.71 (m, 6H), 2.45 (d, J=7.1 Hz, 2H), 2.29 (s, 6H), 1.91 (m, 1H), 1.64 (s, 9H), 0.94 (d, J=9.5 Hz, 6H)
EXAMPLE 29
Synthesis of 5-iso-butyl-3-{2-[4-(2,4-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 29]
[0116] Compound 29 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0117] Yield: 69.2%
[0118] 1 H NMR (300 MHz, CDCl 3 ) δ 7.31-7.52 (m, 5H), 6.86-7.02 (m, 3H), 6.39 and 6.27 (s, 1H), 4.39 (brs, 1H), 4.19 and 3.90 (s, 2H), 3.09 (m, 2H), 2.66-3.02 (m, 8H), 2.62 (m, 2H), 2.50 (m, 2H), 2.26 (s, 3H), 2.21 (s, 3H), 1.80 (m, 1H), 0.85 (m, 6H)
EXAMPLE 30
Synthesis of 3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-5-(furan-2-yl)-1-phenylpyrazole [Compound 30]
[0119] Compound 30 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0120] Yield: 92.2%
[0121] 1 H NMR (300 MHz, CDCl 3 ) δ 7.28-7.51 (m, 6H), 6.90 (m, 3H), 6.76 (s, 1H), 6.30 (m, 1H), 5.97 (d, J=2.9 Hz, 1H), 4.99 (brs, 1H), 3.93 (s, 2H), 2.55-3.42 (m, 12H), 2.25 (s, 3H), 2.18 (s, 3H)
EXAMPLE 31
Synthesis of 3-{2-[4-(2,4-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-1,5-diphenylpyrazole [Compound 31]
[0122] Compound 31 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0123] Yield: 89.1%
[0124] 1 H NMR (300 MHz, CDCl 3 ) δ 7.27-7.38 (m, 8H), 7.23 (m, 2H), 6.97 (t, J=8.3 Hz, 2H), 6.86 (d, J=8.0 Hz, 1H), 6.60 (s, 1H), 4.30 (brs, 1H), 4.07 (s, 2H), 3.00 (t, J=5.9 Hz, 2H), 2.87 (m, 4H), 2.71 (t, J=5.9 Hz, 2H), 2.64 9m, 4H), 2.28 (s, 3H), 2.26 (s, 3H)
EXAMPLE 32
Synthesis of 1-t-butyl-3-{2-[4-(2,4-dimethyl phenyl)piperazin-1-yl]ethyl}aminomethyl-5-(4-methyl)phenylpyrazole [Compound 32]
[0125] Compound 32 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0126] Yield: 67.0%
[0127] 1 H NMR (300 MHz, CDCl 3 ) δ 7.12-7.24 (m, 4H), 6.86-7.03 (m, 3H), 6.25 and 6.10 (s, 1H), 4.75 (brs, 1H), 4.15 and 3.86 (s, 2H), 3.13 (t, J=5.8 Hz, 2H), 2.89 (m, 4H), 2.82 (t, J=5.8 Hz, 2H), 2.65 (m, 4H), 2.42 (s, 3H), 2.27 (s, 3H), 2.25 (s, 3H), 1.43 (s, 9H)
EXAMPLE 33
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]-ethyl}aminomethylpyrazole [Compound 33]
[0128] Compound 33 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butyl pyrazole-3-carbaldehyde were used.
[0129] Yield: 60.3%
[0130] 1 H NMR (300 MHz, CDCl 3 ) δ 7.19-7.43 (m, 4H), 6.85-7.05 (m, 3H), 6.30 and 6.12 (s, 1H), 5.42 (brs, 1H), 4.13 and 3.84 (s, 2H), 2.54-3.18 (m, 12H), 2.26 (m, 6H), 1.42 (s, 9H)
EXAMPLE 34
Synthesis of 5-(4-cyclohexyl phenyl)-3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 34]
[0131] Compound 34 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 5-(4-cyclohexyl phenyl)-1-phenyl pyrazole-3-carbaldehyde were used.
[0132] Yield: 52.8%
[0133] 1 H NMR (300 MHz, CDCl 3 ) δ 7.19-7.37 (m, 5H), 7.03-7.17 (m, 4H), 6.84-7.01 (m, 3H), 6.61 (s, 1H), 5.4 (brs, 1H), 3.93 (s, 2H), 2.68-3.26 (m, 12H), 2.46 (m, 1H), 2.21 (m, 6H), 1.66-1.95 (m, 6H), 1.37 (m, 4H)
EXAMPLE 35
Synthesis of 3-{2-[4-(2,4-dimethylphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 35]
[0134] Compound 35 was prepared using the same method as that of Example 1 except that 4-(2,4-dimethylphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0135] Yield: 56.2%
[0136] 1 H NMR (300 MHz, CDCl 3 ) δ 7.24-7.38 (m, 3H), 7.02-7.13 (m, 3H), 6.87-7.01 (m, 3H), 6.74-6.86 (m, 3H), 6.55 and 6.47 (s, 1H), 4.63 (brs, 1H), 4.13 and 3.91 (s, 2H), 3.18 (m, 4H), 3.05 (m, 2H), 2.83 (m, 4H), 2.76 (m, 2H), 2.63 (m, 4H), 2.27 (s, 3H), 2.24 (s, 3H), 1.54-1.75 (m, 6H)
EXAMPLE 36
Synthesis of 3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-5-methylpyrazole [Compound 36]
[0137] Compound 36 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-15 methylpyrazole-3-carbaldehyde were used.
[0138] Yield: 30.1%
[0139] 1 H NMR (300 MHz, CDCl 3 ) δ 6.76-6.97 (m, 4H), 6.17 (s, 1H), 4.86 (brs, 1H), 3.97 (s, 2H), 3.75 (s, 3H), 2.91-3.15 (m, 6H), 2.55-2.81 (m, 9H)
EXAMPLE 37
Synthesis of 3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 37]
[0140] Compound 37 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-methyl 1-phenylpyrazole-3-carbaldehyde were used.
[0141] Yield: 22.1%
[0142] 1 H NMR (300 MHz, CDCl 3 ) δ 7.53 (d, J=7.2 Hz, 2H), 7.45 (t, J=7.5 Hz, 2H), 7.37 (d, J=7.3 Hz, 1H), 6.83-6.92 (m, 4H), 6.20 (s, 1H), 3.85 (s, 2H), 3.78 (s, 3H), 3.07 (t, J=4.7 Hz, 4H), 2.73 (t, J=5.9 Hz, 2H), 2.52-2.60 (m, 6H), 2.33 (s, 3H)
EXAMPLE 38
Synthesis of 1-t-butyl-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-5-propylpyrazole [Compound 38]
[0143] Compound 38 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0144] Yield: 34.2%
[0145] 1 H NMR (300 MHz, CDCl 3 ) δ 6.83-6.92 (m, 4H), 6.04 (s, 1H), 3.96 (s, 2H), 3.77 (s, 3H), 3.09 (m, 4H), 2.82 (t, J=5.6 Hz, 2H), 2.52-2.62 (m, 6H), 2.45 (m, 2H), 1.41-1.68 (m, 11H), 0.95 (t, J=7.3 Hz, 3H)
EXAMPLE 39
Synthesis of 3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-5-propyl-1-phenylpyrazole [Compound 39]
[0146] Compound 39 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0147] Yield: 41.3%
[0148] 1 H NMR (300 MHz, CDCl 3 ) δ 7.39-7.46 (m, 5H), 6.82-6.85 (m, 4H), 6.24 (s, 1H), 3.04 (m, 4H), 2.91 (t, J=5.6 Hz, 2H), 2.57-2.77 (m, 8H), 1.60 (m, 2H), 0.92 (t, J=7.3 Hz, 3H)
EXAMPLE 40
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 40]
[0149] Compound 40 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0150] Yield: 35.2%
[0151] 1 H NMR (300 MHz, CDCl 3 ) δ 6.55-6.59 (m, 4H), 6.17 (s, 1H), 3.96 (s, 2H), 3.76 (s, 3H), 2.91-3.16 (m, 6H), 2.52-2.78 (m, 8H), 1.98 (m, 1H), 1.60 (s, 9H), 0.98 (d, J=6.3 Hz, 6H)
EXAMPLE 41
Synthesis of 2-t-butyl-5-iso-butyl-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 41]
[0152] Compound 41 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0153] Yield: 29.7%
[0154] 1 H NMR (300 MHz, CDCl 3 ) δ 6.75-6.92 (m, 4H), 6.01 (s, 1H), 3.96 (s, 2H), 3.77 (s, 3H), 3.09 (t, J=4.6 Hz, 4H), 2.81 (t, J=5.8 Hz, 2H), 2.57-2.68 (m, 6H), 2.43 (d, J=7.1 Hz, 2H), 1.89 (m, 1H), 1.62 (s, 9H), 0.93 (d, J=6.6 Hz, 6H)
EXAMPLE 42
Synthesis of 5-iso-butyl-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl pyrazole [Compound 42]
[0155] Compound 42 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0156] Yield: 24.2%
[0157] 1 H NMR (300 MHz, CDCl 3 ) δ 7.30-7.55 (m, 5H), 6.69-6.94 (m, 4H), 6.24 (s, 1H), 3.97 (s, 2H), 3.76 (s, 3H), 3.03 (m, 4H), 2.92 (m, 2H), 2.56-2.77 (m, 6H), 2.50 (d, J=6.9 Hz, 2H), 1.82 (m, 1H), 0.86 (d, J=6.3 Hz, 6H)
EXAMPLE 43
Synthesis of 5-(furan-2-yl)-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl pyrazole [Compound 43]
[0158] Compound 43 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0159] Yield: 74.1%
[0160] 1 H NMR (300 MHz, CDCl 3 ) δ 7.21-7.53 (m, 6H), 6.74-6.91 (m, 4H), 6.72 (s, 1H), 6.30 (m, 1H), 5.95 (m, 1H), 3.99 (s, 2H), 3.82 (s, 3H), 3.71 (m, 4H), 3.11 (m, 4H), 2.85 (m, 2H), 2.76 (m, 2H)
EXAMPLE 44
Synthesis of 3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-1,5-phenylpyrazole [Compound 44]
[0161] Compound 44 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0162] Yield: 47.1%
[0163] 1 H NMR (300 MHz, CDCl 3 ) δ 7.25-7.37 (m, 8H), 7.23 (m, 2H), 6.78-6.87 (m, 4H), 6.60 (s, 1H), 4.09 (s, 2H), 3.77 (s, 3H), 3.01 (m, 6H), 2.70 (t, J=5.8 Hz, 2H), 2.63 (m, 4H)
EXAMPLE 45
Synthesis of 1-t-butyl-5-(4-methylphenyl)-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 45]
[0164] Compound 45 was prepared using the same method as that Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0165] Yield: 95.9%
[0166] 1 H NMR (300 MHz, CDCl 3 ) δ 7.04-7.25 (m, 4H), 6.72-6.94 (m, 4H), 6.45 (s, 1H), 4.07 (s, 2H), 3.69 (s, 3H), 2.53-3.55 (m, 12H), 2.39 (s, 3H), 1.42 (s, 9H)
EXAMPLE 46
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 46]
[0167] Compound 46 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0168] Yield: 86.0%
[0169] 1 H NMR (300 MHz, CDCl 3 ) δ 7.14-7.43 (m, 4H), 6.69-6.94 (m, 4H), 6.14 and 6.06 (s, 1H), 4.20 and 4.07 (s, 2H), 3.74 (s, 3H), 2.45-3.42 (m, 12H), 1.40 (s, 9H)
EXAMPLE 47
Synthesis of 5-(4-cyclohexyl phenyl)-3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl pyrazole [Compound 47]
[0170] Compound 47 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 5-(4-cyclohexylphenyl)-1-phenylpyrazole-3-carbaldehyde were used.
[0171] Yield: 89.1%
[0172] 1 H NMR (300 MHz, CDCl 3 ) δ 7.17-7.41 (m, 5H), 6.96-7.15 (m, 4H), 6.66-6.90 (m, 4H), 6.46 (s, 1H), 4.04 (s, 2H), 3.87 (s, 3H), 2.55-3.40 (m, 12H), 2.46 (m, 1H), 1.64-1.95 (m, 6H), 1.37 (m, 4H)
EXAMPLE 48
Synthesis of 3-{2-[4-(4-methoxyphenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 48]
[0173] Compound 48 was prepared using the same method as that of Example 1 except that 4-(4-methoxyphenyl)piperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0174] Yield: 88.9%
[0175] 1 H NMR (300 MHz, CDCl 3 ) δ 7.17-7.44 (m, 5H), 6.98-7.15 (m, 2H), 6.88-6.69 (m, 6H), 6.59 and 6.46 (s, 1H), 4.89 (brs, 1H), 4.18 and 3.90 (s, 2H), 3.75 (s, 3H), 3.13 (m, 4H), 2.99 (m, 2H), 2.72 (m, 4H), 2.61 (m, 2H), 1.44-1.81 (m, 6H), 1.26 (m, 4H)
EXAMPLE 49
Synthesis of 5-methyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 49]
[0176] Compound 49 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0177] Yield: 59.6%
[0178] 1 H NMR (300 MHz, CDCl 3 ) δ 8.11 (d, J=9.3 Hz, 2H), 7.23-7.56 (m, 5H), 6.76 (m, 2H), 6.28 and 6.20 (s, 1H), 4.04 and 3.84 (s, 2H), 3.34 (m, 4H), 2.97 (m, 2H), 2.70 (t, J=5.6 Hz, 2H), 2.60 (m, 4H), 2.33 (s, 3H)
EXAMPLE 50
Synthesis of 1-t-butyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-5-propylpyrazole [Compound 50]
[0179] Compound 50 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0180] Yield: 95.6%
[0181] 1 H NMR (300 MHz, CDCl 3 ) δ 8.12 (d, J=9.4 Hz, 2H), 6.82 (d, J=9.4 Hz, 2H), 6.02 (s, 1H), 3.95 (s, 2H), 3.42 (t, J=5.0 Hz, 4H), 2.81 (t, J=5.8 Hz, 2H), 2.55-2.66 (m, 6H), 2.53 (m, 2H), 1.54-1.71 (m, 11H), 0.94 (t, J=7.4 Hz, 3H)
EXAMPLE 51
Synthesis of 3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 51]
[0182] Compound 51 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0183] Yield: 78.6%
[0184] 1 H NMR (300 MHz, CDCl 3 ) δ 8.09 (d, J=9.3 Hz, 2H), 7.31-7.55 (m, 5H), 6.76 (d, J=9.4 Hz, 2H), 6.23 (s, 1H), 3.94 (s, 2H), 3.36 (t, J=4.7 Hz, 4H), 2.88 (t, J=5.8 Hz, 4H), 2.47-2.71 (m, 6H), 1.61 (m, 2H), 0.97 (t, J=7.3 Hz, 3H)
EXAMPLE 52
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 52]
[0185] Compound 52 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0186] Yield: 74.5%
[0187] 1 H NMR (300 MHz, CDCl 3 ) δ 8.11 (d, J=9.3 Hz, 2H), 6.81 (d, J=9.3 Hz, 2H), 5.95 (s, 1H), 3.95 (s, 2H), 3.41 (t, J=4.7 Hz, 4H), 2.81 (t, J=5.7 Hz, 2H), 2.54-2.68 (m, 6H), 2.43 (d, J=7.1 Hz, 2H), 1.88 (m, 1H), 1.62 (s, 9H), 0.92 (d, J=6.6 Hz, 6H)
EXAMPLE 53
Synthesis of 5-iso-butyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 53]
[0188] Compound 53 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0189] Yield: 79.3%
[0190] 1 H NMR (300 MHz, CDCl 3 ) δ 8.09 (d, J=9.2 Hz, 2H), 7.33-7.54 (m, 5H), 6.75 (d, J=9.2 Hz, 2H), 6.22 and 6.17 (s, 1H), 3.94 and 3.81 (s, 2H), 3.36 (m, 4H), 2.89 (t, J=5.5 Hz, 2H), 2.54-2.75 (m, 6H), 2.50 (d, J=7.0 Hz, 2H), 1.81 (m, 1H), 0.86 (d, J=6.5 Hz, 6H)
EXAMPLE 54
Synthesis of 5-(furan-2-yl)-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 54]
[0191] Compound 54 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0192] Yield: 93.3%
[0193] 1 H NMR (300 MHz, CDCl 3 ) δ 8.08 (m, 2H), 7.31-7.52 (m, 6H), 6.79 (s, 1H), 6.70 (m, 2H), 6.33 (m, 1H), 6.95 (m, 1H), 4.14 (s, 2H), 3.89 (m, 2H), 3.35 (m, 4H), 2.70 (m, 2H), 2.58 (m, 4H)
EXAMPLE 55
Synthesis of 1,5-diphenyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 55]
[0194] Compound 55 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0195] Yield: 68.5%
[0196] 1 H NMR (300 MHz, CDCl 3 ) δ 8.10 (d, J=9.3 Hz, 2H), 7.25-7.39 (m, 8H), 7.23 (m, 2H), 6.75 (d, J=9.4 Hz, 2H), 6.55 (s, 1H), 4.02 (s, 2H), 3.36 (t, J=4.7 Hz, 4H), 2.95 (t, J=5.8 Hz, 2H), 2.66 (t, J=5.8 Hz, 2H), 2.60 (t, J=4.7 Hz, 4H)
EXAMPLE 56
Synthesis of 1-t-butyl-5-(4-methylphenyl)-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 56]
[0197] Compound 56 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0198] Yield: 69.4%
[0199] 1 H NMR (300 MHz, CDCl 3 ) δ 8.09 (d, J=7.6 Hz, 2H), 7.11-7.24 (m, 4H), 6.76 (d, J=8.2 Hz, 2H), 6.30 and 6.11 (s, 1H), 4.20 and 3.94 (s, 2H), 3.40 (m, 4H), 2.83 (m, 2H), 2.54-2.75 (m, 6H), 2.41 (s, 3H), 1.42 (s, 9H)
EXAMPLE 57
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 57]
[0200] Compound 57 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0201] Yield: 50.4%
[0202] 1 H NMR (300 MHz, CDCl 3 ) δ 8.09 (d, J=8.9 Hz, 2H), 7.37 (m, 2H), 7.26 (m, 2H), 6.78 (d, J=8.9 Hz, 2H), 6.17 and 6.07 (s, 1H), 4.08 and 3.71 (s, 2H), 3.52 (m, 4H), 2.51-3.16 (m, 8H), 1.42 (s, 9H)
EXAMPLE 58
Synthesis of 5-(4-cyclohexylphenyl)-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 58]
[0203] Compound 58 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 5-(4-cyclohexyphenyl)-1-phenylpyrazole-3-carbaldehyde were used.
[0204] Yield: 78.1%
[0205] 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=9.0 Hz, 2H), 7.19-7.42 (m, 5H), 6.99-7.16 (m, 4H), 6.69 (d, J=9.2 Hz, 2H), 6.59 (s, 1H), 4.06 (s, 2H), 3.38 (m, 4H), 2.78-3.15 (m, 4H), 2.69 (m, 4H), 2.47 (m, 1H), 1.65-1.94 (m, 6H), 1.34 (m, 4H)
EXAMPLE 59
Synthesis of 1-phenyl-5-(4-piperidin-1-yl)phenyl-3-{2-[4-(4-nitrophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 59]
[0206] Compound 59 was prepared using the same method as that of Example 1 except that 4-(4-nitrophenyl)piperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0207] Yield: 81.5%
[0208] 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=9.0 Hz, 2H), 7.24-7.43 (m, 5H), 7.05 (d, J=8.5 Hz, 2H), 6.78 (d, J=8.6 Hz, 2H), 6.66 (d, J=9.3 Hz, 2H), 6.55 (s, 1H), 4.06 (s, 2H), 3.36 (m, 4H), 3.06-3.39 (m, 6H), 2.98 (m, 2H), 2.57 (m, 4H), 1.45-1.75 (m, 6H)
EXAMPLE 60
Synthesis of 3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-20 methylpyrazole [Compound 60]
[0209] Compound 60 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-methylpyrazole-3-carbaldehyde were used.
[0210] Yield: 39.4%
[0211] 1 H NMR (300 MHz, CDCl 3 ) δ 7.02-7.10 (m, 2H), 6.86-7.01 (m, 2H), 6.16 (s, 1H), 3.99 (s, 2H), 3.08 (m, 4H), 3.00 (t, J=5.5 Hz, 2H), 2.73 (t, J=6.7 Hz, 4H), 2.58-2.69 (m, 5H)
EXAMPLE 61
Synthesis of 3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 61]
[0212] Compound 61 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0213] Yield: 87.4%
[0214] 1 H NMR (300 MHz, CDCl 3 ) δ 7.52 (m, 2H), 7.44 (m, 2H), 7.36 (d, J=6.5 Hz, 1H), 7.04 (d, J=6.8 Hz, 1H), 6.83-6.99 (m, 3H), 6.19 (s, 1H), 3.83 (s, 2H), 3.06 (m, 4H), 2.70 (m, 2H), 2.41-2.66 (m, 6H), 2.23 (s, 3H)
EXAMPLE 62
Synthesis of 1-t-butyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-propyl pyrazole [Compound 62]
[0215] Compound 62 was prepared using the same method as Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0216] Yield: 76.7%
[0217] 1 H NMR (300 MHz, CDCl 3 ) δ 6.98 (m, 1H), 6.78-6.93 (m, 3H), 5.96 (s, 1H), 3.87 (s, 2H), 3.03 (m, 4H), 2.73 (t, J=5.7 Hz, 2H), 2.48-2.62 (m, 6H), 2.45 (d, J=7.9 Hz, 2H), 1.43-1.65 (m, 11H), 0.88 (t, J=7.3 Hz, 3H)
EXAMPLE 63
Synthesis of 3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 63]
[0218] Compound 63 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0219] Yield: 59.3%
[0220] 1 H NMR (300 MHz, CDCl 3 ) δ 7.25-7.62 (m, 5H), 7.02 (d, J=7.3 Hz, 1H), 6.74-6.99 (m, 3H), 6.28 (s, 1H), 4.15 (brs, 1H), 3.99 (s, 2H), 3.05 (m, 4H), 2.94 (m, 2H), 2.43-2.76 (m, 8H), 1.59 (m, 2H), 0.91 (m, 3H)
EXAMPLE 64
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 64]
[0221] Compound 64 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0222] Yield: 76.7%
[0223] 1 H NMR (300 MHz, CDCl 3 ) δ 7.01-7.09 (m, 2H), 6.87-7.00 (m, 2H), 6.01 (s, 1H), 3.95 (s, 1H), 3.11 (m, 4H), 2.81 (t, J=5.9 Hz, 2H), 2.55-2.68 (m, 6H), 2.44 (d, J=7.1 Hz, 2H), 1.87 (m, 1H), 1.63 (s, 9H), 0.93 (d, J=6.6 Hz, 6H)
EXAMPLE 65
Synthesis of 2-t-butyl-5-iso-butyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 65]
[0224] Compound 65 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0225] Yield: 60.2%
[0226] 1 H NMR (300 MHz, CDCl 3 ) δ 6.83-7.17 (m, 4H), 6.18 (s, 1H), 5.93 (brs, 1H), 3.99 (s, 2H), 3.06 (m, 4H), 2.95 (m, 2H), 2.52-2.83 (m, 8H), 1.97 (m, 1H), 1.57 (s, 9H), 0.95 (m, 6H)
EXAMPLE 66
Synthesis of 5-iso-butyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 66]
[0227] Compound 66 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0228] Yield: 71.8%
[0229] 1 H NMR (300 MHz, CDCl 3 ) δ 7.44 (m, 2H), 7.40 (m, 3H), 7.01 (m, 1H), 6.92 (m, 3H), 6.21 (s, 1H), 3.93 (s, 2H), 3.07 (m, 4H), 2.89 (t, J=6.0 Hz, 2H), 2.58-2.74 (m, 6H), 2.51 (d, J=6.1 Hz, 2H), 1.83 (m, 1H), 0.87 (d, J=6.6 Hz, 6H)
EXAMPLE 67
Synthesis of 3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-(furan-2-yl)-1-phenylpyrazole [Compound 67]
[0230] Compound 67 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0231] Yield: 86.3%
[0232] 1 H NMR (300 MHz, CDCl 3 ) δ 7.41-7.52 (m, 4H), 7.38 (m, 1H), 6.86-7.13 (m, 5H), 6.68 (s, 1H), 6.33 (m, 1H), 5.96 (m, 1H), 3.97 (s, 2H), 3.08 (m, 4H), 2.90 (t, J=5.8 Hz, 2H), 2.51-2.73 (m, 6H)
EXAMPLE 68
Synthesis of 1,5-diphenyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 68]
[0233] Compound 68 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0234] Yield: 74.5%
[0235] 1 H NMR (300 MHz, CDCl 3 ) δ 7.18-7.37 (m, 10H), 6.83-7.08 (m, 4H), 6.59 (s, 1H), 4.49 (brs, 1H), 4.07 (s, 2H), 3.06 (m, 4H), 2.99 (m, 2H), 2.59-2.69 (m, 6H)
EXAMPLE 69
Synthesis of 1-t-butyl-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-(4-methylphenyl)pyrazole [Compound 69]
[0236] Compound 69 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0237] Yield: 89.4%
[0238] 1 H NMR (300 MHz, CDCl 3 ) δ 7.12-7.24 (m, 5H), 6.86-7.09 (m, 5H), 6.19 (s, 1H), 4.31 (brs, 1H), 4.05 (s, 2H), 3.10 (m, 4H), 3.03 (t, J=5.8 Hz, 2H), 2.75 (t, J=5.8 Hz, 2H), 2.67 (m, 4H), 2.40 (s, 3H), 1.43 (s, 9H)
EXAMPLE 70
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 70]
[0239] Compound 70 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0240] Yield: 74.2%
[0241] 1 H NMR (300 MHz, CDCl 3 ) δ 7.35 (d, J=8.2 Hz, 2H), 7.25 (d, J=8.3 Hz, 2H), 7.01-7.12 (m, 2H), 6.87-6.99 (m, 2H), 6.17 (s, 1H), 3.97 (s, 2H), 3.10 (m, 4H), 2.96 (t, J=5.8 Hz, 2H), 2.56-2.79 (m, 6H), 1.43 (s, 9H)
EXAMPLE 71
Synthesis of 5-(4-cyclohexylphenyl)-3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 71]
[0242] Compound 71 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 5-(4-cyclohexylphenyl)-1-phenyl pyrazole-3-carbaldehyde were used.
[0243] Yield: 64.8%
[0244] 1 H NMR (300 MHz, CDCl 3 ) δ 7.24-7.39 (m, 5H), 7.08-7.17 (m, 4H), 7.01-7.07 (m, 2H), 6.83-6.99 (m, 3H), 6.52 and 6.47 (s, 1H), 4.02 and 3.82 (s, 2H), 3.06 (m, 4H), 2.96 (t, J=5.8 Hz, 2H), 2.55-2.80 (m, 6H), 2.48 (m, 1H), 1.68-1.94 (m, 6H), 1.38 (t, J=9.9 Hz, 4H)
EXAMPLE 72
Synthesis of 3-{2-[4-(2-fluorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 72]
[0245] Compound 72 was prepared using the same method as that of Example 1 except that 4-(2-fluorophenyl)piperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0246] Yield: 74.3%
[0247] 1 H NMR (300 MHz, CDCl 3 ) δ 7.28-7.37 (m, 5H), 6.77-7.11 (m, 8H), 6.48 (s, 1H), 4.04 (s, 2H), 3.18 (t, J=5.1 Hz, 4H), 3.05 (m, 4H), 2.98 (t, J=5.9 Hz, 2H), 2.69 (m, 2H), 2.64 (m, 4H), 1.54-1.75 (m, 6H)
EXAMPLE 73
Synthesis of 3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-methylpyrazole [Compound 73]
[0248] Compound 73 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 5-methylpyrazole-3-carbaldehyde were used.
[0249] Yield: 60.4%
[0250] 1 H NMR (300 MHz, CDCl 3 ) δ 7.16 (t, J=8.1 Hz, 1H), 6.73-6.87 (m, 3H), 6.17 (s, 1H), 4.90 (brs, 1H), 3.99 (s, 2H), 3.17 (m, 4H), 3.00 (t, J=5.8 Hz, 2H), 2.73 (m, 4H), 2.60 (m, 2H), 2.04 (2, 3H)
EXAMPLE 74
Synthesis of 3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 74]
[0251] Compound 74 was prepared using the same method as Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0252] Yield: 65.4%
[0253] 1 H NMR (300 MHz, CDCl 3 ) δ 7.49 (m, 3H), 7.39 (m, 2H), 7.12 (t, J=7.8 Hz, 1H), 6.79 (d, J=7.2 Hz, 1H), 6.67 (m, 2H), 6.51 (s, 1H), 4.32 (s, 2H), 3.19 (m, 2H), 3.03 (m, 4H), 2.84 (m, 2H), 2.59 (m, 4H), 2.31 (s, 3H)
EXAMPLE 75
Synthesis of 1-t-butyl-3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-propyl pyrazole [Compound 75]
[0254] Compound 75 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0255] Yield: 76.5%
[0256] 1 H NMR (300 MHz, CDCl 3 ) δ 7.26 (s, 2H), 7.16 (t, J=8.1 Hz, 1H), 6.74-6.92 (m, 3H), 6.03 (s, 1H), 3.18 (t, J=5.0 Hz, 4H), 2.80 (t, J=5.9 Hz, 2H), 2.54-2.64 (m, 6H), 2.52 (m, 2H)
EXAMPLE 76
Synthesis of 3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 76]
[0257] Compound 75 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0258] Yield: 48.5%
[0259] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.53 (m, 5H), 7.15 (t, J=8.1 Hz, 1H), 6.71-6.90 (m, 3H), 6.32 (s, 1H), 3.89 (s, 2H), 3.18 (m, 4H), 2.83 (m, 2H), 2.51-2.74 (m, 8H), 1.65 (m, 2H), 0.94 (t, J=7.4 Hz, 3H)
EXAMPLE 77
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 77]
[0260] Compound 77 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0261] Yield: 77.7%
[0262] 1 H NMR (300 MHz, CDCl 3 ) δ 7.20 (t, J=7.8 Hz, 1H), 6.90 (s, 1H), 6.82 (m, 2H), 6.0 (s, 1H), 3.99 (s, 2H), 3.22 (m, 4H), 2.84 (m, 2H), 2.52-2.74 (m, 6H), 2.46 (d, J=6.9 Hz, 2H), 1.92 (m, 1 HO, 1.65 (s, 9H), 0.96 (d, J=6.3 Hz, 6H)
EXAMPLE 78
Synthesis of 2-t-butyl-5-iso-butyl-3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 78]
[0263] Compound 78 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 2-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0264] Yield: 54.8%
[0265] 1 H NMR (300 MHz, CDCl 3 ) δ 7.16 (t, J=8.1 Hz, 1H), 6.87 (s, 1H), 6.60 (m, 2H), 6.00 (s, 1H), 3.95(s, 2H), 3.18 (m, 4H), 2.80 (t, J=5.7 Hz, 2H), 2.51-2.67 (m, 6H), 2.44 (d, J=7.1 Hz, 2H), 1.90 (m, 1H), 1.63 (s, 9H), 0.93 (d, J=6.6 Hz, 6H)
EXAMPLE 79
Synthesis of 5-iso-butyl-3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 79]
[0266] Compound 79 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0267] Yield: 47.7%
[0268] 1 H NMR (300 MHz, CDCl 3 ) δ 7.31-7.58 (m, 5H), 7.14 (t, J=8.1 Hz, 1H), 6.80 (m, 2H), 6.68-6.78 (m, 2H), 6.21 (s, 1H), 3.94 (s, 2H), 3.12 (m, 4H), 2.89 (t, J=5.7 Hz, 2H), 2.52-2.69 (m, 6H), 2.51 (d, J=7.5 Hz, 2H), 1.82 (m, 1H), 1.26 (s, 9H), 0.87 (d, J=6.6 Hz, 6H)
EXAMPLE 80
Synthesis of 3-{2-[4-(3-chlorophenyl)piperazin-1-yl]ethyl}aminomethyl-5-(furan-2-yl)-1-phenylpyrazole [Compound 80]
[0269] Compound 80 was prepared using the same method as that of Example 1 except that 4-(3-chlorophenyl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0270] Yield: 68.6%
[0271] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.56 (m, 6H), 7.13 (t, J=7.8 Hz, 1H), 6.71-6.90 (m, 3H), 6.67 (s, 1H), 6.33 (m, 1H), 5.97 (m, 1H), 3.99 (s, 2H), 3.13 (m, 4H), 2.90 (m, 2H), 2.48-2.71 (m, 6H)
EXAMPLE 81
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 81]
[0272] Compound 81 was prepared was obtained using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-methyl-1-phenyl pyrazole-3-carbaldehyde were used.
[0273] Yield: 71%
[0274] 1 H NMR (300 MHz, CDCl 3 ) δ 7.33-7.46 (m, 8H), 7.12-7.32 (m, 7H), 6.27 (s, 1H), 4.22 (s, 1H), 3.98 (s, 2H), 2.93 (t, J=6.0 Hz, 2H), 2.64 (t, J=6.0 Hz, 2H), 2.50 (m, 4H), 2.38 (m, 4H), 2.29 (s, 3H)
[0275] 13 C NMR (75 MHz, CDCl 3 ) δ 148.6, 142.7, 140.1, 139.5, 129.0, 128.4, 127.8, 127.7, 126.9, 124.8, 106.4, 76.1, 56.0, 53.2, 51.6, 45.9, 44.6, 12.3
[0276] IR (KBr, cm −1 ) 3356 (—NH), 2924, 2810, 1502, 1452, 1008
[0277] FABHRMS m/z C 30 H 36 N 5 (M+H) + calculated value: 466.2971, measured value: 466.2983
EXAMPLE 82
Synthesis of 1-t-butyl-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-5-propyl pyrazole [Compound 82]
[0278] Compound 82 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0279] Yield: 70%
[0280] 1 H NMR (300 MHz, CDCl 3 ) δ 7.42 (d, J=7.1 Hz, 4H), 7.28 (t, J=7.3 Hz, 4H), 7.18 (t, J=7.3 Hz, 2H), 6.01 (s, 1H), 4.23 (s, 1H), 3.91 (s, 2H), 2.76 (t, J=6.0 Hz, 2H), 2.36-2.59 (m, 12H), 1.52-1.68 (m, 11H), 0.95 (t, J=7.4 Hz, 3H)
[0281] 13 C NMR (75 MHz, CDCl 3 ) δ 149.9, 142.7, 141.6, 128.4, 127.9, 126.9, 105.5, 59.5, 57.7, 53.5, 51.9, 46.7, 46.0, 30.3, 23.0, 14.0 MP=81-81° C.
EXAMPLE 83
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 83]
[0282] Compound 83 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0283] Yield: 69%
[0284] 1 H NMR (300 MHz, CDCl 3 ) δ 7.30-7.47 (m, 8H), 7.22-7.29 (m, 4H), 7.12-7.21 (m, 3H), 6.29 (s, 1H), 4.15 (s, 1H), 4.02(s, 2H), 2.96 (t, J=5.7 Hz, 2H), 2.66 (t, J=5.7 Hz, 2H), 2.25-2.62 (m, 8H), 2.37 (m, 2H), 1.59 (m, 2H), 0.89 (t, J=7.3 Hz, 3H)
[0285] 13 C NMR (75 MHz, CDCl 3 ) δ 147.9, 145.2, 144.5, 142.6, 139.5, 129.0, 128.9, 128.4, 128.0, 127.8, 126.9, 125.3, 104.9, 76.1, 55.6, 53.1, 51.6, 28.2, 22.0, 13.7
[0286] IR (KBr, cm −1 ) 3356 (—NH), 2958, 2810, 1500, 1452, 1010
[0287] FABHRMS m/z C 32 H 40 N 5 (M+H) + Calculated Value: 494.3284, Measured Value: 494.3305
EXAMPLE 84
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 84]
[0288] Compound 84 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0289] Yield: 82%
[0290] 1 H NMR (300 MHz, CDCl 3 ) δ 7.43 (d, J=7.3 Hz, 4H), 7.28 (t, J=7.3 Hz, 4H), 7.18 (t, J=7.3 Hz, 2H), 5.99 (s, 1H), 4.23 (s, 1H), 3.92 (s, 2H), 2.76 (t, J=5.8 Hz, 2H), 2.44-2.57 (m, 12H), 1.86 (m, 1H), 1.61 (s, 9H), 0.92 (d, J=6.6 Hz, 6H)
[0291] 13 C NMR (75 MHz, CDCl 3 ) δ 149.0, 142.7, 141.4, 128.4, 127.9, 126.9, 106.2, 76.2, 59.4, 57.7, 53.5, 51.8, 46.6, 46.0, 37.4, 30.3, 28.8, 22.5
[0292] MP=64-65° C.
EXAMPLE 85
Synthesis of 5-iso-butyl-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 85]
[0293] Compound 85 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0294] Yield: 86%
[0295] 1 H NMR (300 MHz, CDCl 3 ) δ 7.35-7.47 (m, 8H), 7.23-7.32 (m, 5H), 7.12-7.23 (m, 2H), 6.27 (s, 1H), 4.16 (s, 1H), 4.01 (s, 2H), 2.93 (t, J=5.8 Hz, 2H), 2.64 (t, J=5.9 Hz, 4H), 2.37-2.56 (m, 6H), 2.37 (m, 2H), 1.79 (m, 1H), 0.84 (d, J=6.5 Hz, 6H)
[0296] 13 C NMR (75 MHz, CDCl 3 ) δ 148.4, 144.3, 142.6, 139.6, 129.0, 128.9, 128.4, 128.0, 127.8, 126.8, 125.6, 105.4, 76.1, 55.9, 53.1, 51.6, 45.8, 44.5, 35.0, 29.6, 28.3, 22.3
[0297] IR (KBr, cm −1 ) 3386 (—NH), 2956, 2810, 1502, 1452, 1008
[0298] FABHRMS m/z C 33 H 42 N 5 (M+H) + Calculated value: 508.3440, Measured value: 508.3413
EXAMPLE 86
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-5-(2-furyl)-1-phenylpyrazole [Compound 86]
[0299] Compound 86 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0300] Yield: 48%
[0301] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.50 (m, 10H), 7.22-7.31 (m, 5H), 7.19 (s, 1H) 6.67 (m, 1H), 6.32 (m, 1H), 5.94 (m, 1H), 4.18 (s, 2H), 3.99 (s, 2H), 2.90 (m, 2H), 2.26-2.70 (m, 10H)
EXAMPLE 87
Synthesis of 1,5-diphenyl-3-{2-[4-(4-diphenyl methyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 87]
[0302] Compound 87 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0303] Yield: 74%
[0304] 1 H NMR (300 MHz, CDCl 3 ) δ 7.36-7.39 (m, 4H), 7.22-7.35 (m, 12H), 7.14-7.21 (m, 4H), 6.53 (s, 1H), 4.19 (s, 1H), 4.00 (s, 2H), 2.91 (t, J=6.0 Hz, 2H), 2.62 (t, J=6.0 Hz, 2H), 2.51 (m, 4H), 2.41 (m, 4H)
EXAMPLE 88
Synthesis of 1-t-butyl-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-5-(4-methylphenyl)pyrazole [Compound 88]
[0305] Compound 88 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde were used.
[0306] Yield: 27%
[0307] 1 H NMR (300 MHz, CDCl 3 ) δ 7.35-7.48 (m, 4H), 7.20-7.34 (m, 4H), 7.06-7.20 (m, 6H), 6.10 (s, 1H), 4.20 (s, 1H), 3.96 (s, 2H), 2.98 (m, 2H), 2.66 (m, 4H), 2.45-2.59 (m, 6H), 2.41 (s, 3H), 1.40 (s, 9H)
EXAMPLE 89
Synthesis of 1-t-butyl-5-(4-chlorophenyl)-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 89]
[0308] Compound 89 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butylpyrazole-3-carbaldehyde were used.
[0309] Yield: 74%
[0310] 1 H NMR (300 MHz, CDCl 3 ) δ 7.36-7.46 (m, 4H), 7.22-7.35 (m, 7H), 7.13-7.21 (m, 3H), 6.17 (s, 1H), 4.19 (s, 1H), 3.97 (s, 2H), 2.96 (t, J=5.8 Hz, 2H), 2.66 (t, J=5.8 Hz, 2H), 2.28-2.57 (m, 8H), 1.40 (s, 9H)
[0311] 13 C NMR (75 MHz, CDCl 3 ) δ 144.4, 142.6, 134.6, 132.2, 131.5, 128.4, 128.0, 127.8, 126.9, 108.8, 61.3, 55.5, 53.1, 51.7, 45.6, 44.2, 31.1
[0312] IR (KBr, cm −1 ) 3315 (—NH), 2932, 2812, 1450, 1092, 1008, 910
[0313] FABHRMS m/z C 33 H 41 ClN 5 (M+H) + calculated value: 542.3047, measured value: 542.3050
EXAMPLE 90
Synthesis of 5-(4-cyclohexylphenyl)-3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 90]
[0314] Compound 90 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 5-(4-cyclohexyl phenyl)-1-phenylpyrazole-3-carbaldehyde were used.
[0315] Yield: 72%
[0316] 1 H NMR (300 MHz, CDCl 3 ) δ 7.40 (t, J=8.0 Hz, 4H), 7.20-7.30 (m, 9H), 7.18 (d, J=7.1 Hz, 2H), 7.04 (d, J=8.7 Hz, 2H), 6.79 (d, J=8.7 Hz, 2H), 6.46 (s, 1H), 4.25 (s, 1H), 4.04 (s, 2H), 2.66 (t, J=5.9 Hz, 2H), 2.33-2.62 (m, 11H), 1.68 (m, 4H), 1.44-1.63 (m, 6H)
EXAMPLE 91
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidin-1-yl)phenylpyrazole [Compound 91]
[0317] Compound 91 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylethylamine and 1-phenyl-5-(4-(piperidin-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0318] Yield: 83%
[0319] 1 H NMR (300 MHz, CDCl 3 ) δ 7.39 (d, J=7.2 Hz, 4H), 7.22-7.35 (m, 8H), 7.19 (d, J=7.1 Hz, 2H), 7.06-7.14 (m, 5H), 6.50 (s, 1H), 4.18 (s, 1H), 4.01 (s, 2H), 2.93 (t, J=5.6 Hz, 2H), 2.63 (t, J=5.6 Hz, 2H), 2.31-2.59 (m, 8H), 1.71-1.93 (m, 6H), 1.39 (t, J=9.7 Hz, 4H)
EXAMPLE 92
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 92]
[0320] Compound 92 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0321] Yield: 58%
[0322] 1 H NMR (300 MHz, CDCl 3 ) δ 7.71 (m, 1H), 7.54 (m, 1H), 7.41 (d, J=7.4 Hz, 2H), 7.30-7.49 (m, 6H), 7.26 (d, J=6.7 Hz, 2H), 7.21 (d, J=8.8 Hz, 1H), 6.27 (s, 1H), 4.12 (s, 1H), 4.04 (s, 2H), 2.71-2.93 (m, 6H), 2.67 (t, J=5.6 Hz, 2H), 2.49 (m, 4H), 2.30 (s, 3H),
[0323] 13 C NMR (75 MHz, CDCl 3 ) δ 167.7, 142.1, 141.2, 140.4, 139.4, 132.4, 130.9, 129.1, 129.0, 128.8, 128.7, 128.6, 127.7, 127.2, 124.8, 106.5, 75.4, 55.2, 53.0, 51.5, 45.4, 44.2, 12.3
EXAMPLE 93
Synthesis of 1-t-butyl-3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-5-propylpyrazole [Compound 93]
[0324] Compound 93 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-propyl-1-t-butylpyrazole-3-carbaldehyde were used.
[0325] Yield: 86%
[0326] 1 H NMR (300 MHz, CDCl 3 ) δ 7.33-7.41 (m, 4H), 7.16-7.32 (m, 5H), 6.01 (s, 1H), 4.21 (s, 1H), 3.91 (s, 2H), 2.75 (t, J=5.9 Hz, 2H), 2.53 (t, J=7.6 Hz, 4H), 7.31-7.46 (m, 8H), 1.54-1.69 (m, 11H), 0.95 (t, J=7.3 Hz, 3H)
[0327] 13 C NMR (75 MHz, CDCl 3 ) δ 149.9, 142.1, 141.6, 141.3, 132.5, 129.2, 128.6, 128.5, 127.8, 127.1, 105.5, 75.4, 59.5, 57.7, 53.5, 51.8, 46.7, 46.0, 30.4, 30.3, 23.0, 14.0
EXAMPLE 94
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-propylpyrazole [Compound 94]
[0328] Compound 94 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-propyl-1-phenylpyrazole-3-carbaldehyde were used.
[0329] Yield: 95%
[0330] 1 H NMR (300 MHz, CDCl 3 ) δ 7.30-7.45 (m, 8H), 7.13-7.29 (m, 6H), 6.26 (s, 1H), 4.14 (s, 1H), 3.99 (s, 2H), 2.92 (t, J=5.9 Hz, 2H), 2.63 (t, J=5.9 Hz, 2H), 2.56 (t, J=7.7 Hz, 4H), 2.47 (m, 4H), 2.35 (m, 2H), 1.47-1.66 (m, 2H), 0.90 (t, J=7.3 Hz, 3H)
[0331] 13 C NMR (75 MHz, CDCl 3 ) δ 148.6, 145.1, 142.1, 141.3, 139.6, 132.5, 129.1, 129.0, 128.6, 128.5, 127.9, 127.7, 127.1, 125.3, 104.8, 75.4, 56.0, 53.1, 51.6, 46.0, 44.7, 28.2, 22.0, 13.7
[0332] IR (KBr, cm −1 ) 3376 (—NH), 2958, 2928, 2812, 1502, 1010
[0333] FABHRMS m/z C 32 H 39 ClN 5 (M+H) + calculated value: 528.2894, measured value: 528.2895
EXAMPLE 95
Synthesis of 1-t-butyl-5-iso-butyl-3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethylpyrazole [Compound 95]
[0334] Compound 95 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 1-t-butyl-5-iso-butylpyrazole-3-carbaldehyde were used.
[0335] Yield: 68%
[0336] 1 H NMR (300 MHz, CDCl 3 ) δ 7.37 (m, 4H), 7.16-7.34 (m, 5H), 5.98 (s, 1H), 4.21 (s, 1H), 3.91 (s, 2H), 2.75 (t, J=5.6 Hz, 2H), 2.53 (t, J=5.6 Hz, 2H), 2.30-2.49 (m, 10H), 1.85 (m, 1H), 1.61 (s, 9H), 0.91 (d, J=6.5 Hz, 6H)
[0337] 13 C NMR (75 MHz, CDCl 3 ) δ 149.0, 142.1, 141.4, 141.3, 132.5, 129.2, 128.6, 128.5, 127.8, 127.1, 106.2, 75.4, 59.5, 57.7, 53.4, 51.8, 46.6, 46.0, 37.5, 30.3, 28.8, 22.5
EXAMPLE 96
Synthesis of 5-iso-butyl-3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-1-phenylpyrazole [Compound 96]
[0338] Compound 96 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-iso-butyl-1-phenylpyrazole-3-carbaldehyde were used.
[0339] Yield: 95%
[0340] 1 H NMR (300 MHz, CDCl 3 ) δ 7.12-7.51 (m, 14H), 6.28 (s, 1H), 4.19 (s, 1H), 3.86 (s, 2H), 2.90 (m, 4H), 2.77 (m, 4H), 2.35-2.61 (m, 6H), 1.80 (m, 1H), 0.84 (d, J=5.1 Hz, 6H)
[0341] 13 C NMR (75 MHz, CDCl 3 ) δ 149.1, 143.9, 141.6, 140.8, 139.8, 132.6, 128.9, 128.6, 128.6, 127.8, 127.6, 127.2, 125.6, 106.5, 74.9, 54.8, 53.0, 51.5, 50.2, 48.7, 35.1, 28.3, 22.3
EXAMPLE 97
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-5-(2-furyl)-1-phenylpyrazole [Compound 97]
[0342] Compound 97 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 1-phenyl-5-(2-furyl)pyrazole-3-carbaldehyde were used.
[0343] Yield: 62%
[0344] 1 H NMR (300 MHz, CDCl 3 ) δ 7.29-7.44 (m, 10H), 7.26 (d, J=7.9 Hz, 4H), 7.22 (s, 1H), 6.67 (t, J=7.8 Hz, 1H), 6.32 (m, 1H), 5.93 (m, 1H), 4.14 (s, 1H), 4.03 (s, 2H), 2.94 (t, J=5.7 Hz, 2H), 2.65 (t, J=6.0 Hz, 4H), 2.50 (m, 4H), 2.36 (m, 2H)
[0345] 13 C NMR (75 MHz, CDCl 3 ) δ 144.1, 142.6, 142.4, 142.1, 141.3, 139.9, 135.5, 135.0, 132.5, 129.1, 129.0, 129.0, 128.6, 128.6, 127.7, 127.1, 125.7, 125.6, 111.2, 109.0, 105.4, 56.0, 53.1, 51.5, 45.8, 44.6, 29.7
[0346] IR (KBr, cm −1 ) 3276 (—NH), 2926, 2814, 1504, 1010, 910
[0347] FABHRMS m/z C 33 H 35 ClN 5 O (M+H) + Calculated Value: 552.2507, Measured Value: 552.2530
EXAMPLE 98
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-1,5-diphenylpyrazole [Compound 98]
[0348] Compound 98 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0349] Yield: 61%
[0350] 1 H NMR (300 MHz, CDCl 3 ) δ 7.34-7.41 (m, 4H), 7.23-7.33 (m, 10H), 7.14-7.22 (m, 5H), 6.53 (s, 1H), 4.16 (s, 1H), 4.00 (s, 2H), 2.91 (t, J=5.6 Hz, 2H), 2.61 (t, J=5.6 Hz, 2H), 2.49 (m, 4H), 2.38 (m, 4H)
EXAMPLE 99
Synthesis of 1-t-butyl-3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]-ethyl}aminomethyl-5-(4-methylphenyl)pyrazole [Compound 99]
[0351] Compound 99 was prepared using the same method as that of Example 1 except for using 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 1-t-butyl-5-(4-methylphenyl)pyrazole-3-carbaldehyde.
[0352] Yield: 41%
[0353] 1 H NMR (300 MHz, CDCl 3 ) δ 7.32-7.40 (m, 4H), 7.18-7.31 (m, 5H), 7.13 (d, J=5.8 Hz, 2H), 7.08 (d, J=6.3 Hz, 2H), 6.15 (s, 1H), 4.18 (s, 1H), 4.06 (s, 2H), 2.72 (t, J=5.6 Hz, 4H), 2.49 (m, 4H), 2.32-2.45 (m, 7H), 1.38 (s, 9H)
[0354] 13 C NMR (75 MHz, CDCl 3 ) δ 141.9, 141.1, 138.5, 132.6, 130.4, 130.1, 129.1, 128.7, 128.6, 128.5, 128.4, 127.7, 127.2, 108.8, 61.5, 52.8, 51.6, 45.0, 43.5, 31.1, 31.1, 29.7, 21.3
[0355] IR (KBr, cm −1 ) 3356 (—NH), 2924, 2814, 1450, 1010, 912, 806
[0356] FABHRMS m/z C 34 H 44 ClN 5 (M+H) + Calculated Value: 556.3207, Measured Value: 556.3207
EXAMPLE 100
Synthesis of 1-t-butyl-3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-5-(4-chlorophenyl)pyrazole [Compound 100]
[0357] Compound 100 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-(4-chlorophenyl)-1-t-butyl pyrazole-3-carbaldehyde were used.
[0358] Yield: 57%
[0359] 1 H NMR (300 MHz, CDCl 3 ) δ 7.30-7.41 (m, 6H), 7.08-7.29 (m, 8H), 6.22 (s, 1H), 4.18 (s, 1H), 4.05 (s, 2H), 3.03 (t, J=5.6 Hz, 2H), 2.72 (m, 4H), 2.30-2.59 (m, 6H), 1.39 (s, 9H)
[0360] 13 C NMR (75 MHz, CDCl 3 ) δ 142.8, 141.9, 141.1, 134.8, 132.6, 131.9, 131.5, 131.5, 129.1, 128.7, 128.6, 128.1, 128.0, 127.7, 127.2, 109.1, 61.5, 61.0, 54.5, 52.9, 51.6, 45.0, 43.5, 31.1, 29.7
[0361] IR (KBr, cm −1 ) 3386 (—NH), 2928, 2816, 1488, 1092, 912
[0362] FABHRMS m/z C 33 H 40 ClN 5 (M+H) + Calculated Value: 576.2657, Measured Value: 576.2661
EXAMPLE 101
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-5-(4-cyclohexylphenyl)-1-phenylpyrazole [Compound 101]
[0363] Compound 101 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 5-(4-cyclohexyl phenyl)-1-phenyl pyrazole-3-carbaldehyde were used.
[0364] Yield: 31%
[0365] 1 H NMR (300 MHz, CDCl 3 ) δ 7.31-7.39 (m, 6H), 7.11-7.30 (m, 8H), 7.06-7.16 (m, 3H), 7.04 (m, 1H), 6.50 (s, 1H), 4.13 (s, 1H), 4.05 (s, 2H), 2.99 (t, J=5.5 Hz, 2H), 2.66 (t, J=5.4 Hz, 4H), 2.41-2.69 (m, 6H), 2.36 (m, 1H), 1.70-1.94 (m, 6H), 1.39 (t, J=9.7 Hz, 4H)
EXAMPLE 102
Synthesis of 3-{2-[4-(4-chlorobenzhydryl)piperazin-1-yl]ethyl}aminomethyl-1-phenyl-5-(4-piperidine-1-ylphenyl)pyrazole [Compound 102]
[0366] Compound 102 was prepared using the same method as that of Example 1 except that 4-(4-chlorobenzhydryl)piperazin-1-ylethylamine and 1-phenyl-5-(4-piperidine-1-yl)phenyl)pyrazole-3-carbaldehyde were used.
[0367] Yield: 86.2%
[0368] 1 H NMR (300 MHz, CDCl 3 ) δ 7.15-7.40 (m, 14H), 7.00 (m, 2H), 6.76 (m, 2H), 6.47 (s, 1H), 6.01 (brs, 1H), 4.24 (s, 1H), 4.11 (s, 2H), 2.56-2.77 (m, 6H), 2.49 (m, 6H), 2.32 (m, 2H), 1.51-1.74 (m, 6H)
[0369] 13 C NMR (75 MHz, CDCl 3 ) δ 176.2, 170.4, 151.6, 147.4, 144.8, 141.6, 139.9, 129.9, 129.3, 129.0, 129.0, 128.8, 128.7, 128.6, 128.6, 128.5, 127.7, 125.1, 115.2, 106.2, 74.9, 56.4, 54.7, 52.8, 51.5, 50.6, 49.5, 25.6, 24.2
EXAMPLE 103
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 103]
[0370] Compound 103 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylpropylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0371] Yield: 49.0%
[0372] 1 H NMR (300 MHz, CDCl 3 ) δ7.36 (m, 5H), 6.97 (m, 1H), 6.88 (m, 2H), 6.55 (s, 1H), 4.14 (m, 2H), 3.24 (m, 2H), 2.70 (m, 10H), 2.27 (s, 3H), 2.23 (s, 3H), 2.11 (s, 3H), 2.02 (m, 2H)
EXAMPLE 104
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propyl}aminomethyl-1,5-diphenylpyrazole [Compound 104]
[0373] Compound 104 was prepared using the same method as that of Example 1 except that 4-(2,3-dimethylphenyl)piperazin-1-ylpropylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0374] Yield: 43.6%
[0375] 1 H NMR (300 MHz, CDCl 3 ) δ 7.56 (d, J=7.7 Hz, 2H), 7.45 (t, J=7.5 Hz, 2H), 7.35 (t, J=7.0 Hz, 1H), 7.08 (t, J=7.6 Hz, 1H), 6.92 (m, 2H), 6.22 (s, 1H), 3.81 (m, 2H), 2.91 (m, 4H), 2.66 (m, 8H), 2.46 (t, J=6.9 Hz, 2H), 2.27 (s, 3H), 2.22 (s, 3H), 1.69 (m, 4H), 0.96 (t, J=8.3 Hz, 3H)
EXAMPLE 105
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]propyl}aminomethyl-5-methyl-1-phenylpyrazole [Compound 105]
[0376] Compound 105 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylpropylamine and 5-methyl-1-phenylpyrazole-3-carbaldehyde were used.
[0377] Yield: 55.9%
[0378] 1 H NMR (300 MHz, CDCl 3 ) δ 7.36 (m, 6H), 7.28 (m, 2H), 7.21 (m, 4H), 7.15 (m, 3H), 6.44 (s, 1H), 4.06 (s, 2H), 3.95 (s, 2H), 3.13 (m, 2H), 2.54 (m, 4H), 2.31 (m, 4H), 2.02 (m, 2H), 1.93 (m, 2H), 1.24 (s, 3H)
EXAMPLE 106
Synthesis of 3-{2-[4-(4-diphenylmethyl)piperazin-1-yl]propyl}aminomethyl-1,5-diphenylpyrazole [compound 106]
[0379] Compound 106 was prepared using the same method as that of Example 1 except that 4-diphenylmethylpiperazin-1-ylpropylamine and 1,5-diphenylpyrazole-3-carbaldehyde were used.
[0380] Yield: 53.2%
[0381] 1 H NMR (300 MHz, CDCl 3 ) δ 7.51 (m, 2H), 7.41 (m, 6H), 7.26 (m, 4H), 7.18 (m, 3H), 6.19 (s, 1H), 4.20 (s, 1H), 3.78 (s, 2H), 2.65 (m, 4H), 2.39 (m, 8H), 2.05 (m, 2H), 1.71 (m, 4H), 1.01 (m, 3H)
EXAMPLE 107
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}methylaminomethyl-5-methyl-1-phenylpyrazole [Compound 107]
[0382] 3-2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethylaminomethyl-5-methyl-1-phenylpyrazole (30 mg, 0.074 mmol) and formaldehyde (0.06 ml, 0.743 mmol) were dissolved in 5 ml of purified CH 2 Cl 2 and stirred at room temperature for 1 hour. NaBH(OAc) 3 (47.24 mg, 0.223 mmol) was added thereto and stirred for 6 hours at room temperature. The reaction progress and the completion were confirmed using TLC (CH 2 Cl 2 :MeOH=5:1). Upon completion of the reaction, water was added to the reaction mixture and the aqueous layer was extracted with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , filtered and then concentrated under reduced pressure. The concentrate was separated by column chromatography (CH 2 Cl 2 :MeOH=10:1) to obtain the titled compound.
[0383] Yield: 77.4%
[0384] 1 H NMR (300 MHz, CDCl 3 ) δ 7.44 (m, 5H), 7.06 (m, 1H), 6.91 (m, 2H), 6.27 (s, 1H), 3.75 (m, 2H), 2.93 (m, 6H), 2.75 (m, 6H), 2.45 (s, 3H), 2.33 (s, 3H), 2.26 (s, 3H), 2.21 (s, 3H)
EXAMPLE 108
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}methylaminomethyl-1-phenyl-5-propylpyrazole [Compound 108]
[0385] Compound 108 was prepared from 3-2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethylaminomethyl-1-phenyl-5-propylpyrazole using the same method as that of Example 107.
[0386] Yield: 87.2%
[0387] 1 H NMR (300 MHz, CDCl 3 ) δ 7.65 (d, J=7.4 Hz, 2H), 7.45 (t, J=7.2 Hz, 2H), 7.35 (m, 1H), 7.08 (t, J=7.5 Hz, 1H), 6.91 (d, J=7.9 Hz, 2H), 6.20 (s, 1H), 3.53 (s, 2H), 2.91 (m, 4H), 2.59 (m, 10H), 2.28 (s, 6H), 2.19 (s, 3H), 1.73 (m, 2H), 1.00 (m, 3H)
EXAMPLE 109
Synthesis of 3-{2-[4-(2,3-dimethyl phenyl)piperazin-1-yl]ethyl}ethylaminoethyl-5-methyl-1-phenylpyrazole [Compound 109]
[0388] 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminoethyl-5-methyl-1-phenylpyrazole (30 mg, 0.074 mmol) and acetaldehyde (0.04 ml, 0.743 mmol) were dissolved in 5 ml of purified CH 2 Cl 2 and stirred for 1 hour at room temperature. NaBH(OAc) 3 (47.24 mg, 0.223 mmol) was added thereto and stirred for 10 hours at room temperature. The reaction progress and completion was confirmed using TLC (CH 2 Cl 2 :MeOH=5:1). Upon completion of the reaction, water was added to the reaction mixture and the aqueous layer was extracted with CH 2 Cl 2 . The organic layer was dried over anhydrous MgSO 4 , filtered and then was concentrated under reduced pressure. The concentrated solution was separated using column chromatography (CH 2 Cl 2 :MeOH=10:1) to obtain the titled compound.
[0389] Yield: 87.3%
[0390] 1 H NMR (300 MHz, CDCl 3 ) δ 7.44 (m, 5H), 7.07 (m, 1H), 6.91 (m, 2H), 6.33 (s, 1H), 3.92 (s, 2H), 2.93 (m, 6H), 2.82 (m, 4H), 2.73 (m, 4H), 2.34 (s, 3H), 2.27 (s, 3H), 2.21 (s, 3H), 1.23 (t, J=8.5 Hz, 3H)
EXAMPLE 110
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}ethylaminoethyl-1-phenyl-5-propylpyrazole [Compound 110]
[0391] Compound 110 was prepared from 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]ethyl}aminoethyl-1-phenyl-5-propylpyrazole using the same method as that of Example 109.
[0392] Yield: 84.5%
[0393] 1 H NMR (300 MHz, CDCl 3 ) δ 7.63 (d, J=7.2 Hz, 2H), 7.44 (t, J=7.8 Hz, 2H), 7.35 (m, 1H), 7.07 (t, J=7.3 Hz, 1H), 6.90 (d, J=7.6 Hz, 2H), 6.21 (s, 1H), 3.62 (s, 2H), 2.89 (m, 4H), 2.66 (m, 4H), 2.59 (m, 4H), 2.45 (m, 2H), 2.27 (s, 3H), 2.21 (s, 3H), 1.72 (m, 4H), 0.89 (m, 6H)
EXAMPLE 111
Synthesis of 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propyl}ethylaminoethyl-1-phenyl-5-propylpyrazole [Compound 111]
[0394] Compound 111 was prepared from 3-{2-[4-(2,3-dimethylphenyl)piperazin-1-yl]propyl}aminoethyl-1-phenyl-5-propylpyrazole using the same method as that of Example 109.
[0395] Yield: 60.9%
[0396] 1 H NMR (300 MHz, CDCl 3 ) δ 7.45 (m, 5H), 7.07 (t, J=7.7 Hz, 1H), 6.89 (m, 2H), 6.46 (s, 1H), 4.08 (s, 2H), 2.98 (m, 4H), 2.87 (m, 4H), 2.68 (m, 4H), 2.58 (m, 2H), 2.34 (s, 3H), 2.27 (s, 3H), 2.19 (s, 3H), 1.37 (m, 2H), 0.89 (m, 3H)
[0397] The following Table 2 summarizes the substituents according to Example 1 to Example 111 and the corresponding reaction scheme.
TABLE 2 Example n R1 R2 R3 R4 1 1 phenyl hydrogen hydrogen methyl 2 1 phenyl hydrogen 1-phenyl methyl 3 1 phenyl hydrogen 1-t-butyl propyl 4 1 phenyl hydrogen 1-phenyl propyl 5 1 phenyl hydrogen 1-t-butyl iso-butyl 6 1 phenyl hydrogen 2-t-butyl iso-butyl 7 1 phenyl hydrogen 2-t-butyl iso-butyl 8 1 phenyl hydrogen 1-phenyl 2-furyl 9 1 phenyl hydrogen 1-phenyl phenyl 10 1 phenyl hydrogen 1-t-butyl 4-methylphenyl 11 1 phenyl hydrogen 1-t-butyl 4-chlorophenyl 12 1 phenyl hydrogen 1-phenyl 4-cyclohexylphenyl 13 1 phenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 14 1 2,3-dimethylphenyl hydrogen 1-phenyl methyl 15 1 2,3-dimethylphenyl hydrogen 1-t-butyl propyl 16 1 2,3-dimethylphenyl hydrogen 1-phenyl propyl 17 1 2,3-dimethylphenyl hydrogen 1-t-butyl iso-butyl 18 1 2,3-dimethylphenyl hydrogen 1-phenyl iso-butyl 19 1 2,3-dimethylphenyl hydrogen 1-phenyl 2-furyl 20 1 2,3-dimethylphenyl hydrogen 1-phenyl phenyl 21 1 2,3-dimethylphenyl hydrogen 1-t-butyl 4-methylphenyl 22 1 2,3-dimethylphenyl hydrogen 1-t-butyl 4-chlorophenyl 23 1 2,3-dimethylphenyl hydrogen 1-phenyl 4-cyclohexylphenyl 24 1 2,3-dimethylphenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 25 1 2,3-dimethylphenyl hydrogen 1-phenyl methyl 26 1 2,3-dimethylphenyl hydrogen 1-t-butyl propyl 27 1 2,3-dimethylphenyl hydrogen 1-phenyl propyl 28 1 2,3-dimethylphenyl hydrogen 1-t-butyl iso-butyl 29 1 2,3-dimethylphenyl hydrogen 1-phenyl iso-butyl 30 1 2,3-dimethylphenyl hydrogen 1-phenyl 2-furyl 31 1 2,3-dimethylphenyl hydrogen 1-phenyl phenyl 32 1 2,3-dimethylphenyl hydrogen 1-t-butyl 4-methylphenyl 33 1 2,3-dimethylphenyl hydrogen 1-t-butyl 4-chlorophenyl 34 1 2,3-dimethylphenyl hydrogen 1-phenyl 4-cyclohexylphenyl 35 1 2,3-dimethylphenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 36 1 4-methoxyphenyl hydrogen hydrogen methyl 37 1 4-methoxyphenyl hydrogen 1-phenyl methyl 38 1 4-methoxyphenyl hydrogen 1-t-butyl propyl 39 1 4-methoxyphenyl hydrogen 1-phenyl propyl 40 1 4-methoxyphenyl hydrogen 1-t-butyl iso-butyl 41 1 4-methoxyphenyl hydrogen 2-t-butyl iso-butyl 42 1 4-methoxyphenyl hydrogen 1-phenyl iso-butyl 43 1 4-methoxyphenyl hydrogen 1-phenyl 2-furyl 44 1 4-methoxyphenyl hydrogen 1-phenyl phenyl 45 1 4-methoxyphenyl hydrogen 1-t-butyl 4-methylphenyl 46 1 4-methoxyphenyl hydrogen 1-t-butyl 4-chlorophenyl 47 1 4-methoxyphenyl hydrogen 1-phenyl 4-cyclohexylphenyl 48 1 4-methoxyphenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 49 1 4-nitrophenyl hydrogen 1-phenyl methyl 50 1 4-nitrophenyl hydrogen 1-t-butyl propyl 51 1 4-nitrophenyl hydrogen 1~phenyl propyl 52 1 4-nitrophenyl hydrogen 1-t-butyl iso-butyl 53 1 4-nitrophenyl hydrogen 1-phenyl iso-butyl 54 1 4-nitrophenyl hydrogen 1-phenyl 2-furyl 55 1 4-nitrophenyl hydrogen 1-phenyl phenyl 56 1 4-nitrophenyl hydrogen 1-t-butyl 4-methylphenyl 57 1 4-nitrophenyl hydrogen 1-t-butyl 4-chlorophenyl 58 1 4-nitrophenyl hydrogen 1-phenyl 4-cyclohexylphenyl 59 1 4-nitrophenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 60 1 2-flurophenyl hydrogen hydrogen methyl 61 1 2-flurophenyl hydrogen 1-phenyl methyl 62 1 2-flurophenyl hydrogen 1-t-butyl propyl 63 1 2-flurophenyl hydrogen 1-phenyl propyl 64 1 2-flurophenyl hydrogen 1-t-butyl iso-butyl 65 1 2-flurophenyl hydrogen 2-t-butyl iso-butyl 66 1 2-flurophenyl hydrogen 1-phenyl iso-butyl 67 1 2-flurophenyl hydrogen 1-phenyl 2-furyl 68 1 2-flurophenyl hydrogen 1-phenyl phenyl 69 1 2-flurophenyl hydrogen 1-t-butyl 4-methylphenyl 70 1 2-flurophenyl hydrogen 1-t-butyl 4-chlorophenyl 71 1 2-flurophenyl hydrogen 1-phenyl 4-cyclohexylphenyl 72 1 2-flurophenyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 73 1 3-chlorophenyl hydrogen hydrogen methyl 74 1 3-chlorophenyl hydrogen 1-phenyl methyl 75 1 3-chlorophenyl hydrogen 1-t-butyl propyl 76 1 3-chlorophenyl hydrogen 1-phenyl propyl 77 1 3-chlorophenyl hydrogen 1-t-butyl iso-butyl 78 1 3-chlorophenyl hydrogen 2-t-butyl iso-butyl 79 1 3-chlorophenyl hydrogen 1-phenyl iso-butyl 80 1 3-chlorophenyl hydrogen 1-phenyl 2-furyl 81 1 diphenylmethyl hydrogen 1-phenyl methyl 82 1 diphenylmethyl hydrogen 1-t-butyl propyl 83 1 diphenylmethyl hydrogen 1-phenyl propyl 84 1 diphenylmethyl hydrogen 1-t-butyl iso-butyl 85 1 diphenylmethyl hydrogen 1-phenyl iso-butyl 86 1 diphenylmethyl hydrogen 1-phenyl 2-furyl 87 1 diphenylmethyl hydrogen 1-phenyl phenyl 88 1 diphenylmethyl hydrogen 1-t-butyl 4-methylphenyl 89 1 diphenylmethyl hydrogen 1-t-butyl 4-chlorophenyl 90 1 diphenylmethyl hydrogen 1-phenyl 4-cyclohexylphenyl 91 1 diphenylmethyl hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 92 1 4-chlorobenzhydril hydrogen 1-phenyl methyl 93 1 4-chlorobenzhydril hydrogen 1-t-butyl propyl 94 1 4-chlorobenzhydril hydrogen 1-phenyl propyl 95 1 4-chlorobenzhydril hydrogen 1-t-butyl iso-butyl 96 1 4-chlorobenzhydril hydrogen 1-phenyl iso-butyl 97 1 4-chlorobenzhydril hydrogen 1-phenyl 2-furyl 98 1 4-chlorobenzhydril hydrogen 1-phenyl phenyl 99 1 4-chlorobenzhydril hydrogen 1-t-butyl 4-methylphenyl 100 1 4-chlorobenzhydril hydrogen 1-t-butyl 4-chlorophenyl 101 1 4-chlorobenzhydril hydrogen 1-phenyl 4-cyclohexylphenyl 102 1 4-chlorobenzhydril hydrogen 1-phenyl 4-(piperidine-1- yl)phenyl 103 2 2,3-dimethylphenyl hydrogen 1-phenyl methyl 104 2 2,3-dimethylphenyl hydrogen 1-phenyl phenyl 105 2 diphenylmethyl hydrogen 1-phenyl methyl 106 2 diphenylmethyl hydrogen 1-phenyl phenyl
[0398] Example n R1 R2 R3 R4 107 1 2,3-dimethylphenyl methyl 1-phenyl methyl 108 1 2,3-dimethylphenyl methyl 1-phenyl propyl 109 1 2,3-dimethylphenyl ethyl 1-phenyl methyl 110 1 2,3-dimethylphenyl ethyl 1-phenyl propyl 111 2 2,3-dimethylphenyl ethyl 1-phenyl propyl
Evaluation of Pharmacological Effects
[0399] In order to evaluate the pharmaceutical effects induced by the compounds of the present invention, the inhibitory effects were examined according to the following procedure. As the first step, those that show more than 50% of inhibition to the calcium channel (α 1H ) expressed in Xenopus oocytes were screened. For the second step, α 1G Ca 2+ channel activities expressed in HEK 293 cells were measured to determine the effective inhibition concentration IC 50 .
[0000] Measurement of T-Type Ca 2+ Channel Blocking Activity of HEK293 Cells by Using Electrophysiological Method
[0400] The culture medium was prepared by adding 10% fetal bovine serum (FBS) and 1% penicillin/streptomycin (v/v) to Dulbecco's modified Eagle's medium (DMEM). The cells were cultured in an incubator having a wet condition of 95% air/5% CO 2 at 37° C. The medium was replaced every 3 to 4 days and the cells were sub-cultured every week such that only the cells that expressed α 1G T-type Ca 2+ channels could be grown using G-418 (0.5 mg/ml) solution. The cells that were used to measure T-type Ca 2+ channel activity were incubated on a cover slip coated by poly-L-lysine (0.5 mg/ml) every time they were sub-cultured and then recorded after 2 to 3 days. T-type Ca 2+ channel currents at the single-cell level were determined by the electrophysiological whole-cells patch clamp technique using EPC-9 amplifier (HEKA, German). Extracellular solution of NaCl 140 mM, CaCl 2 2 mM, HEPES 10 mM (pH 7.4), and intracellular solution of KCl 130 mM, HEPES 10 mM, EGTA 11 mM, MgATP 5 mM (pH 7.4) were used for T-type Ca 2+ channel blocking activity. As the low voltage-activated T-type Ca 2+ channel activity protocol, a fine glass electrode of 3-4 MD resistance containing the above-prepared intracellular solution was inserted into a single cell to become the whole-cell recording mode, followed by fixing the potential of the cell membrane at −100 mV and measuring the inward current of the T-type Ca 2+ channel activity when hypopolarized at −30 mV (50 ms duration) every 15 seconds. Each compound was dissolved in 100% dimethylsulfoxide (DMSO) to prepare 10 mM stock solution, and then the effect of T-type Ca 2+ channel current at 1,000 fold diluted concentration of 10 μM (including 0.1% DMSO) was initially measured before IC 50 values were determined by testing the effects at the concentration range for the IC 50 measurement (in general, 0.1-100 μM). Specifically, cells were treated with each compound along with the extracellular solution until T-type Ca 2+ channel currents were stabilized under whole-cell voltage-clamp conditions and the inhibition level of the peak current due to the compound was calculated and expressed in percentage. From these results the effective inhibition concentration was determined, and the results thereof are shown in the following Table 3.
TABLE 3 % Inhibition in % Inhibition in compound oocyte (100 μM) HEK293 (10 μM) IC 50 (μM) compound 4 80.14 94.5 ± 2.8 0.30 ± 0.03 compound 7 77.08 87.9 ± 2.7 0.82 ± 0.04 compound 15 27.50 79.4 ± 1.6 1.43 ± 0.15 compound 16 74.60 95.9 ± 0.7 0.58 ± 0.05 compound 18 92.04 92.7 ± 5.7 1.02 ± 0.10 compound 37 — 53.0 ± 1.6 9.41 ± 0.55 compound 39 67.83 91.6 ± 0.5 0.90 ± 0.07 compound 42 73.34 95.6 ± 1.8 1.04 ± 0.15 compound 51 51.27 95.3 ± 1.4 0.66 ± 0.07 compound 52 56.43 94/1 ± 0.5 1.77 ± 0.20 compound 53 74.44 94.8 ± 1.3 1.06 ± 0.02 compound 63 54.94 93.8 ± 1.4 0.66 ± 0.04 compound 76 44.68 75.8 ± 1.0 0.90 ± 0.09 compound 81 95.42 97.4 ± 1.3 0.57 ± 0.06 compound 82 24.76 60.5 ± 0.6 4.42 ± 0.89 compound 83 97.81 92.4 ± 1.8 0.30 ± 0.04 compound 84 40.35 89.9 ± 0.3 2.19 ± 0.03 compound 92 34.52 79.2 ± 3.3 0.33 ± 0.66 compound 94 92.93 100 0.65 ± 0.03 Mibefradil 86.0 — 0.84
[0401] As shown in the above results of the experiments, the compounds of present invention as represented by Formula 1 has an inhibitory effect of T-type Ca 2+ channel, and particularly Compounds 4, 7, 16, 51, 63, 81, 83, 92, 94 were shown to have inhibitory effect of T-type Ca 2+ channel similar to or stronger than that of mibefradil.
[0402] The present invention provides novel compounds and the preparation method thereof. Since the compounds of the present invention can selectively block T-type Ca 2+ ion channels, they are much more effective in treating pain, high blood pressure and epilepsy than any other conventional drugs.
|
The present invention provides for novel piperazinylalkylpyrazole derivatives, the preparation method thereof and the selective T-type calcium channel blocking activity thereof. Particularly, it provides a piperazinylalkylpyrazole derivative as represented by the formula set forth below or its pharmaceutically acceptable salts, and its preparation method thereof.
The compound of Formula 1 is a novel piperazinylalkylpyrazole derivative, which particulary has T-type Ca 2+ channel blocking effect and thus can be useful as a therapeutic agent for nerve and muscle pain.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to automatic inflators for inflatable articles such as life rafts, life vests, and the like. More particularly, this invention relates to inflators that are actuated automatically upon immersion in water.
2. Description of the Background Art
Presently, there exists many types of inflators designed to inflate inflatable articles such as personal floatation devices (life vests, rings and horseshoes), life rafts, buoys and emergency signaling equipment. Manual inflators typically comprise a body for receiving the neck of a cartridge of compressed gas such as carbon dioxide. A reciprocating piercing pin is disposed within the body of the inflator for piercing the frangible seal of the cartridge to permit compressed gas therein to flow into a manifold assembly of the inflator and then into the article to be inflated. Typically, a manually movable firing lever is operatively connected to the piercing pin such that the piercing pin pierces the frangible seal of the gas cartridge upon jerking of a ball lanyard. U.S. Pat. No. 3,809,288, the disclosure of which is hereby incorporated by reference herein, illustrates one particular embodiment of a manual inflator.
While manual inflators work suitably well, it was quickly learned that in an emergency situation, the person needing the assistance of the inflatable device, such as a downed aviator, injured person, or a man overboard, would fail or be unable to manually activate the inflator. Accordingly, it was realized that a means should be provided for automatically activating the inflator in such an emergency situation.
In response to this realized inadequacy of the prior art manual inflators, water-activated automatic inflators were developed which, when exposed to a fluid such as water, automatically activated the piercing pin of the inflator when immersed in water thereby causing inflation of the inflatable device. Typical water-activated automatic inflators comprise a water activated trigger assembly including a water destructible or dissolvable element, often referred to as a “bobbin”, which retains a spring-loaded actuator pin in a cocked position in alignment with a piercing pin. Upon exposure to water, the “pill” contained within the bobbin immediately starts dissolving and then destructs altogether once it loses sufficient rigidity and therefore the bobbin loses its ability to hold-back the spring-loaded actuator pin in its cocked position. The spring-loaded actuator pin is thus released to forcibly move from its cocked position to an actuated position to strike the piercing pin, either directly or indirectly by means of an intermediate transfer pin. Upon striking the piercing pin, the pin fractures the seal of the cartridge thereby allowing the gas contained therein to flow into the inflatable device to inflate the same. Representative automatic actuators for inflators are disclosed in U.S. Pat. Nos. 3,059,814, 3,091,782, 3,426,942, 3,579,964, 3,702,014, 3,757,371, 3,910,457, 3,997,079, 4,223,805, 4,267,944, 4,260,075, 4,382,231, 4,436,159, 4,513,248, 4,627,823, 5,076,468, 5,601,124, 5,685,455, 5,562,233, 5,370,567, 5,333,756, 4,488,546 and 5,694,986, the disclosures of which are hereby incorporated by reference herein.
While the above referenced automatic inflators operate quite well in inflating inflatable devices in the event of an emergency situation, one major disadvantage to these automatic inflators is the tendency of their bobbins to prematurely destruct in non-emergency situations by exposure of the pill contained therein to excessive humidity. Bobbin pills of various designs and chemical compositions have been used to minimize their susceptibility to humidity. Indeed, the problem of premature and unintentional activation of automatic inflators is so acute that it is not uncommon for the water-destructible bobbins of the automatic inflators to be replaced on a regular basis as part of a periodic maintenance program, particularly when the inflators are employed in humid weather conditions or around water. In this regard, it is noted that each of the prior art water-activated automatic inflators disclosed in the above referenced patents teach a structure which may easily be disassembled to facilitate the replacement of the water destructible bobbin so that the inflator may be periodically maintained by replacing the bobbin. In order to minimize such periodic maintenance, there therefore exists a need for an improved bobbin pill that is less susceptible to humid weather conditions and yet retains its ability to immediately dissolve upon being immersed in water.
Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the inflation art.
Another object of this invention is to provide an improved bobbin pill design for an automatic inflator that is less susceptible to humid weather conditions that may prematurely activate the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design for an automatic inflator that provides sufficient strength to retain the actuator pin in its cocked position and thereby minimize premature activation of the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design for a bobbin of an automatic inflator that comprises at least one surface having an undulating configuration having an increased strength to hold-back the spring-loaded actuator pin and an increased surface area to facilitate dissolving once exposed to water to thereby be less susceptible to humid weather conditions that may otherwise result in the premature activation of the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design for an automatic inflator that comprises a surface having an undulating configuration applied to opposing surfaces of the bobbin pill, with the opposing undulations being aligned with respect to each other to maximize the increased strength to hold-back the spring-loaded actuator pin while still being capable of easily dissolving once exposed to water to thereby be less susceptible to humid weather conditions that may otherwise result in the premature activation of the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design of various shapes such as annular-shaped (flat and dome-configured) with a center hole, disk-shaped without a center hole, cylindrical-shaped, etc. for use with the respective style of automatic inflator, each such pill shape including an undulating surface configuration that increases the strength to hold-back the spring-loaded actuator pin while still being capable of easily dissolving once exposed to water to thereby be less susceptible to humid weather conditions that may otherwise result in the premature activation of the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design for an automatic inflator that comprises non-uniform thickness having an increased strength to hold-back the spring-loaded actuator pin yet still being easily dissolvable once exposed to water to thereby be less susceptible to humid weather conditions that may otherwise result in the premature activation of the automatic inflator in non-emergency situations.
Another object of this invention is to provide an improved bobbin pill design of various shapes such as annular-shaped (flat and dome-configured) with a center hole, disk-shaped without a center hole, cylindrical-shaped, etc. for use with the respective style of automatic inflator, each such shape including a non-uniform thickness that increases the strength to hold-back the spring-loaded actuator pin while still being capable of easily dissolving once exposed to water.
These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be obtained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a more comprehensive understanding of the invention may be obtained by referring to the summary of the invention, and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
The invention is defined by the appended claims with the specific embodiment shown in the attached drawings. For the purposes of summarizing the invention, the invention comprises an improved pill of a bobbin for a water-activated automatic inflator that is less susceptible to humid weather conditions that may otherwise prematurely activate the automatic inflator in non-emergency situations. In one embodiment, the pill of the bobbin of the invention comprises at least one surface having an undulating configuration. The undulating surface configuration increases the strength of the bobbin pill to hold-back the spring-loaded actuator pin and increases the surface area to enhance dissolving once exposed to water. In another embodiment, the pill of the bobbin of the invention comprises a non-uniform thickness that is configured to increase the strength of the bobbin pill to hold-back the spring-loaded actuator pin while still being able to be easily dissolved once exposed to water. The undulating configuration and the non-uniform thickness features of the invention may be both utilized to achieve a bobbin pill having both an undulating surface configuration and a non-uniform thickness.
The pill of the bobbin may comprise various shapes, with each such shape including the undulating surface configuration and/or non-uniform configuration in accordance with the invention, such as annular-shaped with a center hole, disk-shaped without a center hole, cylindrical-shaped, etc. for use with the respective style of automatic inflator. In this manner, it should be appreciated that in accordance with the invention, the undulating surface configuration and/or the non-uniform thickness may be incorporated into virtually all bobbin pills of different shapes and therefore the invention is adaptable to virtually all existing makes and models of water-activated inflators.
The foregoing has outlined rather broadly, the more pertinent and prominent features of the present invention. The detailed description of the invention that follows is offered so that the present contribution to the art may be more fully appreciated. Additional features of the invention will be described hereinafter. These form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other methods and 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 structures 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 succinct understanding of the nature and objects of the invention, reference should be directed to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a longitudinal cross-sectional view of a particular style of an automatic inflator assembly showing the various internal parts and their relative position to one another;
FIG. 1A is a distal plan view of automatic inflator's bobbin assembly having the improved pill of the invention installed therein;
FIG. 1B is a proximal plan view of FIG. 1A;
FIG. 1C is a diametric cross-sectional view of FIG. 1A;
FIG. 2A is a plan view of the first embodiment of the pill design of the invention;
FIG. 2B is an edge view of FIG. 2A showing the first embodiment of the pill design of the invention with the undulating proximal and distal surfaces thereof, with such undulations of the distal and proximal surfaces of the pill being out-of-phase with each other;
FIG. 2C is a cross-sectional view of FIG. 2B along lines 2 C— 2 C;
FIG. 3A is a plan view of the second embodiment of the pill design of the invention;
FIG. 3B is an edge view of FIG. 3A showing the cross-sectional configuration of the second embodiment of the pill design of the invention with the undulating proximal and distal surfaces thereof, with such undulations of the distal and proximal surfaces of the pill being in-phase with each other;
FIG. 3C is a cross-sectional view of FIG. 3B along lines 3 C— 3 C;
FIG. 4A is a plan view of the third embodiment of the pill design of the invention in which the undulations are in a checkerboard or quilted configuration.
FIG. 4B is an edge view of FIG. 4A showing the third embodiment of the pill design of the invention with such checkerboard undulations of the distal and proximal surfaces of the pill being out-of-phase with each other;
FIG. 4C is a cross-sectional view of FIG. 4B along lines 4 C— 4 C;
FIG. 5A is a plan view of the fourth embodiment of the pill design of the invention in which the undulations are positioned concentrically;
FIG. 5B is an edge view of FIG. 5A showing the fourth second embodiment of the pill design of the invention;
FIG. 5C is a cross-sectional view of FIG. 5B along lines 5 C— 5 C showing the concentric undulations of the distal and proximal surfaces of the pill being out-of-phase with each other;
FIG. 6A is a plan view of the fifth embodiment of the pill design of the invention having a non-uniform configuration with a thicker inside edge and a thinner outside edge;
FIG. 6B is an edge view of FIG. 6A showing the fifth embodiment of the pill design of the invention;
FIG. 6C is a cross-sectional view of FIG. 6B along lines 6 C— 6 C showing the frusto-conical cross-sectional configuration of the non-uniform configuration;
FIG. 7A is a plan view of the sixth embodiment of the pill design of the invention having a non-uniform configuration with thicker inside and outside edges and a thinner middle portion;
FIG. 7B is an edge view of FIG. 7A showing the sixth embodiment of the pill design of the invention; and
FIG. 7C is a cross-sectional view of FIG. 7B along lines 7 C— 7 C showing the double frusto-conical cross-sectional configuration of the non-uniform configuration.
Similar reference numerals refer to similar parts throughout the several figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an exemplary automatic inflator 10 as comprising an inflator body 12 , an actuator body assembly 14 , and a cylindrical cap assembly 16 . The inflator body 12 has a longitudinal central bore, generally indicated by numeral 18 , having a proximal end and a distal end and which is sized to receive a piercing pin assembly 20 reciprocatably positioned therein so that a gas-containing cartridge 22 is pierced when the piercing pin assembly 20 is forcibly moved proximally towards the cartridge 22 . The piercing pin assembly 20 comprises a piercing pin 24 having a distal end portion 26 , a sealing gasket 28 , and a small compression spring 30 . A conventional metal insert 32 , having interior threads 34 and gasket 36 , is molded in situ within the upper portion of the inflator body 12 . The gas-containing cartridge 22 is threaded into the metal insert 32 . The gasket 36 assures that the gas-containing cartridge 22 is sealed within the metal insert 32 .
The automatic inflator includes a manual actuator. As seen in FIG. 1, the manual actuator means includes a lever 38 , of generally an L-shape, pivotally mounted to the distal portion of the inflator body 12 by a pivot pin 40 which passes through the inflator body 12 , a hole 42 located in the distal portion of the lever 38 , and a second slot portion 44 of an intermediate transfer pin 46 . The distal end portion 48 of the lever 38 has a cam extension 50 which forcibly engages the distal end 28 of the piercing pin assembly 20 when the lever 38 is pulled, thereby causing the gas-containing cartridge 22 to be pierced. A lanyard handle 52 is connected to the lever 38 .
The pivot pin 40 fixedly secures the actuator body assembly 14 to the inflator body 12 . The actuator body assembly 14 of the invention is generally comprised of an actuator body 54 , an actuator pin 55 , the intermediate transfer pin 46 , a conventional O-ring 56 , and a bobbin assembly 58 . A heavy spring 57 urges the head 55 H of the actuator pin 55 forwardly against the bobbin assembly 58 .
As better shown in FIGS. 1A-1C, the bobbin assembly 58 includes a generally cylindrical design with a center portion with longitudinal fingers 60 positioned parallel to each other and an outside wall portion 62 . An annular-shaped bobbin pill 64 with a center hole 66 is positioned between the outside wall portion 62 and the longitudinal fingers 60 to retain the fingers 60 in their longitudinal position. So long as the longitudinal fingers 60 are retained in their parallel position by the bobbin pill 64 , the tips of them form a seat for receiving the head 55 H of the spring-loaded actuator pin 55 and holding the spring-loaded actuator pin 55 back against the force of the spring 57 in a “cocked” position.
However, once the bobbin pill 64 is dissolved, the longitudinal fingers 60 are allowed to flex radially outwardly under the pressure of the spring-loaded actuator pin 55 . As they flex outwardly, their tips spread apart and no longer form a seat for the head 55 H of the actuator pin 55 , whereupon the actuator pin 55 is urged to move forwardly under the force of the spring 57 to actuate the pierce pin 20 via the transfer pin 46 (i.e., the actuator 10 is automatically “fired”). Thus, it can be appreciated that the bobbin pill 64 must have sufficient strength to hold-back the spring-loaded actuator pin 55 and yet must be dissolvable once exposed to water to allow the fingers 60 to flex radially outwardly and allow the actuator pin 55 to fire.
The first embodiment of the bobbin pill 64 of the invention is illustrated in FIGS. 2 A, 2 B and 2 C. As shown, the opposing distal and proximal surfaces 70 and 72 include undulations 74 with each peak 76 and trough 78 thereof extending radially from the center of the pill 64 . As best shown in FIG. 2B, the undulations 24 are out of phase with respect to each other by 180 degrees such that the peaks 76 and troughs 78 of the proximal surface 72 are respectively aligned with the peaks 76 and troughs 78 of the opposing distal surface 70 (i.e., the opposing peaks 76 and troughs 78 are aligned).
FIGS. 3 A, 3 B, and 3 C illustrate the second embodiment of the bobbin pill 64 of the invention, which is similar in configuration with the first embodiment, but with the undulations 74 of the distal and proximal surfaces 70 and 72 being oriented in-phase with each other (see FIG. 3 B). As such, the troughs 78 of the proximal surface 72 are aligned with the peaks 76 of the distal surface 70 and the peaks 76 of the proximal surface 72 are aligned with the troughs 78 of the distal surface 70 (i.e., the opposing peaks 76 and troughs 78 are not aligned).
The out-of-phase alignment of the undulations 74 on the distal and proximal surfaces 70 and 72 as shown in FIG. 2 is the most preferred. It is believed that the out-of-phase relative orientation provides as much compressive strength as the in-phase orientation of the second embodiment, but increases the rate of dissolving when exposed to water due to the aligned troughs 78 of the undulations 74 .
It is noted that due to the annular configuration of the pill 64 , the width of each of the undulations 74 formed on the surfaces 76 and 78 should narrow from the outside to the inside of the pill 64 , as best shown in the respective embodiments of FIGS. 2A and 3A. In this manner, as best shown in the respective embodiments of FIG. 2C and 3C, the distance between opposing troughs 78 (FIG. 2B) and between the opposing troughs 78 and peaks 76 is the greatest toward the center 66 of the bobbin pill 64 and radially decreases toward the outside of the pill 64 . This results in a frustro-conical cross-sectional configuration (i.e., a non-uniform configuration) that achieves greater compressive strength along the lumen of the pill 60 to better withstand the forces exerted by the fingers 60 of the bobbin assembly 58 .
FIGS. 4 A, 4 B, and 4 C illustrate the third embodiment of the bobbin pill 64 of the invention with the undulations 74 of the distal and proximal surfaces 70 and 72 being formed in a checkerboard configuration. As shown in FIG. 4C, the pill 64 comprises a non-uniform configuration 65 including a frustro-conical cross-sectional configuration. As noted above, this achieves greater compressive strength along the lumen of the pill 60 to better withstand the forces exerted by the fingers 60 of the bobbin assembly 58 . It is noted that although shown oriented out-of-phase with each other (see FIG. 4 B), the undulations 74 may be aligned to be in-phase similar to the in-phase alignment of the undulations 74 of FIG. 3 .
FIGS. 5 A, 5 B, and 5 C illustrate the fourth embodiment of the bobbin pill 64 of the invention with the undulations 74 of the distal and proximal surfaces 70 and 72 being oriented concentrically instead of radially as shown in FIGS. 3 and 4. The concentric undulations may be aligned to be out-of-phase as shown in FIG. 5C or in-phase (not shown).
FIGS. 6 A, 6 B, and 6 C illustrate the fifth embodiment of the bobbin pill 64 of the invention having a non-uniform configuration. More specifically, as best shown in FIG. 6C, bobbin pill 64 has a generally non-uniform cross-sectional configuration having a thinner outer edge 64 OE with a step 64 S and a thicker inner edge 64 IE that defines a generally frustro-conical cross-sectional configuration, preferably formed at a 10 degree angle. As such, the increased thickness of the pill 60 along the inside edge 64 IE that engages the fingers 60 of the bobbin assembly 58 significantly increases the ability to withstand the compressive forces thereof caused by the actuator pin 55 and spring 97 .
FIGS. 7 A, 7 B, and 7 C illustrate the sixth embodiment of the bobbin pill 64 of the invention having another non-uniform configuration similar to that of the fourth embodiment but with a double frustro-conical cross-sectional configuration. More specifically, referring to FIG. 7C, the double frustro-conical cross-sectional configuration includes thicker outer and inner edges 64 OE & 64 IE and a thinner middle portion 64 M thereby defining the double frustro-conical cross-sectional configuration. As such, the reduced thickness of the pill 64 along its middle portion assures that it will easily dissolve when immersed in water.
The foregoing detailed description has been principally directed to pills for bobbins used in automatic inflators manufactured by the assignee of this invention. However, it should be appreciated that without departing from the spirit and scope of this invention, the above-described undulations and non-uniform configurations may be applied to pills of other designs (e.g., disk-shaped without a center hole, cylindrical-shaped, etc.) of other makes or models of inflators manufactured by third parties. For example, inflators manufactured by Bernhardt Apparatebau GmbH in accordance with U.S. Pat. Nos. 5,685,455, 5,562,233, 5,370,567, 5,333,756, 4,488,546, the disclosures of which are hereby incorporated by reference herein, typically utilize a disk-shaped pill that could be, in accordance with the present invention, adapted to include the undulations and/or non-uniform configurations described herein.
The chemical composition of the pill 64 is typically composed of microcrystalline cellulose that is compressed into the desired configurations. This composition is selected for its characteristics of being resistant to moisture from humid weather conditions while maximizing compressive strength. The method of compressing the powder into the pill 64 often produces an outer surface that resembles a thin skin that enhances the pill's 64 resistance to humid weather conditions. Indeed, chemical additives may be combined with the cellulose powder to enhance the pill's 64 resistance to humidity and increase its compressed forces.
The present invention includes that contained in the appended claims as well as that of the foregoing description. Although this description has been described in its preferred form with a certain degree of particularity, it should be understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, combination, or arrangement of parts thereof may be resorted to without departing from the spirit and scope of the invention.
Now that the invention has been described,
|
A pill for insertion into a bobbin of a bobbin assembly of an automatic inflator, the pill including a distal surface and a proximal surface, at least one of the surfaces including an undulating configuration.
| 1
|
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention generally relates to hand held log splitters. More particularly, the present invention relates to telescoping log splitters of the type that impact and split wood (or other workpiece) by repeated upward and downward movements. Prior art patents relating to the subject matter can be found in U.S. Class 173, subclasses 90 and 91 and U.S. Class 144, subclass 193C.
II. Description of the Prior Art
It is well recognized by those skilled in the art that the best firewood results from logs that have been broken up or split. Usually logs to be burned in home fire places or wood-burning stoves is quartered into convenient sections. Although relatively larger logs can be used with modern wood burning stoves, they are easier to move and store if split or quartered. Accordingly it has long been recognized in the art that devices for splitting logs or portions of logs are advantageous.
While the prior art reflects various forms of powered devices for splitting wood, it is highly advantageous from a price and convenience standpoint to provide a completely manual device. The prior art reflects a number of arrangements where one or more pieces are fitted coaxially together so that a single operator can reciprocate them relative to each other. As one coaxial portion is reciprocated upwardly and downwardly, a weight associated with the apparatus forcibly impacts a lower tool which engages the log.
A sliding log splitter device as seen in U.S. Pat. No. 4,308,903. This log splitter includes a wedge shaped tool which impacts the log. The tool is attached to an upwardly extending rod received coaxially within the body of a reciprocating device. Weights within the top of the body ultimately make impact to provide a driving effect.
A similar reciprocal, hand held log splitter is seen in Meacham, U.S. Pat. No. 4,280,540. Nokes, U.S. Pat. No. 4,254,808, discloses a reciprocating device which is impacted by a hammer. Another reciprocating device is U.S. Pat. No. 4,327,787 wherein an outer pipe can be moved upwardly and downwardly over an inner shaft by a handle and various impact tools can be interchanged.
U.S. Pat. No. 3,519,087 shows a reciprocating device in which the rod projects outwardly coaxially from the outer sleeve and weights are disposed on the top. By reciprocating a device the weights impact the load to provide a driving function as generally described above.
U.S. Pat. No. 5,042,591 discloses a reciprocating fence post installer. It includes a central body adapted to be generally coaxially disposed over the post, and an impact mechanism having a handle which is reciprocated upwardly and downwardly relative to the body.
A stake driver in which reciprocal movement is employed is also seen in U.S. Pat. No. 5,085,281. Similar "slide" hammer stake driving devices are seen in U.S. Pat. Nos. 4,101,088, 5,042,591 and 5,085,281.
However "slide hammers" of this character can be very difficult to control. The point of impact must be carefully controlled for stability. Moreover, an acceptable device must be easily switched between transportation and use modes for safety. Further, it is important that the weight transferring mechanism be properly centered so that all of the implement components are carefully maintained in proper coaxial relationship. The latter construction can prevent twisting or binding forces from interfering with the smooth operation of the tool.
SUMMARY OF THE INVENTION
My hand-operated device can easily split wood or logs, and it can be used with interchangeable tools for a variety of other purposes.
In the best mode, my invention is used as a log splitter. The splitter comprises an outer, elongated sleeve equipped with handles for gripping by a user. A rigid, elongated tool control shaft is coaxially received within the sleeve. The sleeve and the shaft are telescopingly extended and retracted in use. A selected cutting tool such as a wedge or the like is removably coupled to the shaft emanating from the sleeve. The selected tool is manually placed in engagement with the workpiece, and thereafter pounded into the target as the sleeve vigorously hammers the shaft downwardly.
The rigid outer sleeve includes an internal weight coaxially disposed at its top. This weight periodically impacts the top of the shaft when the sleeve is forcibly drawn downwardly. Smooth operation of the shaft and sleeve is insured by critical alignment guides disposed within an annulus between the shaft and the sleeve.
My guide construction minimize twisting and binding forces to prevent jamming. An upper guide is coaxially secured to the top of the control shaft. The upper guide slides within the annulus as the sleeve slides relative to the shaft. A lower guide coaxially secured to the sleeve bottom is coaxially penetrated by the shaft. The upper and lower guides contact one another when the sleeve and shaft are maximally telescoped apart. The guides thus prevent the parts from separating when the sleeve is lifted as high as possible. An easy to use locking system temporarily secures the splitter in a retracted position ideal for transportation.
I have provided various tools for use with different workpieces. Any selected tool can be quick coupled to the control shaft through a quick release collar system. Separate tools are provided for splitting hard woods and softer wood or pines. Tools for cutting roots and for breaking up pavement are also disclosed. Each tool terminates in an upper nut that mates with a threaded stub projecting from the control shaft. A jam nut and lock washer are frictionally tightened against the upper nut to at least temporarily fasten the chosen tool. With a simple wrench the operator can quickly change between the desired tool.
Thus a primary object of my invention is to provide a highly stable and safe slide hammer for splitting logs and the like.
Another fundamental object of my invention is to provide a safe slide hammer for splitting logs.
Another object is to provide a slide hammer of the character described which can be disposed safely between transportation and usage positions or orientations.
Another object is to provide a highly reliable slide hammer in which the coaxial relationship of working parts is smoothly maintained.
Thus another object is to provide a slide hammer device of the character described which is inherently stable and easy to hold.
Another object is to provide a slide hammer of the character described which resists bending and binding.
Therefore another object is to minimize service requirements.
A further object is to provide a wood splitter that can be conveniently used by one person.
Another important object is to provide a manually operated wood splitter that telescopically extends or retracts without jamming.
Another object is to provide a slide hammer device of the character described that can employed with a variety of different tools for different purposes.
Another basic object is to provide a log splitting device that can be safely used and transported by a single workman.
Yet another important object is to provide a log splitter of the character described wherein the stability of all the parts is enhanced and the operator is not forced to assume an unstable or an unsafe position during use.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1 is a pictorial view of my Hand-Held Log Splitter shown with the pieces telescoped apart;
FIG. 2 is a pictorial view similar to FIG. 1, but showing the device disposed in an impact position;
FIG. 3 is an front elevational view of the best mode;
FIG. 4 is a side elevational view taken from a position generally from the left of FIG. 3;
FIG. 5 is a top plan view taken from a position generally above FIG. 3;
FIG. 6 is a bottom plan view taken from a position generally from the underside of FIG. 3;
FIG. 7 is a front elevational view similar to FIG. 3, but showing the pieces telescoped apart, and illustrating an alternative impact tool (i.e., a root cutter);
FIG. 8 is a side elevational view taken generally from the left of FIG. 7;
FIG. 9 is a longitudinal sectional view of the tool taken generally along line 9--9 of FIG. 3, but showing an alternative impact tool;
FIG. 9A is an elevational view taken generally along line 9a--9a of FIG. 9;
FIG. 10 is a longitudinal, sectional view taken generally along line 10--10 of FIG. 7 with moved positions indicated by dashed lines, and showing an alternative impact tool;
FIG. 10a is a side elevational view of an alternative impact tool taken generally along line 10--10 of FIG. 10;
FIG. 11 is a partially exploded isometric view of the best mode with portions broken away or shown in section for clarity;
FIG. 12 is a pictorial view similar to FIGS. 1 and 2, showing an alternative embodiment; and,
FIG. 13 is a side elevational view of the device of FIG. 12.
DETAILED DESCRIPTION
Referring initially now to FIGS. 1 through 6, a preferred embodiment of my Hand-held log splitter been generally designated by the reference numeral 20. Splitter 20 includes a handle 22, to be hereinafter to be described in detail, which can be manually grasped by a typical workman 24 to split wood such as log 26. In the preferred embodiment the implement is reciprocated upwardly and downwardly as respectively indicated the arrows 28 and 29 in FIGS. 1 and 2. In each of its various embodiments the splitter 20 can be removably connected to different tools. In FIGS. 1-6, a rigid, generally wedge shaped tool 30 is illustrated for directly contacting and splitting logs 26. As hereinafter described, other workpiece-engaging tools may be used with my invention, so it is not limited to log splitting.
With additional reference now directed to FIGS. 7-11, my tool comprises a rigid, elongated tool control shaft 40 which is removably, threadably coupled to a selected tool 30. Shaft 40 is coaxially received within an outer, rigid sleeve 46 to which the handle structure 22 is mounted. The top of the sleeve has been designated by the reference numeral 50. The bottom of the sleeve has been designated by the reference numeral 51 (FIGS. 6-9). The bottom 41 of the shaft 40 is threadably coupled to the tool 30 for a quick connection or disconnection as hereinafter described.
Shaft 40 is coaxially, telescopingly mated within outer sleeve 46. When the apparatus is retracted (i.e., FIG. 9) the top 42 of shaft 40 is disposed adjacent sleeve top 50. As best viewed by comparing FIGS. 7-10, for example, the shaft 40 and the sleeve 46 are axially displaceable with respect to one another. The sleeve 46 may be reciprocated upwardly and downwardly relative to the shaft. When the sleeve 46 is driven downwardly to the impact position, as in FIG. 9, the shaft, while telescopingly received within the sleeve, is driven downwardly by impact into the workpiece.
A vent hole 43 disposed within sleeve 46 adjacent weight 60 allows air to be evacuated between the sleeve weight 60 and the shaft top 42 during operation. In the upward stroke, illustrated in FIG. 1, air is drawn into the annulus 68 through the orifice 43. In the downward stroke air is exhausted through the annulus to depressurize the chamber resulting between the coaxially moving parts.
Rigid sleeve 50 preferably comprises an elongated piece of steel pipe. Coaxially fitted within sleeve top 50 is a weight 60 which seals top 50. Weight 60 periodically impacts shaft 40 during tool use, hitting the top 42 of shaft 40 when the sleeve is reciprocated downwardly. As relative coaxial sliding and telescoping movement occurs, alignment is maintained by a pair of guides 64 and 66 (i.e., FIGS. 9-11). The guide structure and arrangement is important to prevent twisting and binding forces from jamming the invention. It is very important that all moving parts be maintained coaxially and truly centered.
Accordingly, an upper guide 64 is coaxially secured to the top 42 of the shaft. Guide 64 moves with the shaft 40 within sleeve 46. The guide substantially coaxially occupies annulus 68 formed between the shaft 40 and the sleeve 46. Upper guide 64 is coaxially slidable within annulus 68 and it travels within the annulus upwardly and downwardly with respect to the sleeve as indicated in FIG. 10.
The second, lower guide 66 is coaxially secured within the sleeve at its bottom 51. Lower guide 66 is coaxially disposed within the annulus 68 between shaft 40 and sleeve body 46. It is coaxially penetrated by the shaft 40. When the sleeve is lifted upwardly (i.e., FIG. 10), guide 64 will contact guide 66, preventing disassociation of the shaft 40 from sleeve 46.
Importantly, locking means 80 can temporarily maintain the implement in a safe transportation position. As best seen in FIG. 11, locking means 80 preferably comprises a generally "L" shaped lever 84 which is twistably operated. Lever 84 includes a handle portion 87 adapted to be grasped by a workman to twist the locking means between secured and loose positions. A threaded, integral shank 89 is mated to the threaded passageway 90 presented by bolt 94 welded to the sleeve. This passageway extends through the bottom 51 of the sleeve and the lower guide 66. An intermediate jam nut 94 is included to lock the apparatus to positively jam the locking mechanism into a locking position during transportation. When the lock 84 is properly secured, the threaded shank 89 frictionally contacts internal shaft 40 to prevent relative telescoping displacement between the sleeve and the shaft. Of course, locking mechanism 80 must be "unlocked" in order to free the device 20 for usage.
In each of the embodiments, the various tools 30, 30A (FIGS. 7, 8), 30B (FIG. 9, 9a) and 30C (FIGS. 10, 10a) are quick coupled to the apparatus. A quick release collar means 100 is preferably employed to interconnect the various tools with the apparatus. Each of the tools 30-30C terminates in an upper nut 102 which receives a threaded stub 103 projecting downwardly from the bottom 41 of shaft 40. Stub 103 is thus threadably received within nut 102 comprising part of the quick release means 100. An intermediate jam nut 104 and lock washer 105 (FIG. 11) are captivated upon stub 103. When installing the various tools, stub 103 is turned tightly into nut 102 whereupon jam nut 104 is tensioned against washer 105 and nut 102, and the chosen tool is permanently affixed.
The preferred log splitting wedge 30 is best seen in FIGS. 1-6. Tool 30 is generally wedge-shaped as revealed in FIGS. 3 and 6, terminating in a sharp lower point 110 adapted to initially engage and split the wood as indicated in FIGS. 1 and 2. The bottom edge 111 (FIGS. 4) is generally flat. The opposite tool sides 112 (FIGS. 4, 6) taper downwardly to sharpened edge 111. A pair of relief slots 114 defined in sides 112 make it easier to withdraw the wedge when it is temporarily jammed within the log or workpiece. Although tool 30 is ideal for splitting wood, I have found that it works with a variety of other items as well. However, it is recommended that the alternative tools 30A-30C be considered as well.
Turning now to FIG. 7 and 8, an alternative tool 30A has a generally wedge-shaped body 115 which terminates in a relatively blunt point 116. Importantly, a notch 117 (FIG. 8) is defined beneath wedge 30A to circumscribe a root or the like, Tool 30A is ideally adapted to cutting tree roots.
Turning to FIGS. 9 and 9A, the cutting wedge 30B is ideal for "softer" targets such as pine. Tool 30B also has a wedge-shaped profile as illustrated in FIG. 9A. However, its lower cutting edge 118 (FIG. 9) is larger and broader the cutting edge 111 (FIG. 4) previously described. I have found tool 30B ideal for breaking up relatively loose, partially disintegrated debris such as old pavement, rotted trees and the like.
Turning to FIGS. 10-10A, alternative tool 30C comprises a relatively heavyweight, pointed hammer having solid body 122 terminating in a relatively short, wedged portion 124. The hammer 30c is ideal for breaking up small portions of asphalt and concrete sidewalks and the like.
The preferred handle 22 comprises a pair of generally "C" shaped members 140 and 141 having horizontal portions 140A and 141A (FIG. 7) adapted to be manually grasped by a user. Workman 24 may simply place his hands within either of the enclosed regions 154, 155 and grip an adjacent handle portions 140A, 141A.
An alternative handle construction 22A is seen in FIG. 13. Here, instead of a single "C" shaped portion, there are three spaced apart portions to receive the hands of the user of different heights. Alternative handle 22A (FIG. 13) includes a pair of parallel, spaced apart vertical rails 160, 161 which are secured to the sleeve 46 by a plurality of spaced apart, horizontal braces 164-167. Three distinct pairs of compartments thus exist; these pairs are respectively designated by the reference numerals 170, 171 and 172 (FIG. 13). Depending upon the orientation of the worker, where he is standing, and the type of object being impacted, a worker will be able to efficiently grasp and control the apparatus.
OPERATION
The device should be locked for safe transportation to the intended location. During transportation it is important that the locking mechanism 80, previously described, be satisfactorily tight. To lock the apparatus, the locking handle 87 is forcibly rotated until the shaft bottom 41 is forcibly jammed with the sleeve to prevent inadvertent dislodging. When arriving at the work site, the lock may be easily opened once the appropriated tool is selected.
Tool selection includes the tools 30, 30A, 30B and 30C, previously described. Normally for splitting wood, wedges 30 or 30B are appropriate. For splitting younger, hardwoods the smaller dimensioned wedge 30 (FIG. 1 and 2) is recommended.
The selected wedge is removed through the quick connect/disconnect collar means 100, described previously. By taking an appropriate wrench, jam nut 104 can be dislodged from frictional engagement with the collar means nut 102 secured to the tool.
Then the operator should orient himself in a safe and convenient orientation. It is important that the operator stand in stable position, and that he use both hands for the job. Once the selected tool engages the workpiece (i.e., wedge 30 starts to engage log 26) tool 30 will become relatively, firmly locked within the workpiece.
As the handle is tightly grasped, the sleeve may be repeatedly moved upwardly and downwardly. Slow, deliberate movement is important. At this time stability is increased because the upper and lower guides cooperate to maintain everything in coaxial alignment as the parts telescopingly extend and retract. As relative displacement between the sleeve and the shaft occur, the shaft 40 slides within the lower guide 66 fixed at the bottom of the sleeve. Similarly, the upper guide 64 secured to the top of the shaft slides within the sleeve interior. To facilitate this movement, grease can be injected through nipple 91. Also, relatively small quantities of lubricating oil be periodically injected through vent hole 43.
Ease of use is enhanced by the fact that the weight 60 is disposed substantially on top of the sleeve, and contacts the top of shaft 40 rather than the bottom. As best viewed in FIG. 2, when the weight impacts the shaft, the point of impact will be adjacent the hands of the user, where the shock forces can be most easily braced and maintained. Further, since the weight point of impact is on top of the apparatus shaft 40, I have found that kinetic energy is more readily transferred since it readily distributes into the workpiece through the construction disclosed. In other words, it is much easier to "hit the sweet spot" and my apparatus does not leave one's hand "ringing" from impact.
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
|
A hand-operated, reciprocating slide hammer device for splitting wood or other workpieces. The splitter comprises an outer, elongated sleeve that internally receives a rigid, elongated tool control shaft. The sleeve is equipped with handles for gripping by a user so it may be first manually lifted upwardly and then forcibly drawn downwardly. An internal weight coaxially disposed at the sleeve top periodically slams the shaft when the sleeve is hammered downwardly. Alternate cutting tools including wedges, a root cutter, and an asphalt hammer, are disclosed. The selected tool is removably coupled to the shaft through a quick release collar system. The selected tool is manually placed in engagement with the workpiece, and thereafter pounded into the target as the sleeve vigorously hammers the shaft downwardly. Smooth, jam-free operation is insured by critical alignment guides disposed within an annulus between the shaft and the sleeve, and a venting orifice that facilitates periodic oiling.
| 1
|
RELATED APPLICATIONS
This patent application is related to U.S. Pat. No. 5,324,161 entitled “REFUSE RECEPTACLE CHARGING HOPPER” issued on Jun. 28, 1994 in the name of Helmut B. Thobe. The above patent is hereby incorporated into the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a refuse receptacle and, more specifically, to a refuse receptacle having an improved charging hopper for compacting the refuse and a walking floor to remove the refused from the receptacle.
2. Description of the Prior Art
Refuse receptacles have been in use for a long time. One type of refuse handling apparatus includes a loading mechanism which feeds refuse to a holding receptacle whenever the refuse is compressed or compacted by a ram or press which forms part of the loading mechanism. Such apparatus is usually mounted on a truck or like vehicle and can be used in the collection of domestic refuse. Examples of such devices are described in U.S. Pat. Nos. 3,874,529, 3,881,613, 4,050,594, 4,298,306, 4,637,306 and 4,786,228. Devices of this type suffer from the disadvantage that they are generally complicated and, as a result, expensive and difficult to maintain.
U.S. Patent 5,324,161 discloses a refuse receptacle charging hopper. The charging hopper helps to overcome many of the disadvantages of the prior art. However, debris has a tendency to become stuck in the arms and cylinders of the control member. Furthermore, the control member is only designed to work in a single compartment refuse receptacle.
Therefore, a need existed to provide an improved refuse receptacle. The improved refuse receptacle must be able to overcome the problems associated with prior art refuse receptacle. The refuse receptacle must be able to keep debris from becoming stuck in the arms and cylinders of the control member. The refuse receptacle must further have a control member which may be used in a multiple compartment refuse receptacle. The improved refuse receptacle must further be able to easily unload the refuse once the refuse is collected.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, it is an object of the present invention to provide an improved refuse receptacle.
It is another object of the present invention to provide an improved refuse receptacle which must be able to overcome the problems associated with prior art refuse receptacle.
It is still another object of the present invention to provide an improved refuse receptacle that is able to keep debris from becoming stuck in the arms and cylinders of the control member.
It is another object of the present invention to provide an improved refuse receptacle that has a control member which may be used in a multiple compartment refuse receptacle.
It is yet another object of the present invention to provide an improved refuse receptacle that is able to easily unload the refuse once the refuse is collected.
BRIEF DESCRIPTION OF THE EMBODIMENTS
In accordance with one embodiment of the present invention, a refuse handling apparatus having a collection receptacle is disclosed. The collection receptacle on the refuse handling apparatus has a charging hopper having a first opening for loading material into the charging hopper, a second opening through which material can be discharged from the charging hopper, the second opening being disposed below the first opening when the apparatus is in use. The charging hopper has a curved guide surface therein which extends between the first and second openings so as to form a slide for directing material towards the second opening. A control member is provided and has a work head which is mounted for movement within the charging hopper about a pivot axis which extends generally horizontally when the apparatus is in use. The control member is pivotally movable about the pivot axis between a first position in which the work head is spaced from and disposed above the second opening, and a second position in which the work head is adjacent or within the second opening. The curved guide surface of the hopper is generally complementary to the arc of movement of the lower most part of the work head between the first and second positions. The work head is disposed adjacent the guide surface and in close proximity thereto during movement between the first and second positions. The control member has a top surface of the work head, and a lower surface curved to substantially the same arc as the guide surface. The top surface is shaped to act as a sloping surface when the work head is in the first position to guide material towards the second opening, and wherein the top surface is at all times exposed to the hopper and the first opening so that material may enter into the first opening and the hopper irrespective of the position of the control member at and between the first position and the second position. The control member further has a block having a front wall, the top surface, the lower surface, and side walls, the front wall being arranged to push the material through the second opening and, to compact the material within the receptacle. Each of the side walls has a section which is complementary to the guide surface, the section of the side walls and the lower surface of the control member being adjacent to the guide surface of the charging hopper whereby when the control member moves from the second position to the first position the leading edge of the control member defined by the end of the top surface most remote from the front wall and the lower surface will tend to scrape material off the guide surface onto the top surface. Mounting arms are provided which have the work head operatively connected to one end thereof, the other ends of the mounting arms being mounted for pivotal movement about the pivot axis. A pivot tube is coupled to the mounting arms. The pivot tube is used for maintaining stability between the mounting arms and to ensure proper movement of the control member.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, as well as a preferred mode of use, and advantages thereof, will best be understood by reference to the following detailed description of illustrated embodiments when read in conjunction with the accompanying drawings.
FIG. 1 is an elevated perspective of the improved refuse receptacle of the present invention.
FIG. 2 is a side view of the charging hopper used in the container section of the improved refuse receptacle.
FIG. 3 is a plan view of the charging hopper used in the container section of the improved refuse receptacle.
FIG. 4 is an end elevated view of the drive means used in the charging hopper of the improved refuse receptacle.
FIG. 5 is a schematic perspective view of a control member used in the charging hopper of the improved refuse receptacle.
FIG. 6A is an elevated front and rear perspective view of the control member used in the improved refuse receptacle of the present invention.
FIG. 6B is a side view of the control member used in the improved refuse receptacle of the present invention, the opposite side being a mirror image thereof.
FIG. 6C is a top view of the control member used in the improved refuse receptacle of the present invention.
FIG. 6D is an exploded view of the control member used in the improved refuse receptacle of the present invention.
FIG. 7A is an elevated perspective view of a second embodiment of the control member used in the improved refuse receptacle of the present invention.
FIG. 7B is an elevated perspective view of another embodiment of the control member used in the improved refuse receptacle of the present invention.
FIG. 8 is an elevated front and rear perspective view of the collection receptacle used in the improved refuse receptacle of the present invention.
FIG. 9 is a rear view of the moving floor used in the improved refuse receptacle of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, an improved refuse receptacle 100 (hereinafter receptacle 100 ) is shown. The receptacle 100 overcomes many of the problems associated with prior art receptacles. The receptacle 100 is designed to keep debris from becoming stuck in the arms 18 and drive means 27 of the control member 10 . The receptacle 100 is further able to have a control member 10 which may be used in a multiple compartment refuse receptacle. The improved receptacle 100 is also able to easily unload the refuse once the refuse is collected.
Referring to FIG. 1, the receptacle 100 is shown. The receptacle 100 can be a standard garbage truck which has been modified, a stationary, or a break away compactor. In the Figures, a standard garbage truck is shown implementing the present invention. However, this should not be seen as to limit the scope of the present invention.
The receptacle 100 has a collection receptacle 200 which is coupled to a frame of the receptacle 100 . The collection receptacle 200 is used to store the garbage which is collected. A loading arm 56 is also coupled to the receptacle 100 . The loading arm 56 is used to pick up refuse bins and discharge the contents through a chute 57 to the collection receptacle 200 .
The collection receptacle 200 has a charging hopper 3 . The charging hopper 3 has a side wall 5 with a first opening 6 in its top and a second opening 7 in a lower region of the side wall 5 . The charging hopper 3 further includes a base wall 8 having a curved surface 9 , which forms a slide directed from the first opening 6 towards the second opening 7 . In the particular application shown in FIG. 1, material from chute 57 is directed through the first opening 6 and material is passed through the second opening 7 into the collection receptacle 200 .
The charging hopper 3 further includes a control member 10 having a work head 12 disposed within the charging hopper 3 . The control member 10 being mounted for movement about a pivot axis 20 which extends generally horizontally as shown. The work head 12 moves in an arc about the pivot axis 20 between a first or raised position in which the work head 12 is spaced from the second opening 7 and a second or lowered position in which the work head 12 is adjacent or within the second opening.
The work head 12 , as shown is in the form of a wedge having a front wall 14 , a top wall 15 and side walls 16 . In operation the front wall 14 is arranged to push the material in the charging hopper 3 through the second opening 7 and where necessary compact the material within the collection receptacle 200 .
The side walls 16 of the work head 12 each have a curved lower edge 17 which is complementary to the curved guide surface 9 of the charging hopper 3 , the curved lower edges 17 of the side wall of the work head 12 being adjacent to the curved guide surface of the charging hopper 3 . As best seen in FIG. 2 the top wall 15 and side walls 16 converge towards one another in the direction of the trailing edge of work head 12 . Thus when in the raised position as shown in FIG. 2, the work head 12 does not interfere with the opening 6 of the charging hopper 3 .
The control member 10 further includes a pair of mounting arms 18 which have the work head 12 operatively connected to one thereof, the other ends being mounted for pivotal movement about the pivot axis 20 in suitable bearings 19 . The mounting arms 18 are disposed at the sides of the work head so as to ensure a minimum of interference at the first opening 6 .
The top wall 15 of the work head 12 forms a cover above the second opening 7 when the control member is in the lowered or second position so that material being loaded into the charging hopper 3 through opening 6 will not interfere with the material being discharged through the second opening. As best seen in FIG. 2, when the work head 12 is in the first or raised position, the top wall is positioned such that it is adjacent the side wall 31 of the charging hopper 3 .
Drive means 25 causes movement of the control member 10 between the first and second positions. The drive means 25 is in the form of hydraulic pistons/cylinder assemblies 27 operatively interconnected between the mounting arms 18 and the charging hopper 3 . The piston/cylinder assemblies 27 are mounted on pivot pins 28 and 29 on the charging hopper 3 and the mounting arms 18 respectively.
As may be seen more clearly in FIGS. 6A-6D, the control member 10 has a pivot tube 50 . The pivot tube 50 has a mounting collar 51 connected to each end of the pivot tube 50 . The pivot tube 50 via the mounting collars 51 is coupled to both mounting arms 18 and the cylindrical crank arms 52 . Each mounting arm 18 and cylinder crank arm 52 has an opening at the top thereof. The pivot tube 50 extends through the openings and is coupled to a first mounting collar 51 . The mounting collar 51 extends through the openings and is coupled to mounting arms 18 and the cylinder crank arms 52 . The pivot tube 50 is then coupled to the second mounting collar 51 where the second mounting arm 18 and the second cylinder crank arm 52 are coupled to. The drive means 25 are then connected to the cylinder arms 52 via the cylinder crank arms ears 53 . The pivot tube 50 helps to maintain stability between mounting arms 18 and the cylinder crank arms 52 . The pivot tube 50 and the cylinder crank arms 52 also helps one to mount the drive means 25 outside of the charging hopper 3 . This allows for simple service and maintenance and longer life of the receptacle 100 .
If trash blocks the driving means 25 , the control member 10 will be unable to move. Thus, a protective cover 59 is placed over the driving means 25 . The protective cover 59 is placed over both driving means 25 and is coupled to the control member 10 . The protective cover 59 is designed to allow the control member 10 to move freely but prevent garbage from blocking and jamming the driving means 25 . The protective cover 59 can be made out of any type of material. In general, a light weight metal is used. However, this should not be seen as to limit the scope of the present invention.
Referring now to FIG. 7A, another embodiment of the control member 10 is shown. In this embodiment, the control member 10 is a two piece control member 10 . A two piece control member 10 is used in a receptacle 100 which collects different types of refuse. For example, a receptacle 100 that collects both recyclable and non-recyclable items. In this case, the collection receptacle 200 will be divided into two compartments: one for recyclable items and another for non-recyclable items. The charging hopper 3 is similar as described above. The main difference is that the charging hopper 3 is designed to have two separate openings for receiving the different types of garbage. The control member 10 is also divided into two components to move and compact the items in each compartment of the collection receptacle 200 . The control member 10 is similar to that described above. The main difference is that the working head 12 is divided into two sections. Additional mounting arms 18 are positioned between each section of the working head 12 to provided additional support. The pivot tube 50 runs through openings in each of the mounting arms and is coupled to the drive means 25 . The drive means 25 may be configured to drive both sections of the control member 10 together or individually. It should be noted that the control member may be divided into more than two sections. The showing of two sections should not be seen as to limit the scope of the present invention.
Referring to FIG. 7B, another embodiment of the control member 10 is shown. In this embodiment, the control member 10 is a two piece control member 10 and similar to that shown and described above. The main difference is that the working head 12 which is divided into two sections are positioned in a vertical manner such that one head is positioned above a second head. This is done so that while one head is compacting the refuse, the second head can be used to scrape material off of the collection receptacle.
In a prior art refuse receptacles, in order to empty the collection receptacle, one end of the collection receptacle is raised. The other end of the collection receptacle is opened so that the collected garbage can discharged from the collection receptacle. Referring to FIG. 9, an internal view of the collection receptacle 200 is shown. The collection receptacle 200 has a moving floor 60 . The moving floor 60 will discard the garbage from the rear of the collection receptacle 200 without having the collection receptacle 200 having to be raised. The moving floor 60 has a plurality of floor boards 62 . The floor boards 62 may be made out of any type of material. In general a light weight metal is used. However, this should not be seen as to limit the scope of the present invention. The floor board 62 is generally in the form of a hollow rectangular tubing having a channeling 64 formed there through. A plurality of wheel member 66 are mounted to each floor board and are located in the channeling 64 . The wheel member 66 will allow the floor board to in a forward and reverse manner. When the floor boards 62 move in conjuction with one another, the garbage stored in the collection receptacle 200 will be moved and discarded out of the collection receptacle 200 .
In operation, material such as refuse can be loaded into the charging hopper 3 through the first opening 6 thereof. With the control member 10 in the first or raised position the material falls onto the curved guide surface on the base of the charging hopper 3 and under the influence of gravity is directed towards the second opening 7 from where it passes into the holding receptacle 51 .
Activation of the drive means 25 causes the control member 10 to move from the first position where the work head 12 is raised to the second position where it is disposed adjacent the second opening 7 and thereby forcing the material into the holding receptacle and when necessary compacting or compressing the material. As shown in FIG. 2, the arcuate length of the lower surface of control member 10 adjacent guide surface 9 is less than half the arcuate swing of the control member 10 between the first position and the second position.
In the second or lowered position the top wall 15 of the work head 12 forms a barrier over the second opening 7 thereby ensuring that any material deposited in the charging hopper 3 with the control member in the second position does not interfere with the compressing action of the work head. Further activation of the drive means causes the control member to return to the first position where the operation can be repeated.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.
|
A material handling apparatus comprising a charging hopper having an upper first opening through which material can be loaded into the charging hopper and a lower second opening through which material can be discharged from the charging hopper. The apparatus includes a control member having a work head having one or more sections which is mounted for movement within the charging hopper about a pivot axis which extends generally laterally with respect to the normal upright operative position of the apparatus. The control member is pivotally movable about the pivot axis between a first position in which the work head is spaced from and disposed above the second opening, and a second position in which the work head is adjacent or within the second opening. The control member has a plurality of arms for pivotally mounting control member. A pivot bar is coupled to the mounting arms for maintaining stability between the mounting arms and to ensure proper movement of the control member.
| 1
|
FIELD OF THE INVENTION
The present invention relates to apparatus and methods for the storage of, photographs on photograph page album inserts within a photograph album.
BACKGROUND OF THE INVENTION
Photograph albums use a number of different types of page inserts. The page inserts retain the photographs and in turn the page inserts are retained by the binder of the photograph album. Photograph albums can use two types of mechanisms for retaining page inserts therein. One mechanism uses either posts, generally round posts, or openable and closeable rings to retain the photograph album page insert. Another mechanism uses a ribbon or a strap to retain the photograph album page insert. Heretofore, photograph album page inserts which are suitable for use with a photograph album using one of the above-described mechanisms are not suitable for use with a photograph album using the other above-described mechanism. Therefore, photograph album page inserts must be separately manufactured to fit the different types of photograph albums available. This requires that inventory be kept with respect to two separate items and that appropriate amounts of each type of insert, which may not be in equal demand, be produced, ordered and stocked by manufacturers and sellers of photograph album page inserts. Also, those photograph album page inserts which are manufactured to be used with the ribbon-retaining type photograph albums generally require the use of metal retaining clips which the ribbons are threaded through. The clips are held in place by a separate binder, generally of paper or cardboard which must be affixed to the rest of the page insert, which requires additional manufacturing materials and steps.
Accordingly, it would be desirable to provide a photograph album page insert that can be easily manufactured and that can be securely retained in a photograph album using either of the above-described mechanisms of retaining page inserts.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention there is provided a page insert having a first transparent sheet, a second transparent sheet and a non-transparent sheet sandwiched between the first and second transparent sheets. At least one of the transparent sheets has an edge, and adjacent the edge at least one of the transparent sheets has at least two different shaped openings therethrough.
In accordance with another aspect of the present invention there is provided a page insert having an edge, the edge having disposed adjacent thereto at least two keyhole shaped holes therethrough.
In accordance with yet another aspect of the present invention there is provided a photograph album page insert securable in a first photograph album, and securable in a second photograph album. The first album includes at least one first securing element, and the second album including at least one second securing element different than the first securing element. The page insert includes at least a first sheet having a top edge, a bottom edge, a left edge and a right edge. The page insert also includes a pocket for retaining a photograph therein. The first sheet also has at least one first standardly shaped hole defined therethrough and further has at least one second standardly shaped ribbon slot defined therethrough. The at least one first securing element can securely register with the at least one first standardly shaped hole and the at least one second securing element can securely register with the at least one second standardly shaped ribbon slot.
In accordance with another aspect of the present invention there is provided a photograph album containing a page insert as described above.
Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, various features of preferred embodiments of the invention.
DESCRIPTION OF THE FIGURES
The detailed description of the invention will be made with reference to the accompanying drawings, where like numerals designate corresponding parts of the figures. The drawings are meant to be generally illustrative of various examples of the present invention, but are merely examples and are not meant to be limiting of the scope of the invention.
FIG. 1 depicts a prior art photograph album page insert which is suitable for use in a photograph album which uses rings or posts as a securing element.
FIG. 2 depicts a prior art photograph album page insert which is suitable for use in a photograph album which uses a ribbon or strap as a securing element.
FIG. 3 depicts one embodiment of a photograph album page insert of the present invention which is suitable for use in a photograph album which uses rings or posts or a ribbon or a strap as a securing element.
FIG. 4 depicts another embodiment of a photograph album page insert of the present invention which is suitable for use in a photograph album which uses rings or posts or a ribbon or a strap as a securing element.
FIG. 5 depicts an embodiment of an opening suitable for use with a page insert of the present invention.
FIG. 6 depicts three different binder sections of a photograph album page insert suitable for use in a photograph album which uses rings or posts as a securing element.
FIG. 7 depicts a photograph album having a plurality of posts as securing elements including the page insert of FIG. 3.
FIG. 8 depicts a photograph album having a plurality of rings as securing elements including the page insert of FIG. 3.
FIG. 9 depicts a photograph album having a plurality of ribbons as securing elements including the page insert of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a prior art photograph album page insert 10 which includes a pocket 12 and a pocket insert 14. A left tab portion 16 includes two holes 18a and 18b which can be used with photograph albums which use either a post or a ring to engage holes 18a and 18b and thereby retain photograph album page inserts therein.
FIG. 2 depicts a prior art photograph album page insert 20 which includes a pocket 22 and a pocket insert 24. A left tab portion 26 includes two retaining clips 28a and 28b which can be used with photograph albums which use either a ribbon or a strap to engage retaining clips 28a and 28b and thereby retain photograph album page inserts therein.
FIG. 3 depicts one embodiment of a photograph album page insert 30, of the present invention, which includes a pocket 32 and a pocket insert 34. Pocket 32 is formed from first sheet 33 and second sheet 35. A left tab portion 36 includes a first opening 37a having hole portion 38a and slot portion 39a and a second opening 37b having hole portion 38b and slot portion 39b. First and second openings 37a and 37b can engage a securing element in photograph albums which use either a post or a ring, the ring or post engaging hole portions 37a and 37b, or can engage a securing element in photograph albums which use either a ribbon or a strap, the ribbon or strap engaging slot portions 39a and 39b. The ribbon or strap can either fit entirely within slot portions 39a and 39b or can overhang into hole portions 38a and 38b.
FIG. 4 depicts another embodiment of a photograph album page insert 40, of the present invention, which includes a pocket 42 and a pocket insert 44. Pocket 42 is formed from first sheet 43 and second sheet 45. A left tab portion 46 includes first openings, holes 48a and 48b, and second openings, slots 49a and 49b. In this particular embodiment, holes 48a and 48b are not continuous with slots 49a and 49b. It is to be understood that slots 49a and 49b can be positioned to the left of, to the right of, above or, as depicted, below holes 48a and 48b.
The pockets 32 and 42 of photograph album page inserts 30 and 40 can be formed of various materials which are preferably transparent, but which may be colored or translucent. Such materials include but are not limited to hard plastic, soft plastic, thermoplastic, acetate sheets, and the like. In alternative embodiments, a pocket can be formed from other than two sheets such as first sheets 33 or 43, and second sheets 35 or 45. For example, a first sheet 33 or 43 can be used alone and a pocket can be formed on the sheet which will retain a photograph thereon. The pocket can be formed from slots in the sheets which the corners of photographs can be fit into to be retained therein. In another embodiment, retaining means, such as adhesive corners can be used as pockets to retain photographs on first sheet 33 or 43.
In a particular embodiment, sheets 33 and 35 or 43 and 45 can be sealed together to provide a number of pockets which will fit various standard sized photographs such as 3 inches by 5 inches, 4 inches by 6 inches and other sizes as are known in the art.
In another particular embodiment, sheets 33 and 35 and 43 and 45 can be attached to each other along a portion of each sheet intermediate between an edge of each sheet and the center of each sheet, for example, along seam 31 and 41 respectively.
Particular embodiments of the present invention can use pocket inserts 34 and 44, however, in some embodiments, for example, those in which sheets 33 and 35 or 43 and 45 form pockets, pocket inserts need not be used. Pocket inserts can be made from materials including but not limited to paper, cardboard, plastic and the like. Photographs can be placed on pocket inserts 34 and 44, which in one embodiment, can contain an adhesive or can adhere to the material forming pockets 32 and 42, thereby retaining the photographs placed thereon. Alternatively, pocket inserts 34 and 44 can contain slots which the corners of photographs can be fit into to retain them. In another embodiment, pocket inserts 34 and 44 can be plain sheets, and adhesives or adhesive tape or photograph retaining means, such as adhesive corners can be used to retain photographs thereon.
Holes 38a, 38; 48a and 48b; 50, 68a and 68b; 72a and 72b; 74a and 74b; 76a and 76b and 71a, 75 and 79 are depicted as circular, however, other shapes such as squares, triangles, other polygons and combinations thereof are within the scope of the present invention. The size of the holes as set forth above can also vary. Preferably, the holes are of a size which will securely engage a post or ring. In a particular embodiment, the holes are about a quarter of an inch in diameter. Two holes are depicted, however, a single hole or three or more holes are within the scope of the present invention. The holes are preferably disposed on the left side of page inserts 30 and 40. However, the holes can be disposed on the top, bottom or right side of page inserts 30 and 40. In a preferred embodiment, the hole is a standardly shaped hole which will securely engage standard shaped and sized posts or rings and similar securing elements standardly used in photograph albums to secure page inserts thereto.
The width of slots 39a, 39b; 49a, 49b; 50b, 50c; 70a, 70b; 74a, 74b; and slots 78a, 78b can vary depending upon the thickness of ribbon or strap they may be used with. Preferably, the above-referenced slots snugly engage a ribbon or strap inserted therein. In a preferred embodiment, the slot is a standardly shaped ribbon slot which will securely engage standard shaped and sized ribbons and straps and similar securing elements standardly used in photograph albums to secure page inserts thereto. In a particular embodiment, the slots are about one sixteenths of an inch in width. Any combination of holes and slots described above which are different from each other comprise at least two different shaped openings. Preferably, as shown in FIGS. 3-6c, the width of the holes 38a, 38; 48a and 48b; 50, 68a and 68b; 72a and 72b; 74a and 74b; 76a and 76b and 71a, 75 and 79 is wider than the width of the slots 39a, 39b; 49a, 49b; 50b, 50c; 70a, 70b; 74a, 74b; and 78a, 78b.
FIG. 5 depicts an opening 50a which includes slots 50b and 50c. Opening 50a can be disposed at any point along line a. At one extreme, when opening 50a is at the top of line a only slot 50c remains, when opening 50a is at the bottom of line a only slot 50b remains. When opening 50a is exactly intermediate on line a, slot 50b and 50c are equal, as 50a moves along line a slot 50b and 50c are increased or reduced in size correspondingly. All of these combinations of opening 50a and slots 50b and 50c are defined herein as keyhole shaped holes. Additionally, all combinations of opening 50a and slots 50b and 50c define openings which at least partially overlap thereby defining keyhole shaped holes. That is, a keyhole shaped hole is one wherein an opening overlaps a slot at any point along the longitudinal extent of the slot, wherein the opening has a width wider than that of the slot. In contrast, hole 48a and slot 49a and hole 49b and slot 49b depict openings which do not overlap.
FIG. 6 depicts three variant left tab portions 66a, 66b and 66c illustrating various arrangements of holes including: 68a and b and 71a and slots 70a and 70b; 72a and b and 75 and slots 74a and 74b; and 76a and b and 79 and slots 78a and 78b. It is to be understood that these arrangements of holes and slots could be disposed on the right tab, top or bottom portion of a photograph album page insert.
FIGS. 7-9 show page insert 30, as described above, disposed in a photograph album 100 including a binder 102 and various page insert securing elements. In FIG. 7 the page insert securing element is a post 104; in FIG. 8 the page insert securing element is a ring 106; and in FIG. 9 the page insert securing element is a ribbon 108. It will be understood that the various page insert securing elements can be employed with the various page inserts 30, 40 and variations thereof described above.
The presently disclosed embodiments are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
In accordance with one aspect of the present invention there is provided a page insert having a first transparent sheet, a second transparent sheet and a non-transparent sheet sandwiched between the first and second transparent sheets. At least one of the transparent sheets has an edge, and adjacent the edge at least one of the transparent sheets has at least two different shaped openings therethrough.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an optically active pyrimidine compound which is a liquid crystal compound useful as an electrooptic element wherein the response of the ferroelectric smectic liquid crystal to an electric field is utilized.
2. Description of the Prior Art
Liquid crystals have been employed as various electrooptic elements such as a display device of a watch or an electronic calculator. Most of liquid crystal display devices which have been put into practical use hitherto are those wherein the dielectric orientation effect of a nematic or cholesteric liquid crystal is utilized. However the application of these liquid crystals to a display device involving a large number of pixels is accompanied by some troubles such as a low response, poor contrast caused by the lack of drive margin and unsatisfactory visual angles. Therefore there has been frequently attempted to develop a MOS or TFT panel involving formation of a switching device for each pixel.
U.S. Pat. No. 4,367,924 has disclosed a liquid crystal device wherein a smectic phase based on a novel displaying principle is used to thereby overcome the disadvantages as described above.
Further it has been known that a liquid crystal compound exhibiting a C* or H phase consisting of optically active molecules generally has an electrical dipole density P and is ferroelectric. Such a chiral smectic liquid crystal having electrical dipoles is more strongly affected by an electric field than dielectric anisotropic ones. As a result, the polarity of P is made parallel to the direction of the electric field. Thus the direction of the molecules can be controlled by reversing the direction of the applied electric field. Then the average change in the direction of the major axes of these molecules is detected with the use of two polarizing plates. Thus the liquid crystal can be used as an electrooptic element.
The effect of the spontaneous polarization of this electrooptic element, wherein the response of the smectic C* or H phase to an electric field is utilized, and the electric field exert an action 10 3 to 10 4 times as high as those of dielectric anisotropic ones. Thus the former shows a high-speed response compared with a TN liquid crystal device. Further it is possible to impart thereto a memory function by appropriately controlling the orientation. Therefore it is expected to apply the same to a high-speed optical shutter or to a display of a large capacity.
There have been synthesized various chiral smectic liquid crystal compounds having a ferroelectricity and the properties thereof have been studied.
For example, an optically active 2-(4-alkoxyphenyl)-5-alkylpyrimidine compound and an optically active 2-(4-substituted alkoxyphenyl)-5-alkylpyrimidine compound have been proposed each as a compound which is stable to water and shows a chiral smectic phase within a wide range of temperature in Japanese Patent Laid-Open Nos. 93170/1986 and 129169/1986, respectively.
However each compound as described above is available only within a restricted range of temperature. Namely, its insufficient properties, in particular, at a low temperature make it unsatisfactory from the practical viewpoint.
SUMMARY OF THE INVENTION
It is the main object of the present invention to provide a compound useful as a liquid crystal which is suitable for preparing a composition available over an unlimited temperature range and, in particular, having a liquid crystal temperature lower than room temperature.
We have studied on a pyrimidine liquid crystal compound which shows a chiral smectic phase over a widened temperature range. As a result, we have found that an optically active pyrimidine compound of the following general formula, which has a specific alkoxy group, i.e., the alkyl group bonded to the asymmetric carbon atom substituted by a chlorine atom at the β-position, shows a chiral smectic phase over a wide range of temperature involving a low temperature region, thus completing the present invention. ##STR2## wherein m is 1 to 12;
n is 4 to 18; and
*C represents an asymmetric carbon atom.
DETAILED DESCRIPTION OF THE INVENTION
The compound of the present invention is represented by the above general formula can be prepared by a common method used in synthesizing phenylpyrimidine compounds.
For example, it may be prepared by etherifying 5-alkyl-2-(4-hydroxyphenyl)pyrimidine with the corresponding optically active alcohol; or by etherifying 4-cyanophenol with the corresponding optically active alcohol and converting the resulting product into pyrimidine in a conventional manner.
A 5-alkyl-2-(4-hydroxyphenyl)pyrimidine compound may be prepared by a conventional method comprising, for example, converting 4-cyanophenol into a benzyl ether in a conventional manner, converting the resulting ether into 4-benzyloxy-benzamidine hydrochloride, reacting the obtained product with an n-alkylmalonic acid diester to give a 2-(4-benzyloxyphenyl)-4,6-dihydroxy-5-n-alkyl-pyrimidine and then chlorinating and reducing the product.
The optically active 6-chloro-4-methylalkanol compound to be used as the starting material in the preparation of the compound of the present invention may be obtained by alkylating (R)-(+)-citronellic acid to give an (R)-2,6-dimethyl-8-oxoalkene-2 (cf. Japanese Patent Application No. 251129/1985 applied by us) followed by reduction of the same; or by alkylating optically active 3,7-dimethyl-6-octenal with the corresponding alkylmagnesium halide and chlorinating the optically active 2,6-dimethyl-8-hydroxyalkene thus obtained to give 2,6-dimethyl-8-chloroalkene-2 followed by oxidation and reduction tha same.
The obtained compound of the present invention as represented by the above general formula can be used alone as a liquid crystal material. Alternately it can be mixed with other liquid crystal compound(s).
To further illustrate the present invention, the following Examples will be given.
EXAMPLE 1
Synthesis of 2-(4-(6-chloro-4-methyloctoxy)-phenyl)-5-n-decylpyrimidine
(1) Preparation of 6-chloro-4-methyloctanol
18.2 g of optically active 2,6-dimethyl-8-oxodecene was dissolved in 50 ml of ethanol. 1.9 g of sodium borohydride was added thereto within five minutes at room temperature and the resulting mixture was stirred at room temperature for two hours.
The reaction mixture was sufficiently concentrated and 50 ml of water was added thereto. Then the mixture was extracted with ether, washed with a saturated saline solution and dried. After distilling off the solvent, the residue was distilled to thereby give 15.5 g of 2,6-dimethyl-8-hydroxydecene-2 as a fraction having a boiling point of 79° to 80° C. under a pressure of 1 mmHg.
13.8 g of the 2,6-dimethyl-8-hydroxydecene-2 was dissolved in 75 ml of carbon tetrachloride and 21.0 g of triphenylphosphine was added thereto. The mixture thus obtained was stirred under reflux for three hours. After distilling off the solvent, the mixture was extracted with hexane. The hexane was distilled off and then the residue was distilled to thereby give 6.9 g of 2,6-dimethyl-8-chlorodecene-2 as a fraction having a boiling point of 118° to 120° C. under a pressure of 16 mmHg.
5.0 g of the 2,6-dimethyl-8-chlorodecene-2, 100 ml of methanol and 100 ml of dichloromethane were cooled together to -40° C. To the mixture, oxygen gas containing 0.04 g/l of ozone was bubbled at a rate of 120 l/hr for 30 minutes. Subsequently nitrogen gas was bubbled thereto to thereby remove excessive ozone.
Then 4.2 g of sodium borohydride was added thereto at the same temperature and the resulting mixture was allowed to reach the room temperature within one hour. Subsequently it was stirred at room temperature for additional one hour. After allowing to stand overnight, 100 ml of toluene was added to the reaction mixture. Then the resulting mixture was poured into 200 ml of a 5% aqueous solution of hydrochloric acid and stirred at room temperature for one hour. The toluene phase was collected, washed with a saturated saline solution and dried. After distilling off the solvent, the residue was distilled to thereby give 3.2 g of the aimed 6-chloro-4-methyloctanol as a fraction having a boiling point of 69° to 70° C. under a pressure of 0.1 mmHg.
(2) Preparation of 2-(4-(6-chloro-4-methyloctoxy)phenyl)-5-n-decylpyrimidine
6-chloro-4-methyloctyl tosylate was obtained by tosylating 1.8 g of the 6-chloro-4-methyloctanol as prepared in (1) with the use of 2.1 g of toluenesulfonyl chloride and 1.2 g of triethylamine in a conventional manner.
1.0 g of 2-(4-hydroxyphenyl)-5-n-decylpyrimidine, 0.19 g of finely powdered sodium hydroxide and 10 ml of methyl ethyl ketone were stirred together under reflux for one hour. Then 1.6 g of the tosylate as described above was added thereto and the resulting mixture was further stirred under reflux for eight hours. After removing the solvent, diethyl ether was added to the residue and the obtained mixture was neutralized in a 5% aqueous solution of hydrochloric acid. After removing the solvent, 1.5 g of a pale yellow and oily product was obtained. The product was purified on a silica gel column with the use of hexane/ether (9/1) as a developing solvent. Thus 1.4 g of 2-(4-(6-chloro-4-methyloctoxy)phenyl-5-n-decylpyrimidine having a purity of 99.8% was obtained.
Infrared spectroscopy (cm -1 ): 2940(vs), 2860(s), 1610(s), 1585(s), 1540(w), 1515(w), 1460(m), 1430(vs), 1380(w), 1330(w), 1330(w), 1255(vs), 1170(s), 1105(w), 1020(m), 930(vw), 845(w), 800(m), and 610(w).
This compound was poured into a transparent glass electrode cell of 2 μm in thickness, which had been subjected to orientation by rubbing, and heated to 90° C. to thereby give an isotropic liquid.
The liquid crystal cell thus obtained was cooled under a crossed Nicol prism while applying rectangular pulses (15 V. 1 Hz) thereto. As a result, definite switching behaviors were observed within a temperature range of 28.5° C. to -5° C.
Further the following phase transition was observed under a polarization microscope: ##STR3##
It has been confirmed that the above compound of the present invention shows an Sc* phase over a wide temperature range, i.e., over 30° C. involving a temperature as low as -5° C., which obviously suggests that it is suitable for the preparation of a composition showing a low liquid crystal temperature.
In contrast thereto, each of the compounds as described in Japanese Patent Laid-Open No. 93170/1986 and No. 129169/1986 having an ethyl group as the alkyl group bonded to the asymmetric carbon atom shows an Sc* phase at a temperature exceeding approximately 15° C., when employed alone. Thus the physical properties thereof at a low temperature are unsatisfactory.
EXAMPLE 2
Synthesis of 2-(4-(6-chloro-4-methylnonyloxy)-5-n-decylpyrimidine
The procedure of Example 1 was followed except that the 6-chloro-4-methyloctanol was replaced by 6-chloro-4-methylnonanol to thereby give the title compound.
Infrared spectroscopy (cm -1 ): 2940(vs), 2860(s), 1610(s), 1585(s), 1540(w), 1515(w), 1460(m), 1430(vs), 1380(w), 1330(w), 1330(w), 1255(vs), 1170(s), 1105(w), 1020(m), 930(vw), 845(w), 800(m), and 610(w).
This compound was poured into a transparent glass electrode cell of 2 μm in thickness, which had been subjected to orientation by rubbing, and heated to 90° C. to thereby give an isotropic liquid.
The liquid crystal cell thus obtained was cooled under a crossed Nicol prism while applying rectangular pulses (15 V. 1 Hz) thereto. As a result, definite switching behaviors were observed within a temperature range of 27.5° C. to -7.5° C.
Further the following phase transition was observed under a polarization microscope: ##STR4##
It has been confirmed that the above compound of the present invention shows an Sc* phase over a wide temperature range, i.e., 35° C. involving a temperature as low as -7.5° C. and that it shows an Sx phase under the Sc* phase and maintains the smectic domain state even at a temperature of -15° C. or below, which obviously suggests that it is suitable for the preparation of a composition showing a low liquid crystal temperature.
EXAMPLE 3
Synthesis of 2-(4-(6-chloro-4-methyloctoxy)phenyl)-5-n-octylpyrimidine
The procedure of Example 1 was followed except that the 2-(4-hydroxyphenyl)-5-n-decylpyrimidine was replaced by 2-(4-hydroxyphenyl)-5-n-octylpyrimidine to thereby give the title compound.
Infrared spectroscopy (cm -1 ): 2940(vs), 2860(s), 1610(s), 1585(s), 1540(w), 1515(w), 1460(m), 1430(vs), 1380(w), 1330(w), 1330(w), 1255(vs), 1170(s), 1105(w), 1020(m), 930(vw), 845(w), 800(m), and 610(w).
The following phase transition was observed under a polarization microscope: ##STR5##
Thus the compound of the present invention is useful as a liquid crystal compound suitable for the preparation of a composition having a liquid crystal temperature lower than room temperature and as a blending agent suitable for the preparation of a composition having a liquid crystal temperature lower than room temperature.
|
The present invention discloses an optically active pyrimidine compound represented by the following general formula: ##STR1## wherein m is 1 to 12;
n is 4 to 18; and
*C represents an asymmetric carbon atom.
The pyrimidine compound of the present invention is a liquid crystal compound useful as an electrooptic element wherein the response of the ferroelectric liquid crystal to an electric field is utilized.
| 2
|
BACKGROUND OF THE INVENTION
The present invention concerns a procedure for regulating the evaporation rate and the layer buildup in the production of optically effective thin layers in a vacuum on substrates with controlled evaporator power and with continuous measurement of the optical behavior of the deposited layer.
In the description of this invention, "optical behavior" means the influence on the amplitude, phase and the spectral dependence of the light (used for measurement) by the layer under consideration. Deposited, optically effective layers change, for example, transmission, reflection, phase and state of polarization of the measuring light. These effects can be used for measuring purposes as described below.
It is known in the art how to influence the evaporation rate of substance required in the production of thin layers by controlling the energy supply. It is also known in the art how to determine the transmission of reflection behavior of the deposited layer by means of a light or a light bundle, for German Pat. DT-AS No. 1 548 262. The result of such measurement is usually used to interrupt the evaporation process after attaining certain layer properties. The evaporation time determining the properties of the deposited layer is not influenced thereby. Finally it is also known to follow layer buildup as a function of time and to interrupt the evaporation process by continuously monitoring the transmission or reflection behavior of monochromatic light and counting the maximums or minimums. The number of maximums or minimums, dependent on the wavelength of the light used, permits an inference as to the thickness of the layer (German Pat. DT-AS No. 1 214 970). Also with this known measuring method, only the layer thickness, but not the duration of their production is involved.
In this application, the term "optically effective layers" will include all layers which change the optical properties of the substrate. They may be reflection-reducing layers, filter layers on lenses and other glasses which reflect or transmit, part of the electromagnetic radiation in the visible and/or invisible range. The wavelength range under consideration in this application extends from ultraviolet to the far infrared. The optical effectiveness relates, above all, to low-loss amplitude changes of the reflected or transmitted radiation. It also includes layers which change the phase or the polarization state of the light used for the measurement.
Optically effective layers may have both a homogeneous or (in an individual layer) nonhomogeneous composition or may consist of a combination of a number of layers with low and high refractivity, as are encountered, for example, with the so-called interference filters which have the remarkable property of compensating to a great extent errors in the thickness of individual layers, if the individual layers have the optical thickness of quarter-wavelengths of the light used for measurement of multiples thereof. This presupposes, however, that the subsequent layer grows together with the preceding layers till the desired properties are reached. Hence, not the properties of the individual layer, but the effect of the totality of the layers determine the effect attained. From this follows, that especially multiple layers of the stated type may be manufactured only by using optical measuring procedures, but not by using mechanical measuring procedures, in order to obtain the desired close tolerances. For example, weighing methods cannot determine the partial or total optical effect. When using a quartz resonator for determining layer thickness, the type and the partial pressure of the unavoidable gas remainder in the vacuum chamber play an appreciable part in view of the accuracy of the measurement result.
In view of the overall properties of optically effective thin layers, recently progressively closer tolerances have been determined. This presupposes that the manufacturing method for the layers is, to a high degree, reproducible in order to obtain always layers with the same constant characteristics. This does not only apply to the numerous surface layers of complex optical systems, but especially for eyeglasses, in particular sunglasses. It is self-understood that, for example, in case of eyeglass breakage, replacement by a glass with different optical properties is not permissible. Color differences are particularly intolerable.
Accordingly, it is an object of the present invention to provide a procedure for obtaining high reproducibility of all properties of optically effective layers during their manufacture with extremely simple operation of the evaporator device.
Another object of the present invention is to provide an arrangement of the foregoing character which may be economically fabricated and has a substantially long operating life.
A further object of the present invention is to provide an arrangement, as described, in which the component parts are readily accessible for maintaining them in service.
SUMMARY OF THE INVENTION
The objects of the present invention are achieved by providing that the evaporation is started at a given evaporator power. Starting with the change of the optical bahavior of the layer, the resulting measured result, after forming the time derivative, is continuously compared with the output signal of a signal generator which reproduces the temporal course (rate of change) of the optical properties during layer buildup under optimum conditions. The difference signal of the comparison is used to increase the evaporator power if the layer buildup lags, and to reduce it if the layer buildup is too fast.
The invention is based on the following principle. To obtain a uniform quality of the layers, it absolutely is necessary to complete the evaporation process for each individual layer in a fixed period of time. For a certain spatial arrangement of evaporator and substrate, this fixed period results in optimum uniformity of the thickness distribution in the substrates which, in most cases, are arranged in many ways. The invention is based on the principle of evaporation with constant evaporation rate or constant power input to the evaporation device. In principle, it consists in a correction of the evaporator power (whose order of magnitude is given) by a time-dependent control of the layer buildup, i.e., of the process of creating the layer. If the layer buildup is delayed with respect to the given time program, the evaporator power is increased by the proper amount. However, if the layer buildup proceeds too rapidly, the evaporator power is reduced by a suitable amount.
The procedure of the subject invention has the advantage that all layers of different charges are built up under precisely the same reproducible conditions as previous charges. Deviations with respect to the optical and mechanical properties are reduced to a minimum. Among the mechanical properties are the adhesive strength, mar resistance and freedom from pores as well as the resistance to chemical, in particular atmospheric influences. Also, the uniformity of layers on substrates of the same charge with a different spatial position relative to the evaporator source is increased considerably. In addition, the influence of different heat transfers from the evaporator to the maerial to be evaporated, is compensated by the regulation. With strict regulation for constant electric power on the evaporator, for instance, a change in heat transfer from the evaporator to the material to be evaporated would lead to a change in the evaporation rate. In this connection, there is a change in heat transfer due to different granulated material size of the evapoated material and possible influences of chemical reactions between evaporator and evaporation material. Above all, the regulation procedure of the present invention makes posible operation of such an evaporation device by personnel without scientific background, without increasing the rate of rejects.
Continuous measurement of the reflection and transmission behavior of the layer, especially with the use of monochromatic light, leads to measured values which have a time-dependent behavior in such a way that, for example, the reflection of the layer up to the thickness of a quarter wavelength of the light used in the measurement decreases, and then increases up to a layer thickness of half a wavelength to the initial value. It then decreases up to a layer thickness of three-quarter wavelength and so forth. Such a curve has been described in German Pat. DT-AS No. 1 214 970 in detail. However, direct use of the measurement result which has a temporal cosine curve for the transmission and reflection properties as a function of the layer thickness growth, runs into difficulties. The reason is that the curve in question has very flat maximums and minimums which does not permit exact timewise limitation of the evaporation process in the maximums and minimums. However, by forming the time derivative the following is achieved. The curve in question at the maximums and minimums has a zero crossing which is convenient for shutoff and regulating purposes. The zero crossing can be used for the precise termination of the evaporation process of each individual layer.
The design in accordance with the present invention of the signal generator used for generating the nominal (reference) value is made with the suitable selection of electrical and/or mechanical elements. The curve shape of the output signal is determined on the basis of the above-described theoretical considerations: transmission and reflection change with a growing layer according to a sine function and the time derivative changes according to a cosine function. For example, the time dependent course of the curve can be found empirically, by statistical investigations and analyses during and/or after the manufacture of optically effective layers. With respect to order of magnitude, one requires for the passage (crossing) of a half-wave, i.e., the buildup of a layer thickness of half-wavelength of the light used, a time of several minutes. The time rate of change of the optical properties is identical with the time derivative of the measurement result of the layer under optimum conditions. Consequently, with complete agreement of the time curves of measurement result and output signal of the signal generator, it is not necessary to interfere with the power regulation of the evaporator. By using the derivative of the pure measured value one has the special advantage that the regulation becomes independent of timewise fluctuations of the origin and of deviations of the scale value of an indicating instrument.
An arrangement for carrying out the regulating procedure of the present invention consists of an evaporator inside a vacuum chamber and an associated substrate holder, a device for regulating the evaporator power with a measuring device for the evaporator power, and a feedback of the measured value to a correcting element for the evaporator power. In addition, there is provided a device for continuous measurement and differentiating the optical behavior of the layer during the buildup. The output of the measuring device for the optical behavior, together with the differentiated output of the signal generator, which determines the timewise course of the change of optical properties during layer buildup under optimum conditions, is connected to a comparator device. The output of the latter, together with the output of the measuring device for the evaporator power, is connected to the correcting element for the evaporator power.
In accordance with the present invention, furthermore, the output of a signal generator for a power program is connected to the output of the measuring device for the evaporator power. Such a power program is also obtained empirically. The power program takes into consideration the preheating and melting of the evaporation material in the evaporator.
It is advantageous to use as measuring device for the evaporator power, a device for converting electric power into electromagnetic radiation in connection with a radiation receiver tuned thereto. In principle, such an arrangement is an amplifier of simple design with high gain, long lifetime and hence high operational safety. The electromagnetic radiator, represented most simply by an incandescent lamp, has the advantage of responding immediately to a change in current or voltage and of emitting a suitable changed light flux which is communicated immediately to the radiation receiver tuned thereto.
The present invention provides further a signal generator for the power program, which is designed in such a way that after termination of the melting process, a switching pulse is generated which is applied to a circuit element for adding the comparison (reference) value from the reflection or transmission measurement and from the signal generator. The pulse is also applied to an aperture drive for releasing the evaporator by an aperture (diaphragm). This results in a fully automatic start of the evaporation process. The end of the melting process is determined empirically, i.e., by simple observation. The resulting time interval holds, if necessary with a safety margin, for all further melting processes of the same evaporation material. By simultaneous starting of the signal generator with the desired sine-shaped output voltage in accordance with the time-dependent nominal value curve, there is made possible a nominal-actual value comparison of the deposited layer. This results in the stated correction of the pre-set power value for the evaporator during the entire evaporation process. Termination of the evaporation process is accomplished by determining the zero crossing of the time derivative of the measured result, by means of a thus triggered control signal which again closes the aperture, i.e., rotates the diaphragm over the evaporator.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
A schematic sectional view showing the components of the present invention and their interrelationships.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the FIGURE, there are provided substrates 10 or optical lenses on which the layer to be vaporized is precipitated. By means of claws (not shown), the substrates are mounted in a holdng device 12 consisting of a spherical dish 13 with suitable cutouts and a rod 14 whose position is adjustable. Below substrate 10 is a so-called thermic evaporator 15 for evaporating the evaporation material. The evaporator rests on two studs 16 and 17 which also are used for supplying current and pass via vacuum gaskets (bushings) 19 and 20 through a base plate 18. The parts mentioned are enclosed by a vacuum-tight bell-shaped cover 21 which rests on base plate 18 with a circumferential seal of gasket 22 in between. A vacuum of 2 × 10 -5 torr, for example, sufficient for the evaporation process, is produced by a pump which is connected via a pipeline 23 to the base plate 18.
The current for the evaporator 15 is furnished by a power source which is connected via terminals 24 to a power regulating unit 25 in the form of a variable-ratio transformer. To the variable-ratio transformer, there is connected a transformer 26. This transformer converts the heater voltage to a value which, with the given electric conductivity of the evaporator 15, produces the required heating power.
Parallel to transformer 26, or to the evaporator 15, there is connected a measuring device 27 for the evaporator power. This measuring device consisfs of a device 28 for converting electric power into electromagnetic radiation, and a radiation receiver 29 that is properly adjusted. Visual connection exists between devices 28 and 29 so that at least part of the radiation emitted by device 28 arrives at radiation receiver or pickup 29. Radiation receiver 29 is connected via lines 30 and 31 with an input control 32 to whose input terminal 33 a variable nominal value can be applied. In the input control 32, a comparison is made with the nominal voltage supplied via lines 30 and 31. The output of the input control 32 is connected via a line 34 with an amplifier 35 whose output is connected via a line 36 to a correcting element 37. In the case at hand, the correcting element 37 is a servomotor which is coupled via an adjusting shaft 38 to the adjusting device of the variable-ratio transformer 25.
The mode of operation of the above arrangement is as follows. If, for example, there is at terminals 24 a voltage which leads to an excessive mean heating power of evaporator 15, the electromagnetic radiation power emitted by device 28 is necessarily increased. That part of the radiation incident on the radiation receiver 29 produces a corresponding actual value. Via the previously stated circuit elements, this leads to a downward adjustment of the variable-ratio transformer 25 so that the heating power at the evaporator 15 is reduced to the set value. In case of insufficient voltage at terminals 24 and the resulting insufficient mean power of evaporator 15, the reverse action takes place. Because of the high amplification ratio (gain) of the measuring device 27, the evaporator power is regulated extremely rapidly with minimum deviations from the desired value so that the power in the evaporator is kept at a practically constant value.
Inside the bell-shaped cover 21, in addition to the already mentioned parts, there is a light source 40 (surrounded by a cover) which emits a bunched light beam 41. The light beam strikes one of substrates 10, and is there resolved into a reflected component 41a and a transmitted component 41b. The reflected component 41a is delivered to a photo receiver 42, and the transmitted component 41b is delivered to a photo receiver 43. It is possible to use either the measured value of one or the other photo receiver for the evaluation, or the combined output signals of both photo receivers jointly, e.g., for obtaining the difference in order to determine the absorption. The outputs of photo receivers 42, and 43 are connected respectively, via lines 44 and 45 to an amplifier 46, and then via line 47 to a differential element 48 in which the derivative of the measured values is formed. The output of the differential element 48 is connected via line 49 to a comparison device 50. The output of a signal generator 51, which provides the temporal couse of the change of optical properties during layer buildup under optimum conditions, is connected via line 52 to comparison device 50. In this comparison device, the nominal value coming from signal generator 51 is compared with the actual values coming from photo receivers 42 or 43. The difference signal formed as a result of the comparison is connected via circuit element 53 and line 54 to line 34. As a result, the difference signal, together with the output of the measuring device 27 or of the input control 32, is connected via amplifier 35 to the correcting element 37 for the evaporator power.
Input terminal 33 is connected via line 55 to an additional signal generator 56 which provides a power program for the evaporator 15. However, to input terminal there may also be applied a nominal value adjustable by means of a potentiometer. The nominal value or program applied to the input terminal 33 is not affected by external influences. Signal generator 56 has an additional output. There, on the basis of the given program, after the melting process is over, a switching pulse is generated which is connected via line 57 or 58, to an actuator 59 for the circuit element 53. The same output is connected via line 57 and a connection line 60 to an aperture drive 61 which, by means of an actuating shaft 62, drives a disk-like aperture or diaphragm 63 by means of which the evaporator 15 can be covered completely. During the generation of the switching pulse in signal generator 56, circuit element 53 is closed and diaphragm or aperture 63 is opened so that the actual evaporation process may start.
The mode of operation of the overall arrangement is as follows. After loading the evaporator 15 and the substrate holder 12, and after evacuation of the bell-shaped cover 21, circuit element 53 is, at first, still open. On the basis of the fixed power program provided by signal generator 56, the power of evaporator 15 is regulated to this value. The input is made in such a way that a preheating and melting of the evaporation material is definitely brought about. As soon as the switching pulse is generated in the signal generator 56, actuator 59 closes control or switching element 53 and opens aperture 63 so that the evaporation process starts. At the same time, pulse generator 51 is started.
As long as the time derivative of the measuring result of the photo receiver 42 or 43, at the output of the differential element 48 does not deviate from the output of signal generator 51, there is formed in the comparison element the output signal "0" which, of course, does not affect the feedback signal of the measuring device 27. But, if deviations from the given nominal values are recorded in photo receivers 42 or 43, the comparison or reference device 50 forms a difference signal which influences the feedback signal of the measuring device 27 to the correcting element 37. If one of the two photo receivers 42 or 43, records too rapid a layer growth, the feedback signal of the measuring device 27 is affected in such a way that the variable-ratio transformer 25 is reduced to a lower evaporator temperature or evaporation rate. In the opposite case, the variable-ratio transformer 25 is increased so that the temperature of evaporator 15 and hence the evaporation rate increases. The rate of change of the evaporation rate amounts only to a fraction of a period of the measured values so that the system is more than sufficiently free from inertia. Differential element 48 has an additional output which is connected via line 64 to line 60 and hence to the aperture drive 61, in order to stop the evaporation process after reading the desired layer thickness.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention, and therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
|
An arrangement for regulating the evaporation rate and the layer buildup in the production of optically effective thin layers in a vacuum on substrates with controlled evaporator power and with continuous measuring of the optical characteristics of the deposited layer. The evaporation is started with a given evaporator power and with the start of change of the optical characteristics of the layer, the measured result after forming the time derivative is continuously compared with the output signal of a signal generator. This output signal reproduces the time rate of change of the optical properties during the layer buildup. The difference signal of the comparison signal is used to increase the evaporator power if the layer buildup lags, and to reduce this power if the layer buildup is too fast.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates to compositions, methods, and apparatuses for improving the inhibition of scale deposition. More specifically, the invention relates to a method of inhibiting scale deposition in process solution distribution systems consisting of piping, spray nozzles, and emitter tubes such as those used in heap leach mining operations.
[0004] In heap leach mining operations, a heap of valuable mineral containing ore is placed on a containment liner system (also known as a heap leach pad) and continuously sprayed or irrigated with a process solution, commonly referred to as barren solution, to wet the entire ore heap. The barren solution selectively extracts or leaches the valuable mineral(s) in the ore as the solution infiltrates through the ore heap. Thesolution collected after leaching which contains the targeted ,valuable mineral(s) is known as pregnant solution. The pregnant solution is collected at the bottom of the ore heap and is transported to processing equipment, where the targeted valuable mineral(s) are selectively separated or recovered and barren solution is recycled to the heap. If lower than desired targeted mineral concentration is achieved in the pregnant solution, this solution, often referred to a lean pregnant solution, can be recycled to the heap for further leaching.
[0005] One problem commonly faced in heap leach mining operations is the precipitation and accumulation of mineral scale deposits in process solution distribution systems. Such scale impairs or clogs the flow of the process solution which can result in such problems as incorrect or inadequate dosage of barren or lean pregnant solution added to the heap, damage to solution distribution systems, loss of effectiveness of the solution, and increased energy needed to pump the solution through the solution distribution system. Currently such problems are addressed by feeding scale control reagents to protect the solution distribution system against mineral scale related plugging or damage, and to assure adequate flow rates.
[0006] The quantity or dosage of scale control reagent required for effective deposit control is dependent upon soluble mineral concentrations in the process solution in combination with physical stresses that impact saturation levels. Saturation levels are often highly variable impacted by variations in ore subjected to leach, make-up water volume and composition, process additive rates, and physical stress changes. Dosage rates of scale control reagent are however commonly held constant, often resulting in overdose (reagent waste) or under dose (inadequate control of scale) as conditions vary.
[0007] There thus exists an ongoing need to develop alternative and more efficient methods of controlling scale control reagent dosages applied to process solution distribution systems including those used in heap leach mining operations.
[0008] The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 CFR § 1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
[0009] To satisfy the long-felt but unsolved needs identified above, at least one embodiment of the invention is directed towards a method of inhibiting the accumulation of scale on a surface in contact with a liquid medium. The method comprises the steps of: providing an solution distribution system comprising one or more of: piping, spray nozzles, emitter tubes, and any combination thereof having a length which defines more than one discrete region, each discrete region capable of having different surface temperatures; positioning at least one temperature sensor such that it is constructed and arranged to measure or predict the maximum surface temperature across all discrete regions within the solution distribution system; and applying a scale control reagent to a specific location in the solution distribution system when the measured or predicted surface temperature at that location exceeds a threshold required to initiate inverse solubility scale formation, at a reagent dosage required to prevent scale formation
[0010] Additional features and advantages are described herein, and will be apparent from, the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0012] FIG. 1 is an illustration of using an aspect of the invention to address scale in a heap leach mining operation.
[0013] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated. The drawings are only an exemplification of the principles of the invention and are not intended to limit the invention to the particular embodiments illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
[0015] “Consisting Essentially of” means that the methods and compositions may include additional steps, components, ingredients or the like, but only if the additional steps, components and/or ingredients do not materially alter the basic and novel characteristics of the claimed methods and compositions.
[0016] “Scale Control Reagent” means chemical reagents commonly applied for prevention of mineral scale deposition in aqueous solution environments falling in the general categories of threshold inhibitors, crystal modifiers, dispersants, sequestering agents, and or chelants. Common reagents may contain any combinations of these generic constituents.
[0017] “Heap Leaching” means an industrial mining process to extract precious metals including but not limited to copper, gold, silver, uranium, rare earth metals and other compounds from ore via the application to a heap of the ore of one or more liquid form chemical reagents that percolate through the heap and while so doing absorb specific minerals which then seep out of the heap.
[0018] “Emitter Tube” means a tube or flow line constructed and arranged to transport one or more fluids to a target area (such as for example an ore heap) and to allow for the application (often by dripping) of the fluid onto the target area.
[0019] In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk-Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc) this definition shall control how the term is to be defined in the claims.
[0020] At least one embodiment of the invention is directed towards the prevention of the formation and/or accumulation of scale in process solution distribution systems. Specifically the tendency of scale to form or accumulate at a specific localized spot along emitter tube's length, or in piping leading to the emitter tubes which may break loose and accumulate in the emitter tubes is identified and may be remedied, Piping and emitter tubes are commonly laid out in open areas where they allow for the gradual dripping of barren or lean pregnant solution onto a target area. These pipes and emitter tubes are often exposed to direct sunlight, sometimes in hot, sun intensive climates. In addition the specific materials the solution distribution systems are constructed out of can have high thermal absorbtion properties resulting in heat absorption and transfer to the inner wall of piping and emitter tubes. The cumulative effect is that specific localized portions of the piping and emitter tubes can become hot enough to effect inverse temperature solubility of many scale producing materials. For these materials when the temperature exceeds a threshold precipitation results.
[0021] With exposed piping and emitter tubes, the bulk solution as whole may have an average temperature that is below the threshold for scale formation, but localized pipe and emitter tube surface temperatures where solution contact occurs may be substantially hotter such that localized precipitation and scaling occurs. Once scale starts to form on these surface(s), the established scale can function as a seed or anchor on which more scale can rapidly accumulate.
[0022] In at least one embodiment prediction or measurement of piping and emitter tube heat transfer intensity can be utilized to predict scale control reagent dosage requirements. In at least one embodiment the scale produced is at least in part a result of exposure to sunlight and is therefore broadly predicted based upon ambient temperature, temperature change rates, and commonly available weather related measurements. In at least one embodiment the scale produced is at least in part a result of heat transfer resulting in solution temperature elevation and therefore localized heat intensity prediction may include bulk solution temperatures at various point in the solution distribution system, and temperature change rates.
[0023] In at least one embodiment temperature measurement using a detector or a device that can be used to infer a spike in temperature are used to determine the degree to which process piping or emitter tube's surfaces are being subjected to temperature elevation. In at least one embodiment scale control reagents are fed to a location where it has been. detected that temperature is such that scale would form. In at least one embodiment chemicals are only fed in such an amount or dosage to address the scale in the specific location. so detected. In at least one embodiment scale controlling chemicals are fed to a location where the temperature has exceeded the threshold for formation but insufficient time has elapsed for detectable amounts of scale to form.
[0024] In at least one embodiment the emitter tube is part of a heap leach mining operation. Representative examples of heap leach mining operations the invention may be used within and how emitter tubes are located therein are described at least in U.S. Pat. Nos. 5,030,279 and 4,960,584 and in U.S. Published Patent Application 2013/0125709.
[0025] In at least one embodiment the scale producing heat is at least in part a result of exposure to sunlight and is therefore detected via one or more sunlight measuring or detecting optical sensors. The sensor may be constructed and arranged to measure sunlight intensity and to calculate from that if the temperature of one or more localized locations along the emitter tube will exceed the threshold required for scale formation.
[0026] In at least one embodiment scale control reagent dosage is automatically adjusted if such a determination is made.
[0027] In at least one embodiment the temperature sensor is one item selected from the list consisting of: thermocouple, resistive temperature device, infrared detector, bimetallic device, liquid expansion device, and any combination thereof.
[0028] Referring now to FIG. 1 there is shown an application of the invention. Ore is collected into a heap ( 1 ) lying on a pad ( 4 ). Onto the heap barren solution ( 2 ) is fed via a process distribution system which may comprise a series of emitter tubes each with one or more opening in an emitter tube ( 3 ) and which may open into one or more nozzles. As the solution percolates through the heap ( 1 ) it leaches or solubilizes valuable minerals into pregnant solution which is collected and transferred to a processing plant where the valuable mineral ( 8 ) is then separated from the reagent through one or more recovery processes ( 6 ). In some operations multiple pad area are under leach simultaneously or intermittently, and low concentration pregnant solutions may be recycled back to the heap for additional leaching.
[0029] Because of such variables as tube shape, position, exposure to elements, exposure to sunlight, etc. it is quite likely that the surface of pipint and emitter tubes at one location will become hotter than another location and will become an anchor for scale formation. As a result respectively located sensors may be used to detect localized temperature spikes that can cause scale.
[0030] In at least one embodiment the dosage of the scale control reagent ( 7 ) is so dosed as to assure that adequate dosage of scale control reagent is applied under high temperature stress conditions, and that reduced dosage is applied when temperature stress is relieved.
[0031] In at least one embodiment the scale comprises at least in part CaCO 3 or other common mineral scale forming compound
[0032] In at least one embodiment the scale control reagent is applied according to the methods described in U.S. Pat. No. 5,368,830.
[0033] In at least one embodiment in response to the detection and/or anticipation of at least one localized hot spot in at least a portion of a process distribution system a scale control reagent is introduced into the process distribution system. Such an introduced reagent may be directed to: the localized hot spot, some overall percentage of the process distribution system, or throughout the entire process distribution system. The reagent may be introduced such that it is present wherever the barren solution is also present within the process distribution system. The reagent may be fed in such a manner that it remains present within the hot spot or other portions of the process distribution system for some or all of the time that the detected and/or anticipated temperature spike is manifest. In at least one embodiment the reagent can then be gradually or rapidly cut off from the process distribution system as the localized temperature spike declines or disappears.
[0034] In at least one embodiment a hot simulator is used increase the effectiveness and/or efficiency of a sensor or anticipation method. Often in process distribution systems the pumps that feed reagent or other materials into the pipes and tubes are located quite a distance from the emitter tubes or nozzles, this distance can be 1, 2-10, or more miles. In a hot simulator a section of tubing made from the identical materials as an emitter tube or nozzle and is located within 1000 feet of a pump and affixed to it is a heat sensor. This tubing may or may not be in fluidic communication with the process distribution system and will mirror what is happening downstream in the process distribution system. The closely positioned tubing allows for monitoring of heat spikes without the need for complicated wired or wireless transmission systems. In at least one embodiment scale control reagent is fed into at least a portion of the process distribution system in response to a measurement of a heat spike in a hot simulator and/or in response to the anticipation of a heat spike in a hot simulator. While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments mentioned herein, described herein and/or incorporated herein. In addition the invention encompasses any possible combination that also specifically excludes any one or some of the various embodiments mentioned herein, described herein and/or incorporated herein.
[0035] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0036] All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of I or more, (e.g. 1 to 6.1.), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range. All percentages, ratios and proportions herein are by weight unless otherwise specified.
[0037] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
|
The invention provides methods, compositions, and apparatuses for preventing the formation of scale in heap leach process solution distribution systems comprised of piping, spray nozzels, or emitter tubes. Solution distribution system components often become fouled by scale because of local hot spots more prone to form scale than other locations along the systems length. Positioning sensors that detect periods of high temperature stress and adjusting scale control reagent dosage to send the right amount to inhibit hot spot deposition allows for the control of scale without using wasteful excessive amounts of scale control reagents. This can vastly improve scale control performance under high temperature stress conditions while minimizing scale control reagent waste under less severe stress conditions to reduce the total operating cost of running heap leach mining operations which depend upon well-functioning solution distribution systems
| 2
|
BACKGROUND OF THE INVENTION
[0001] Polycarbonates and their copolymers with polyesters are known thermoplastics valued for their optical clarity as well as their physical and thermal properties. Most of the monomers used to prepare these polymers are ultimately derived from petroleum. With the projected decline in global petroleum reserves over the coming decades, there is a strong desire to identify renewable sources of starting materials for polycarbonate-polyester copolymers. Particularly for applications in which the use of an article molded from a polycarbonate-polyester copolymer is fleeting, there is also a desire for polycarbonate-polyester copolymers with biodegradable linkages that facilitate structural decomposition of the article. There is therefore a desire for new polycarbonate-polyester copolymers that can be prepared using renewable starting materials and that include biodegradable linkages.
BRIEF DESCRIPTION OF THE INVENTION
[0002] The above-described and other drawbacks are alleviated by a polycarbonate-polyester block copolymer, comprising: a polycarbonate block having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; Y is —O— or —O—R 2 —R 3 —O—; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; and n is 2 to about 200; and an aliphatic polyester block having the structure
[0000]
[0000] wherein each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; and q is 2 to about 1,000.
[0003] Another embodiment is a polycarbonate-polylactide block copolymer, comprising: a polycarbonate block having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and a polylactide block having the structure
[0000]
[0000] wherein q 1 is about 50 to about 500.
[0004] Another embodiment is a polycarbonate-polyester diblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; R 2 is a C 6 -C 18 arylene group; R 3 is a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; R 6 is C 6 -C 18 aryl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; n is 2 to about 200; and q is 2 to about 1,000.
[0005] Another embodiment is a polycarbonate-polyester triblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; n is 2 to about 200; and each occurrence of q is 2 to about 1,000.
[0006] Another embodiment is a polycarbonate-polyester diblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; R 2 is a C 6 -C 18 arylene group; R 3 is a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; each occurrence of R 6 is independently a C 6 -C 18 aryl group; n is 2 to about 200; q is 2 to about 1,000; and x is 0 or 1.
[0007] Another embodiment is a polycarbonate-polyester triblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; each occurrence of R 6 is independently a C 6 -C 18 aryl group; n is 2 to about 200; each occurrence of q is 2 to about 1,000; and x is 0 or 1.
[0008] Another embodiment is a polycarbonate-polylactide diblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and q 1 is about 50 to about 500.
[0009] Another embodiment is a polycarbonate-polylactide triblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and each occurrence of q 1 is about 50 to about 500.
[0010] Another embodiment is a polycarbonate-polylactide diblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and q 1 is about 50 to about 500.
[0011] Another embodiment is a polycarbonate-polylactide triblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and each occurrence of q 1 is about 50 to about 500.
[0012] Another embodiment is a composition, comprising: a polycarbonate; and a polycarbonate-polyester block copolymer comprising a polycarbonate block having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; Y is —O— or —O—R 2 —R 3 —O—; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; and n is 2 to about 200; and an aliphatic polyester block having the structure
[0000]
[0000] wherein each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; and q is 2 to about 1,000.
[0013] Another embodiment is a method of preparing a polycarbonate-polyester block copolymer, comprising: conducting a ring-opening polymerization of an aliphatic cyclic ester in the presence of a polycarbonate to form an uncapped polycarbonate-polyester block copolymer; wherein the polycarbonate has the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; Y 1 is C 6 -C 18 aryl or —R 2 —R 3 —OH; and n is 2 to about 200.
[0014] Another embodiment is a method of preparing a polycarbonate-polylactide block copolymer, comprising: conducting a ring-opening polymerization of a lactide in the presence of a polycarbonate to form an uncapped polycarbonate-polylactide block copolymer; wherein the polycarbonate has the structure
[0000]
[0000] wherein R 9 is
[0000]
[0000] and n 1 is about 20 to about 200.
[0015] These and other embodiments, including articles comprising the block copolymers or block copolymer-containing compositions, are described in detail below.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present inventors have discovered that polycarbonate-polyester block copolymers can be prepared by ring-opening polymerization of a cyclic ester in the presence of a polycarbonate with at least one alcohol end group. Many of the cyclic esters suitable for use in the method can be derived from renewable resources. For example, the cyclic dimers known as lactides can be derived from corn.
[0017] One embodiment is a polycarbonate-polyester block copolymer, comprising: a polycarbonate block having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; Y is —O— or —O—R 2 —R 3 —O—; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; and n is 2 to about 200; and an aliphatic polyester block having the structure
[0000]
[0000] wherein each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; and q is 2 to about 1,000.
[0018] In the context of the polycarbonate block, the number of repeat units n can be 2 to about 200, specifically about 20 to about 200, more specifically about 20 to about 100, still more specifically about 20 to about 50. With respect to the divalent group R 1 in the polycarbonate repeat unit, at least about 60 percent of the total number of R 1 groups contain aromatic moieties, and the balance thereof are aliphatic or alicyclic. In one embodiment, each R 1 is a C 6 -C 30 aromatic group, which is a group that contains at least one aromatic moiety. R 1 can be derived from a dihydroxy compound of the formula HO—R 1 —OH, in particular a dihydroxy compound of the formula
[0000] HO-A 1 -Y 1 -A 2 -OH
[0000] wherein each of A 1 and A 2 is a monocyclic divalent aromatic group and Y 1 is a single bond or a bridging group having one or more atoms that separate A 1 from A 2 . In an exemplary embodiment, one atom separates A 1 from A 2 . In one specific embodiment, the polycarbonate is a linear homopolymer derived from bisphenol A, in which each of A 1 and A 2 is p-phenylene and Y 1 is isopropylidene. In this embodiment, R 1 has the structure
[0000]
[0019] In some embodiments, each R 1 can be derived from a dihydroxy aromatic compound of the formula
[0000]
[0000] wherein R a and R b each represent a halogen or C 1 -C 12 alkyl group and can be the same or different; and y and z are each independently integers of 0, 1, 2, 3, 4, or 5. It will be understood that R a is hydrogen when y is 0, and likewise R b is hydrogen when z is 0. Also, X a represents a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C 6 arylene group are disposed ortho, meta, or para to each other on the C 6 arylene group. In one embodiment, the bridging group X a is single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1 -C 18 unsubstituted or substituted hydrocarbylene group. As used herein, the term “hydrocarbyl”, whether used by itself, or as a prefix, suffix, or fragment of another term, refers to a residue that contains only carbon and hydrogen. The residue can be aliphatic or aromatic, straight-chain, cyclic, bicyclic, branched, saturated, or unsaturated. It can also contain combinations of aliphatic, aromatic, straight chain, cyclic, bicyclic, branched, saturated, and unsaturated hydrocarbon moieties. However, when the hydrocarbyl residue is described as substituted, it may, optionally, contain heteroatoms such as halogens, oxygen, nitrogen, sulfur, silicon, or phosphorous over and above the carbon and hydrogen members of the substituent residue. The C 1 -C 18 hydrocarbylene group can be disposed such that the C 6 arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C 1 -C 18 hydrocarbylene group. In one embodiment, y and z are each 1, and R a and R b are each a C 1 -C 3 alkyl group, specifically methyl, disposed meta to the hydroxy group on each arylene group.
[0020] In one embodiment, X a is a substituted or unsubstituted C 3 -C 18 cycloalkylidene; a C 1 -C 25 alkylidene of formula —C(R c )(R d )— wherein R e and R d are each independently hydrogen, C 1 -C 12 alkyl, C 3 -C 12 cycloalkyl, C 7 -C 12 arylalkyl, C 1 -C 12 heteroallyl, or cyclic C 7 -C 12 heteroarylalkyl, or a group of the formula —C(═R e )— wherein R e is a divalent C 1 -C 12 hydrocarbon group. Exemplary groups of this type include methylene, cyclohexylmethylene, ethylidene, neopentylidene, and isopropylidene, as well as 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene. A specific example wherein X a is a substituted cycloalkylidene is the cyclohexylidene-bridged, alkyl-substituted bisphenol of the formula
[0000]
[0000] wherein R a ′ and R b ′ are each independently C 1 -C 12 alkyl, R g is C 1 -C 12 alkyl or halogen, r and s are each independently 1 to 4, and t is 0 to 10. In a specific embodiment, at least one of each of R a ′ and R b ′ are disposed meta to the cyclohexylidene bridging group. The substituents R a ′, R b ′, and R g may, when comprising an appropriate number of carbon atoms, be straight chain, cyclic, bicyclic, branched, saturated, or unsaturated. In an embodiment, R a ′ and R b ′ are each independently C 1 -C 4 alkyl, R g is C 1 -C 4 allyl, r and s are each 1, and t is 0 to 5. In another specific embodiment, R a ′, R b ′ and R g are each methyl, r and s are each 1, and t is 0 or 3. The cyclohexylidene-bridged bisphenol can be the reaction product of two moles of o-cresol with one mole of cyclohexanone. In another exemplary embodiment, the cyclohexylidene-bridged bisphenol is the reaction product of two moles of a cresol with one mole of a hydrogenated isophorone (for example, 1,1,3-trimethyl-3-cyclohexane-5-one). Such cyclohexane-containing bisphenols, for example the reaction product of two moles of a phenol with one mole of a hydrogenated isophorone, are useful for making polycarbonate polymers with high glass transition temperatures and high heat distortion temperatures. Cyclohexyl bisphenol-containing polycarbonates, or a combination comprising at least one of the foregoing with other bisphenol polycarbonates, are supplied by Bayer Co. under the APEC® trade name.
[0021] In another embodiment, X a is a C 1 -C 18 alkylene group, a C 3 -C 18 cycloalkylene group, a fused C 6 -C 18 cycloalkylene group, or a group of the formula —B 1 —W—B 2 — wherein B 1 and B 2 are the same or different C 1 -C 6 alkylene group and W is a C 3 -C 12 cycloalkylidene group or a C 6 -C 16 arylene group.
[0022] X a can also be a substituted C 3-18 cycloalkylidene of the formula
[0000]
[0000] wherein R r , R p , R q , and R t are independently hydrogen, halogen, oxygen, or a C 1 -C 12 unsubstituted or substituted hydrocarbyl group; I is a direct bond, a carbon, or a divalent oxygen, sulfur, or —N(Z)- where Z is hydrogen, halogen, hydroxy, C 1 -C 12 alkyl, C 1 -C 12 alkoxy, or C 1 -C 12 acyl; h is 0, 1, or 2, provided that h is 0 when I is a direct bond, a divalent oxygen, sulfur, or —N(Z)-; j is 1 or 2; i is 0 or 1; and k is 0, 1, 2, or 3, provided that at least two of R r , R p , R q , and R t taken together are a fused cycloaliphatic, aromatic, or heteroaromatic ring. It will be understood that where the fused ring is aromatic, the ring as shown in the preceding structure will have an unsaturated carbon-carbon linkage where the ring is fused. When k is one and i is 0, the ring as shown in the preceding structure contains 4 carbon atoms, when k is 2, the ring as shown in the preceding structure contains 5 carbon atoms, and when k is 3, the ring contains 6 carbon atoms. In one embodiment, two adjacent groups (for example, R q and R t taken together) form an aromatic group, and in another embodiment, R q and R t taken together form one aromatic group and R r and R p taken together form a second aromatic group. When R q and R t taken together form an aromatic group, R p can be a double-bonded oxygen atom, that is, a ketone.
[0023] Other useful aromatic dihydroxy compounds of the formula HO—R 1 —OH include compounds of the formula
[0000]
[0000] wherein each R h is independently a halogen atom, a C 1 -C 10 hydrocarbyl such as a C 1 -C 10 alkyl group, a halogen-substituted C 1 -C 10 alkyl group, a C 6 -C 10 aryl group, or a halogen-substituted C 6 -C 10 aryl group, and n is 0 to 4. In some embodiments, the halogen is bromine.
[0024] Some illustrative examples of specific aromatic dihydroxy compounds include the following: 4,4′-dihydroxybiphenyl, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)diphenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis (hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)isobutene, 1,1-bis(4-hydroxyphenyl)cyclododecane, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 2,2-bis(4-hydroxyphenyl)adamantane, alpha, alpha′-bis(4-hydroxyphenyl)toluene, bis(4-hydroxyphenyl)acetonitrile, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 4,4′-dihydroxybenzophenone, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, 9,9-bis(4-hydroxyphenyl)fluorine, 2,7-dihydroxypyrene, 6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindane bisphenol”), 3,3-bis(4-hydroxyphenyl)phthalimide, 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and 2,7-dihydroxycarbazole, resorcinol, substituted resorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenyl resorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol, 2,4,5,6-tetrabromo resorcinol, or the like; catechol; hydroquinone; substituted hydroquinones such as 2-methyl hydroquinone, 2-ethyl hydroquinone, 2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone, 2-phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, and the like, as well as combinations comprising at least one of the foregoing dihydroxy compounds.
[0025] Further examples of bisphenol compounds include 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)propane (hereinafter “bisphenol A” or “BPA”), 2,2-bis(4-hydroxyphenyl)butane, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl)propane, 3,3-bis(4-hydroxyphenyl)phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). Combinations comprising at least one of the foregoing dihydroxy compounds can also be used. The polycarbonate block may also comprise a polysiloxane-polycarbonate copolymer.
[0026] The polycarbonate block includes an R 2 group and an R 3 group at each end. Each occurrence of R 2 is independently a C 6 -C 18 arylene group, and each occurrence of R 3 is independently a C 1 -C 12 alkylene group. In some embodiments, R 2 is unsubstituted or substituted phenylene (including 1,2-phenylene, 1,3-phenylene, and 1,4-phenylene), and R 3 is C 1 -C 6 alkylene. In some embodiments, R 2 is 1,4-phenylene, and R 3 is methylene.
[0027] The block copolymer includes at least one aliphatic polyester block having the structure
[0000]
[0000] wherein each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; and q is 2 to about 1,000, specifically about 10 to about 800, more specifically about 20 to about 600. In some embodiments, each occurrence of R 4 and R 5 is hydrogen, and p has a value of 1, 2, 3, or 4. In some embodiments, each occurrence of R 4 is hydrogen, each occurrence of R 5 is hydrogen or methyl, and p is 0. In these embodiments, the polyester block is a polyglycolide (R 5 is hydrogen) or a polylactide (R 5 is methyl). When R 4 and R 5 are different, the carbon atom to which they are attached is chiral, and it may have any possible stereochemistry. For example, when R 4 is hydrogen and R 5 is methyl and p is 0, the polyester block may be a poly(L-lactide), a poly(D-lactide), or poly(rac-lactide). In some embodiments, each occurrence of R 4 and R 5 is hydrogen and p is 3; in these embodiments, the polyester block is poly(6-valerolactone). In some embodiments, each occurrence of R 4 and R 5 is hydrogen and p is 4; in these embodiments, the polyester block is poly(ε-caprolactone).
[0028] In addition to the polycarbonate block and the polyester block, the polycarbonate-polyester block copolymer can, optionally, further comprising an end group (especially an end group bound to the polyester block) having the structure
[0000]
[0000] wherein R 6 is a C 6 -C 18 aryl group; and x is 0 or 1. As demonstrated in the working examples below, such aromatic carbonate end groups thermally stabilize the block copolymer. Specific end groups include, for example,
[0000]
[0029] In addition to the polycarbonate block and the polyester block, the polycarbonate-polyester block copolymer can, optionally, further comprising an end group (especially an end group bound to the polycarbonate block) that is a C 6 -C 18 aryl group. Specific C 6 -C 18 aryl groups include, for example,
[0000]
[0030] The polycarbonate-polyester block copolymer can be a diblock copolymer. That is, its polymer blocks can consist of one polycarbonate block and one polyester block. Alternatively, the polycarbonate-polyester block copolymer can be a triblock copolymer. That is, its polymer blocks can consist of one polycarbonate block, and two polyester blocks.
[0031] One embodiment is a polycarbonate-polylactide block copolymer, comprising: a polycarbonate block having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and a polylactide block having the structure
[0000]
[0000] wherein q 1 is about 50 to about 500. This block copolymer can be a diblock copolymer in which the polymer blocks consist of one polycarbonate block and one polylactide block. Alternatively, it can be a triblock copolymer in which the polymer blocks consist of one polycarbonate block and two polylactide blocks. The polycarbonate-polylactide block copolymer may further comprise an end group having the structure
[0000]
[0000] For example, the polycarbonate-polylactide block copolymer can comprise two end groups each independently having the structure
[0000]
[0032] In addition to being described in terms of its component polymer blocks, the polycarbonate-polyester block copolymer may be described in terms of its complete structure. For example, in some embodiments, the polycarbonate-polyester block copolymer is a diblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; R 2 is a C 6 -C 18 arylene group; R 3 is a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; R 6 is C 6 -C 18 aryl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50; and q is 2 to about 1,000, specifically about 10 to about 500, more specifically about 50 to about 500, more specifically about 100 to about 500, even more specifically about 150 to about 500.
[0033] In another embodiment, the polycarbonate-polyester block copolymer is an uncapped triblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50; and each occurrence of q is 2 to about 1,000, specifically about 10 to about 500, more specifically about 50 to about 500, more specifically about 100 to about 500, even more specifically about 150 to about 500.
[0034] In another embodiment, the polycarbonate-polyester block copolymer is a capped diblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; R 2 is a C 6 -C 18 arylene group; R 3 is a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; each occurrence of R 6 is independently a C 6 -C 18 aryl group; n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50; q is 2 to about 1,000, specifically about 10 to about 500, more specifically about 50 to about 500, more specifically about 100 to about 500, even more specifically about 150 to about 500; and x is 0 or 1.
[0035] In another embodiment, the polycarbonate-polyester block copolymer is a capped triblock copolymer having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; each occurrence of R 6 is independently a C 6 -C 18 aryl group; n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50; each occurrence of q is 2 to about 1,000, specifically about 10 to about 500, more specifically about 50 to about 500, more specifically about 100 to about 500, even more specifically about 150 to about 500; and x is 0 or 1.
[0036] In another embodiment, the polycarbonate-polyester block copolymer is an uncapped polycarbonate-polylactide diblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and q 1 is about 50 to about 500.
[0037] In another embodiment, the polycarbonate-polyester block copolymer is an uncapped polycarbonate-polylactide triblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and each occurrence of q 1 is about 50 to about 500.
[0038] In another embodiment, the polycarbonate-polyester block copolymer is a capped polycarbonate-polylactide diblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and q 1 is about 50 to about 500.
[0039] In another embodiment, the polycarbonate-polyester block copolymer is a capped polycarbonate-polylactide triblock copolymer having the structure
[0000]
[0000] wherein n 1 is about 20 to about 200; and each occurrence of q 1 is about 50 to about 500.
[0040] Other embodiments include methods of preparing the polycarbonate-polyester block copolymer. Thus, one embodiment is a method of preparing a polycarbonate-polyester block copolymer, comprising: conducting a ring-opening polymerization of an aliphatic cyclic ester in the presence of a polycarbonate containing at least one alcohol end group to form an uncapped polycarbonate-polyester block copolymer; wherein the polycarbonate has the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; Y 1 is C 6 -C 18 aryl or —R 2 —R 3 —OH; and n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50.
[0041] Aliphatic cyclic esters suitable for use in the method include, for example, glycolide, lactides (including L,L-lactide, D,D-lactide, and rac-lactide), β-propiolactone, β-butyrolactone, γ-butyrolactone, δ-valerolactone, ε-caprolactone, and mixtures thereof. In some embodiments, the cyclic ester is L,L-lactide or rac-lactide.
[0042] The ring-opening polymerization is typically conducted in the presence of a catalyst. Suitable catalysts include, for example, stannous ethoxide, stannous n-butoxide, stannous octoate, magnesium ethoxide, aluminum isopropoxide, zinc n-butoxide, titanium n-butoxide, zirconium n-propoxide, dibutyltin dimethoxide, tributyltin methoxide, and mixtures thereof. Enzymatic catalysts can also be used. In some embodiments, the catalyst comprises comprising stannous octoate (also known as stannous 2-ethylhexanoate; CAS Reg. No. 301-10-0).
[0043] The ring-opening polymerization may be conducted in solution (that is, in the presence of a solvent), or in “bulk” or “melt” (that is, in the absence of a solvent). Solvents suitable for use in solution ring-opening polymerization include, for example, chlorinated solvents (including methylene chloride), tetrahydrofuran, benzene, toluene, and the like, and mixtures thereof.
[0044] The method can, optionally, further include capping the uncapped polycarbonate-polyester block copolymer. Suitable capping agents include, for example, aryl chloroformates (such as phenyl chloroformate), aromatic acid halides (such as benzoyl chloride and toluoyl chlorides), aromatic anhydrides (such as benzoic anhydride), and mixtures thereof.
[0045] One embodiment is a method of preparing a polycarbonate-polylactide block copolymer, comprising: conducting a ring-opening polymerization of a lactide in the presence of a polycarbonate with at least one alcohol end group to form an uncapped polycarbonate-polylactide block copolymer; wherein the polycarbonate has the structure
[0000]
[0000] wherein R 9 is
[0000]
[0000] and n 1 is about 20 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50. The method can, optionally, further comprise reacting the uncapped polycarbonate-polylactide block copolymer with phenyl chloroformate to form a phenyl carbonate-capped polycarbonate-polylactide block copolymer.
[0046] Other embodiments include compositions comprising the polycarbonate-polyester block copolymer. For example, one embodiment is a composition, comprising: a polycarbonate; and a polycarbonate-polyester block copolymer comprising a polycarbonate block having the structure
[0000]
[0000] wherein each occurrence of R 1 is independently a C 6 -C 60 divalent hydrocarbon group, provided that at least 60% of the R 1 groups comprise aromatic moieties; Y is —O— or —O—R 2 —R 3 —O—; each occurrence of R 2 is independently a C 6 -C 18 arylene group; each occurrence of R 3 is independently a C 1 -C 12 alkylene group; and n is 2 to about 200, specifically about 10 to about 100, more specifically about 20 to about 50; and an aliphatic polyester block having the structure
[0000]
[0000] wherein each occurrence of R 4 and R 5 is independently hydrogen or C 1 -C 12 alkyl; each occurrence of p is independently 0, 1, 2, 3, 4, or 5; and q is 2 to about 1,000, specifically about 10 to about 500, more specifically about 50 to about 500, more specifically about 100 to about 500, even more specifically about 150 to about 500. Polycarbonates that are suitable for blending with the polycarbonate-polyester block copolymer include those comprising repeating units having the structure
[0000]
[0000] wherein R 1 has the same definition used above in the context of the polycarbonate block of the polycarbonate-polyester block copolymer. The polycarbonate can have an intrinsic viscosity, as determined in chloroform at 25° C., of about 0.3 to about 1.5 deciliters per gram (dl/gm), specifically about 0.45 to about 1.0 dl/gm. The polycarbonates can have a weight average molecular weight of about 10,000 to about 200,000 atomic mass units, specifically about 20,000 to about 100,000 atomic mass units, as measured by gel permeation chromatography (GPC) using a crosslinked styrene-divinylbenzene column and calibrated to polycarbonate references. GPC samples are prepared at a concentration of about 1 milligram/milliliter, and are eluted at a flow rate of about 1.5 milliliters/minute. The composition can comprise the polycarbonate and the polycarbonate-polyester block copolymer in a weight ratio of about 1:99 to about 99:1, specifically about 10:90 to about 90:10, more specifically about 20:80 to about 80:20. The composition comprising the polycarbonate and the polycarbonate-polyester block copolymer may be prepared by polymer blending methods known in the art, including solution blending and melt blending (for example, melt kneading in an extruder).
[0047] Other embodiments include articles comprising the polycarbonate-polyester block copolymer or a composition comprising the polycarbonate-polyester block copolymer. The polycarbonate-polyester block copolymer is particularly useful for fabricating articles including mobile phone A-covers (front covers), shavers, razors, notebooks, automotive and transportation parts, medical parts and housings, and disposable packaging.
[0048] The invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
[0049] This example describes the preparation of a polycarbonate. The following were added into a 80 L continuously stirred tank reactor (CSTR) equipped with an overhead condenser and a recirculation pump with a flow rate of 40 L/minute: (a) Bisphenol A (5000 grams, 21.9 mole); (b) methylene chloride (26.7 L); (c) deionized water (13.5 liters), (d) 4-hydroxybenzyl alcohol (81.7 grams, 0.66 mole) (e) sodium gluconate (10 grams); and (f) triethylamine (30 grams). Phosgene (2862 grams, 28.9 moles) was added at a rate of 165 grams/minute with simultaneous addition of base (50 weight percent NaOH in deionized water) to maintain the pH of the reaction between 9 and 10. After the complete addition of phosgene, the reaction mixture was purged with nitrogen gas, and the organic layer was extracted. The organic extract was washed once with dilute hydrochloric acid (HCl), and subsequently washed with deionized water by centrifugation. The organic layer was precipitated from methylene chloride into hot steam. The polymer was dried under hot nitrogen before analysis. The polycarbonate product displayed the following characteristics: weight average molecular weight (M w )=27,000, polydispersity index (PDI; M w /M n )=2.4; T g =153° C.
EXAMPLE 2
[0050] This example describes the preparation of a partially capped polycarbonate. The following were added into a 80 liter CSTR equipped with an overhead condenser and a recirculation pump with a flow rate of 40 liters/minute: (a) bisphenol A (5,000 grams, 21.9 moles); (b) methylene chloride (26.7 liters); (c) deionized water (13.5 liters), (d) 4-hydroxybenzyl alcohol (61.3 grams, 0.49 moles) (e) paracumylphenol (35.9 grams, 0.17 moles), (f) sodium gluconate (10 grams); and (g) triethylamine (30 grams). Phosgene (2862 grams, 165 grams/minute, 28.9 moles) was added with simultaneous addition of base (50 weight percent NaOH in deionized water) to maintain the pH of the reaction between 9 and 10. After the complete addition of phosgene, the reaction mixture was purged with nitrogen gas, and the organic layer was extracted. The organic extract was washed once with dilute hydrochloric acid (HCl), and subsequently washed with deionized water by centrifugation. The organic layer was precipitated from methylene chloride into hot steam. The polymer was dried under hot nitrogen before analysis. The polycarbonate product displayed the following characteristics: M w =34,800, PDI=3.95; T g =153° C. It should be noted that polycarbonate product is expected to be a mixture of polycarbonate molecules with two 4-hydroxymethylphenyl end groups, one 4-hydroxymethylphenyl end group and one 4-cumylphenyl end group, and two 4-cumylphenyl end groups.
EXAMPLE 3
[0051] This example describes the preparation of a polycarbonate-polylactide block copolymer using a solution polymerization method.
[0052] In general, of polycarbonate-polyester copolymers were prepared by solution (that is, in the presence of solvent) or bulk (or melt; that is, in the absence of solvent) ring-opening polymerization of a cyclic ester in the presence of a polycarbonate and a catalyst for the ring-opening polymerization. The polycarbonate starting materials were crushed using a mortar and pestle and dried in an oven set at 110° C. for at least four hours. The cyclic ester monomers were kept in a refrigerator when not being used. Stannous octoate (Sn(Oct) 2 ; CAS Reg. No. 301-10-1) was used as the catalyst for the reactions. All glassware was dried overnight in an oven set at 180° C. All reactions were performed under N 2 .
[0053] In a typical reaction, 10.0 grams of racemic lactide (rac-LA; CAS Reg. No. 95-96-5; 0.07 moles), 5 grams of crushed polycarbonate from Example 1 (0.044 millimoles), and 100 milliliters of toluene were added to a 3-necked round bottom flask equipped with a magnetic stir bar, a condenser, and a N 2 inlet and outlet. The solution and contents were allowed to heat to reflux until all of the reactants were completely dissolved. Once dissolved, 2.6 grams (0.56 millimoles) of a Sn(Oct) 2 catalyst solution diluted in toluene was injected into the reaction flask. The reaction was allowed to stir for 1 hour. The solution was allowed to cool, and the product was dissolved in methylene chloride and precipitated drop-wise into methanol. The precipitate was dried in an oven set at 110° C. The M w was measured to be 35,880 g/mol and PDI was 1.47 (relative to polycarbonate standards).
EXAMPLE 4
[0054] This example describes the preparation of a polycarbonate-polylactide block copolymer using a solution polymerization method. In a typical reaction, 5.0 grams of rac-LA (0.035 moles), 5 grams of crushed polycarbonate from Example 1 (0.044 millimoles), and 100 milliliters of toluene were added to a 3-necked round bottom flask equipped with a magnetic stir bar, a condenser, and a N 2 inlet and outlet. The solution and contents were allowed to heat to reflux until all of the reactants were completely dissolved. Once dissolved, 2.6 grams (0.56 millimoles) of a Sn(Oct) 2 catalyst solution diluted in toluene was injected into the reaction flask. The reaction was allowed to stir for 1 hour. The solution was allowed to cool, and the product was dissolved in methylene chloride and precipitated drop-wise into methanol. The precipitate was dried in an oven set at 110° C. The M w was measured to be 51,317 g/mol and PDI was 1.4 (relative to polycarbonate standards).
EXAMPLE 5
[0055] This example describes the preparation of a polycarbonate-polylactide block copolymer using a melt polymerization method. In a typical reaction, 10.0 grams of dry polycarbonate from Example 2 (1.6 millimoles) and 10.0 grams of rac-LA (0.07 mole) were charged to a 3-necked round bottom flask equipped with an overhead mechanical stirrer and a N 2 inlet and outlet. The flask was submersed into an oil bath thermostatted to 155° C., and the contents in the flask were stirred until completely melted. Once the contents were melted, a catalytic amount of Sn(Oct) 2 was added to the flask (0.25-0.5 millimole Sn(Oct) 2 ). The reaction mixture was allowed to stir for 1 hour. After the allotted time, the flask and contents were allowed to cool, and the product was dissolved in CH 2 Cl 2 and precipitated slowly into stirring methanol. The solid was dried in an oven set at 110° C. before further characterization. The M w was measured to be 28,356 g/mol and PDI was 4.7 (relative to polycarbonate standards). Although it was unexpected that the product M w values would be less than that for the polycarbonate starting material, this may be attributable to an offset between gel permeation chromatography retention times for the polycarbonate standards and product block copolymers, which have different solubility parameters in the eluent, methylene chloride.
EXAMPLE 6
[0056] This example describes the preparation of a polycarbonate-polylactide block copolymer using a melt polymerization method. 5.0 grams of dry polycarbonate from Example 2 (0.8 millimoles) and 10.0 grams of rac-LA (0.07 moles) were charged to a 3-necked round bottom flask equipped with an overhead mechanical stirrer and a N 2 inlet and outlet. The flask was submersed into an oil bath thermostatted to 160° C., and the contents in the flask were stirred until completely melted. Once the contents were melted, a catalytic amount of Sn(Oct) 2 was added to the flask (0.25-0.5 millimole Sn(Oct) 2 ). The polymerization was allowed to stir for 1 hour. After the allotted time, the flask and contents were allowed to cool, and the product was dissolved in CH 2 Cl 2 and precipitated slowly into stirring methanol. The solid was dried in an oven set at 110° C. before further characterization. The M w was measured to be 38,398 g/mol and PDI was 1.5 (relative to polycarbonate standards).
EXAMPLE 7
[0057] This example describes the preparation of a polycarbonate-polylactide block copolymer using a melt polymerization method. Into a 1 L 3-necked round bottom flask equipped with an overhead mechanical stirrer, a thermocouple, and a N 2 inlet and outlet was charged 125.0 grams of the polycarbonate from Example 2 (20 millimoles) and 125.0 grams of L,L-lactide (0.87 moles). The flask was place in a heating mantle and the thermocouple was plugged into a variable control temperature device set to a temperature of 190° C. The contents in the flask were stirred until completely melted. Once the contents were melted, a catalytic amount of Sn(Oct) 2 was added to the flask (5.0 millimoles Sn(Oct) 2 ). The polymerization was allowed to stir for 2 hours. After the allotted time, the flask and contents were allowed to cool, and the product was dissolved in CH 2 Cl 2 and precipitated slowly into stirring methanol. The solid was dried in an oven set at 110° C. before further characterization. The M w was measured to be 25,801 g/mol and PDI was 3.8 (relative to polycarbonate standards).
EXAMPLE 8
[0058] This example describes chain end modification of a polycarbonate-polylactide block copolymer. Prior to the reaction, the polycarbonate-polylactide block copolymer prepared in Example 3 was dried in an oven set at 110° C. overnight. Into a 3-necked round bottom flask was charged 5 grams of the polycarbonate-polylactide block copolymer (0.41 millimoles hydroxy groups theoretically, 30 milliliters of tetrahydrofuran (THF), and 0.12 grams of phenyl chloroformate (0.77 millimoles). The reactants were allowed to stir under N 2 , and then 0.1 grams of triethylamine (1.0 millimole) was added drop wise by syringe into the flask. The triethylammonium hydrochloride (TEA-HCl) precipitate was filtered and disposed, and the product was precipitated drop-wise into stirring excess methanol. The material was dried in an oven set at 110° C. The M w was measured to be 38,370 g/mol and PDI was 1.6 (relative to polycarbonate standards).
EXAMPLE 9
[0059] This example describes chain end modification of a polycarbonate-polylactide block copolymer. The Example 5 polycarbonate-polylactide block copolymer was transformed into a phenyl carbonate capped polycarbonate-polylactide block copolymer using the method described in Example 8. The M w was measured to be 29,110 g/mol and PDI was 2.5 (relative to polycarbonate standards).
EXAMPLE 10
[0060] This example describes chain end modification of a polycarbonate-polylactide block copolymer. Into a 1 L 3-necked round bottom flask, 80.0 grams of the Example 8 polycarbonate-polylactide block copolymer (26.8 millimoles total hydroxy groups), 500 milliliters of THF, and 4.2 grams phenyl chloroformate (26.8 millimoles) was combined and stirred until completely dissolved. Using a syringe, 3 grams of triethylamine (30 millimoles) was added drop-wise to the flask. The TEA-HCl precipitate was filtered, and the polymer was concentrated by removing approximately 250 milliliters of THF under vacuum. The polymer was precipitated into stirring methanol (1 liter). The M w was measured to be 20,953 g/mol and PDI was 3.1 (relative to polycarbonate standards).
Characterization of Polycarbonate-Polylactide Copolymers
[0061] In the above examples, several variables were adjusted to achieve a broad range of materials for testing. The monomer to initiator ratio was varied to control the molecular weight of the lactide block, and this directly affected the polycarbonate-polylactide reaction due to the fact that the initiator was one of the copolymer blocks. The reactions were done in solution or in bulk for the ring opening polymerization, and the bulk was preferred for ease of work-up. The kinetics of the ring opening of the lactide in bulk are well known, and most reaction mixtures stopped stirring within 5 to 10 minutes of the addition of Sn(Oct) 2 catalyst due to the high viscosity of the materials in the melt, which developed quickly upon addition of the Sn(Oct) 2 catalyst. Table 1 displays the properties for the materials synthesized. Glass transition temperature (T g ) and melting temperature (T m ) values were measured by differential scanning calorimetry (DSC). Onset degradation temperatures were measured by thermal gravimetric analysis (TGA) and defined as the temperature at which 99 weight percent of the material remains. Mole percent lactic acid was determined by proton nuclear magnetic resonance spectroscopy ( 1 H NMR) using integrated values of the methane protons of poly(lactic acid) versus the aromatic protons of poly(bisphenol A carbonate).
[0000]
TABLE 1
Onset of
Degradation
Mole % lactic
Temperature
acid in
Entry
M w
PDI
(° C.)
T g (° C.)
copolymer
Ex. 1
27,000
2.4
459
153
0
Ex. 2
34,800
4.0
459
153
0
Ex. 3
35,880
1.5
220
121
53
Ex. 4
51,320
1.4
262
134
24
Ex. 5
28,360
3.4
256
50; 121
70
Ex. 6
38,370
1.6
262
124
43
Ex. 7
25,800
3.8
258
n/m
78
Ex. 8
38,400
1.5
169
57
77
Ex. 9
29,110
2.5
283
123
54
Ex. 10
20,950
3.1
281
86; (T m = 196)
79
[0062] The results indicate that the thermal decomposition temperatures were lower in the copolymers as compared to the polycarbonates of Examples 1 and 2. On the other hand, phenyl carbonate-capped polycarbonate-polylactide copolymers showed a significantly higher onset of decomposition temperatures that the non-capped copolymers. See, for example, the phenyl carbonate-capped block copolymer of Example 6 (262° C.) versus the corresponding uncapped block copolymer of Example 3 (220° C.); and the phenyl carbonate-capped block copolymer of Example 9 (283° C.) versus the corresponding uncapped block copolymer of Example 5 (256° C.).
EXAMPLE 10
[0063] This example illustrates the preparation of films comprising the polycarbonate-polylactide block copolymers. The polycarbonate-polylactide block copolymers of Examples 3 to 9 were pressed into films, and the films were translucent to opaque, indicating phase separation/immiscibility of the polylactide and polycarbonate components. In contrast, films prepared from the Example 1 and Example 2 polycarbonates were transparent. In FIG. 1, the transmission electron microscopic image for the Example 1 polycarbonate shows a single continuous phase. Also in FIG. 1, the image for the Example 4 polycarbonate-polylactide block copolymer shows a two-phase system. The lighter images in the TEM image for the polycarbonate-polylactide represent the polylactide domains, which are on the order of 10 to 100 nanometers in size. Most of the polylactide domains have a small, circular particle size, indicative of the controlled nature of the ring opening polymerization and corresponding narrow molecular weight distribution.
[0064] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. 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 language of the claims.
[0065] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
[0066] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.
[0067] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes the degree of error associated with measurement of the particular quantity).
|
A polycarbonate-polyester block copolymer includes a polycarbonate block and a polyester block, each having specific structures. The block copolymer can be prepared, at least in part, from renewable feedstocks. In some forms, the block copolymer includes biodegradable segments that facilitate structural breakdown of objects molded from the block copolymer. Methods of preparing the block copolymer are described as are- compositions that include it and articles prepared from it.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for applying various coating liquids to the surface of a long travelling support (hereinafter, for simplicity designated a "web"). More particularly, the invention relates to a method for applying various coating liquids to the web while preventing a thick coating of the coating liquid which often is formed in a connection between webs.
2. Description of the Prior Art
A conventional process, wherein various coating liquids are applied to a web such as plastic films, paper, metallic sheets, etc., and then dried to obtain desired products, has been widely used in manufacturing photographic films, printing papers, magnetic tapes, adhesive tapes, no-carbon papers, PS formats, etc.
In the process of manufacture as described above, it is advantageous for the coating to be applied in a substantially continuous manner, and in general the coating operation is usually carried out in such a way that a web formed by connecting pieces of webs or web portions having a limited length one after another is fed to a coating station so that the coating operation occurs without interruption. In connecting web portions, the so-called "butt joint" is preferably employed, in which ends of both of the web portions are abutted and connected using, e.g., an adhesive tape as a splicing tape; and it is known to be more advantageous to apply the splicing tape to the surface on which the coating liquid is to be applied than on the opposite surface of the web, and it is known to pre-apply a surface treatment to the splicing tape so that the surface characteristic of the splicing tape will be substantially the same as that of the surface of web to which the coating liquid is applied.
However, if a fluid coating liquid is applied to the web splice thus formed in a continuous manner, several significant disadvantages, which have been heretofore encountered, are produced principally following, i.e., downstream of, the splice.
One disadvantage is such that bubbles are formed due to the presence of air between the web surface directly following the splice and the coated layer, and these bubbles adhere to coating nozzles so that the coated surface over a considerable length is adversely affected by streaks or the like. Another disadvantage is that uncoated or extremely thinly coated portions and thereafter locally thickly coated portions are formed in the coating applied to the surface of the web directly following the splicing tape due to the step-like discontinuous changes at the trailing edge of the splicing tape in the splice and the presence of air as described above. A considerable amount of time is required to dry the thickly coated portions in a subsequent drying process as compared with the other portions properly coated. If the drying process does not have sufficient capacity to dry the thickly coated portion, the result is that the thickly coated portion remains undried, the undried coated liquid is transferred onto rollers or the like to contaminate the equipment and thereby damage the coating properly applied, leading to fatal defects in the product produced. For this reason, where the equipment is contaminated, the manufacturing operation must be stopped for cleaning, which results in a marked reduction in production efficiency. Conversely, where the undried portion is to be prevented from occurring, sufficient drying capacity for the locally thickly coated portion must be provided in the drying process. This thickly coated portion, however, is not useful as a product but is discarded, and therefore it is extremely uneconomical to spend money for drying those portions ultimately to be discarded.
While the splicing of web portions has been described above, similar coating failures such as coating irregularities also occur if the surface of the web to which a liquid is to be applied has other types of discontinuities such as projections, steps, or the like.
Several proposals have been made to prevent the aforementioned coating failures caused by discontinuities formed by the splicing tape or the like.
One such device is disclosed in U.S. Pat. No. 3,531,362. Briefly, this method comprises (1) applying an oily hydrophobic material to the discontinuities, the surface of the web adjacent thereto, and the following portion of the discontinuities, or (2) providing an inclination to the discontinuities so as to eliminate the wedge-like space formed in the trailing edge of the discontinuities prior to applying the coating liquid to the web.
However, in the above-described method (1), generally, if the coating liquid is aqueous in nature, the oily hydrophobic material tends to produce a poor adhesion relative to the coating and the coating after drying tends to peel off by application of a small external force. Furthermore, this method requires an operation wherein a surface treatment is applied using an oily hydrophobic treating liquid to the discontinuities. However, this operation tends to result in equipment contamination by the treating liquid and a contamination of other portions of the web. Moreover, a dryer must be provided if it is desired to sufficiently dry those portions to which the treating liquid has once been applied.
In addition, the above-described method (2) is not practical in terms of the actual shape and thickness of the splicing adhesive tape. That is, splicing tapes generally used for this purpose are made by applying an adhesive to elements having a thickness of about 10 to 50 microns, with most tapes having a total thickness formed by the element plus the adhesive of about 30 to 100 microns. In order to effectively use this method, the adhesive portion should also be inclined as well. However, it is very difficult to incline the trailing edge of such a thin tape either in pre-treatment or in treatment after the tape has been applied.
Also, the method wherein an inclination is formed by inserting a packing such as rubber cement between the trailing edge and the web surface after the tape has been applied is complicated and at the same time other portions of web and the equipment tend to be contaminated similarly to the afore-mentioned treatment using the oily hydrophobic material.
Another method is disclosed in British Pat. No. 1,243,663. This method comprises pre-spraying and adhering water to at least the trailing edge of a splicing tape, and applying the coating liquid before the water has completely dried.
However, this method possesses several disadvantages in that (a) a complicated device is required to detect the splicing tape immediately before a coating station to apply water to the trailing edge of the splicing tape; (b) after water is applied to the web, the web can not be supported, for example, by rollers, etc., so that the layout of the web passage in the vicinity of the coating station is limited; and (c) where the web absorbs water with difficulty, water drops on the web adhere to coating devices such as coating nozzles, thus adversely affecting the coating operation thereafter.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method which avoids and overcomes coating failures such as coating irregularities produced in the areas following a discontinuity when a layer of a coating liquid is applied to the surface of a web having discontinuities, such as a tape splice or the like.
A further object of the present invention is to provide a method which can completely eliminate risks of equipment contamination or contamination of other portions of the web in avoiding and overcoming the above-described coating difficulties.
Another object of the present invention is to provide a method which is convenient and effective, without using treating liquids whose handling is limited, in avoiding and overcoming the above-described coating difficulties.
Still another object of the present invention is to enable a reduction in drying capacity to thus provide an economical drying process through the avoidance of the above-described difficulties and the elimination of locally thick coating.
The present invention provides a method for applying a coating liquid to a travelling web having discontinuities formed on the surface to be coated due to web splices or the like, comprising treating the support prior to coating a liquid in such a way that the level of the surface to be coated following the discontinuity is made coplanar to or higher than the highest portion of the discontinuity thereby overcoming coating difficulties such as coating irregularities.
The description "discontinuous area" or "discontinuity" is used herein to designate relatively abrupt changes in the surface levels of adjacent surface areas, e.g., drops or steplike changes in the surface level. In addition, the terms "leading", "preceding", "succeeding", "trailing" and "following" have been used to designate physical position or location and are used in reference to the direction of travel of the web.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a splice in section showing the mode of layer formation in which a liquid is coated without applying any treatment to a web spliced by a butt joint.
FIG. 8 is a schematic illustration of a splice in section in which a high speed coating is effected.
FIGS. 2, 3, 4, 5, 6, 7 and 9 are schematic illustrations in section showing a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For a more complete understanding of the present invention, reference may be made to the following detailed description which may be read in connection with the accompanying drawings.
FIG. 1 schematically illustrates the mode of a layer formation where untreated spliced portions are coated with a liquid. The trailing end of a preceding web portion 1 and the leading end of a succeeding web portion 2 are joined by a so-called "butt joint" using a splicing tape 3 adhered along a seam between both web portions. The web travels in the direction as indicated by the arrow toward a coating station. A space formed 4 of a coating liquid is a substantially liquid material, this material being uniformly coated on the surface of the web and thereafter solidified and dried. However, uniform coating may not be attained in the vicinity of the splice due to the presence of a discontinuity in the surface of the web caused by the splicing tape. That is, as shown in FIG. 1, an extremely thinly coated or uncoated portion directly following the splicing tape and thereafter a locally thickly coated portion are produced. Air accompanied by the trailing edge of the splicing tape is trapped in a spaceformed by the trailing edge of the splicing tape 3, the surface of the succeeding web portion 2, and the layer 4 of the coating liquid is to produce a bubble 5 or to produce a bubble 6 while being entrained into the layer 4 of the coating liquid. Further, these bubbles 5 and 6 are often trapped by a coating nozzle to produce a coating failure, the so-called "streaks", thus adversely affecting the surface of the layer.
It is believed that such phenomenon as described above is produced due to the presence of a step-like discontinuity on the surface of web to be coated. As the trailing edge of the splicing tape 3 passes through the coating station, air is trapped in a space formed by the trailing edge of the splicing tape 3, the surface of web portion 2 and the layer of coating liquid, and the layer of the coating liquid in that portion covers a thin layer of air. As the coating proceeds further, the air thus trapped and the layer of the coating liquid covering the air slip on the surface of the succeeding web portion 2 and move backward in the direction of travel of the web. At this time, it is believed that the air trapped in this space is pulled into the layer of the coating liquid to form air bubbles 5 and 6, while the layer of the coating liquid which has moved backward forms a thickly coated portion.
The above-described locally thickly coated portion produced by the phenomenon as described above remains undried in the drying process even after other properly coated portions have been dried, and a dryer having a larger capacity than needed must be provided to dry such an undried portion. However, this thickly coated portion is not useful as a product but is discarded, thus a great amount of waste is produced due to the above-described coating failures.
In the following embodiments, the layer of coating liquid is not shown unless otherwise specified for the purpose of simplicity.
FIG. 2 illustrates a preferred form of the present invention.
Quite similar to the case shown in FIG. 1, the trailing end of the preceding web portion 1 and the leading end of the succeeding web portion 2 are spliced by means of the splicing tape 3. However, in this specific embodiment, the succeeding web portion 2 is worked stepwise or reduced in thickness directly behind the splicing tape 3 to form a step 7. This step 7 has height h which is substantially equal to the thickness of the splicing tape 3. From this arrangement, the surface 8 of the splicing tape 3 and the surface 9 of the succeeding web 2 are substantially coplanar, thus eliminating a discontinuity in levels therebetween. When the spliced web thus treated travels in the direction indicated by the arrow into the coating station, it has been found that no coating failure occurs directly following the splicing tape 3, in contrast to that shown in FIG. 1.
From the assumption that the above-described coating failure is attributed to the air accompanying the trailing edge of the tape and that the air is due to the presence of the step between the surface of the splicing tape 3 and the surface of the succeeding web portion 2, it can be naturally considered that the above-described coating failure can be eliminated by removing the step so that the surface of the splicing tape 3 is coplanar with the surface of the succeeding web portion 2.
In the actual process, such a succeeding web portion 2 downstream of the splicing tape 3 can be worked or thickness reduced in a relatively simple manner, for example, by the incorporation of a pressing means of simple construction into a web splicing device, or by the provision of a pair of press rollers whose surfaces are formed with the step in the process prior to the coating station whereby the web can be suitably pressed.
FIG. 3 illustrates another embodiment of the present invention.
In this embodiment, the preceding web portion 1 and the succeeding web portion 2 are butt connected by applying a splicing tape 3 to the surface of the web opposite the surface to be coated. Specifically, a gap g is formed between the web portion ends. If the web having the splice as hereinbefore described is moved in the direction as indicated by the arrow, it has been found no coating failure downstream of the discontinuity occurs despite the presence of the gap g in the surface to be coated and the presence of the discontinuity.
From the assumption as previously described that the air trapped within the space formed by the trailing edge of the splicing tape 3, the surface of the succeeding web portion 2, and the layer 4 of coating liquid slips on the surface of the succeeding web portion 2 and a thickly coated portion is formed at a portion where this slip stops, it may be considered that the air accompanying the trailing edge of the preceding web portion 1 is trapped in this gap g leaving no room for slipping, and thus no coating failures such as coating irregularities are produced.
FIG. 4 illustrates still another embodiment of the present invention. In FIG. 4, the preceding web portion 1 and the succeeding web portion 2 are butt connected using a splicing tape 3, the succeeding web portion 2 being formed with a step 7 at a point downstream at a distance of l from the trailing edge of the splicing tape 3. Here, the height h of the step 7 is substantially the same as the thickness of the splicing tape 3. If a web having the connection as hereinbefore described is driven in the direction as indicated by the arrow, it has been found no coating failure attributed to the discontinuity of the surface of the web occurs. If may also be considered that the accompanying air is trapped in a space between the trailing edge of the splicing tape 3 and the step 7 similar to the case shown in FIG. 3.
Suitable values of the gap g and the distance l from the trailing edge of the splicing tape to the step cannot be set forth unequivocally since they differ depending upon the kind of coating liquid, the surface characteristics of the web, the thickness of the splicing tape, the height of the step, the speed of coating, the quantity of the coating and the like.
Preferably, these values are determined experimentally under the actual use conditions required. In general, for both gap g and distance l, a smaller value is preferred, and excellent results can be obtained with a value ranging from approximately 0 to 15 mm.
FIG. 5 illustrates another embodiment of the present invention. In FIG. 5, the height h of the step 7 shown in FIG. 2 is made greater than the thickness of the splicing tape 3 by the thickness of the layer 4 of the coating liquid. If a web having the connection as hereinbefore described is driven in the direction as indicated by the arrow, into the coating station, it has been found no coating failures attributed to the discontinuity of the web surface occur.
The reason for this is not apparent, but on considering the fact that no coating failure is produced in the surface of the splicing tape 3 even when the coating is carried out with the spliced web receiving no treatment as shown in FIG. 1, coating failure would not also be produced in the case shown in FIG. 5.
FIG. 6 illustrates still another embodiment of the present invention. The arrangement in FIG. 6 is a further improvement in the arrangement in FIG. 4, wherein the step 7 is formed so that the height h is greater than the thickness of the splicing tape 3 by the thickness of the layer of coating liquid 4. If a web having the splice as hereinbefore described is driven in the direction as shown by the arrow into the coating station, it has been found no coating failure attributed to the discontinuity of the web surface occurs. Also in this case similar to that shown in FIG. 4, the distance l from the trailing edge of the splicing tape 3 to the step 7 desirably has a smaller value, and excellent results has been obtained with a distance ranging from approximately 0 to 15 mm.
From the foregoing embodiments, it will be appreciated that the position and height of the step 7 provided in the succeeding web portion 2 downstream of the splicing tape 3 can be varied over a considerably wide range. From this reason, extreme dimensional accuracy is not required when the step is formed in the succeeding web portion 2 using a tool, whereby the arrangement of the invention is advantageous in terms of the equipment required and easy to accomplish. With respect to the relationship between the thickness of the splicing tape 3 and the height h of the step 7, the height of the step 7 can be made greater than the thickness of the other as previously discussed, but the upper limit thereof is indefinite. Better results may still be obtained if at least the height h of the step 7 is greater than the thickness of the splicing tape 3 by an amount equal to the thickness of the layer 4 of the coating liquid.
However, the extent mentioned above is not considered to be a limit and, even when the height h of the step 7 is greater than this extent, coating failure is not observed either. However, a limit apparently exists. For example, in the case of bead coating, the dimension of the gap between the coating nozzle and the coating roll must be such that the splice of the web can be passed therethrough easily. Therefore, such a limit is defined in connection with the coating device and is not a result per se of a limitation in the method of the invention.
Further, as is described hereinafter, where the coating speed is extremely high, coating failure sometimes occurs even at the leading edge of the splicing tape 3. Accordingly, it is difficult to set forth the limit unequivocably. From the above, it can be understood that the height h of the step 7 is principally determined depending on the coating device and should be determined, experimentally under actual processing conditions. Indeed, theoretically it is preferable that the height of the step 7 be equal to the height of the splicing tape 3 so that the thickness of the step is not determined strictly and a wide tolerance is permitted.
FIG. 7 illustrates another embodiment wherein the coating speed is extremely high. In layer formation in the vicinity of the connection where the coating speed is great, it is well known that unlike the case in FIG. 1 coating failure is produced also in front of the connection as shown in FIG. 8. Since it is apparent that such coating failure is attributed to the discontinuity of the web surface in the connection, it is assumed that the coating failure could be solved by removal of the discontinuity. FIG. 7 illustrates an arrangement wherein a step 10 is formed not only in the succeeding web portion 2 but also in the preceding web portion 1 so that the surface of the preceding web portion 1, the surface of the splicing tape 3 and the surface of the succeeding web portion 2 are all substantially the same height that is coplanar. If a web having the connection as hereinabove described is moved in the direction as indicated by the arrow into the coating station, it has been found no coating failure attributed to the discontinuity of web is produced.
FIG. 9 illustrates a further embodiment of the present invention. The preceding web portion 1 and the succeeding web portion 2 are butt joined by a splicing tape 3 adhered on the surface to be coated, with a step 7 being formed in the succeeding web portion 2, and with the upper surface of the splicing tape 3 and the upper surface of the succeeding web portion 2 being made substantially coplanar. Further, following the step 7 a back tape 11 of substantially the same thickness as that of the splicing tape 3 is adhered on the surface opposite the surface to be coated. It has been often experienced that the height of the step of the web worked as shown in FIGS. 2, 4, 5, 6 and 7 is decreased when a strong external force is received before the web is coated. In general, since coating is carried out while the web is held by coating rolls, the height of the step can be accurately maintained as set during the time of coating if the back tape is provided as shown in FIG. 9, thus obtaining markedly improved results.
While the foregoing embodiments have been described only with respect to the case where a butt joint is employed, the invention can also be applied to those cases where other connecting methods such as a lap joint are employed. Moreover, the present invention can also be applied to those cases where discontinuous portions such as creases, or steps are present in the web surface to be coated.
The following examples are given to illustrate the present invention and its effects in greater detail.
EXAMPLE 1
Web portions of triacetyl cellulose having a width of 30 cm and a thickness of 180 microns were butt joined using an adhesive tape having a thickness of 50 microns, and a step of a height of 150 microns was formed in the succeeding web portion at a distance of 7 mm downstream from the trailing edge of the splicing tape. Then, the web portions thus joined were driven at a speed of 50 m/min, and an emulsion for X-ray photography having the properties as given in Table 1 below was applied thereto in a coating amount of 98 cc/m 2 using extrusion coating method. The coated layer after coating was examined, but no coating failure such as coating irregularities in the vicinity of the connection was found.
TABLE 1______________________________________Gelatin Cocentration 5.0 %Viscosity 30.0 cpSpecific Gravity 1.09Surface Tension 42.0 dyne/cm______________________________________
EXAMPLE 2
Web portions of polyethylene terephthalate having a width of 30 cm and a thickness of 175 microns were butt joined using an adhesive tape having a thickness of 60 microns, and a step of a height of 130 microns was formed in the succeeding web portion at a distance of 5 mm downstream from the trailing edge of the splicing tape. Then, the web portions thus connected were driven at a speed of 70 m/min, and an emulsion for X-ray photography the same as that described in Example 1 was applied thereto in a coating amount of 80 cc/m 2 using extrusion coating method. The coated layer after coating was examined, but no coating failure such as coating irregularities in the vicinity of the splice were found.
In accordance with the present invention, the following advantages can be obtained.
1. In the coating of various types of coating liquids to a web having a discontinuous surface such as a connection of web portions produced by a splicing tape or the like, coating failure such as coating irregularities tending to be produced downstream of the discontinuity can be avoided to thereby provide a uniform and better coating.
2. Generation of bubbles tending to be produced downstream of the discontinuity attributed to the discontinuity in the web surface and adherence of the bubbles to the coating nozzle can be avoided so that better coating without any defects in the surface of the coating due to these bubbles, for example, the so-called streaks, can be achieved.
3. Coating failure tending to be produced downstream of the discontinuity attributed to the discontinuity in the web surface, particularly, a remarkably thick coating, can be avoided so that an extra drying which has been required in order to dry such a thickly coated portion can be omitted, or the drying ability can be considerably increased using the same drying device as heretofore employed.
4. Coating failure tending to be produced downstream of the discontinuity attributed to the discontinuity in the web surface, particularly remarkably thickly coating, can be avoided so that risks of equipment contamination produced due to the thickly coated and undried portion can be eliminated, and in addition, production does not have to be discontinued for the purpose of cleaning the equipment thereby considerably increasing production efficiency.
5. Coating failure tending to be produced downstream of the discontinuity attributed to the discontinuity in the web surface can be avoided with a simple device and in a convenient manner without the use of treating liquids whose handling is limiting. 6. Coating failure tending to be produced downstream of the discontinuity attributed to the discontinuity in the web surface is remarkably found particularly in high speed coating and is easily produced also upstream of the discontinuity in the high speed coating, which results in a limit to the coating speed thus hindering the accomplishment of high speed coating. Conversely, the present invention overcomes these disadvantages noted above and enables the requirements of high speed coating to be met.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
|
A method for applying various coating liquids on the surface of a travelling web, such as plastic films, paper, metallic sheets, etc., with a discontinuity thereon, e.g., due to a connection of pieces of the web comprising preworking a web portion so that the web surface downstream of the discontinuity is coplanar to or higher than the maximum height of the discontinuity, whereby irregularities in coating of liquids are eliminated.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an ironing device having a housing and a pumping device for transporting fluid from a receptacle onto an ironing article.
[0003] German Patent 198 29 675 A1 discloses an ironing device with a housing in which is disposed a pumping device with a diaphragm pump. The diaphragm pump has a pump chamber whose volume can be varied by a pump element. A feeder having a return valve is led from a receptacle integrated into the housing to the pump chamber and a pressure pipe having a return valve is led from the pump chamber to a spray nozzle. The pump element can be operated by an operating part, with the operating part being fashioned as a ductile diaphragm. The diaphragm pump can transport fluid from the receptacle through the spray nozzle onto an ironing article.
SUMMARY OF THE INVENTION
[0004] It is accordingly an object of the invention to provide an ironing device that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices of this general type and that creates a constructively simple ironing device having few locations between a receptacle and an outlet of a fluid that are simple to seal.
[0005] With the foregoing and other objects in view, there is provided, in accordance with the invention, an ironing device, including a housing, a receptacle holding fluid, and a pumping device for transporting the fluid from the receptacle onto an ironing article. The receptacle is fluidically connected to the housing. The pumping device is disposed in the housing, is fluidically connected to the receptacle, and has at least one hose pump for pumping the fluid.
[0006] Particularly few locations, which are simple to seal, between the receptacle and an outlet of the fluid can be reached with a hose pump when a single-piece hose is led from the receptacle through a pump part of the hose pump to a connection of a spray nozzle and/or a single-piece hose is led from a receptacle through a pump part of the hose pump to a connection of a steam chamber. The configuration provides a corresponding reduction in sealing outlay, additional components, assembly space, weight, assembling outlay, and costs.
[0007] The invention prevents pump parts, apart from the hose, from coming in contact with the fluid by providing moving displacers and bearings thereof to act upon the hose and thereby effect a pumping action. Such hose pumps are safe to run dry or, respectively, can be operated without fluid without causing damage. Such pumps are also particularly reliable.
[0008] Given hose pumps, scaling can be mostly prevented in the area of the pump. The hose coming in contact with the fluid is always set free from lime as a result of its motion or, respectively, deformation, and the hose protects the other pump parts from the fluid. Furthermore, hose pumps can obtain a desired conveying capacity in a constructively simple way through a hose cross-section. The hose pump forms a regenerative or self-priming system, so that a constant conveying capacity can be obtained independently of a level in the receptacle.
[0009] The hoses can be simply and flexibly laid in the housing, so that a particularly simple installation is possible. The hose can be produced from different materials appearing expedient to someone skilled in the art, with the hose being particularly made of flexible, conventional plastics. Silicone hoses are preferably utilized because water is typically used for moistening the ironing article.
[0010] In accordance with another feature of the invention, the receptacle can be disposed in the housing and/or outside the housing. A separate external receptacle can be fashioned with a large volume particularly for large amounts of ironing articles. A hose provided for a separate receptacle can be led to a connecting point that is integrated into the housing of the ironing device, whereby a hose of a separate receptacle can be connected to the connecting point. However, it is also possible that a sufficiently long hose to a separate receptacle already is disposed in the housing. The hose can be disposed in a retaining space in the housing, so that it can be wound up and unwound on a rotatable axle.
[0011] In accordance with a further feature of the invention, the at least one hose pump has a pump part, the housing has a spray nozzle with a nozzle connection, and at least one single-piece hose fluidically connects the receptacle to the nozzle connection through the pump part.
[0012] Instead of guiding a number of single-piece hoses from the receptacle through a pump part of the hose pump, it is also generally possible to provide a number of hoses and/or channels at a branch point with fluid by a hose led through the pump part, for example, a hose led from the receptacle through the pump part can provide for a channel branch point, which is integrated into the housing and can be controlled by an operator, whereby, proceeding from the channel branch point, individual outlets can be provided with fluid via a channel system integrated into the housing.
[0013] In accordance with an added feature of the invention, the housing has a steam chamber with a chamber connection, the at least one single-piece hose is at least two single-piece hoses, and at least one of the two single-piece hoses fluidically connects the receptacle to the chamber connection through the pump part.
[0014] In accordance with an additional feature of the invention, the at least one hose pump has a pump part, the housing has a steam chamber with a chamber connection, and at least one single-piece hose fluidically connects the receptacle to the chamber connection through the pump part.
[0015] In accordance with yet another feature of the invention, the receptacle is separate from the housing, the at least one hose pump has a pump part, and at least one hose is fluidically connected to the separate receptacle through the pump part.
[0016] In accordance with yet a further feature of the invention, at least one single-piece hose has a hose part and fluidically connects the receptacle to the pumping device through the pump part at a hose part, and the at least one hose pump has at least one displacer rolling off onto the hose part.
[0017] Given hose pumps, a pumping action is generally achieved in that driven displacers act upon a hose. The displacers can perform different movements that appear expedient to someone skilled in the art, for example, a displacer of a hose diaphragm pump having a return valve in flow direction in front of the displacer and a return valve in flow direction behind the displacer can execute a translational rocking motion perpendicular to the axis of the hose.
[0018] In accordance with yet an added feature of the invention, at least one displacer is at least two displacers, and one of the two displacers prevents a backflow of the fluid into the receptacle.
[0019] Hose pumps having at least one displacer rolling off onto a hose part are particularly advantageously utilized. As a result of the rolling motion of the displacer carried out on the hose part, a flow direction can be determined, so that at least one return valve can be foregone vis-a-vis the previously described hose diaphragm pump. If the hose pump has at least two displacers, advantageously, three or more displacers, one displacer always can be used for preventing a backflow into the receptacle, return valves can be completely foregone, and a particularly simple and cost-efficient hose pump can be obtained.
[0020] In accordance with yet an additional feature of the invention, at least one part of the hose pump is extrusion-coated given the production of the housing, namely a bearing component of at least one displacer, which is normally fashioned in a fixed manner relative to the housing. Additional mounting parts can be foregone and the assembling outlay, the weight, and the expenses can be reduced. Furthermore, additional components can be omitted by fashioning at least one part of the hose pump as one piece with the housing. A bearing component of at least one displacer is particularly advantageous for such a purpose.
[0021] In accordance with again another feature of the invention, at least a part of the at least one hose pump is formed in one piece or integral with the housing.
[0022] In accordance with again a further feature of the invention, the at least one displacer has a bearing component formed in one piece with the housing.
[0023] In accordance with again an added feature of the invention, the at least one hose pump has at least one part produced from plastic.
[0024] If at least one part of the hose pump or preferably the entire hose pump is composed of plastic, it can be particularly simply and cost-efficiently realized. Moreover, it is advantageous to fashion individual components as one piece with the housing that normally is produced from plastic.
[0025] In accordance with a concomitant feature of the invention, there is provided a motor connected to the at least one hose pump for operating the at least one hose pump.
[0026] An operation can manually operate the hose pump or, more advantageously, a motor can operate the hose pump, particularly, an electromotor, so that high operating comfort can be achieved.
[0027] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0028] Although the invention is illustrated and described herein as embodied in an ironing device, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0029] The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a cross-sectional view of an ironing device according to the invention; and
[0031] [0031]FIG. 2 is an enlarged, exploded, perspective view of a pumping device of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case.
[0033] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a schematically represented ironing device having a plastic housing 10 that is attached to a heatable metal ironing sole 34 . A handle 33 is molded onto a side of the housing 10 opposite the ironing sole 34 . A receptacle 13 is integrated into the housing 10 above the ironing sole 34 in the direction of the handle 33 . A pumping device 11 also is disposed in the housing 10 through which liquid 12 , particularly water, can be transported from the container 13 and/or a separate container 14 onto an ironing article.
[0034] The pumping device 11 inventively has a hose pump 15 (FIG. 2). A first single-piece silicone hose 16 is led from the receptacle 13 through a pump part 18 of the hose pump 15 to a connection 19 of a spray nozzle 21 and a second single-piece silicone hose 22 is led through the pump part 18 of the hose pump 15 to a connection 24 of a steam chamber 26 . The steam chamber 26 is disposed directly above or, respectively, on the side of the ironing sole 34 facing the handle 33 . A press switch 45 integrated at the handle 33 can operate the spray nozzle 21 .
[0035] A third single-piece silicone hose 17 is led from the receptacle 14 through the pump part 18 of the hose pump 15 to a connection 20 of the spray nozzle 21 and a fourth single-piece silicone hose 23 is led through the pump part 18 of the hose pump 15 to a connection 25 of the steam chamber 26 .
[0036] The pump part 18 is firmly connected to the housing 10 through a cover 30 and through a flange 31 that is screwed down with the housing 10 . It is also possible to realize the pump part as one piece with a housing of the ironing device. Three cylindrical displacers 27 , 28 , 29 are disposed in the pump part 18 , are driven by an electromotor 32 , and can be rolled off onto the four silicone hoses 16 , 17 , 22 , 23 for generating a pumping action. The electromotor 32 is provided with current through non-illustrated current cables that are led through a cable channel 44 into the housing 10 to the electromotor 32 .
[0037] The electromotor 32 has a motor shaft 35 , which, in a mounted state, is led through a first bearing 36 in the cover 30 , through a middle area past the three cylindrical displacers 27 , 28 , 29 , and through a second bearing 37 in the pump part 18 . The motor shaft 35 drives the displacers 27 , 28 , 29 in a frictionally engaged fashion, namely, comparable to a sun wheel driving a planet. The pump part 18 , the displacers 27 , 28 , 29 , the cover 30 , and the flange 31 are fashioned preferably as plastic molded parts.
[0038] The silicone hoses 16 , 17 , 22 , 23 are led through four non-illustrated openings at a bottom side 38 of the pump part 18 into the pump part 18 , are disposed djacent one another at an inside wall of the pump part 18 to an upper side 39 and through four openings 40 , 41 , 42 , 43 out of the pump part 18 . The displacers 27 , 28 , 29 roll off onto the inside wall through the silicone hoses 16 , 17 , 22 , 23 and generate a squeezing motion of the silicone hoses 16 , 17 , 22 , 23 continuing in flow direction or, respectively, press the silicone hoses 16 , 17 , 22 , 23 flat against the inside wall. Prior to a displacer 27 , 28 , or 29 being lifted off by the silicone hoses 16 , 17 , 22 , 23 , a following displacer 27 , 28 , or 29 presses the silicone hoses 16 , 17 , 22 , 23 flat against the inside wall of the pump part 18 , so that the fluid cannot flow back into the receptacle 13 or, respectively, 14 .
|
An ironing device includes a housing, a receptacle holding fluid, and a pumping device for transporting the fluid from the receptacle onto an ironing article. The receptacle is fluidically connected to the housing and the pumping device is disposed in the housing, is fluidically connected to the receptacle, and has at least one hose pump for pumping the fluid.
| 3
|
FIELD OF THE INVENTION
The present invention relates to a ferritic stainless steel having excellent corrosion resistance and mechanical properties both in the base metal and the welded portion.
BACKGROUND OF THE INVENTION
Ferritic stainless steels containing no nickel as an alloying element have advantages that their production cost is low and they are free from various types of stress corrosion cracking, but on the other hand have disadvantages that general corrosion resistance is poor and their weldability, corrosion resistance and mechanical properties in welded portions are poor so that they have been restricted in their wide application, particularly their application in the fields such as chemical plants where high degree of material reliability is required. Presently, austenitic stainless steels have been mostly used in these fields, but they have a defect of the susceptibility to stress corrosion cracking so that their reliability in these fields is not enough.
In recent years, several new grades of austenitic stainless steels have been proposed as stress corrosion resistant steels, but most of them do not always show reliable resistance to stress corrosion cracking in actual services although they are immune to cracking in boiling 42% MgCl 2 solution.
This is due to the fact that the laboratory test condition in boiling 42% MgCl 2 solution is not identical to the actual condition in service. Therefore, great cares have been required in selection of the test condition for development of new corrosion resistant steels, particularly new corrosion resistant steels having satisfactory resistance to stress corrosion cracking. If such cares are not taken, the resultant steels have not practical utility.
The present inventors have conducted studies and development works taking these considerations and have succeeded in development of a novel ferritic stainless steel which is free from any type of stress corrosion cracking, having similar or better corrosion resistance than that of an austenitic stainless steel, and which has eliminated poor weldability and deterioration of corrosion resistance and mechanical properties in welded portions with which the conventional ferritic stainless steels confront inherently.
SUMMARY OF THE INVENTION
The gist of the present invention lies in a corrosion resistant ferritic stainless steel of high reliable and high-purity, which comprises;
C ≦ 0.015%
S ≦ 0.30%
mn ≦ 0.30%
P ≦ 0.040%
s ≦ 0.030%
cr : 18.00 to 25.00%
Ni ≦ 0.20%
Cu ≦ 0.20%
Mo : 1.50 to 3.50%
N ≦ 0.015%
ti : 4 × (C + N)% to 0.50%
Nb : 8 × (C + N)% to 1.00%
wherein
Ti/Nb = 0.5 to 1.2, and (Ti + Nb)/(C + N) ≧ 8.0
in case of C + N < 0.017%
(ti + Nb)/(C + N) ≧ 16.0
in case of C + N ≧ 0.017%, the balance being iron and unavoidable impurities.
The most important feature of the present invention is the addition of Ti and Nb in combination.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in details referring to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the corrosion resistances to hydrochloric acid of the stainless steel of the present invention in comparison with that of a conventional similar steel.
FIG. 2 shows the effects of contents of chromium and molybdenum on the corrosion resistant zone in the hydrochloric acid solution. The corrosion resistant zone has been got by finding the test conditions of the HCl concentration and temperature of the acid solution, on which the lower corrosion rate than 0.1 g/m 2 hr., then comparing with that of SUS304 or SUS316.
FIG. 3 is a graph showing effects of contents of chromium and molybdenum on the pitting corrosion resistance. (5% FeCl 3 + N/20 HCl, 30° C, 48 hrs.)
FIG. 4 is a graph showing the intergranular corrosion susceptibility of a sensitized ferritic stainless steel in respect to C + N and Ti + Nb.
FIG. 5 is a graph showing the relationship between the grain size of the weld metal and the contents of stabilizing elements.
FIG. 6 is a graph showing impact values of the base metal, the heat-affected zone and the weld metal at various temperatures.
FIG. 7 is a graph showing the deep drawability.
As is well known, it is effective for improvement of general corrosion resistance of a stainless steel to increase the content of chromium and to add molybdenum.
The present inventors have found that the addition of molybdenum contributes significantly for improvement of corrosion resistance, particularly in a weak acidic environment (see FIG. 1) and that a 17% Cr - 1% Mo steel shows better corrosion resistance than SUS304 steel when used, for example, in the top of an oil rectifying column.
As clearly understood from FIG. 2, which shows the effect of the molybdenum content on the resistance against hydrochloric acid expressed by the acid solution conditions with a corrosion rate not larger than 0.1 g/m 2 hr. compared with that of SUS304 and SUS316. However, even with a chromium content beyond 25% or with a molybdenum content beyond 3.5%, no remarkable expansion of the zone is observed.
As seen from FIG. 3 which shows the relationship between the pitting corrosion resistances and the contents of chromium and molybdenum, the pitting corrosion resistance can be improved by increasing the contents of chromium and molybdenum, so that it is possible to combine the chromium content and the molybdenum content in a way to provide similar or better properties as compared with those of SUS304 or SUS316. For example, a 19Cr - 2 Mo steel and a 18Cr - 3 Mo steel shows better acid resistance, pitting corrosion resistance and rust resistance than those of SUS304 at worst, and in some cases shows similar properties as compared with those of SUS316.
Regarding the corrosion resistance of welded portions, the conventional ferritic stainless steels, SUS430 or SUS434, are very susceptible to coarsening of the ferrite grain and the martensite formation when heated to a temperature higher than about 900° C by welding heat, and at the same time solid dissolution of carbo-nitrides is caused thereby. When the welded portion is cooled secondary precipitation of the carbo-nitrides is caused at the ferrite grain boundaries or at the ferrite-martensite boundaries so that the steel is readily susceptible to the intergranular corrosion and intergranular stress corrosion cracking even in a very weak corrosive medium, such as a city water.
The above phenomenon is seen also in an austenitic stainless steel, and for its elimination, lowering of the carbon content, and additions of stabilization elements such as titanium and niobium may be considered as an effective measure.
Among these measures, it is very difficult to eliminate the problem of intergranular corrosion cracking by the lowering of carbon and nitrogen content alone. For example, in a 17 - 20% Cr stainless steel, the intergranular corrosion cracking can not be prevented even with a lowered carbon content of 0.001 to 0.002% and a lowered nitrogen content of 0.004 to 0.007%. It is extremely difficult to lower the carbon and nitrogen contents below the above level in a commercial mass production.
Therefore, for prevention of the intergranular corrosion, it is essential to add stabilizing elements.
The object of addition of stabilizing elements is, therefore, to restrict the precipitation of chromium carbide or chromium nitride at the grain boundaries, and for solving this problem it is more reasonable to consider the total of carbon and nitrogen contents than to consider them separately. Therefore, the addition of the stabilizing elements should be expressed by "amount of stabilizing elements/(C + N)" rather than by "Ti/C" or "Nb/C" as used in the austenitic stainless steels.
The addition of Ti or Nb for the purpose of improving the intergranular corrosion resistance has been known in the austenitic stainless steels as SUS321 and SUS347.
In case of ferritic stainless steel, however, the metallurgical principle of their addition in an austenitic stainless steel does not apply at all. This is considered to be due to the difference in the sensitization temperature; the ferritic stainless steel is sensitized during cooling from a high heating temperature, at which the solid-solutions of carbon and nitrogen increase and then their solubilities decrease more than the austenitic steels, so that more than stoichiometrical amount of titanium and niobium is required.
In fact, it is also known in the conventional art to add titanium and niobium as a stabilizing element in a ferritic stainless steel, but in most cases titanium and niobium are not added in combination as in the present invention for the purpose of improvement of properties.
In exceptional cases of the conventional art where both titanium and niobium are added in combination, niobium is considered as mere substitution for titanium and niobium is added in a small amount for substituting part of titanium. This conventional art is based on the technical thought that niobium is almost equal to titanium for the purpose of combining carbon and nitrogen.
Whereas in the present invention more importance is given on niobium which is added for improvement of properties, particularly toughness, and excessive addition of titanium is avoided because it causes surface defects as mentioned hereinafter, and the most important feature of the present invention lies in that a specific proportion for both of the titanium and niobium contents is defined by the Ti/Nb ratio and the ratio is defined as from 0.5 to 1.2 so as to eliminate the surface defects and to improve intergranular corrosion cracking resistance, toughness and ductility in weld metal.
Reason for defining the upper limit of 1.2 for the Ti/Nb ratio is that ductility of the weld metal is required in some cases and such cases it is necessary to add titanium in a relatively large amount. However, excessive addition of titanium causes surface defects in the final product without any advantage. Thus the upper limit of 1.2 is defined as the range free from the surface defect problem.
On the other hand, in cases where the ductility in the welded portion does not cause a problem, a smaller addition of titanium is enough, and it is desirable to maintain the Ti/Nb ratio within a range from 0.5 to 1.0.
The facts found by the present inventors regarding the addition of titanium and niobium are shown in FIG. 4. According to the discovery the addition varies depending on the content of C + N, and it is necessary to satisfy the following conditions.
(Ti + Nb) ≧ 8 × (C + N) in case of C + N < 0.017%
(ti + Nb) ≧ 16 × (C + N) in case of C + N ≧ 0.017%
the most important feature of the present invention lies in the above point.
In applications where the corrosive condition is less severe, or the sensitization of the steel during the welding or the cooling after the welding is slight, the addition of titanium and niobium may be smaller, but the high level of reliability as required in chemical plants can not be obtained unless the above conditions are satisfied.
The addition of titanium and niobium in combination as defined in the present invention is based on the results of various experiments set forth below. The basic principle underlying the present invention is that since the stainless steel as directed to by the present invention is to be used for general purposes the welded portion must have similar properties such as corrosion and mechanical properties as those of the base metal. If the welded portion is susceptible to any total defect, a high purity, corrosion resistant stainless steel can not be provided.
The effects of the addition of titanium and niobium on the steel properties are set forth below.
ADDITION OF TI
1. intergranular corrosion cracking is prevented for the welded portion just as for the base metal.
2. Ductility of the welded portion is improved.
3. Toughness of the welded portion is lowered.
4. Surface defects are caused in the base metal in case of excessive addition.
ADDITION OF NB
1. intergranular corrosion cracking is prevented for the welded portion just as for the base metal.
2. Ductility of the welded portion is shown in Table 4. With the niobium addition alone, the ductility of the welded portion is for inferior to that of the base metal, although bending property and Erichsen property of the welded portion are improved just as the base metal. These facts correspond well to the grain size in the welded portion shown in FIG. 5. Thus, A weld metal of finer grain size provides better ductility, and this effect is only slight in case of the niobium addition alone, but is very remarkable in case of the niobium and titanium addition in combination.
3. Regarding toughness of the welded portion, the lowering of the content of C + N, as is known, is primarily effective, but in case of a given content of C + N, the embrittle fracture transition temperature is lowered by an appropriate addition of Nb while it is raised by the titanium addition. Whereas, when both titanium and niobium are added in combination, high impact absorption energy and a low embrittle fracture transition temperature without adverse effects by titanium are obtained. This is remarkable improvement as compared with the ductility of the welded portion of the conventional stainless steel SUS430.
4. A stainless steel containing titanium, as is well known, readily absorbs nitrogen during its steel making process, and very susceptible to surface defects due to titanium containing non-metallic inclusions. In order to prevent the above problem, there is nothing but to prevent the nitrogen absorption or to lower the titanium content. As mentioned hereinbefore, however, it is not possible to lower the titanium content unlimitedly in view of the intergranular corrosion resistance. Thus, in this point the addition of niobium in combination with titanium exert its significance. All of the steels shown in examples are free from the surface defect.
5. The above descriptions are made from the consideration for obtaining improved properties for the welded portion just as for the base metal. It will be necessary to make description from the point of drawability of a thin cold rolled steel sheet. It is conventionally known that addition of titanium is more effective than addition of niobium for improvement of deep-drawability. Also in the present invention, this favourable effect of the titanium addition is maintained and good deep-drawability as shown in FIG. 7 is obtained.
From consideration of the whole effect of individual stabilizing elements on the various properties, as shown in Table 6, excellent properties better than and unexpectable from those obtained by the titanium addition alone or the niobium addition alone can be obtained by the titanium and niobium addition in combination.
60 Ni and/or Cu content must be less than 0.20% for elimination of the susceptibilities of stress corrosion crackings, for example in C1 - containing solution or acidic hydrogen sulfide solution. Though these points are well-known the present inventors have found the upper limits of these elements in the system of 17 Cr- 1 Mo - Ti.Nb or 19 Cr - 2 Mo - Ti.Nb.
7. The steel according to the present invention remains a ferrite single phase steel under any heat treatment condition due to its main components and high purity. Therefore, contrary to the conventional ferritic stainless steel, the steel of the present invention does not harden and does not show sensitivity to the intergranular corrosion even when it is subjected to a heat history at high temperatures (about 900° C or higher). As for the heat treatment of the final product, 850° to 950° C is generally desirable. In this case, the heat treatment can be done in the same heat treatment furnace as used for the conventional steel, and when higher productivity is desired, it is possible to perform the heat treatment at higher temperatures and in a shorter time. Therefore, the present invention has remarkable advantage over the prior art in respect of production aspect.
Also, due to the addition of titanium, the cold rolled steel sheet produced from the steel of the present invention shows a high level of deep-drawability and ridging property, and shows only very small fluctuation in these properties due to the heat treatment condition, which is otherwise remarkable in the mass-production.
The ferritic steel as hot worked generally shows low toughness and ductility at ordinary temperature. In order to eliminate this defect, the content of C + N should be lowered. However, if the carbon content is maintained at not more than 0.15% and the nitrogen content at not more than 0.015%, for example C + N = 0.012% as in the steel of the present invention, and still the steel as hot worked is susceptible to embrittlement fracture when impact is given, cooling after the hot working should be done slowly when the cross sectional dimention is large. These restrictions are common to all of the conventional ferritic stainless steels and are not peculiar to the steel of the present invention, and do not hinder the mass-production of the stainless steel of the present invention at low cost.
Chromium is a main element which increases corrosion resistance, and as chromium increases the corrosion resistance increases as shown in FIG. 2.
However, excessive addition of chromium will cause lowering of toughness so that there are caused difficulties in production. Thus the upper limit of chromium is set at 25.00%.
Molybdenum, similar as chromium, improves corrosion resistance. Molybdenum contents beyond 3.5% do not give any additional effects, and thus the range from 1.50 to 3.50% has been set for molybdenum.
Carbon and nitrogen are elements which deteriorates intergranular corrosion resistance, but their adverse effect can be prevented by addition of titanium and niobium. However, excessive contents of carbon and nitrogen require increased addition of titanium and niobium, so that cleanness of the steel is lowered and deterioration of toughness in the welded portion is caused. Therefore, it is desirable that carbon and nitrogen contents are maintained at their commercially attainable levels, thus not larger than 0.015% and not larger than 0.015% respectively, and it is more desirable that they are maintained as low as possible.
Titanium and niobium are elements effective to improve the intergranular corrosion resistance and properties of the welded portion, and their required contents depend on the contents of carbon and nitrogen. For exemption from the intergranular corrosion and intergranular stress corrosion cracking, the following conditions must be satisfied:
(Ti + N) ≧ 8 × (C + N) in case of C + N < 0.017%, and
(Ti + Nb) ≧ 16 × (C + N) in case of C + N > 0.017%.
Further, titanium and niobium should be added in combination with Ti/Nb ratio from 0.5 to 1.2.
Therefore, the lower limits for titanium and niobium have been set as not lower than four times of C + N and not lower than eight times of C + N respectively.
On the other hand, excessive addition of titanium and niobium deteriorate the cleanness of the steel and the toughness. Therefore, the upper limits of titanium and niobium have been set as not larger than 0.50%, and not larger than 1.00%. When the carbon content is not larger than 0.015% and the nitrogen content is not larger than 0.015%, both titanium and niobium can satisfy the above conditions.
Regarding silicon and manganese, selection of starting materials and strong decarburization are necessary from the point of commercial steel making process so as to maintain both silicon and manganese contents at 0.30% or lower. If these elements are to be re-added in a form of alloy, the harmful carbon and nitrogen contents increase to produce adverse effects on all of the steel properties and require complicated control of addition of stabilization elements. When metallic silicon and metallic manganese, for example, are added for the purpose of avoiding increase of the carbon and nitrogen contents, this causes increased steel production cost and hinders the object to provide a steel for general use.
From the reasons set forth above, both the silicon and manganese contents are limited to 0.30% or lower.
Regarding nickel and copper, it is known that a ferrite stainless steel is sensitive to stress corrosion cracking when it contains nickel and copper. According to the results of stress corrosion cracking tests in boiling 42% MgCl 2 solution and in acidic solution of hydrogen sulfide, and various tests in actual plants, it has been found that when 0.5% nickel is contained in the steel of the present invention sensitivity to cracking appears, while when 0.21% nickel is contained no such sensitivity appears.
Similar tendencies are considered to appear in case of copper also, and thus the upper limit of the copper content has been set at 0.20%. Both of nickel and copper are limited within an impurity range, and it is necessary that these elements are maintained at 0.2% or lower, respectively.
Regarding impurities such as phosphorus and sulfur, these elements may be present at a similar level as seen in the conventional stainless steels SUS430 and SUS434, because there is no substantial effects caused on the corrosion resistance and mechanical properties of the base metal and the welded portion when the contents of these elements are changed over their conventional ranges.
There is no specific limitation on the production method of the ferritic stainless steel of the present invention, and conventional arts for steel-making and treatment such as rolling and heat treatments may be applied.
The present invention will be more clearly understood from the following example.
EXAMPLE
Table 1 shows steel compositions within the scope of the present invention and their corrosion resistance at the welded portion in comparison with those of some conventional steel compositions.
As for the testing methods, JIS sulfuric acid-copper sulfate test was used for the intergranular corrosion test, and tests in H 2 SO 4 -acidified solution, or HCl-acidified, H 2 S-saturated solution at high temperature and high pressure were used for the intergranular stress corrosion cracking test.
The first test is widely used for detecting the intergranular corrosion susceptibility of an austenitic stainless steel, and is also applicable to a ferritic stainless steel although its condition is somewhat severe. Rather, if the test piece passes this severe sulfuric acid-copper sulfate test, the steel can be safely regarded that it has better intergranular corrosion resistance than that of an austenitic stainless steel. The latter test, a high temperature, high pressurized and H 2 SO 4 -acidified solution test, provides conditions contemplated in many environments such as steam heat exchangers and condensors for naphtha cracking.
All of the convention ferritic stainless steels set forth in Table 1 are attached when they are subjected to 1200° C heat treatment which is contemplated to take place during welding, while the steels containing titanium and niobium according to the present invention are free from the corrosion.
Table 2 shows results of the stress corrosion cracking test in a neutral high temperature and high pressurized water containing chloride ions, and Table 3 shows results of tests on stress corrosion cracking due to hydrogen sulfide very often seen in oil refining plants and puls making plants. All of the conventional austenitic stainless steels, when treated by a solid solution treatment or by a sensitization treatment, show sensitivity to cracking, and the conventional ferritic stainless steels show more sensitivity to cracking than the austenitic stainless steel when they are in a sensitized condition, although they are exempt from the cracking when they are in annealed condition. Whereas the ferritic stainless steels containing titanium and niobium according to the present invention are exempt from the cracking when they are in an annealed condition or in a sensitized condition.
Table 4 shows the mechanical properties of the welded portion. The conventional steels show coarsening of the ferrite grains by a high temperature heating of 1200° C or higher and formation of the austenite phase.
When titanium and niobium are added, no austenite phase is formed and the coarsening of the ferrite grains are suppressed so that ductility of the welded portion is improved. Also, the properties of the welded joints of the steel E according to the present invention are shown in Table 5.
Table 1__________________________________________________________________________Intergranular Corrosion Resistance and Intergranular StressCorrosion Cracking Resistance__________________________________________________________________________ Chemical Composition (Weight %)Steel Grades C Si Mn P S Ni Cu Cr Mo__________________________________________________________________________SUS 430 0.060 0.60 0.45 0.023 0.006 0.15 0.05 16.49 --SUS 434 0.050 0.51 0.46 0.024 0.008 0.16 0.06 16.51 1.0320Cr-2Mo-Ti 0.007 0.11 0.10 0.009 0.007 0.08 0.02 20.19 2.1419Cr-2Mo-Nb 0.010 0.12 0.20 0.019 0.010 0.09 0.02 18.96 2.10Present Invention Steel A 0.004 0.15 0.20 0.019 0.010 0.07 0.03 19.32 2.06Present Invention Steel B 0.004 0.11 0.20 0.019 0.010 0.07 0.03 18.87 2.07Present Invention Steel C 0.011 0.14 0.20 0.020 0.010 0.08 0.04 17.96 2.10Present Invention Steel D 0.007 0.12 0.15 0.029 0.007 0.14 0.06 18.80 2.07Present Invention Steel E 0.008 0.09 0.17 0.026 0.007 0.12 0.06 18.95 2.05SUS 304 0.05 0.69 1.03 0.026 0.008 8.91 0.29 18.35 --SUS 316 0.06 0.71 1.00 0.019 0.008 13.15 0.35 16.80 2.34__________________________________________________________________________ Intergranular Corrosion(*) Stress Corrosion Chemical Composition Corrosion Inter- Cracking at High (Weight %) Rate granular Temperature andSteel Grades Ti Nb N Ti/Nb Ti+Nb/C+N (g/m.sup.2 hr) cracking High Pressure__________________________________________________________________________ (**)SUS 430 -- -- -- -- -- 3.62 YES Intergranular CrackingSUS 434 -- -- -- -- -- 3.25 " "20Cr-2Mo-Ti 0.19 -- 0.011 -- 10.5 0.44 " "19Cr-2Mo-Nb -- 0.33 0.014 -- 13.8 0.25 " "Present Invention Steel A 0.09 0.16 0.011 0.56 16.7 0.065 NO No crackingPresent Invention Steel B 0.12 0.20 0.011 0.6 21.3 0.035 " "Present Invention Steel C 0.17 0.31 0.013 0.55 20.0 0.033 " "Present Invention Steel D 0.37 0.32 0.011 1.16 38.4 0.020 " "Present Invention Steel E 0.15 0.27 0.009 0.56 30.5 0.020 " "SUS 304 -- -- -- -- -- -- -- --SUS 316 -- -- -- -- -- -- -- --__________________________________________________________________________ (*)As annealed at 1200° C for 5min. then air cooled. Sulfuric Acid-Copper Sulfate Corrosion Test (JIS G 0575)? (**)As annealed at 1200° C for 5min. then air cooled. H.sub.2 SO.sub.4 is added to high purity water of 1 × 10.sup.6 Ωcm to adjust pH to 3.9? Initially dissolved oxygen: 8 ppm? 300° C 85 atm 100hr × 3 periods Shape of test piece: 1.sup.t × 15.sup.w × 100.sup.l 10R U bended and restricted
Table 2______________________________________Stress Corrosion Cracking at High Temperature andHigh Pressure As Annealed As Sensitized Cl.sup.- Cl.sup.- Cl.sup.- Cl.sup.- 30 ppm 600 ppm 30 ppm 600 ppm______________________________________SUS 304 O O X X X X X XPresent O O O O O O O OInventionSteel ASteel C O O O O O O O O______________________________________Condition of SensitizationSUS 304 650° C 2 hr ACOthers 1200° C 5 min ACTest Piece 1.5.sup.t × 15.sup.w × 100.sup.l mm, 1OR, U-bended and restrictedTest Solution Pure Water + Na.sub.2 Cl(Cl.sup.- = 30 or 600 ppm) 300° C 87 Kg/cm.sup.2 300 hrEstimation X Cracking , O No Cracking______________________________________
Table 3______________________________________Stress Corrosion Cracking in Hydrogen Sulfide Solution As Annealed As Sensitized______________________________________SUS 304 X X (180 μ) X X (130 μ)SUS 434 O O X X (380 μ)PresentInvention A O O O OSteelInvention C O O O OSteel______________________________________Heat Treatment and Test Piece are same as in Table 2.Test Solution: Aqueous Solution having pH value of 3.0 with addition of hydrochloric acid, continuously blown with H.sub.2 S gas or 80° C for 15 days.Estimation : X Cracking , the figures in parentheses represent the maximum crack depth O No cracking______________________________________
Table 4__________________________________________________________________________Effect of Stabilization Element on Mechanical Propertiesof Welded Portions Tensile Bending Test Erichsen Value Treating Strength 180° U (Plate thicknessSteel Grades Conditions δB(Kg/mm.sup.2) El(%) R=1.sup.t R=0.5.sup.t R=O.sup.t 2 mm)__________________________________________________________________________ Annealing A 51.0 33.8 O O O 11.6219Cr-2Mo-Nb HAZ equivalent S* 50.0 21.0 X X X 5.31 Welded portion W** 52.0 27.0 0 0 0 6.92Present A 47.9 34.8 O O O 12.02invention B S 47.5 33.0 O O O 11.12Steel W 49.8 31.3 O O O 11.28Present A 51.2 30.5 O O O 12.21invention C S 46.4 29.5 O O O 11.28Steel W 51.6 29.5 O O O 11.51__________________________________________________________________________ *Heat treatment condition equivalent to that of welding heat affected zone: 1200° C 5min AC? **Welding condition: TIG welded without filler 70A, 10V, 10 cpm Ar gas(10l/min) shielded?
Table 5__________________________________________________________________________Properties of Weld Joints (Present Invention Steel E) Welding Condition Tensile Test Bending Test δBPlate Current Speed Shield Back kg/ Front Back Erichsen ValueThickness A cpm gas l/min gas l/min mm.sup.2 El % Side Side mm (n=3)__________________________________________________________________________1.0 70 50 Ar.sub.10 -- 52.3 30.5 no crack- no crack- 9.96/10.48 10.18 ing at ing at adhesion adhesion 40 20 15 Ar.sub.5 50.8 14.5 " " 6.98/9.67 8.06 80 60 15 " 45.7 15.8 " " 7.15/7.26 7.231.0.sup.t -- -- -- -- 52.0 31.3 " " 10.56/10.92 10.62Base Metal1.5 70 20 15 5 50.3 16.0 " " 8.00/8.75 8.36 90 20 15 5 47.2 10.0 " " 8.68/9.75 9.19 140 60 15 5 50.6 22.0 " " 9.33/9.45 9.371.5.sup.tBase Metal -- -- -- -- 51.2 33.5 " " 11.08/11.38 11.19__________________________________________________________________________Remarks 1) TIG But Welding : without filler (no flyer) Tensile Test : JIS 13-B C-direnction welding, R.D. (Roll Direction) tension__________________________________________________________________________
Table 6______________________________________Effects of Stabilization Elements Properties of Welded PortionStabili- Intergranularzation Surface Corrosion Duc- Tough- GeneralElements Defects Resistance tility ness Estimation______________________________________Ti X O Δ X XNb O O X O XTi+Nb O O O O O______________________________________ (The stabilization elements are added in an amount enough to assure the intergranular corrosion resistance of the welded portion.) O: well usable in the wide Δ: usable only under limited X: no usable
|
A highly corrosion resistant ferritic stainless steel comprising;
C ≦ 0.015%
Si ≦ 0.30%
Mn ≦ 0.30%
P ≦ 0.040%
S ≦ 0.030%
Cr : 18.00 to 25.00%
Ni ≦ 0.20%
Cu ≦ 0.20%
Mo : 1.50 - 3.50%
N ≦ 0.015%
Ti : 4 × (C + N)% to 0.50%, and
Nb : 8 × (C + N)% to 1.00%, wherein
Ti/Nb : 0.5 to 1.2
(Ti + Nb)/(C + N) ≧ 8.0 in case of (C + N) < 0.017%, and
(Ti + Nb)/(C + N) ≦ 16.0 in case of (C + N) ≧ 0.017%
with the balance being iron and unavoidable impurities.
| 2
|
BACKGROUND OF THE INVENTION
This invention generally relates to method and apparatus for determining the moisture content of materials, and more particularly relates to a dual wavelength infrared technique for measuring moisture content.
As is well known, knowledge about the exact amount of water or moisture present in materials or substances is important for the accurate control of many industrial processes. For example, in the process of making asphalt paving material, sand and gravel, which are collectively referred to as aggregate, are generally mixed with a bituminous or asphalt liquid. However, if the aggregate is not sufficiently hot, the asphalt liquid will not properly adhere to the sand and gravel. Therefore, a large burner is typically used to heat the aggregate before mixing the aggregate with the asphalt liquid. In such process, it is important to know the initial moisture content of the aggregate because that effects how many BTUs are required to heat the aggregate to a sufficient temperature. Therefore, with knowledge regarding the moisture content of the aggregate, the burner can be continuously and accurately regulated. If too little heat is applied, the aggregate will not be sufficiently heated; conversely, if too much heat is applied, the aggregate may be too hot and the energy efficiency of the process will be degraded. In this and other industrial processing systems, the various stages such as the regulation of the burner are controlled by a process computer. In such arrangement, it is desirable to provide the process computer continuously with real time electrical signals representative of the moisture content of the aggregate so that the burner firing rate can be optimized.
Moisture content is generally defined as the ratio of water weight divided by the material weight plus the water weight. One conventional prior art method for determining moisture content is referred to as the water evaporation method. A sample of a material such as aggregate is first weighed, and then it is heated for a sufficient period of time to evaporate or drive off all of the moisture within the sample. Next, the sample is reweighed. The material weight plus water weight is, of course, provided by the initial weighing, and the water weight is the difference between the first weighing and the reweighing after the water has been driven off. One problem with this method is that it requires a substantial amount of time and is labor intensive. Further, the method is not readily adapted to a continuous monitoring system that determines the real time moisture content of a substance such as aggregate immediately prior to a stage where knowledge of moisture content is critical. In fact, aggregate would typically not have a homogenous moisture content, and by the time that one sample on a conveyor belt is analyzed, the aggregate entering the next stage may have an entirely different moisture content.
Another method for determining the moisture content of materials or substances such as aggregate is referred to as the microwave method. Microwave energy is propagated through the aggregate and its conveyor belt, and the theory is that the magnitude of the microwave energy on the other side of the conveyor is a function of the water or moisture content in the aggregate. That is, the more moisture that is present in the aggregate, the more attenuated the microwave energy will be at a detector on the opposite side. This method has a number of apparent disadvantages. First, a relatively high microwave energy power level is required to compensate for energy losses in the conveyor belt and the aggregate itself. Second, the accuracy of the measurement is very limited. That is, it is very difficult to measure small incremental changes in power level caused by absorption by the moisture. Further, the consistency, lossiness and thickness of the aggregate must be very accurately regulated to prevent these factors from becoming variables in the microwave measurements.
Another method of determining moisture content of a sample takes advantage of the fact that infrared energy is known to be absorbed by water at very specific wavelengths. That is, the absorptivity of infrared energy by water or moisture is known to be dependent on wavelength. In one commercially available system, the material, such as aggregate moving on a conveyor belt, is illuminated with broadband infrared energy, and a reflection sensor is positioned immediately above the aggregate. The reflected infrared energy power spectrum is altered according to the amount of moisture on the surface of the aggregate. For example, if the sample has a relatively large amount of moisture on the surface, reflection of energy at wavelengths of high water absorption will be greatly reduced while reflections of energy at wavelengths of low water absorption will be less attenuated by the surface moisture. The spectrum of reflected energy is filtered using wavelength selective optics mounted in a chopper wheel. More particularly, the sensor includes a stationary broadband infrared detector positioned behind a chopper wheel having a plurality of narrow band pass filters each disposed at a different angular orientation around the wheel. Thus, as the wheel rotates, narrow band pass filters of different wavelengths sequentially cover the infrared detector. During a first time period, the infrared detector is exposed to infrared energy of a first wavelength λ1 having a first water absorption characteristic because this is the only light permitted to pass the filter disposed in front of the infrared detector. Then, during a second time period, the infrared detector is exposed to infrared energy of a second wavelength λ2 having a second water absorption characteristic because this is the only light permitted to pass the filter disposed in front of the infrared detector during the second time period. As a result, the detector provides sequential pulses having amplitudes which are a function of the absorption of infrared energy of the respective wavelengths by the surface moisture of the material. For example, the reflection of infrared energy at one of the wavelengths λ1 is not readily absorbed by the surface moisture and thus provides a reference value relating to the surface parameters or characteristics of the material (e.g. how much side reflection there is). The reflection of infrared energy at the other wavelength λ2 is more readily absorbed in surface moisture and thus provides a measure of the surface moisture. By taking the ratio of the pulses for λ1 and λ2, a value proportional to the surface moisture is obtained, and surface moisture generally corresponds to the moisture content of the material. The ratio of λ1 and λ2 can be compared or correlated with data derived from similar measurements previously taken on materials or substances of known moisture content.
The chopper wheel approach, however, has some drawbacks. First, the chopper wheel has to be rotated thereby requiring a drive motor and other associated moving mechanical components that increase the cost and reduce the reliability of the sensor. Also, the transmitted power levels of energy at λ1 and λ2 are relatively weak because they are only a portion of the broadband energy used to illuminate the sample. As such, the ambient light becomes a much more critical factor thus sometimes necessitating the use of shields to shade the sensor and sampled region. It is also apparent that the sensor would have a relatively low signal-to-noise ratio.
SUMMARY OF THE INVENTION
In accordance with the invention, a method comprises the steps of irradiating a sample of unknown moisture content with a frequency band of light of a first wavelength having a first moisture absorptivity characteristic for a first time interval and providing a first signal corresponding to the magnitude of the first wavelength light reflecting from the sample. Then, the sample is irradiated with a frequency band of light of a second wavelength having a second moisture absorptivity characteristic for a second time interval and a second signal is provided which corresponds to the magnitude of the second wavelength light reflecting from the sample during the second time interval. In response to the first and second signals, a third signal is then determined which corresponds to the moisture content of the sample. It is preferable that the determining step comprises the step of correlating the first and second signals to light reflecting signals of the first and second wavelengths measured on samples of known moisture content. It may also be preferable that the correlating step comprises the step of comparing a ratio of the first and second signals to ratios of the light reflecting signals of the first and second wavelengths measured on samples of known moisture content. Further, the first and second signal providing steps may comprise the step of subtracting ambient light levels from respective measurements made during said first and second time intervals. The first wavelength may be at approximately 880 nanometers and the second may be wavelength at approximately 950 nanometers.
The invention can also be practiced by a method comprising the steps of activating a first light source of a first wavelength for a predetermined time period to direct light of the first wavelength onto a sample of a substance of unknown moisture content while measuring light adjacent to the sample to produce a first electrical signal corresponding to the magnitude of light of the first wavelength reflecting from the sample. Subsequently, a step includes activating a second light source of a second wavelength for a predetermined time period to direct light of the second wavelength onto the sample while measuring light of the second wavelength reflecting from the sample to produce a second electrical signal corresponding to the magnitude of light of the second wavelength reflecting from the sample. Then, the moisture content of the sample is determined by correlating the first and second electrical signals with data derived from measurements of light of the first and second wavelengths reflected from samples of known moisture content.
The invention may also be practiced by an apparatus comprising means for directing light of a first wavelength onto a sample of unknown moisture content during a first time period and directing light of a second wavelength onto the sample during a second time period. The apparatus further comprises means for providing first and second electrical signals respectively corresponding to light of the first and second wavelengths reflecting from the samples during the respective first and second time periods, and means responsive to the first and second electrical signals for providing a third signal corresponding to the moisture content of the sample. The first wavelength light directing means may comprise a bank of light emitting diodes emitting infrared energy having a wavelength of approximately 880 nanometers, and the second wavelength light directing means may comprise a bank of light emitting diodes emitting infrared energy having a wavelength of approximately 950 nanometers.
With such arrangement, measurements of reflected light at two discrete wavelengths having two water absorption characteristics are provided without the use of moving parts such as a prior art chopper wheel with narrow bandpass filters. In particular, rather than directing broadband light onto the sample and then filtering the spectrum to determine the spectral content at two discrete wavelengths, the sample is sequentially irradiated with light limited to two discrete wavelengths. Therefore, a broadband detector can be used to measure the reflected light at both wavelengths without the need for multiple filters and associated wheel rotating apparatus. Another advantage is that the light at the wavelengths of interest is intensified thereby providing an enhanced signal-to-noise ratio which reduces or eliminates the need for associated shading apparatus around the sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantages will be more fully understood with reference to the drawings wherein:
FIG. 1 is a sectioned view of a dual wavelength moisture sensor disposed above a material being transported on a conveyor belt;
FIG. 2 is a bottom view of the moisture sensor of FIG. 1;
FIG. 3 is a bottom view of an alternate embodiment of a moisture sensor;
FIG. 4 is a side sectioned view of FIG. 3 taken along line 4--4;
FIG. 5 is a block diagram of a moisture sensing system embodying the moisture sensor of FIGS. 1 or 3; and
FIGS. 6A-C show respective timing diagrams of the 880 and 950 nanometer wavelength drivers and the corresponding output of the IR detector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a dual wavelength infrared moisture sensor 10 is positioned above a conveyor 12 which carries a material or substance 14 of unknown moisture content. For purposes here, moisture content is generally defined as the weight of the water in the material divided by the material weight plus the weight of the water. This moisture content value is an important parameter in the controlling of many industrial processes such as, for example, the making of asphalt. For example, substance 14 may be sand and/or gravel which are collectively referred to as aggregate in the process of making asphalt for road paving. Conveyor 12 includes a belt 16 supported by rollers 18 a-c which are captured by respective brackets 20a-d mounted to the walls 22a and b and floor 24 of channel 26. In the depiction of FIG. 1, the substance 14 or aggregate is being conveyed towards the viewer. Infrared moisture sensor 10 is supported by a stand 28 connected to wall 22a. It may also be desirable to mount a levelling blade (not shown) between walls 22a and b to make the upper surface of aggregate 14 more uniformly level to increase the accuracy of the moisture content measuring method to be described subsequently herein.
Infrared or IR moisture sensor 10 includes a downwardly directed parabolic reflector 30 having a highly reflective or mirror-like internal surface 32. The lower open end of parabolic reflector 30 is covered by an infrared transmissive or transparent window 34 which prevents foreign matter from entering reflector 30. Typically, window 34 may be made from a clear material such as acrylic.
A dual wavelength infrared emitter section 36 is here suitably disposed within parabolic reflector 30, and includes a vertical cylinder 38 surrounding a horizontal plate, here a printed circuit board 40 on which a plurality of narrow-band light emissive devices such as photo-emissive diodes or LEDs 42a and b are mounted.
As shown in FIG. 2, LEDs 42a and b are spaced around printed circuit board 40 in some predetermined pattern providing a desired uniformity of emitted light here infrared energy from vertical cylinder 38. A plurality or bank of LEDs 42a are here depicted as darkened circles, and may typically represent eighteen 23-milliwatt LEDs that emit a discrete or narrow band of light or infrared energy having a center or characteristic wavelength of 880 nanometers. A plurality or bank of LEDs 42b are here depicted as open circles, and may typically represent eighteen 14-milliwatt LEDs that emit a discrete or narrow band of light or infrared energy having a center or characteristic wavelength of 950 nanometers. Infrared detector or photosensor such as photosensitive diode 44 is mounted on top of dual wavelength infrared emitter section 36 and is covered with a long pass filter 37 to filter out light below a predetermined wavelength such as, for example, 830 nanometers. One example of photosensitive diode 44 is a VTS 7080 photodiode by E. G. & G Vactec of St. Louis, Missouri. The internal surface 32 of parabolic reflector 30 is configured to direct a substantial portion of light or infrared energy entering parabolic reflector 30 onto photosensitive diode 44.
Referring to FIGS. 3 & 4, infrared moisture sensor 46 is an alternate embodiment to infrared moisture sensor 10. Here, rather than having a large parabolic reflector 30 for the photosensitive diode 44 as in the parabolic optics configuration of FIG. 1, each infrared emitter or LED 42a and b is provided with a individual parabolic mirror 48 to direct or intensify the emitted light or infrared energy down towards the substance or aggregate 14 under test. In contrast, the vertical cylinder 38 of infrared moisture sensor 10 in FIG. 1 helps to concentrate the collectively emitted light to a relatively small region or sample portion 49 of the substance 14. In a typical array optics configuration as shown in FIGS. 3 and 4, twenty-six 23-milliwatt LEDs of 880 nanometer wavelength and twenty-six 14-milliwatt LEDs of 950 nanometers wavelength are mounted to printed circuit board 50. As shown in FIG. 3, the 880 nanometer wavelength LEDs 42a are represented by dark circles while the 950 nanometer wavelength LEDs 42b are represented by open circles. Also dispersed in the array of LEDs 42a and b are a plurality of broadband infrared detectors here photosensitive diodes 44. The LEDs 42a and b and photosensitive diodes 44 are separated by Lexan spacers 52 and the underside of infrared moisture sensor 46 is covered by an infrared transmissive shield, here an acrylic window 54 to keep foreign matter off of infrared moisture sensor 46. Each of the photosensitive diodes 44 is covered by an 830 nanometer long pass filter 56 to filter out interfering light.
Referring to FIG. 5, a block diagram shows a dual wavelength moisture sensing system 58 which uses the infrared moisture sensor 10 or 46 to advantage. Source selector 60 is fed by clock 62, and provides enabling signals on lines 64 and 66 to respective diode drivers 68 and 70. In response to the enabling signals, diode drivers 68 and 70 alternately provide pulsed drive signals to respective 880 nanometer diodes 42a and 950 nanometer diodes 42b. As a result, whether using the infrared moisture sensor 10 of FIG. 1 or the alternate infrared moisture sensor 46 of FIG. 3, a sample portion 49 of the substance 14 or material here shown as aggregate is illuminated with sequential infrared light pulses or flashes of different wavelength (e.g. 880 nanometers and 950 nanometers). A portion of light reflected from aggregate 14 is incident on the IR detector 44 or photosensitive diode and, in the case of FIG. 3, a plurality or bank of photosensitive diodes 44. In response to the incident light or infrared energy, the infrared detector 44 provides a low level signal on line 72 which is amplified by amplifier 74 before being digitized by analog-to-digital converter ADC 76. The output of ADC 76 is processed by microprocessor 78 in a manner to be described subsequently.
More particularly, with reference to FIGS. 6A and B, source selector 60 receives clocking pulses such as, for example, at a 10 kilohertz rate, and initially provides an enabling signal on line 64 that causes diode driver 68 to synchronously provide a drive pulse 80 to all of the 880 nanometer wavelength diodes 42a. For example, as shown in FIG. 6A, the 880 nanometer driver 68 may typically provide a drive pulse having a time duration of 12 milliseconds during which time all of the 880 nanometer wavelength LEDs 42a are activated. In the case of the parabolic reflector optics configuration shown in FIG. 1, each of the 880 nanometer wavelength LEDs 42a turn on for 12 milliseconds and provide a directive beam of light or infrared energy down vertical cylinder 38 onto a sample portion 49 of substance 14 here shown as aggregate. In the case of the array optics configuration shown in FIG. 3, each one of the 880 nanometer wavelength LEDs 42a is turned on or activated for 12 milliseconds and each directs each own individual beam onto a sample portion 49 of substance 14. Following 12-millisecond millisecond pulse 80, the output of source selector 60 becomes inactive for 12 milliseconds, as shown in FIGS. 6A and 6B. Then an enabling pulse is provided to diode driver 70 which in turn synchronously provides a drive pulse 82 to all of the 950 nanometer wavelength diodes 42b. In a manner described above for the 880 nanometer wavelength LEDs 42a, a sample portion 49 of the substance 14 is illuminated by one or more directive beams of 950 nanometer wavelength energy. Following the termination of pulse 82, the source selector 60 outputs to diode drivers 68 and 70 are inactive for 14 milliseconds, and then the same timing sequence is initiated again. In short, all of the 880 nanometer wavelength LEDs 40a are pulsed on in unison every 50 milliseconds for a time duration or interval of 12 milliseconds, and all of the 950 nanometer wavelength LEDs 42b are pulsed on in unison every 50 milliseconds for a time duration or interval of 12 milliseconds, and the pulses are noncoincidental.
In further discussion of the operation of dual wavelength moisture sensing system 58, narrow band infrared energy from the respective 880 nanometer and 950 nanometer wavelength pulses is reflected from the sample region 49 of substance 14 as depicted in FIG. 1. More specifically, the 880 nanometer wavelength light 84 is depicted by a solid arrow, and the 950 nanometer wavelength light 86 is depicted by a dashed arrow. A portion of this light 84 and 86 enters parabolic reflector 30 and is directed onto IR detector here photosensitive diode 44. In the case of the array optics configuration of FIG. 3, individual directive beams from the LEDs 42a and b are reflected backup through window 54 and long pass filter 56 to photosensitive diodes 44 whose outputs are summed.
As shown in FIG. 6C, the IR detector output or the output of one or ganged photosensitive diodes 44 is a series or sequence of spaced pulses 88-91, each corresponding to a respective one of the pulses of light or infrared energy, emitted by respective LEDs 42a and b. For example, pulse 88 corresponds to the first 12 millisecond activation of the 880 nanometer wavelength LEDs 42a, and pulse 89 corresponds to the first 12 millisecond activation of the 950 nanometer wavelength LEDs 42b. Pulses 90 and 91 correspond to subsequent activations of respective banks of LEDs 42a and b. After amplification in amplifier 74, pulses 88-91 are converted to digital signals and the respective 12 millisecond time periods are each sampled 128 times. These samples are added and then divided by 128 to provide an average amplitude during the pulse period. It is further noted that there are inactive time periods 92 and 93 of 12 and 14 milliseconds between respective alternating wavelength light pulses 88-90. During these inactive periods 92 and 93 when neither LEDs 42a nor 42b are active, the low level electrical signal at the output of the IR detector or photosensitive diode 44 corresponds to the ambient light level. Therefore, 128 samples are also taken and averaged during time periods 92 and 93, and these values are subtracted from the respective average values for respective preceding pulses 88 and 89. Thus, the normalized average magnitudes of pulses 88 and 89, here defined as V 1 and V 2 , correspond to or are representative of the magnitude of light or IR energy of respective wavelengths 880 nanometers and 950 nanometers that reflects from the sample portion 49 of the material or substance 14 being analyzed.
As is well known, light or infrared energy is absorbed by water at very specific wavelengths. In particular, infrared energy at a wavelength of 950 nanometers is more readily absorbed than infrared energy at a wavelength of 880 nanometers. Therefore, by using the reflected 880 nanometer light as a reference value corresponding to the relative characteristics or parameters of the surface of the sample portion 49, here aggregate, the reflected 950 nanometer wavelength light provides a measure or is proportional to the water moisture on the surface of the sample portion 49. More specifically, the ratio, and in particular the ratio of (V 1 -V 2 )/V 1 , where V 1 is the larger of the two reflected voltages, provides a value representative of or corresponding to the moisture content of the sample portion 49.
In order to determine the actual moisture content of the sample, or more particularly the sampled portion 49 of material or substance 14 illuminated by LEDs 42a and b, microprocessor 78 looks up the ratio (V 1 -V 2 ) /V 1 in a table of data correlating similar precalibrated ratios to moisture content. Alternatively, microprocessor 78 may calculate or interpolate the present moisture content from on site measurements on samples of known moisture content. For example, infrared moisture sensor 10 or 46 can be used to generate (V 1 -V 2 ) / V 1 ratios for samples of known moisture content, and the present (V 1 -V 2 ) / V 1 ratio can be interpolated therefrom. For example, a (V 1 -V 2 ) / V 1 ratio can be measured for a sample that is then weighed, dried, and reweighed to determine the precise moisture content using a conventional moisture evaporation technique. This corresponding data is then entered into microprocessor 78. Next, the (V 1 -V 2 ) / V 1 ratio is measured for a wetter sample and the same weighing process performed to provide another data point of (V 1 -V 2 ) / V 1 to present moisture content. By interpolating these two precalibrated data points of known moisture content, the corresponding moisture content for the presently measured (V 1 -V 2 ) / V 1 ratio can be calculated using well known methodology.
In summary, a first bank of LEDs 42a is activated during a first time period to illuminate a sample portion 49 with a narrow frequency band of light having a first moisture absorption characteristic. The reflected light of this wavelength λ1 is measured during the first time period. Then, a second bank of LEDs 42b is activated during a second time period to illuminate the sample portion 49 with a narrow frequency band of light having a second moisture absorption characteristic. The reflected light of this wavelength λ2 is measured during the second time period. Optionally, the ambient light level can be subtracted from each of the measured reflected light levels to eliminate this factor as a variable. In any event, a ratio of the reflected light levels at the two different wavelengths λ1 and λ2 is correlated with similar ratios derived from similarly measured samples of known moisture content. By illuminating with narrow frequency band light from two different sources such as LEDs 42a and b rather that illuminating with a broadband source and then filtering, no moving parts such as a chopper wheel with filters are required. Further a better signal-to-noise ratio is provided because of the high intensity of the light at the wavelengths of interest.
This concludes the description of the preferred embodiment. A reading of it by one skilled in the art will bring to mind many alterations and modifications without departing from the spirit and scope of the invention. Therefore, it is intended that the scope of the invention be limited only by the appended claims.
|
Method and apparatus for determining moisture content of materials by irradiating a sample of unknown moisture content with a narrow frequency band of light at a first wavelength during a first time period and a narrow frequency band of light of a second wavelength during a second time period. The two wavelengths of light have different water absorptive characteristics, and therefore are reflected by varying degrees depending on the surface moisture on the material. The respective reflections are measured by a single common detector, and a value corresponding to the ambient light is subtracted from each measurement. A ratio of the resultant values is then correlated with data derived from precalibration measurements of samples of known moisture content.
| 6
|
BACKGROUND INFORMATION
1. Field of the Invention
The present invention relates to saw chain cutting elements such as cutting links and in particular it relates to a cutting element and structure therefore for sawing hard, abrasive aggregate material.
2. Background of the Invention
Chain saws are efficient tools for cutting hard, abrasive material including aggregate materials such as formations of rock and stone, composite mixtures such as concrete, building blocks, brick and the like. Chain saws adapted for use on such aggregate materials take the general form of traditional chain saws as applied to wood products. The cutting elements of a saw chain for cutting hard abrasive material differ widely, however, from the traditional wood cutting saw chain.
The saw chains for cutting hard abrasive materials generally utilize rectangular cutting blocks mounted to support links of the saw chain. The cutting blocks are typically a matrix of material in which hard wear resistant cutting elements such as industrial diamonds are randomly distributed. The cutting blocks vary in several respects but generally are fixedly attached across a side link pair of the saw chain such as by weldments. Regardless of their configuration, they present a large surface area of the cutting block for abrading contact with the material to be cut, and the blocks are arranged so that the saw kerf produced exceeds the width of the basic chain chassis.
Cutting aggregate material is an abrading or crushing action rather than a severing, i.e., chip removal, action. The cutting blocks establish surface-to-surface contact with the material to be cut and the movement of blocks and pressure against the material reduces the material to fine particles. The aggregate material and the fine particles produced are very abrasive. The abrasive nature of this material inflicts severe wear conditions upon the saw chain components. The saw chain traveling in the kerf rubs against the side walls of the kerf, and this can rapidly wear away the saw chain rivet heads. A further problem is that the leading edge of the block produces the greatest cutting action and experiences the greatest wear. The area of the block succeeding the leading edge tends to inefficiently re-crush the material already removed, rather than productively remove additional material. The result is an inefficient use of the succeeding portions of the block.
Another problem with such cutting blocks, has been the uneven distribution of the cutting elements throughout the matrix. As the cutting block wears down, the number of exposed cutting elements, e.g., diamonds, can vary, i.e., more or fewer diamonds being exposed along one cutting area than another. Also, the leading and side edges of the block tend to erode or wear away at a faster rate than the rest of the block resulting in a crowned wear pattern. This crown makes it difficult to maintain the kerf width. As the blocks become tapered due to the crowned wear pattern, the chain can bind in the kerf. Kerf width is better maintained by removing the material in the corners of the kerf, but the corners of the cutting blocks tend to be the weakest part of the cutting block and often fail in this respect. Also, the corners of the kerf are not under the same constant cutting action as is the center portion of the kerf. This is due in part to assembly tolerance, i.e., lateral misalignment of individual blocks on the chain. A first block may be well centered on the chain and produce the desired kerf, but a succeeding block may be laterally offset. The outward extending corner of the offset block removes additional material, i.e., outside the desired kerf width, while the opposite corner does little or no cutting. Other blocks must remove the material skipped in the kerf corner by the offset block. Overall, the cutting block corners experience greater wear.
Accordingly, it is desirable that a saw chain for cutting aggregate material be better adapted to withstand the abrasion present in such cutting environments but with more efficient use of the abrasive particles, and better maintain a desired kerf width for improved cutting with less operator applied force. The subject matter of the present invention provides these and other advantages for an aggregate cutting saw chain.
Abrasive tools have heretofore included a diamond mesh cutting element whereby an underlying mesh structure receives a well distributed collection of hard particles, e.g., industrial diamonds, and the entire assembly is secured as a composite material by compression and sintering. Such composite material abrasive tools are shown and described in U.S. Pat. No. 5,049,165 issued Sep. 17, 1991 to Naum N. Tselesin, and entitled Composite Material; and in U.S. Pat. No. 4,925,457 issued May 15, 1990 to Peter T. deKok and Naum N. Tselesin and entitled Abrasive Tool and Method for Making. The disclosures of U.S. Pat. Nos. 4,925,457 and 5,049,165 are herewith incorporated fully herein by reference.
BRIEF SUMMARY OF THE INVENTION
In a first embodiment of the present invention, right and left cutting elements attach to a corresponding right and left support links. Each of the right and left support links are paired with a side link or tie strap. The cutting element is a mesh comprising abrasive material formed by uniformly distributing and securing hard, wear resistant particles, such as industrial diamonds, in the openings of a mesh. The cutting mesh is bonded to the support links by an adhesive agent such as industrial epoxy or by brazing. The bonding agent may also include a layer of wearable or consumable material to provide additional support for the cutting mesh on the support links.
According to one aspect of the invention, the mesh cutting element defines a surface inclined relative to the travel direction of the saw chain and has a formed section extending downwardly a short distance along the side of the support link. In the illustrated preferred configuration, only the trailing or top most edge of the mesh cutting element operatively engages the material to be cut. A formed guard extending upwardly from the front portion of the support link stabilizes the inclined surface of the cutting element. The guard portion of the support link includes a minimal surface area in contact with the material to be cut and wears away along with the mesh cutting element so that the guard does not impede the cutting action.
In a second illustrated embodiment of the present invention, the mesh cutting element is provided on the inclined top and on select portions of the depending skirts of a formed cover. The cover is secured to the side link pair by a bonding agent. The mesh cutting element portions on the sides of the cover maintain uniform kerf width. Also, it acts as a stabilizing surface riding against the side walls of the kerf.
As a further advantage, the cover fits over a side link pair of the saw chain with the depending skirts extending downwardly along each side of side link pairs to cover and retain headless fastening rivets that join the succeeding links. A headless fastener is disclosed in the concurrent and commonly assigned U.S. patent application Ser. No. 718,223 entitled Saw Chain Having Headless Fastener. This headless fastener does not extend beyond the side surface of the side links and avoids premature failure, i.e., by excess wear, of the fasteners. However, the headless fastener in the referenced U.S. patent Application relies on a formed section of the rivet, received in the center drive link, to retain the rivet in the assembled position. The rivet must be formed under close tolerances and must be forcibly pressed in place. In the present invention, the depending skirts eliminate the need for the formed section and thus simplify production of headless fasteners.
The inclination of the planar surface of the mesh, whether it is on a support link or the cover, applies only a relatively small area of the trailing edge of the mesh cutting element to the material to be cut. This reduces the area of contact between the material to be cut and the cutting element, and thereby reduces the force required to accomplish the cutting action. Also, the trailing edge withstands the impact forces within the kerf better than the leading edge. The mesh cutting element presents a row of abrading particles along this trailing edge for cutting across the width of the kerf and, because of the selected incline, a limited and consistent number of the abrading particles engage the aggregate material at a time. The selected inclination of the surface of the cutting element takes into account the configuration of abrasive particles of the cutting element including, generally, usable height of and spacing between the abrasive particles. Efficient utilization of the cutting element is thereby achieved.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the following portion of this specification. Both the organization and method of operation of the invention, together with further advantages and objects thereof, may best be understood by reference to the following description taken with the accompanying drawings wherein like reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a side view of a chain saw suited for cutting hard abrasive material utilizing a saw chain according to a first illustrated embodiment of the present invention;
FIG. 2 is view of a section of the saw chain of FIG. 1;
FIG. 3 is an enlarged view of the saw chain of FIG. 2 as taken along lines 3--3 of FIG. 2;
FIG. 4 is an enlarged view of the saw chain as taken along lines 4--4 of FIG. 3;
FIG. 5 is a side view of a saw chain according to a second illustrated embodiment of the present invention;
FIG. 6 is a sectional view of the saw chain of FIG. 5 as taken along lines 6--6 of FIG. 5; and
FIG. 7 is a sectional view of a cover mountable to a side link pair supporting conventional cutting blocks.
FIG. 8 illustrates selection of inclination for the mesh cutting element of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a chain saw 10 adapted for cutting hard abrasive material. The chain saw 10 has a power head 12 transmitting power at its drive sprocket 13 to the saw chain 14 entrained around the sprocket 13 and guide bar 16. The guide bar 16 has internal channels and ports 17 to deliver a flushing and lubricating fluid to the guide groove 18 of the guide bar 16 and the saw chain 14 as carried within the groove 18. The fluid is supplied to the guide bar 16 via piping 20.
FIGS. 2-4 further illustrate the saw chain 14 of FIG. 1. FIG. 2 shows a short length section of the chain saw 14 and FIGS. 3 and 4 show sectional views of the saw chain 14. Chain 14 is assembled into an endless loop for entrainment on the guide bar 16 of the chain saw 10 of FIG. 1 in a conventional manner. The saw chain 14 has center drive links 22 pivotally connected to right hand and left hand support links 24, 26. The right hand and left hand support links 24, 26 alternate in sequence in conventional manner, with each support link 24, 26 paired with an opposing tie strap 25. The center drive links 22, the right and left hand support links 24, 26 and the tie straps 22 are suitably bored for receiving connecting fasteners 30, e.g., rivets. The center drive links 22 have tangs 28 engageable by the drive sprocket 13 of the chain saw 10 to propel the saw chain around the guide bar 16. The tangs 28 travel in the guide groove 18 of the guide bar 16.
The right and left hand support links are constructed in a manner generally similar to cutter links of conventional wood cutting saw chains. The following detail is for a right hand support link 26, but it is representative of the left hand support link 24 as well. The right hand support link 26 has a mesh cutting element 34 mounted on a formed top plate support structure 32. The support structure 32 is inclined at an angle α to an axis 36 (FIG. 2) extending through the fastener receiving bores 38, 40 in the support link 24 when the chain 14 is straight. In the illustrated embodiment, the angle α is on the order of 12 degrees, but may range between 8 and 30 degrees. The mesh cutting element 34 is thereby inclined relative to the travel path 50 of the chain 14 as it travels along the guide bar 16.
The mesh cutting element 34 is an abrading element formed by select placement of hard, wear resistant particles 34, diamonds in the preferred embodiment, organized as rows of particles 34a, 34b, 34c, 34d, and 34e in the openings of a wire mesh 35. The particles 34 are held in the openings of the mesh 35 by being at least partially embedded in a bonding agent 46, such as sintered metal powers. U.S. Pat. No. 4,925,457 issued May 15, 1990 to Peter T. deKok and Naum N. Tselesin and entitled Abrasive Tool and Method for Making, and U.S. Pat. No. 5,049,165 issued Sep. 17, 1991 to Naum N. Tselesin and entitled Composite Material show generally the method and structural characteristics of abrasive material formed by select placement of hard wear resistant particles in the openings of a mesh 35. The disclosures of U.S. Pat. Nos. 4,925,457 and 5,049,165 are generally applicable to the present invention as for the basic construction of a cutting element 34 and are incorporated herein fully by reference thereto.
In FIG. 3, the mesh cutting element 34 includes a portion 42 bent downward (as viewed in the figure) and extending outward slightly beyond the side edge 44 of the support link 26. The enlarged sectional view of FIG. 4 illustrates a preferred mounting arrangement of the mesh element 34 to the support 32, and an ideal wear pattern over the life of a first particle row 34a of element 34. The mesh cutting element 34 attaches by bonding agent 49, e.g., an industrial acrylic adhesive or the like, to a layer of consumable material 48 such as hard rubber or epoxy. The consumable material 48, in turn, is secured to the underlying support 32. The mesh 35 provides a base to which the hard particles, such as diamonds in the preferred embodiment, are bonded. In this embodiment, the mesh 35 is formed of a fine steel wire. In the alternative, the mesh cutting element 34 could be bonded directly to the support 32.
The mesh cutting element 34 is inclined relative to the travel path 50 of the chain 14 and with respect to the material to be cut. The mesh cutting element 34 presents its trailing edge, or top most edge in the view of FIG. 4, to the material to be cut. With only the trailing edge of the mesh cutting element 34 in abrading contact with the aggregate material a limited and consistent portion of element 34 abrades the material to be cut at any given time. This inclined relationship to the material to be cut remains as trailing edge portion of cutting element 34 wears away. The dashed lines 52 of FIG. 4 represent planes of the material to be cut, i.e., the base of the kerf as the cut progresses, and also indicate the wear pattern of the mesh cutting element 34.
As the mesh cutting element 34 wears at its trailing edge, some of the consumable material 48 following the cutting element 34 also wears away. However, it always leaves a next row of particles in abrading contact with the material to be cut. For example, the particles of row 34a are available to cut as the cutting element 34 wears away through the planes at reference numerals 52a and 52b. As row 34a wears away, the next forward row 34b comes into contact with the material to be cut and remains available through the planes 52b and 52c. Successively more forward rows 34c, 34d and 34e come into play, i.e., engage and wear away the material to be cut, as cutting element 34 further wears away through planes 52d and 52e. Since the underlying consumable material may be abraded away, it does not interfere with the cutting action of element 34, and it does provide structural backing for element 34 throughout abrasion thereof.
Referring again to FIG. 2, the chain 14 includes a tapered stabilizing guard portion 60 forward of the support 32 and the mesh cutting element 34. The guard 60 has a similarly inclined surface 62 that precedes the mesh cutting element 34. The inclined surface 62 of the guard 60 stabilizes the mesh cutting element 34 and prevents direct impact of element 34 with objects, e.g., reinforcing bar that may be present in the aggregate material. The pointed tip 64 at the trailing edge of the inclined surface 62 provides a minimal surface area in contact with the material to be cut. The tip 64 has a wear rate equal to or exceeding the wear rate of the mesh cutting element 34 so as not to interfere with the cutting action of the mesh cutting element 34. As a cutting force is applied to the cutting element, the stability of the cutting element is maintained by the guard 60. In this manner the guard portion 60 contributes to better stability of the cutting element 34 during operation, i.e., maintains the desired angular relation 10 between element 34 and the material to be cut.
The left hand cutter link 24 is similar to the right hand cutter link 26. The left hand cutter link 24 has the mesh cutting element 34 extending on the side of the link so that in the assembled chain 14 the mesh cutting elements 34 extend on each side of the chain 14 to produce a kerf width slightly wider than that of the basic chain chassis for protecting the fasteners 30. The left hand cutter link also has a guard portion 60 preceding the mesh cutting element 34.
In FIG. 5 a second embodiment of the present invention is a saw chain 70 also for use on the chain saw 10 of FIG. 1. The saw chain 70 has center drive links 72 pivotally connected to support links 74. The support links 74 are inverted U-shaped members having opposing spaced side portions 74a and 74b joined by top portion 74c as shown in FIG. 6. The support links 74 are pivotally joined to the center drive links 72 by straight shank fasteners or pins 76, fitting in bores 86, 88 of the support links 74 and the center drive links 72. The fasteners 76 are of a length to fit flush with the outer surfaces of the links 74.
A shaped cover 80 is fitted to the links 74 after the drive links 72 and the support links 74 have been pivotally joined in assembly by the insertion of the fasteners 76. The cover 80 has depending skirts 82 that extend downwardly on each side of the link 74 a sufficient distance to cover at least a portion of the bores 86, 88 in the link 74 and thereby retain the fastener 76 in the assembly. Because the cover 80 retains the fastener 76 within the bores 86, 88 the fastener 76 may be a simple straight shank element. As may be appreciated, a straight shank fastener reduces cost and makes assembly less complicated, i.e., no need to turn rivet heads or to press a center portion of the fastener into the drive link bore.
Cover 80 is produced with abrasive particles, e.g., diamond crystals, positioned in a wire mesh, at selected areas of its carrier. The carrier of the diamond mesh material, therefore, may serve as the basic structure of the cover 80. Surface 90 of cover 80 is provided with the mesh and abrasive particles over its entire surface. Each skirt 82 has select areas, indicated at 92, also provided with cutting elements. This configuration maintains the desired kerf width and, in addition, provides a stabilizing surface engaging the side walls of the kerf.
The cover 80 is fixedly bonded to the link 74 by a bonding agent 84 such as by an industrial adhesive or brazing. The bonding agent 84 fills the void between the top of the link 74 and the cover 80. The bonding agent 84 in addition to bonding the cover 80 to the link 74 provides added support and acts as a backup buffer for the cutting elements on the inclined surface 90 of the cover 80.
The cover 80 is mounted to the support link 74 with the surface 90 inclined relative to the axis of the chain travel path so that only the upper (in the view of FIG. 5) trailing edge of the surface 90 engages the material to be cut. More particularly, surface 90 is inclined at an angle o to an axis 96 extending through the fastener receiving bores 86, 88 in the support links 74. In this embodiment the angle α is preferably on the order of 12 degrees, but may range between 8 and 30 degrees. The cutting element thereby engages the material to be cut with a limited surface area and wears away in a manner similar to that illustrated in FIG. 4. The inclined surface 90 of the cover 80 tends to reduce damage due to impacts by its own ramping effect. The surface 90 also allows the chain 70 to better engage and pass by unusually resistent objects encountered in the material to be cut.
The links 74 with covers 80 may be positioned at each interval between succeeding center drive links 22 or they may be alternated with formed guards such as disclosed in the commonly assigned U.S. patent application Ser. No. 730,192 titled Saw Chain For Aggregate Material.
In FIG. 7, a cover 100 for use with side links 74 and having conventional diamond matrix cutting blocks 104 mounted thereon is shown. The cover 100 has an upper surface 102 on which cutting blocks 104 fixedly mount as by brazing. The cover 100 has depending skirts 108 that extend to cover the ends of the straight-shank fasteners 106, pivotally joining the drive links 105 and side links 74, and thereby secure fasteners 106 in place. The cover 100 is fixedly fastened to the side links 74 as by welding. The cutting blocks 104 are in turn affixed to the cover by weldments or adhesives.
FIG. 8 illustrates variation in the angle α as a function of the arrangement and character of the selected abrasive particles, e.g., diamonds in the illustrated embodiment. More particularly, abrasive particles are arranged on the wearable sloped surface of the diamond mesh cutting element 34 with reference to the usable height of and spacing between rows of the abrasive particles. By such arrangement, each row can be fully utilized in sequence during a sustained cutting operation for consistent cutting and maximally efficient use of the abrasive particles.
FIG. 8 illustrates a general model for the angle α and its relationship to the value H, the usable height of the abrasive particles, and to the value S, the separation between rows of abrasive particles. In FIG. 8, the effective cutting life or usable height of each particle is defined as the maximum amount of wear that an abrasive particle can sustain before its cutting function deteriorates and a new row of abrasive particles must engage the workpiece. Thus, the dimension H corresponds to that portion of the abrasive particle able to sustain an acceptable cutting or abrading ability as it wears during a cutting operation. As may be appreciated, this cutting function may be dependent upon the fragmentation characteristics of the selected abrasive particle. The dimension S represents a structural characteristic of the diamond mesh cutting element 34 corresponding to the diameter of the abrasive particles and the size of the wire mesh 35. The angle α, i.e., the angle of the inclined surface of cutting element 34 relative to the axis 36 (FIG. 2) may be selected as:
α=Tan.sup.-1 (H/S)
In testing typical abrasive particles for wear characteristics, the value H may be approximately 0.005 inches and the value S approximately 0.020 inches. In this configuration, and according to the model of FIG. 8, the ideal design slope for such a cutting element 34 would be:
α=Tan.sup.-1 (0.005/0.020)=14°
By using an abrasive particle of the same general size but having a more frangible wear characteristic, the effective cutting life, i.e., the dimension H, may be increased to 0.010 inches. With the same structural spacing, i.e., 0.020 inches, the ideal slope of the cutting element 34 would be approximately 26.5 degrees. As may be appreciated by those skilled in the art, many variations in the angle α may be obtained by variation in the wear characteristics of the selected abrasive particles and in the particle organization, i.e., dimensions and relative spacing of the selected abrasive particles.
Accordingly, this controlled exposure of abrasive particles to the workpiece maximizes the overall wear life of the cutting element 34 because a minimum, but sufficient, number of abrasive particles are being worn away during a cutting operation at any given time. A consistent cutting action results.
It will be apparent to those skilled in the art that modifications and variations may be made without departing from the true spirit and scope of the invention. For example, the cutting element with its inclined mesh cutting surface herein described may be applied to a circular saw. Also, a variety of abrasive particles other than diamonds may be used in the cutting elements shown herein. The invention is therefore not to be limited to the embodiments described and illustrated but is to be determined by the appended claims.
|
A saw chain for cutting hard abradable material is shown and described. The saw chain cuts with an abrasive particle impregnated mesh structure. In one embodiment, the saw chain has right and left support links carrying the diamond mesh upon inclined support surfaces inclined relative to the travel axis of the saw chain. The abrasive particle impregnated mesh contacts the material to be cut only adjacent its trailing edge. A consumable material exists between the impregnated mesh and the support surface. The impregnated mesh may extend downward along the side of the support link to maintain a constant kerf width. In another embodiment, a formed cover is mounted on joined side link pairs of the saw chain. The cover has an abrasive particle impregnated mesh on an inclined surface and on select areas of its side skirts. The skirts cover as least a portion of the bores in the drive links and support links to retain and protect the fasteners therein.
| 1
|
BACKGROUND OF THE INVENTION
The invention is based on an apparatus for regulating the idling rpm of an internal combustion engine of the generic type described by the preamble to the main claim. An apparatus for regulating the idling rpm of an internal combustion engine is already known, but this apparatus has the disadvantage that if there is slightly increased pressure on the gas pedal, the regulation apparatus attempts to lower the increasing engine rpm once again by closing the bypass line. If while this situation prevails the gas pedal is then retracted once again, closing the throttle valve, then the intake tube pressure downstream of the throttle valve is rapidly reduced, and the engine will receive too little air to continue running. This can cause the engine to stop, because the reduced rpm is established only after a certain "dead time" has elapsed, and the correction in the regulation which is thereupon effected by means of opening the bypass line likewise takes effect only after a certain "dead time" has elapsed.
OBJECT AND SUMMARY OF THE INVENTION
The apparatus according to the invention for regulating the idling rpm of an internal combustion engine having the characteristics of the main claim has the advantage over the prior art that it utilizes the signal for the change in intake tube pressure downstream of the throttle valve, which is a faster signal than the signal pertaining to rpm. As a result, if there is an abrupt closure of the throttle valve and an attendant abrupt drop in intake tube pressure downstream of the throttle valve, the apparatus according to the invention prevents engine stalling by increasing the supplementary air quantity.
Advantageous modifications of and improvements to the apparatus disclosed in the main claim can be attained by means of the characteristics disclosed in the dependent claims.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 2 shows a second exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 3 shows in cross section a third exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 4 shows in cross section a fourth exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 5 shows in cross section a fifth exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 6 shows in cross section a sixth exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine;
FIG. 7 shows an electrical circuit diagram; and
FIG. 8 shows in cross section a seventh exemplary embodiment of an apparatus for regulating the idling rpm of an internal combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first exemplary embodiment, shown in FIG. 1, of an apparatus for regulating the idling rpm of an internal combustion engine, air required for combustion flows through an air filter 1 into an intake tube section 2 upstream of a throttle valve 3 acting as the throttling device and flows downstream of the throttle valve 3 via an intake tube section 4 to an internal combustion engine 5. A bypass line 7 having a connection 8 upstream of an electromagnetically actuatable bypass valve 9 and a connection 10 downstream of the bypass valve 9 bypasses the throttle valve 3. The bypass line 7 is controlled by means of an electronic control device into which the values of operating characteristics 12 of the engine, such as the signal for rpm derived from the ignition distributor, the engine temperature or the position of the throttle valve, are fed. The flowthrough cross section of the bypass line 7 is variable by the bypass valve 9, when the throttle valve 3 is in the idling position, in such a manner that if the engine rpm should drop, the flowthrough cross section of the bypass line is increased, and thus more supplementary air flows through the bypass line 7 around the throttle valve 3, while if there is an increase in the idling rpm then the flowthrough cross section of the bypass line 7--and thus the quantity of supplementary air flowing through the bypass line 7--is reduced.
A shunt line 14 is disposed such that it bypasses the bypass valve 9. This shunt line 14 connects the intake tube section 2 upstream of the throttle valve 3 with the intake tube section 4 downstream of the throttle valve 3. The shunt line 14 could just as well branch off from the bypass line 7 before the bypass valve 9, as indicated by broken lines at 14', and then discharge back into the bypass line 7 after the bypass valve 9. The flowthrough cross section of the shunt line 14 is controllable by a pressure-sensing adjusting element 15. The pressure-sensing element 15 has a diaphragm 16 in the form of a yielding wall, which separates a first chamber 17, communicating with the intake tube section 4 downstream of the throttle valve 3, from a second chamber 18, which communicates with the first chamber 17 via a throttle restriction 19. The communication between the first chamber 17 and the second chamber 18 could equally well be effected via a throttle restriction 19' in the diaphragm 16. A movable valve element 20 is coupled with the diaphragm 16, opening the flowthrough cross section of the shunt line 14 to a greater or lesser extent in accordance with the pressure forces at either side of the diaphragm 16.
Now, if there is slight pressure on the gas pedal, that is, if the throttle valve is opened somewhat, then the rpm of the engine 5 increases somewhat, and the regulation apparatus attempts to counteract this by closing the bypass valve 9. If the gas pedal is retracted at this time, that is, if the throttle valve closes after being slightly opened, then the intake tube pressure downstream of the throttle valve 3 drops rapidly. The result is that the engine 5 receives too little air, and as a consequence, the rpm will drop. This drop in rpm of the engine 5 occurs only after a certain dead time, however, and since the regulation of the bypass valve 9 also takes effect, opening the bypass valve 9, only after a certain dead time, it can happen that the engine will come to a stop. In order to prevent this from happening, the first chamber 17 of the adjusting element 15 is connected via the underpressure line 21 with the intake tube section 4 downstream of the throttle valve 3. As a result, when there is an abrupt drop in the intake tube pressure downstream of the throttle valve 3, the diaphragm 16 of the adjusting element 15 is moved inward into the first chamber 17. This pulls the movable valve element 20 in the opening direction of the shunt line 14, so that there is a delivery of supplementary air to the engine via the shunt line 14, past the bypass valve 9, virtually without delay after there has been a pressure drop downstream of the throttle valve 3. This occurs before the drop in the rpm of the engine 5 has become so extensive that regulation effected via the bypass valve 9 would occur too late and the engine would stop. Since the first chamber 17 and the second chamber 18 of the adjusting element 15 communicate with one another via the throttle restriction 19 or 19', the supply of supplementary air is effected via the shunt line 14 in a manner which is limited in terms of time, until virtually equal pressure again prevails in the two chambers 17 and 18, and the movable valve element 20 closes the shunt line 14. The adjusting element 15 thus has a differentiation function.
In the following exemplary embodiments, elements having the same function as those of the first embodiment shown in FIG. 1 and in comparison with one another are identified by the same reference numerals. The bypass valve 9' shown in FIG. 2 has a valve housing 23, in which an electromagnet system is provided, having an electromagnet coil 24 and an armature 25 movably disposed therein. An actuation rod 26 is connected with the armature 25, being slidably supported at bearing points 27, 28 and having a restoring spring 30 engaging its end 29. The actuation rod 26 is likewise connected with a valve piston 31 acting as the movable valve element of the bypass valve 9'. The movement of the actuation rod 26 causes the valve piston 31 to be axially movable within a cylinder bore 32. The valve piston 31 has a control face 33 on the right, transversely disposed relative to the actuation rod 26, and a counterpart face 34 on the side remote therefrom. The intake tube pressure in the intake tube section 2 upstream of the throttle valve 3 is exerted via the connection 8 on the control face 33. Depending upon the state of excitation of the electromagnet system 24, 25, the valve piston 31 covers to a greater or lesser extent an valve opening 35, by way of which the supplementary air can flow from the connection 8 to the connection 10. The counterpart face 34 of the valve piston 31 defines a work chamber 36 which communicates via at least one throttle restriction with a control chamber 37, which is defined on one side by the control face 33 and communicates with the intake tube pressure upstream of the throttle valve 3. Serving as the throttle restriction between the work chamber 36 and the control chamber 37 may be either the annular gap 38 between the circumference of the valve piston 31 and the diameter of the cylinder bore 32, or a throttle restriction 39 disposed in the valve piston 31. In like manner, a check valve 40 may be disposed in the valve piston 31 in a line connecting the work chamber 36 and the control chamber 37, the check valve 40 opening toward the control chamber 37 when there is a certain overpressure in the work chamber 36. The work chamber 36 is defined on the other side by a diaphragm 41 in the form of a yielding wall, on the side of which remote from the work chamber 36 a compression spring 43 is supported within an underpressure chamber 42. The underpressure chamber 42 communicates via the underpressure line 21 with the intake tube section 4 downstream of the throttle valve 3. When the electromagnet system 24, 25 is the nonexcited state, the valve piston 31 is displaced toward the left, as viewed in the drawing, by the restoring spring 30 to such an extent that the valve opening 35 is fully opened, and thus the maximum quantity of supplementary air can flow through the bypass line 7. Now, if a sudden drop occurs in the intake tube pressure downstream of the throttle valve 3, in a state in which the valve piston 31 is at least partially closing the valve opening 35, then the diaphragm 41 is moved into the underpressure chamber 42, counter to the force of the compression spring 43. The result of this is that the pressure in the work chamber 36 also drops, and because of the differing pressures acting on either side of the valve piston the piston 31 is moved into the work chamber 36. Thus, the valve opening 35 is opened wider, so that a larger quantity of supplementary air is delivered via the bypass line 7. The displacement is limited in terms of time, until the pressures in the work chamber 36 and the control chamber 37 have been equalized via the throttle restriction 38, 39. With an appropriate embodiment of the throttle restriction 38, 39 and of the work chamber 36, this time-related behavior can be set in a desired manner. In order to prevent a displacement of the valve piston 31 in the case of an abrupt pressure increase in the intake the section 4 downstream of the throttle valve 3, the check valve 40 is provided. If there is an abrupt increase in pressure in the work chamber 36, a pressure equalization with the control chamber 37 can be effected by way of this check valve 40.
In the case of the bypass valve 9" of FIG. 3, an actuation member 45 supported at the bearing points 27, 28 is connected with the armature 25 and is engaged via a spring plate 46 by the restoring spring 30. The restoring spring 30 and one end 47 protrude into a cavity 48 of the valve piston 49. There is not a fixed coupling between the end 47 and the valve piston 49; instead, a differential pressure spring 50 supported on the control face 33 of the valve piston 49 tends to keep the valve piston 49 in contact with the end 47 of the actuation member 45. The valve piston 49 has a circumferential groove 51, which depending on the position of the valve piston 49 overlaps a control slit 52 communicating with the connection 8 (that is, with the intake tube pressure upstream of the throttle valve 3) to a greater or lesser extent. At the other side, the circumferential groove 51 has openings 53 toward the control face 33 of the valve piston 49, at which the intake tube pressure downstream of the throttle valve 3 prevails. The work chamber 36, into which the valve piston protrudes with its counterpart face 34, communicates via the throttling annular gap 38, which is formed between the circumference of the valve piston 49 and the diameter of the cylinder bore 32, with the intake tube pressure downstream of the throttle valve 3 at the control face 33; if necessary, the work chamber 36 may extend via the bearing points 27, 28 as far as a flushing chamber 54, which is enclosed between the housing 23 and the electromagnet system 24, 25. The electrical connection of the electromagnet system is effected via a plug connection 55. When the electromagnet system 24, 25 is not excited, the restoring spring 30 displaces the actuation member 45 so far to the right that the valve piston 49 is held in the open position of the bypass valve 9". If the electromagnet system 24, 25 is now excited, then the actuation member 45 is drawn toward the left, and the valve piston 49, because of the spring force of the differential pressure spring 50, follows up this movement, moving in the closing direction of the bypass valve. The spring force of the restoring spring 30 is greater than that of the differential pressure spring 50. Now when the valve piston 49 is in a position in which the control slit 52 is completely closed, or is at least only partially open, if there is a sudden drop in the intake tube pressure 4 downstream of the throttle valve 3, then the valve piston 49, acting as a pressure-sensing adjusting element, is displaced toward the right, counter to the force of the differential pressure spring 50, as the result of the differing pressures being exerted at either end of the valve piston 49, thus moving away from the actuation member 45. The result is that the control slit 52 is opened wider, and a greater quantity of supplementary air can flow through the bypass valve 9". This displacement of the valve piston 49 is effected in a time-limited manner until such time as the pressure in the work chamber 36 has dropped, via the throttling annular gap 38, far enough that the pressure force exerted on the counterpart face 34 is equal to the pressure force exerted on the control face 33 and the force of the differential pressure spring 50, causing the valve piston 49 to return to a state of contact with the end 47 of the actuation member 45. The differential pressure spring 50 advantageously has a steeply inclined spring characteristic, so that if there is an abrupt reduction in pressure in the intake tube downstream of the throttle valve 3 when the bypass valve is virtually closed, a smaller pressure drop engaging the valve piston 49 is required to displace the valve piston into the opening position than would be the case in a more widely opened position of the valve piston 49.
The bypass valve 9"' shown in FIG. 4 differs from the bypass valve 9" of FIG. 3 substantially in that the restoring spring 45 engages the left end of the actuation member 30 via the spring plate 46. Thus when the electromagnet system 24, 25 is not excited, the actuation member 45 is displaced toward the left, and the valve piston 49, again acting as a pressure-sensing adjusting element loosely contacting the end 47, is caused by the differential pressure spring 50 to follow up the movement of the actuation member 45, that is, into the closing position of the bypass valve 9"'. When the electromagnet system 24, 25 is excited, there is a displacement of the actuation member 45 and accordingly of the valve piston 49 in the opening direction of the bypass valve 9"'.
In the case of the bypass valve 9' v shown in FIG. 5, the valve piston 57 is firmly connected with the actuation rod 26, and in the non-excited state of the electromagnet system 24, 25 it is held by the restoring spring 30 in the opening position of the bypass valve 9' v . On the end of the bypass valve 9' v remote from the valve piston 57, an underpressure chamber 58 is provided which communicates via the bearing points 27, 28 and the non-throttling play at the circumference of the valve piston 57 with the connection 10, and accordingly with the intake tube pressure 4 downstream of the throttle valve 3. The underpressure chamber 58 is separated from an equalization chamber 60 by a yielding wall embodied as a diaphragm 59. The equalization chamber 60 communicates, via a throttle restriction 61 provided by way of example in the diaphragm 59, with the underpressure chamber 58. A knob 62 is secured to the diaphragm in axial alignment with the actuation rod. If there is slight pressure on the gas pedal and then a sudden retraction of the gas pedal, causing an abrupt decrease in pressure in the intake tube downstream of the throttle valve 3, then the diaphragm 59 is moved into the underpressure chamber 58 as the result of the differing pressure forces acting upon it; in consequence, with the knob 62 engaging the actuation rod 26, the diaphragm 59 displaces the valve piston 57 in a time-limited manner in the direction of an enlargement of the opening position of the bypass valve 9' v , until a pressure equalization in the underpressure chamber 58 and the equalization chamber 60 has been effected via the throttle restriction 61.
In the exemplary embodiment according to FIG. 6, the diaphragm 59 does not have a knob 62 for displacing the actuation rod 26; instead, the diaphragm 59 is embodied such that either it is itself electrically conductive or it has an electrically conductive region with which it moves into the underpressure chamber 58 if there is a sudden reduction of the intake tube pressure 4 downstream of the throttle valve 3, thereby closing switch contacts 64, 65 or a switch 66 (FIG. 7). As shown in FIG. 7, the switch 66 or the switch contacts 64, 65 and an electric resistor 67 are disposed in a branch of the current circuit of the electromagnet coil 24 parallel to the electromagnet coil 24. When the switch 66 or the switch contacts 64, 65 close, the electric current I 1 at the electromagnet coil 24 is thus reduced by the amount of the current I 2 flowing over the resistor 67, so that the following formula applies, with I being the current furnished by the control device 11: I 1 =I-1 2 . The reduction of the current I 1 at the electromagnet coil 24 signifies a reduction of the magnetic force of the electromagnet system 24, 25. As a result, the restoring spring 30 displaces the valve piston 57 in the direction of an enlargement of the opening position of the bypass valve 9' v until such time as there has been a re-equalization of pressure in the underpressure chamber 58 and the equalization chamber 60 via the throttle restriction 61, and the diaphragm 59 opens the switch 66 or the switch contacts 64, 65.
The exemplary embodiment of a bypass valve 9 v shown in FIG. 8 differs from the bypass valve 9" shown in FIG. 3 substantially in that the end 47 of the actuation member is firmly connected with the valve piston 49 v and that there is no differential pressure spring 50.
Now, if the valve piston 49 v is in a position in which the control slit 52 is fully closed or is at least only partially opened and a sudden reduction in the intake tube pressure 4 downstream of the throttle valve 3 occurs, then the valve piston 49 v , acting as a pressure-sensing adjusting element, is displaced to the right, counter to the magnetic force, as the result of the differing pressure forces engaging either end of the valve piston 49 v . The result is that the control slit 52 is opened more widely, and a greater quantity of supplementary air can flow through the bypass valve 9 v . This displacement of the valve piston 49 v is effected in a time-limited manner until such time as the pressure in the work chamber 36 has dropped, via the throttling annular gap 38, far enough that the pressure force on the counterpart face 34 is equal to the pressure force on the control face 33.
All the exemplary embodiments accordingly permit an automatic and time-limited supply of supplementary air whenever there is an abrupt drop in intake tube pressure downstream of the throttle valve 3, thus reliably assuring continued operation of the internal combustion engine if there is a sudden retraction of the gas pedal following a previous slight increase in pressure on the gas pedal.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
|
An apparatus is proposed which serves to regulate the idling rpm of an internal combustion engine. The apparatus includes a bypass line bypassing an arbitrarily actuatable throttle valve in the intake tube. An electromagnetically actuatable bypass valve is disposed in the bypass line for the purpose of controlling supplementary air and is triggerable in accordance with operating characteristics of the engine. In addition, a pressure-sensing adjusting element is also provided, which responds to an abrupt reduction in the intake tube pressure downstream of the throttle device. In accordance with the magnitude of the pressure reduction, this pressure-sensing adjusting element effects a time-limited increase in the supplementary air quantity to the intake tube section downstream of the throttle valve. In the event of an abrupt reduction in the intake tube pressure downstream of the throttle valve, caused by the closure of the throttle valve subsequent to a previous, slight increase in pressure on the gas pedal, the apparatus according to the invention prevents the engine from stopping.
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates to making patterns using photoresist materials. BACKGROUND OF THE INVENTION
[0002] Referring now to FIGS. 1 A-I, a known method of making a semiconductor device 10 includes providing a first layer 14 to be etched which may overlie a substrate 12 which may be a semiconductor wafer. The substrate 12 may be any material known to those skilled in the art for making semiconductor devices including, but not limited, to silicon, germanium, silicon and germanium, gallium arsenate, silicon carbide and silicon germanium. The first layer 14 to be etched may be an electrically conductive material or a dielectric. The first layer 14 to be etched is a dielectric such as silicon dioxide, or a low dielectric constant material such as SiOC, SiOF, SiC, SiCN. A first sacrificial layer 16 is provided over the first layer 14 to be etched as shown in FIG. 1A .
[0003] Referring now to FIG. 1B , a first mask 18 is provided and includes transparent portions 20 for transmitting light therethrough and non-transparent portions 22 for blocking light. Light as indicated by the arrows labeled 21 is shown through the first mask 18 exposing portions of the first sacrificial layer 16 . The first sacrificial layer 16 comprises a photoresist material and includes light exposed portions 24 and unexposed portions 26 .
[0004] Referring now to FIG. 1C , the sacrificial layer 16 is developed and the exposed portions 24 removed leaving openings 28 extending through the first sacrificial layer 16 .
[0005] Referring now to FIG. 1D , thereafter the first sacrificial layer 16 is treated to increase the resistance of the first sacrificial layer 16 without intermixing to first resist material 30 coating. The treating of the first sacrificial layer 16 may include at least one of irradiation of the first sacrificial layer 16 with infrared light, broad band ultraviolet light, deep ultraviolet light (for example having a wave length ranging from 193-248 nm) extra ultraviolet light (for example having a wave length of 13.5 nm), e-beam and x-rays. The first sacrificial layer 16 is treated with ion implant hardening to increase resistance to first resist layer 30 from mixing. The first sacrificial layer 16 is treated with a chemical to increase the resistance of the first sacrificial layer from mixing with the first resist layer 30 , such as, but not limited to, exposing the first sacrificial layer 16 to water vapor and then alkoxysilane gas.
[0006] Referring now to FIG. 1E , thereafter, a first photoresist layer 30 is formed over the first sacrificial layer 16 and fills the openings 28 extending through the first sacrificial layer 16 .
[0007] Referring now to FIG. 1F , thereafter, a second mask 32 which includes transparent portions 34 for transmitting light therethrough and non-transparent portions 36 for blocking light is positioned over the structure of FIG. 1E and light is transmitted through the mask creating exposed portions 38 in the first photoresist and unexposed portions 40 in the first photoresist. As will be appreciated from FIG. 1F , the transparent portions 34 of the second mask 32 are much larger than the transparent portions 20 of the first mask.
[0008] Referring now to FIG. 1G , the first photoresist material is developed and the exposed portions removed to provide openings 42 in the first photoresist that communicate with at least one of the openings 28 and the sacrificial layer 16 . If desired, some of the openings 28 in the first sacrificial 16 may be blocked by unexposed portions 40 of the first photoresist layer 30 . As will be appreciated by FIG. 1G , each opening 42 in the first photoresist layer 30 is vertically aligned with at least one opening 28 in the first sacrificial layer 16 . An opening 42 in the first photoresist layer 30 may span a plurality of adjacent openings 28 in the first sacrificial layer 16 . Further, the width of the opening 42 in the first photoresist layer 30 , generally indicated by arrow B, is greater in all directions than the width of the opening 28 in the first sacrificial layer 16 in all directions. Consequently, the cross-sectional area of the opening 42 in the first photoresist layer 30 is greater than the cross-sectional area of the opening 28 in the first sacrificial layer 16 .
[0009] Referring now to FIG. 1H , thereafter, the semiconductor device is etched through the openings 42 and 28 to etch openings 44 through the first layer 14 . The first photoresist layer 30 is etched substantially by the etching material as will be appreciated by the position of the upper surface 41 of the photoresist layer 30 as originally deposited and the position of the upper surface 43 of the etched first photoresist layer 30 . However, due to the treatment of the sacrificial layer 16 , the opening pattern 44 is transfer directly from the sacrificial layer 16 . This allows for much narrower features and greater packing density of features in the first layer 14 . The first layer 14 is silicon dioxide and the etching is accomplished using a plasma etch including CF 4 and CHF 3 . The photoresist layer 30 and the sacrificial layer 16 may be exposed in the above embodiments using KrF light as exposure light as well as, G rays, I rays, ArF light and e-beam
[0010] Referring now to FIGS. 2 A-I, a known method of making a semiconductor device includes providing a first sacrificial layer 16 over a first layer 14 to be etched over a semiconductor substrate 12 as described with respect to FIG. 1A . However, the first sacrificial layer 16 comprises a hard mask such as silicon nitride or silicon oxynitride overlying the first layer 14 . A second sacrificial layer 46 is provided over the first sacrificial layer 16 . The second sacrificial layer 46 comprises a photoresist material.
[0011] Referring now to FIG. 2B , a first mask 18 is provided which again includes transparent portions 20 transmitting light therethrough and non-transparent portions 22 . Light is transmitted through the first mask 18 creating exposed portions 48 and unexposed portions 50 in the second sacrificial layer 46 . Thereafter, the second sacrificial layer 46 is developed and the exposed portions 48 removed producing openings 52 through the second sacrificial layer 46 . The openings 52 expose a portion of the first sacrificial layer 16 .
[0012] Referring now to FIG. 2D , the first sacrificial layer 16 , which is a hard mask, is etched to provide openings 28 extending through the first sacrificial layer 16 exposing portions of the first layer 14 . The silicon nitride may be etched with phosphoric acid in the case of a wet etch, or a plasma generated from CF 4 /O 2 . The second sacrificial layer 46 is removed.
[0013] Referring now to FIG. 2E , a first photoresist layer 30 is formed over the first sacrificial layer 16 so that portions of the photoresist layer fill the openings 28 formed in the first sacrificial layer 16 .
[0014] Referring now to FIG. 2F , thereafter a second mask 32 is provided including transparent portions 34 for transmitting light therethrough and non-transparent portions 36 for blocking light and light is transmitted through the second mask 32 creating exposed portions 38 in the first photoresist layer 30 and unexposed portions 40 in the first photoresist layer 30 .
[0015] Referring now to FIG. 2G , thereafter the photoresist layer 30 is developed and the exposed portions 38 removed leaving openings 42 in the first photoresist layer 30 . An opening 42 in the first photoresist layer 30 may span a plurality of adjacent openings 28 in the first sacrificial layer 16 . Further, the width of the opening 42 in the first photoresist layer 30 generally indicated by arrow B is greater in all directions than the width of the opening 28 in the first sacrificial layer 16 in all directions. Consequently, the cross-sectional area of the opening 42 in the first photoresist layer 30 is greater than the cross-sectional area of the opening 28 in the first sacrificial layer 16 .
[0016] Referring now to FIG. 2H , thereafter the first layer 14 is etched to provide openings 44 therethrough. As will be appreciated from FIG. 2H , the first photoresist layer 30 is substantially etched as will be appreciated from the location of the upper surface 41 indicated by the dotted line of the first photoresist 30 as originally deposited and the upper surface 43 of the etched first photoresist layer 30 . However, because the first sacrificial layer 16 is a hard mask such as silicon nitride, the first sacrificial layer 16 is substantially unaffected by the etching material. This allows for much narrower and more densely packed features to be formed in the first layer 14 . Thereafter, the first photoresist layer 30 and the sacrificial layer 16 are removed as shown in FIG. 2I .
[0017] FIGS. 3 A-E illustrate a known method of making a photoresist structure. A first layer 110 is provided and a first photoresist 112 is provided over the first layer 110 . The first layer 10 may be a metallization layer, dielectric layer, or a semiconductor substrate, for example, a silicon wafer. The first photoresist layer 112 is exposed, developed and patterned to produce a plurality of first photoresist features 114 . Each of the first photoresist features 114 has an upper surface 116 and at least a first sidewall 118 , and typically a second opposite sidewall 120 as shown in FIG. 3B .
[0018] Thereafter, as shown in FIG. 3C , a second photoresist 122 is applied over the structure of FIG. 3B . The upper surface 116 , the first sidewall 118 and the second sidewall 120 , are all covered by the second photoresist material 122 .
[0019] Thereafter, as shown in FIG. 3D , the structure of FIG. 3C is heated to release an acid in the plurality of individual photoresist features 114 . The second photoresist material 122 may be crosslinked upon exposure to the acid released from the plurality of photoresist features 114 . The acid diffuses from the upper surface 116 , first sidewall 118 and second sidewall 120 outwardly into the second photoresist material 122 . Thereafter, the uncrosslinked portions of the second photoresist layer 122 are removed by, for example, developing using a liquid chemical developer to dissolve the soluble regions of the photoresist. The above-described process may be utilized to produce photoresist structures having a relatively narrow gap 148 between structures caused by the crosslinked portion 124 of the first photoresist 112 that extends along each of the first sidewall 118 and the second sidewall 120 from the upper face 16 down to the first layer 110 .
[0020] Sugino et al., U.S. Pat. No. 6,566,040, issued May 20, 2003, discloses a hole pattern or separation pattern of a first resist that is capable of supplying acid formed on a semiconductor substrate. A crosslinking film is formed on the sidewall of the first substrate pattern to obtain a resist pattern having a reduced hole diameter or separation width. Then, the hole diameter or the separation width is further reduced by causing thermal reflow of the crosslinked film. The semiconductor substrate is etched by using a resulting resist pattern as a mask. The water-soluble crosslinking agents used as the second resist include urea crosslinking agents such as urea, alkoxymethylene ureas, N-alkoxymethylene ureas, ethyleneurea, ethylene urea carboxylates and the like, melamine crosslinking agents such as melamine, alkoxymethylene melamines and the like, and amino crosslinking agents such as benzoguanamine, glycoluril and the like. Examples of water-soluble resist materials usable as the second resist include, aside from the water-soluble crosslinking agents used singly or in combination, the mixtures of these resins and crosslinking agents. The material for the first photoresist may be one which makes use of a mechanism capable of generating an acidic component inside the photoresist by an appropriate thermal treatment, and may be either a positive or negative photoresist. Examples of photoresist include novolac resin and a naphthoquinonediazide photosensitive agent. A chemically amplified resist making use of an acid generating mechanism may also be used as the first photoresist.
[0021] Ishibashi et al., U.S. Pat. No. 6,319,853, issued Nov. 20, 2001, discloses a method of producing a pure resist pattern having superior topography smaller than the limit of wavelength of exposure light. A first photoresist pattern containing material capable of producing an acid on exposure to light is coated with a second resist containing material which causes a crosslinking reaction in the presence of an acid. An acid is produced in the photoresist pattern by exposing the pattern to light, thus forming a crosslinked layer along the boundary surface between the first resist pattern and the second resist pattern. As a result, the second resist pattern which is greater than the first resist pattern is formed.
[0022] Tanaka et al., U.S. Pat. No. 6,593,063, issued Jul. 15, 2003, discloses a first resist layer capable of generating an acid formed on a semiconductor base and is developed in a shortened development time than usual. The first resist pattern is covered with a second resist layer containing a material capable of crosslinking in the presence of an acid. The acid is generated in the first resist pattern by application of heat or by exposure to light, and a crosslinked layer is formed in the second resist pattern at the interface with the first resist pattern as a cover layer for the first resist pattern, thereby the first resist pattern is caused to be thickened. The non-crosslinked portion of the second resist pattern is removed and the fine resist pattern is formed. The hole diameter of the resist pattern can be reduced, or the isolation width of a resist pattern may be produced utilizing this method.
SUMMARY OF THE INVENTION
[0023] A process of forming a fine pattern comprising:
[0024] forming a first photoresist layer over a first layer of a semiconductor device;
[0025] exposing portions of the first photoresist layer causing a photochemical reaction therein;
[0026] prior to developing the first photoresist layer, forming a second photoresist layer over the first photoresist layer;
[0027] and wherein at least one of the first photoresist layer and second photoresist layer comprises a photo base generator.
[0028] Other embodiments of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0030] FIG. 1A illustrates a known method of making a semiconductor device including providing a first sacrificial layer over a first layer to be etched.
[0031] FIG. 1B illustrates a known method of making a semiconductor device including selectively exposing portions of the first sacrificial layer.
[0032] FIG. 1C illustrates a known method of making a semiconductor device including removing the exposed portion of the first sacrificial layer providing openings therein.
[0033] FIG. 1D illustrates a known method of making a semiconductor device including treating the first sacrificial layer.
[0034] FIG. 1E illustrates a known method of making a semiconductor device including forming a first photoresist layer over the first sacrificial layer.
[0035] FIG. 1F illustrates a known method of making a semiconductor device exposing portions of the first photoresist layer.
[0036] FIG. 1G illustrates a known method of making a semiconductor device including forming openings in the first photoresist layer that communicate with at least one opening in the first sacrificial layer.
[0037] FIG. 1H illustrates a known method of making a semiconductor device including etching openings in the first layer.
[0038] FIG. 1I illustrates a known method of making a semiconductor device including removing the first photoresist layer and the first sacrificial layer.
[0039] FIG. 2A illustrates a known method of making a semiconductor device including providing a first layer to be etched, a first sacrificial layer over the first layer, and a second sacrificial layer over the first sacrificial layer.
[0040] FIG. 2B illustrates a known method of making a semiconductor device including selectively exposing portions of the second sacrificial layer.
[0041] FIG. 2C illustrates a known method of making a semiconductor device including removing the exposed portion of the second sacrificial layer providing openings therein.
[0042] FIG. 2D illustrates a known method of making a semiconductor device including etching openings through the first sacrificial layer.
[0043] FIG. 2E illustrates a known method of making a semiconductor device including forming a first photoresist layer over the first sacrificial layer.
[0044] FIG. 2F illustrate a known method of making a semiconductor device including forming a first photoresist layer over the first sacrificial layer.
[0045] FIG. 2G illustrates a known method of making a semiconductor device including forming openings in the first photoresist layer that communicate with at least one opening in the first sacrificial layer.
[0046] FIG. 2H illustrates a known method of making a semiconductor device including etching openings in the first layer.
[0047] FIG. 2I illustrates a known method of making a semiconductor device including removing the first photoresist layer and the first sacrificial layer.
[0048] FIG. 3A illustrates a prior art method of forming a photoresist structure including depositing a first photoresist layer on a first layer.
[0049] FIG. 3B illustrates a prior art method including exposing, developing and patterning portions of the first photoresist layer.
[0050] FIG. 3C illustrates a prior art method including depositing a second photoresist layer over the structure of FIG. 3B .
[0051] FIG. 3D illustrates a prior art method including heating features formed by the first photoresist layer to cause an acid to be diffused from the features and crosslinked with the second photoresist layer along the boundary surfaces of the first photoresist features.
[0052] FIG. 3E illustrates a step in a prior art method including developing a second photoresist layer to remove uncrosslinked portions and to produce a photoresist structure having a relatively narrow gap between adjacent photoresist.
[0053] FIG. 4A illustrates one embodiment according to the present invention including forming a first photoresist layer over a first layer of a semiconductor device.
[0054] FIG. 4B illustrates one embodiment according to the present invention exposing portions of the first photoresist layer.
[0055] FIG. 4C illustrates one embodiment according to the present invention including forming a second photoresist layer over the first photoresist layer.
[0056] FIG. 4D illustrates one embodiment according to the present invention including exposing portions of the second photoresist layer.
[0057] FIG. 4E illustrates one embodiment according to the present invention including baking the semiconductor device.
[0058] FIG. 4F illustrates one embodiment according to the present invention including developing the first photoresist layer and the second photoresist layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0060] Referring now to FIGS. 4 A-F, a known method of making a semiconductor device 210 includes providing a first layer 214 to be etched or otherwise further treated or further processed which may overlie a substrate 212 which may be a semiconductor wafer. Alternatively, the first layer 214 may be a semiconductor wafer. The substrate 212 may be any material known to those skilled in the art for making semiconductor devices including, but not limited, to silicon, germanium, silicon and germanium, gallium arsenate, silicon carbide and silicon germanium. The first layer 214 to be etched treated or treated may be an electrically conductive material, a dielectric or a semiconductor substrate. The first layer 214 to be etched, treated or further processed may be a dielectric such as silicon dioxide, or a low dielectric constant material such as SiOC, SiOF, SiC, SiCN. A first photoresist layer 216 is provided over the first layer 214 to be etched as shown in FIG. 4A . The first photoresist layer 216 may be a negative photoresist wherein exposed parts of the negative photoresist become cross-linked and polymerized due to the photochemical reaction, which hardens and remains after development, whereas the unexposed parts are dissolved by the developer solution. Alternatively, the first photoresist layer 216 may be a positive photoresist material, for example, wherein the main component is a novolac resin, and wherein the exposed parts' cross-links break down and become softened due to the photochemical reaction known as photosolubilization and are dissolved by the developer solution and the unexposed parts remain. The first photoresist layer 216 may include a photo acid generator that produces an acid upon exposure to heat or certain light, or the first photoresist layer 216 may include a photo base generator that produces a base upon exposure to heat or certain light.
[0061] Optionally, the first photoresist layer 216 may be baked to evaporate solvents and to densify the photoresist. Referring now to FIG. 4B , a first mask 218 is provided and includes transparent portions 220 for transmitting light therethrough and non-transparent portions 222 for blocking light. Light as indicated by the arrows labeled 221 is shown through the first mask 218 exposing portions of the first photoresist layer 216 . The first photoresist layer 216 now includes light exposed portions 224 and unexposed portions 226 .
[0062] Thereafter, without developing the first photoresist layer 216 , a second photoresist layer 230 is formed over the first photoresist layer 216 as shown in FIG. 4C . The second photoresist layer 230 may be a negative photoresist wherein exposed parts of the negative photoresist become cross-linked and polymerized due to the photochemical reaction, which hardens and remains after development, whereas the unexposed parts are dissolved by the developer solution. Alternatively, the second photoresist layer 230 may be a positive photoresist material, for example wherein the main component is a novolac resin, and wherein the exposed parts' cross-links break down and become softened due to the photochemical reaction known as photosolubilization and are dissolved by the developer solution and the unexposed parts remain. The second photoresist layer 230 may include a photo acid generator that produces an acid upon exposure to heat or certain light, or the second photoresist layer 230 may include a photo base generator that produces a base upon exposure to heat or certain light. The first photoresist layer 216 may include the opposite photo generator from the second photoresist layer 230 . Furthermore, the photoresist layer 216 and 230 also include a cross-linking agent that cross links the photoresist material upon exposure to an acid or a base. For example, the first photoresist layer 216 may include a photo acid generator and a cross-linking agent activated by a base, and the second photoresist layer 230 may include a photo base generator or a cross-linking agent activated by an acid; and conversely, the first photoresist layer 216 may include a photo base generator and a cross-linking agent activated by an acid, and the second photoresist layer 230 may include an photo acid generator or a cross-linking agent activated by a base. The second photoresist layer 230 may be water soluble or with different solvent than first photoresist layer 216 . The second photoresist layer 230 may also produce a base on exposure to heat or light, wherein the base neutralizes the acid produced upon expose of a first photoresist that is a positive photoresist.
[0063] Referring now to FIG. 4D , thereafter, a second mask 232 which includes transparent portions 234 for transmitting light therethrough and non-transparent portions 236 for blocking light is positioned over the structure of FIG. 4C and light is transmitted through the mask creating exposed portions 238 in the first photoresist and unexposed portions 240 in the first photoresist. As will be appreciated from FIG. 4D , at least one of the transparent portions 234 of the second mask 232 or at least one of the light blocking portions 400 of the second mask 232 extends across two adjacent exposed portions of the first photoresist layer 216 or across two adjacent unexposed portion of the first photoresist layer 216 . .
[0064] Referring now to FIG. 4E , thereafter, the semiconductor device 210 of FIG. 4D is exposed to heat, for example in a post exposure bake process causing a base to be released from the second photoresist layer 230 , wherein the base reacts with acid produced in the exposed portion of the first photoresist layer 216 causing at least an upper portion 500 of the exposed portion of the first photoresist layer 216 to be neutrally without cleavage by acid. The un-cleavage positive polymer is not soluble in the developer so that the upper portions 500 are not soluble in the developer.
[0065] Thereafter, as shown in FIG. 4F , the semiconductor device is devolved in a water based developer that removes the second photoresist layer 230 . The developer also removes unprotected, unpolymerized portions 502 (exposed portions in the case of a negative photoresist) of the first photoresist layer, but does not remove the upper portions 500 , unpolymerized portion 224 and polymerized portions 226 (unexposed portions in the case of a negative photoresist) of the first photoresist layer 216 . An opening 502 may be provided through the first photoresist layer 216 after developing.
[0066] In another embodiment as also shown in FIG. 4F , the semiconductor device is devolved in a water based developer that removes the second photoresist layer 230 . The developer also removes unprotected, unpolymerized (polarized, developer soluble) portions 502 (exposed portions in the case of a positive photoresist) of the first photoresist layer, but does not remove the upper polymerized(non polarized, non-soluble to developer) portions 500 , unpolymerized portion 224 and polymerized portions 226 (unexposed portions in the case of a positive photoresist) of the first photoresist layer 216 . An opening 502 may be provided through the first photoresist layer 216 after developing.
[0067] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
|
A process of forming a fine pattern including forming a first photoresist layer over a first layer of a semiconductor device. Portions of the first photoresist layer are exposed causing a photochemical reaction therein. Prior to developing the first photoresist layer, a second photoresist layer is formed over the first photoresist layer, and wherein at least one of the first photoresist layer and second photoresist layer comprises a photo base generator.
| 6
|
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for controlling the length of yarn used by a warp beam knitting machine to produce one rack of knitted fabric.
Warp beam knitting machines incorporate warp beam sections, each section comprising a multiplicity of yarns wound about it. These yarns, forming a yarn sheet, are unwound from the beam section to needle bars where the fabric is knitted. The knitted fabric is accumulated on take-up rolls for later use. The unwinding rate of the yarns delivered to the needle bars is directly proportional to the instantaneous angular velocity of the warp beam section and the instantaneous radii of the yarns about the beam section. Therefore as yarns are unwound from the beam section a constant unwinding rate is obtainable by continuously adjusting the angular velocity of the beam section.
The fabric produced by the warp beam knitting machines consists of rows of loops or stitches, each row being called a course. One course is produced for each revolution of the main shaft of the knitting machine. By definition, a rack of knitted fabric is the length of knitted fabric incorporating 480 courses, which therefore equals 480 revolutions of the main shaft. In addition, a runner-length is defined as the length of yarn unwound from a beam section when one rack of fabric is knitted.
Thus, in order to obtain a uniform rack of knitted fabric, it is necessary that the runner-length of the unwound yarns be held to within very close tolerances. In a typical situation where the runner-length is 60 inches, a deviation of even one inch will produce unacceptable knitted fabric due to puckering, i.e., wrinkling of the normally smooth fabric surface, or due to distortions in the pattern design of the fabric. Thus, if a diamond shaped pattern was sought in the knitted fabric, a wrinkled and distorted diamond pattern would occur. Such wrinkles, distortions, and lack of uniformity in the knitted fabric are, of course, undesirable. In addition, such errors in the runner-length result in increased tension on the yarn filaments which can cause the knitting needles to break.
Warp beam knitting machines presently relay on mechanical devices to regulate the unwinding rate of the yarn and thus the runner-length of the yarn. In particular, these devices:
1. mechanically measure the unwinding rate of the yarn;
2. mechanically transfer this information by means of a chain and sprocket to a regulating spindle where the information is compared to a constant (control) speed worm wheel that monitors the main shaft's angular velocity.
3. mechanically activate a pawl that allows a ratchet wheel to move one position when a difference in angular velocity between the spindle and worm wheel occurs;
4. the ratchet wheel turning a micrometer thread spindle that axially moves a friction ring mounted on a cone driven by the main shaft;
5. a second cone making contact with the friction ring being turned at a faster or slower rate depending upon the axial position of the friction ring; and
6. the driven cone turning the warp beam section and thus adjusting the beam section's angular velocity.
Due to the various mechanical linkages in this device, there is a large time lag between measuring the beam section's unwinding rate and adjusting the friction ring to correct for any change in the unwinding rate. This inherent sluggishness of the present-day controllers therefore allows an undesirable unwinding rate of yarn to exist for a relatively long period of time and thereby produces knitted fabric with nonuniform course density. Also, since the unwinding rate adjustment is relatively coarse, the adjustment inherently overshoots or undershoots the desired unwinding rate and consequently causes the actual unwinding rate to oscillate between two values that bracket the desired unwinding rate. This relatively large oscillating variation of the actual unwinding rate causes the knitted fabric to have noticeable puckering where each change in unwinding rate occurs. Thus, a rack of knitted fabric produced by a knitting machine using present-day controllers has neither the desired course density -- i.e., uses an undesired runner-length of yarn -- nor a uniform course density.
Furthermore, present-day controllers inherently drift from the desired runner-length which necessitates that the operator periodically shut down the knitting machine in order to measure the actual runner-length and make manual adjustment to the driven cone position. Such stoppages further reduce the productivity of knitting machines.
The present invention is able to eliminate the above-mentioned undesirable characteristics of present-day controllers. In particular, the time lag between the sensed change in the yarn unwinding rate and the corresponding control of the beam section's angular velocity is greatly reduced by elminiating the mechanical linkages found in present-day controllers. By removing the pawls and ratchet wheel the present invention is able to eliminate the oscillatory movement of the friction ring which causes the over-correction and undercorrection of the yarn unwinding rate. Indeed, the stepping motor used in the present invention, to adjust the beam section's angular velocity, is able to make very small changes in the yarn unwinding rate that correspond to adjustments to the actual runner-length as small as one hundredth (1/100) of an inch. Therefore any overshoot or undershoot of the desired runner-length is negligible. Furthermore, since the invention is able to control the runner-length of yarn to any desired value set by the operator, there is no need for other means to be employed to measure the runner-length.
The present invention is therefore clearly distinguishable from the prior art. In U.S. Pat. No. 3,626,725 entitled "Runner Checker Apparatus for Warp Knitting Machines", a device is disclosed for measuring the length of yarn fed from a warp beam section of a warp beam knitting machine. This patent discloses an apparatus which is able to display the runner-length of yarn as each rack of fabric is knitted. The disclosed apparatus employs a means for counting pulses related to the yarn unwinding rate, whereby this count is terminated after 480 main shaft revolutions have occurred. This count is then displayed in terms of the runner-length of yarn fed from the beam section. Thus the disclosed apparatus automatically measures the actual runner-length but does not correct it in any manner.
The present invention allows the operator to manually select the desired runner-length by appropriately setting thumb wheel switches. Thus, the present invention does not utilize a counting technique as described in U.S. Pat. No. 3,626,725, but instead controls the runner-length of yarn by continuously monitoring the unwinding rate of the yarn and simultaneously adjusting this unwinding rate continuously to yield the desired runner-length.
The present invention is also clearly distinguishable from U.S. Pat. No. 3,543,360 entitled "Yarn Inspector", wherein a yarn defect detection device is disclosed incorporating a yarn length measuring device for purposes of displaying the defects as a function of yarn length. The present invention does not employ a yarn length measuring device, but instead continuously adjusts the unwinding rate of the yarn to yield a desired runner-length. U.S. Pat. No. 3,543,360 does not employ any type of yarn unwinding rate control device, but merely detects and displays defects in the yarn sheet per selected length increment of the yarn sheet.
Furthermore, U.S. Pat. No. 3,648,338, entitled "Automatic Tension Control Apparatus", does not anticipate the present invention. This patent discloses a device that automatically controls the packing density of filaments on a reel. It utilizes information of the filament speed and information of the desired filament speed to adjust the reel's angular velocity so as to wind the filaments with a predetermined packing density. In addition to being directed toward a different invention, that patent does not teach the use of sampling an error signal related to the difference between a desired and an actual variable and reducing this sampled error to zero by monitoring the amount of control information sent to a parameter-adjusting device. That patent also requires a knowledge of the accumulated number of reel revolutions in order to generate a desired filament speed; whereas the present invention does not require or use such information to control a beam section of a warp beam knitting machine. Furthermore, U.S. Pat. No. 3,648,338 fails to teach the use of an error display system which shows the deviation between the actual and desired variable as a function of the amount of control information sent to the parameter-adjusting device.
SUMMARY OF THE INVENTION
The control apparatus of this invention performs the automatic regulation of the yarn runner-length of a beam section of a warp beam knitting machine by measuring the unwinding rate of the yarn removed from the beam section and comparing this information to a signal proportional to the desired yarn runner-length. This desired runner-length signal is produced by transforming a signal related to the main shaft angular velocity to represent a selected runner-length. Each unit of information proportional to the desired runner-length is compared to the information related to the actual unwinding rate of the yarn and thus the actual runner-length of the yarn. If this comparison of information does not yield one unit of actual runner-length information per one unit of desired runner-length information, i.e., the information is not on a one-for-one basis, an error unit is generated.
The error unit may be positive or negative depending on whether more or less information units from the actual runner-length detector are sensed during one information unit representing the desired runner-length. This error unit information is algebraically added in an error counter to the previous binary number in the counter. This updated binary number representing the total number of error units in the counter is rapidly sampled at a periodic rate into a counter register. This sampled binary number immediately activates a gate mechanism that allows a clocking device to pulse a stepping motor decoder. The decoder then activates a stepping motor which in turn adjusts the beam section's angular velocity and therefore the yarn unwinding rate and runner-length. The number of clock pulses allowed to be fed into the decoder is equal to the number of error unit signals previously sampled into the counter register. That is, the binary number representing the number of error units per sampling interval is reduced by one integer each time a clock pulse is sent to the stepping motor decoder, and when the binary coded number represents zero error units the gate mechanism is turned off preventing any further clock pulses from reaching the stepping motor decoder.
The above stepping control is performed in a period of time less than the sampling rate interval of the error counter and thus the actual runner-length of the yarn always remains within very close tolerances of the desired runner-length. After each sampling of the error counter, it is immediately reset to zero and re-initiates counting of any subsequent error units. After the next sampling interval, the counter is again examined so as to allow any further activation of the stepping motor. If there are no error units contained in the counter at the time of sampling, this information is transferred to the gate mechanisms so as to prevent adjustment of the beam section's angular velocity. The beam section's angular velocity will thus be adjusted only when information is received indicating that the unwinding rate of the yarn, and thus the runner-length of the yarn, has deviated from the desired runner-length.
The above-mentioned operation of the present invention occurs so rapidly that upon completion of 480 revolutions of the main shaft of the warp beam knitting machine the length of yarn actually unwound from the beam section will closely approximate the desired runner-length.
An error display mechanism is also provided by the invention indicating within one tenth of an inch any deviation of the actual runner-length from the desired runner-length. An error counter is utilized that counts the number of error information units sampled by the counter register during 480 revolutions of the main shaft; i.e., while one rack of fabric has been knitted. Since each error information unit represents a fixed runner-length deviation, an algebraic sum is obtainable equal to the deviation of the actual runner-length from the desired runner-length. This information is displayed by an error display device. After 480 revolutions of the main shaft, the error counter is reset to zero and resumes adding incoming error information units until it is again reset after the next 480 revolutions of the main shaft. Thus the error display indicates for each rack of knitted fabric the actual runner-length deviation from the desired runner-length.
If the deviation of the actual runner-length as indicated by the error display device is greater than a predetermined limit -- such as eight-tenths of an inch -- a fail-safe system is activated which will automatically shut down the knitting machine. A fail-safe override system is provided in order to allow the manual operation of the knitting machine.
Furthermore, a mode selector switch is provided that allows use of the runner-length controller in operations other than continuous knitting at a preset runner-length. In particular, the mode selector allows the controller to be used when an intermittent run or a high-speed, low-speed run is desired. When an intermittent run is selected, one of the beam sections of a multibeam section knitting machine is periodically stopped. During these stoppages, it is necessary to inhibit the controlling mechanism of the runner-length controller for that beam section so as to prevent that section from receiving stepping motor control signals during the desired stoppage time. Furthermore, when a high-speed, low-speed operation of the knitting machine is desired, the controller will only control one of the two speeds; i.e., one of the two partial runner-lengths generated by the knitting machine during the knitting of one rack of fabric. The runner-length controller is consequently inhibited during the period of time when the other speed, and therefore the other partial runner-length, is activated by the knitting machine.
Therefore, the present invention provides a means to continuously control the yarn runner-length unwound from a warp beam section of a warp beam knitting machine to within very close tolerances of a preset desired yarn runner-length. The invention also provides a means for displaying any deviation between the actual runner-length and the desired runner-length of the yarn utilized in the knitted fabric. The invention furthermore provides a means for automatically shutting down the knitting machine if this error is greater than a predetermined value. Since the actual yarn runner-length control is continuous and also since the time delay between detection of any deviation in the unwinding rate of the yarn and control related thereto is very small, the fabric knitted by the knitting machine is of much higher quality than otherwise obtainable by similar machines using conventional yarn unwinding rate controllers. Furthermore, a mode selector switch and accompanying circuitry is provided by the present invention so as to allow its use in knitting fabrics with varying course densities.
OBJECTS OF THE INVENTION
Therefore, it is a principal object of the present invention to provide a yarn runner-length controller for warp beam knitting machines that continuously monitors and adjusts the unwinding rate of the yarn so as to provide an acutal runner-length within extremely close tolerances of a desired runner-length.
It is another object of the present invention to provide a yarn runner-length controller that minimizes the time lag between sensing a yarn unwinding rate deviation and adjusting the beam section's angular velocity to eliminate this deviation.
A further object of the present invention is to provide a yarn runner-length controller which eliminates the need to manually measure the yarn runner-length.
Another object of the present invention is to provide a yarn runner-length controller that eliminates the oscillatory movement of the beam section's driving mechanism which is inherent in present-day yarn unwinding rate controllers.
An additional object of the present invention is to provide a yarn runner-length controller capable of continuously displaying the desired and actual runner-length throughout the knitting operation.
A further object of the present invention is to provide a yarn runner-length controller with a display system for indicating any deviation of the actual runner-length from the desired runner-length.
Another object of the present invention is to provide a yarn runner-length controller that is easy to operate.
A further object of the present invention is to provide a yarn runner-length controller that automatically shuts down a warp beam knitting machine when the actual runner-length deviates from a desired runner-length by more than a predetermined amount.
An additional object of the present invention is to provide a yarn runner-length controller that is able to operate in a non-continuous manner.
Other objects of the invention will in part be obvious and will in part appear hereinafter.
THE DRAWINGS
FIG. 1 is a block diagram of a yarn runner-length controller according to the present invention;
FIG. 2 is a schematic diagram of the mode selector, the inhibitor, the up/down gate, and the synchronizer clock shown in FIG. 1;
FIG. 3 is a schematic diagram of the rate multiplier and the main shaft shaper-synchronizer shown in FIG. 1;
FIG. 4 is a schematic diagram of the sense rotational decoder and the beam "DOWN" shaper-synchronizer shown in FIG. 1;
FIG. 5 is a schematic diagram of the beam "UP" shaper-synchronizer, the up/down counter, the up/down zero bias, and the sampling rate clock shown in FIG. 1;
FIG. 6 is a schematic diagram of the magnitude comparator, the zero bias, the stepping motor gates, the stepping motor decoder, and the stepping motor override module shown in FIG. 1;
FIG. 7 is a schematic diagram of the fail-safe module and the fail-safe override module shown in FIG. 1; and
FIG. 8 is a schematic diagram of the reset module and the runner-length counter shown in FIG. 1.
DETAILED DESCRIPTION
The System
As can best be seen in FIG. 1, a yarn runner-length controller 20 of the present invention can be considered to consist of a number of functional blocks. The functional blocks communicate with each other and with a warp beam knitting machine in a novel manner that precisely controls the length of yarn used to produce a rack of knitted fabric. In addition, due to the yarn runner-length controller's continuous control of the yarn unwinding rate from a beam section of the knitting machine, the knitted fabric produced by the machine is of very high quality with a desirable uniform size for each row of knitted fabric.
More particularly, a tachometer or encoder 22 communicates with a main shaft 24 of a warp beam knitting machine and produces 100,000 electrical pulses 26 per every 480 revolutions of the main shaft. Since the length of yarn 27 used per every 480 main shaft revolutions is by definition equal to the yarn runner-length, the 100,000 electrical pulses are directly related to this runner-length.
The electrical pulses 26 from the tachometer 22 are transferred to a rate multiplier 28 where they are digitally transformed to represent a desired yarn runner-length. The desired yarn runner-length is manually selected by setting a series of binary coded decimal (BCD) switches 30. The desired runner-length set on these switches has a resolution of one-tenth of one inch and a maximum value of 999.9 inches. Typical yarn runner-lengths vary from three inches to 200 inches and thus the switches of the present invention have both ample range and resolution to provide any desired runner-length of yarn. The BCD switches 30 produce a binary coded decimal output 32 which represents the desired runner-length of yarn.
The rate multiplier 28 receives the BCD output 32 and the electrical pulses 26 from tachometer 22 and digitally transforms these signals to produce an electrical output 34 containing a series of pulses equal to 100 times the desired runner-length per 100,000 electrical pulses generated by tachometer 22. Therefore rate multiplier 28 generates a series of pulses that represents the desired runner-length with a resolution of one hundredth of an inch. Such a resolution is much finer than any present-day yarn runner-length controllers.
An electrical signal generated by inhibitor 38 on output lines 36 prevents rate multiplier 28 from generating output pulses 34 when inhibitor 38 is activated. The conditions when inhibitor 38 is activated will be discussed further on in this description.
A beam section tachometer or encoder 40 is coupled to the yarn filaments of the beam section and generates a series of electrical pulses corresponding to the length of yarn unwound from the beam section. Since the beam section is uniform, all the yarn filaments unwind from the section at very nearly the same rate; and therefore, a measurement of one or a few yarn filaments is sufficient to ascertain the length of yarn unwound for any other yarn filament of the yarn sheet.
The unwound yarn filaments are then knitted by the needles of the knitting machine. Since the knitting machine's needles pull on the unwound yarn in a discontinuous fashion, the unwinding yarn can be repeatedly jerked causing the unwound yarn to move toward the beam section during each jerking motion. The beam section tachometer 40 senses this reverse motion and generates pulsed output signals 42 and 44 that represent the length of yarn unwound as well as the length that moved toward the beam section. More particularly, output signal 44 represents the length of yarn unwound; i.e., the yarn in the UP position, whereas output signal 42 represents the length of yarn of each jerking motion of the unwound yarn; i.e., the yarn in the DOWN position.
A sense rotational decoder 46 electrically separates the electrical pulses representing the downward movement and the upward movement of the beam section into two sets of electrical pulses, a DOWN output 48 and an UP output 50. As will be discussed more fully later in this description, inhibitor 38 generates an electrical signal on output lines 36 that prevents the transmission of DOWN and UP outputs 48 and 50 when the warp beam knitting machine is in a mode where yarn runner-length control is undesirable. Such modes will be discussed later in the present description.
A synchronizer clock 54 generates high frequency electrical pulses which are transferred to a main shaft shaper-synchronizer 56, a beam DOWN shaper-synchronizer 58, and a beam UP shaper-synchronizer 60.
The main shaft shaper-synchronizer 56 electrically shapes and times the electrical output 34 of rate multiplier 28 so as to be compatible with an up/down gate 62. The electrical pulses from synchronizer clock 54 provide the timing information to the shaper-synchronizer so that incoming electrical pulses from different sources arrive at the up/down gate 62 in a non-simultaneous fashion. Similarly, the beam DOWN shaper-synchronizer 58 and the beam UP shaper-synchronizer 60 provide similar shaping and timing transformation to the DOWN output 48 and UP output 50 respectively.
If there is no jitter in the beam section tachometer 40, only UP output signals 44 are generated by the tachometer. In this case DOWN output signals are not generated by the beam tachometer, and therefore no DOWN output pulses are generated on output line 64 of the beam DOWN shapersynchronizer 58. The output of the main shaft tachometer then causes the generation of a series of pulses on output line 66 of the main shaft shaper-synchronizer 56. The up/down gate 62 then generates a series of pulses on its output line 68 equal to the number of pulses generated by output line 66.
An up/down counter 70 is utilized to account for incoming electrical pulses on output lines 68 and 72. This counter has a binary capacity of 11111111 or 255 decimal (including 0) and is initially set to binary number 10000000 or 128 decimal which is referred to as an arbitrary zero set.
The up/down counter 70 receives the outputs of up/down gate 62 and beam UP shaper-synchronizer 60. For every pulse on output line 68 the up/down counter subtracts one binary integer from the number previously stored in the up/down counter. Similarly, for every pulse received on output line 72, the up/down counter adds one binary integer to this number.
Therefore, for every pulse received by the up/down counter from output line 68 without a corresponding pulse from output line 72, one DOWN error unit is obtained. This error unit is stored by the counter by subtracting one binary integer from its previous number and this unit represents the condition where the actual length of yarn unwound from the beam is one hundredth of an inch less than the desired unwound length. Contrariwise, a pulse received on line 72 without a corresponding pulse on line 68 represents one UP error unit; i.e., the condition where the actual length of yarn unwound is one hundredth of an inch greater than the desired length. This condition is stored by the up/down counter by adding one binary integer to its previous number. Since the initial setting of the up/down counter is at the midpoint of its capacity, the counter has sufficient range to accept a multiplicity of error units in either the UP or DOWN direction.
If, however, the beam section does contain jitter; i.e., the yarn unwinding from the beam section intermittently moves in a reverse direction from its normal unwinding direction, a DOWN output signal is generated by the beam section tachometer 40 which causes pulses to be generated on output line 64 of the beam DOWN shapersynchronizer 58. These pulses represent the reverse motion of the yarn as it unwinds from the beam section and generate pulses on the output line 68 of the up/down gate 62.
Since the jerking motion of the yarn filaments is momentary, the filaments will return to their pre-jitter state. Therefore for every pulse generated in the DOWN direction, the beam tachometer will also produce a pulse in the UP direction. These pulses are transferred to up/down counter 70 via output line 72.
Due to the timing of the pulses on output lines 68 and 72, the up/down counter will first receive the pulse on line 68 and then the pulse on line 72. In turn, the up/down counter 70 will respectively first subtract one binary integer from its pre-existing number and subsequently add one binary integer to this number.
Thus the up/down counter will return to its previous number and effectively neutralize the two pulses generated on the DOWN and the UP outputs of the beam section tachometer. This result represents the actual unwinding condition of the yarn since the yarn did not unwind during the time that jitter existed on the unwinding yarn. More particularly, since the yarn moved in the reverse direction for a given distance and similarly moved in the forward direction an equal distance, a net unwinding length of zero actually occurred. The up/down counter 70 indicates that this has occurred when its previous number is unchanged by the receipt of the error pulses from the up/down gate 68 and the beam UP shaper-synchronizer 60.
If during the interval of time when the yarn is moving toward the beam section, a pulse is received by the up/down gate 62 from the main shaft shaper-synchronizer 56, this pulse and the pulse from the beam DOWN shapersynchronizer will cause two pulses to be generated by up/down gate 62. Therefore, the pulse on output line 72 from the beam UP shaper-synchronizer 60 will cancel out the jitter DOWN pulse but will not affect the pulse from the main shaft shaper-synchronizer.
By receiving pulses from the up/down gate 62 and the beam UP shaper-synchronizer 60, the up/down counter 70 algebraically sums all incoming information regarding the desired runner-length and the actual runnerlength. At any particular instant if the binary number in the up/down counter is less than the zero bias number, (decimal 128), the up/down counter indicates that the actual runnerlength is less than the desired runner-length; and similarly, if the number is greater than the zero bias number, (decimal 128), the up/down counter indicates that the actual runner-length is greater than the desired runner-length. Thus any deviation from the zero bias number is an indication of the direction and magnitude of the error between the actual runner-length and the desired runner-length. As mentioned earlier, each binary integer difference between the zero bias number and the actual number in the counter represents one hundredth of an inch of error.
A counter register 80 retrieves the binary number in the up/down counter representing the amount of error between the actual and desired runner-lengths upon receipt of a rising pulse edge representing a load signal 82 from the sampling rate clock 78. The sampling rate clock generates this pulse every 0.3 seconds where the falling edge of this pulse represents a reset signal 76 that causes the number in the up/down counter to be reset to the zero bias number. Thus the accumulated error in the up/down counter is sampled every 0.3 seconds and is also reset every 0.3 seconds.
Upon receipt of the binary number in the up/down counter, the counter register 80 feeds this binary number to a magnitude comparator 82 via output lines 83. The value of the binary number on lines 83 is denoted as "A" (see FIGS. 1 and 6). Here the binary number is compared to another binary number generated by a zero bias module 84 and transferred on output lines 85. The value of this binary number is denoted as "B". This number is actually identical to the number generated by the up/down zero bias module 74, and thus if the value of A is greater than the value of B, the magnitude comparator will generate a high level output on line 86 and a low level output on lines 88 and 90. Line 86 represents the condition where the binary number on lines 83 is greater than the binary number on lines 85. Similarly, line 90 represents the condition where binary number 83 is less than binary number on lines 85 and line 88 represents the condition where the binary number on lines 83 equals the binary number on lines 85.
Output lines 86, 88 and 90 are connected to stepping motor gates 92. A stepping motor clock 94 generates a series of electrical pulses every 10 milliseconds and transfers these pulses via output lines 96 to stepping motor gates 92. The clock pulses on output line 96 are transferred to gate output line 100 if line 86 is at a high or "ON" level or output line 102 if line 90 is at a high or ON state (A less than B). This former state represents the condition where output lines 83 are greater than the binary number on zero bias output lines 85, thus indicating that the yarn unwinding rate is greater than the desired yarn unwinding rate. Similarly, the latter state represents the reverse condition, where output lines 83 are less than the binary number on zero bias lines 85, thus indicating that the yarn unwinding rate is less than the desired unwinding rate.
The electrical pulses on gate output line 100 or 102 are transferred to a stepping motor decoder 104 where the pulses are electrically buffered and transferred to a stepping motor 106 via output line 108.
Upon receipt of each electrical pulse on output line 108, stepping motor 106 moves one position clockwise or counterclockwise depending upon whether gate output line 100 or gate output line 102 transfers the electrical pulses. Each time the stepping motor moves one position a speed adjusting ring 110 moves an incremental amount along the horizontal axis of a speed adjusting cone 112. Since rotational energy is imparted to speed adjusting ring 110 via a constant speed control cone 114, horizontal movement of the ring will cause the angular velocity of speed adjusting cone 112 to vary by a very small amount. The speed adjusting cone is mechanically coupled to a gear box 116 which in turn is mechanically coupled to the beam section 118 for providing the desired angular velocity to beam section 118. Since the unwinding rate of yarn 27 from the beam section is measured by beam section tachometer 40 with a resolution of one hundredth of an inch, each step by stepping motor 106 in response to an electrical pulse on output line 108 causes the beam section's angular velocity to be adjusted by amount approximately equal to the amount necessary to correct for a hundredth of an inch deviation in yarn runner-length.
More particularly, if after 0.3 seconds one more electrical pulse is received by up/down counter 70 from output line 72 than from output line 68, the binary number in the up/down counter is one binary integer greater than the zero bias number. Therefore, the value of A on output line 83 is greater than the value of B on output line 85, thus causing output line 86 to be in the ON condition. This ON condition causes an electrical pulse to occur on gate output line 100 and finally on output line 108. Since each pulse generated by beam section tachometer 40 represents a hundredth of an inch of yarn, the one extra pulse during the 0.3 second sampling time represents a deviation in the desired unwinding rate of 0.01/0.3, or 0.033 inches per second. Because the unwinding rate of the yarn is equal to the angular velocity of the beam section times the radius of the yarn with respect to the center of the beam section, the amount of angular velocity represented by the unwinding rate deviation is:
Δw = Δ v/R
Δw = 0.033/R
(radians per second); where Δw is the change in angular velocity, Δv is the deviation in unwinding rate, and R is the radius of the unwinding yarn about the beam axis. Since the radius of the yarn about the beam section varies between a predetermined maximum and minimum, an average value of the radius, Rav, is chosen with respect to the amount of angular velocity change per position of stepping motor 106. For a typical knitting machine where Rav is equal to 15 inches, the amount of change in the angular velocity of the beam section per deviation of one hundredth of an inch in runner-length is:
Δw=0.033/Rav (radians/second=0.033/15= 0.0022 radians/second.
Thus each position of stepping motor 106 causes speed adjusting ring 110 to move an incremental amount capable of changing the beam section's angular velocity by the above amount. Since the control cone 114 has a uniform variation in radius throughout its horizontal length, and also since the change in angular velocity of speed adjusting cone 112 is directly proportional to the change in the contacting radius of control cone 114 with speed adjusting ring 110, the above change in angular velocity to the beam section is obtainable regardless of where speed adjusting ring 110 makes contact with control cone 114. Thus the above change in angular velocity of the beam section per positional change of stepping motor 106 is obtainable regardless of the particular angular velocity of the beam section.
In the above situation where the binary number on output line 83 is greater than output line 85, thus causing output line 86 to be in the ON state, gate output line 100 continues to carry electrical pulses from stepping motor clock 94 to stepping motor decoder 104 until output line 88 is in the ON state. At this point the binary number on output line 83 is equal to the binary number on output line 85 and the energization of output line 88 prevents any clocking pulses from stepping motor clock 94 from being transferred to stepping motor decoder 104.
The binary number on output line 83 is changed after each sampling of the up/down counter 70 via the electrical pulses on output lines 101 and 103 from the stepping motor gates. Each electrical pulse on output line 101 causes the binary number in counter register 80 to decrease by one binary integer, and similarly each electrical pulse on output line 103 causes the binary number to increase by one integer. Therefore, the number of electrical pulses transferred to stepping motor decoder 104 is equal to the magnitude of difference between the sampled number in counter register 80 and zero bias 84. It is therefore readily apparent that the amount of change in the angular velocity of the beam section and thus in the actual runner-length of yarn from this beam section is approximately equal to the amount of deviation between the actual and desired runner-length per sampling interval.
Since stepping motor clock 94 produces an electrical pulse every 10 milliseconds, the binary number in counter register 80 is returned to the zero bias binary number before the next sampled error signal from up/down counter 70 is retrieved. Any error between the actual and desired runner-lengths per 0.3 second sampling interval is completely acted upon before the next sampled error signal is retrieved during the following 0.3 second interval. It therefore does not matter whether the amount of angular velocity change in the beam section is exactly equal to that needed to cause the actual amount of yarn unwound to equal the desired amount of yarn unwound per 0.3 second interval, because any remaining deviation between the actual and desired yarn unwinding rates will be resampled by the counter register and re-acted upon by the magnitude comparator. In the actual operation therefore, the rapid sampling of the deviation between the actual and desired unwinding rate of yarn is so swift that an approximate adjustment per sampling interval in the angular velocity of the beam section will yield an actual runner-length of yarn within a few hundredths of one inch of the desired yarn runner-length.
The above sequence of controlling events by yarn runner-length controller 20 also occurs when the binary number on output line 83 is less than the binary number on zero bias output line 85, causing output line 90 to be in the ON state. This state causes stepping motor gates 92 to allow electrical pulses from stepping motor clock output line 96 to be transferred to gate output line 102. These pulses in turn cause stepping motor 106 to move in steps of the opposite direction than when electrical pulses occurred on gate output line 100. Similarly, gate output line 103 will cause the binary number in counter register 80 to be increased by one binary integer each time an electrical pulse occurs on that line. Thus when the binary number on output line 83 equals a zero bias binary number on output line 85, output lines 86 and 90 will be in the OFF state and output line 88 will be in the ON state. This ON state prevents any further electrical pulses from occurring on output line 102 while preventing the initiation of pulses on output line 100.
As best seen in FIG. 1, the present invention also includes a fail-safe module 120 that senses the number of electrical pulses sent to up/down counter 70 via output lines 68 and 72. The fail-safe module algebraically adds these pulses and if the absolute value of this algebraic sum of electrical pulses is greater than 80 -- representing a 0.8 inch deviation between the actual and desired runner-length -- per 480 revolutions of the main shaft 22, it energizes output lines 122 and 123, causing the knitting machine to stop. The information concerning the 480 revolutions of the main shaft is provided by a runner-length counter 124 that accumulates electrical pulses from the main shaft tachometer 22 until 100,000 pulses are received. The 100,000 pulses represent 480 revolutions of the main shaft of the knitting machine. If an absolute value of 80 is not obtained by the fail-safe module during the 480 revolutions of the main shaft, the output line of the fail-safe module remains de-activated and the knitting machine remains energized. In this case fail-safe module is reset to zero counts by the runner-length so as to continue its monitoring of the up/down counter.
The fail-safe module 120 and the rate multiplier 28 are initially reset to zero when "START" line 125 is activated causing a reset module 127 to generate a reset pulse on output lines 129 and 131. The START line is activated when automatic control by yarn runner-length controller 20 is desired. Therefore any binary number previously stored in the fail-safe module is undesired since it is unrelated to the current yarn control operation.
The present invention also includes an external error display incorporating an error counter decoder 126 that receives all electrical pulses on lines 68 and 72 and generates one electrical pulse on output line 128 or 130 for every 10 electrical pulses respectively received. Since every pulse on line 68 or 72 represents a deviation between the actual and desired runner-length of one hundredth of one inch, each output pulse generated by error counter decoder 126 represents a deviation in the actual runner-length of one tenth of one inch. These output lines are connected to an error counter 132 where they are algebraically summed during every 480 revolutions of the main shaft. The binary number accumulated by the error counter after a reset signal is received from runner-length counter 124 represents the total runner-length deviation between the acutal and desired runner-length. This number is continually transferred to an error display 134 via output line 136. The error display transfers the binary number into a visual display representing the decimal value of the binary number. Thus the deviation between the actual and desired length is displayed with a resolution of one tenth of one inch. After 480 revolutions of the main shaft, the runner-length counter will have received 100,000 electrical pulses from the main shaft tachometer 22 and will cause a reset pulse 138 to be transferred to the error counter 132 causing the error counter to reset its accumulated error to a binary number representing zero error. The error counter is then able to display the deviation between the actual and desired runner-length for the next rack of knitted cloth.
The error counter may be designed to transfer on output line 136 only the binary number just prior to reset. This number represents to total deviation of the actual runner-length and could be displayed by error display 134 during the time interval when the following rack of fabric is being knitted. This number when algebraically added to the desired runner-length display on BCD switches 30 yields the actual runner-length for each rack of knitted fabric. Indeed the actual runner-length may be displayed by algebraically adding the electrical pulses on output lines 66, 128 and 130.
The present invention includes a fail-safe override module 140 which prevents the operation of the fail-safe module when the override module is energized. When the fail-safe override module is energized the stepping motor override module 142 is also activated in either an UP or DOWN configuration via input lines 144 and 146 respectively. The stepping motor override module allows the stepping motor decoder 104 to be activated in an UP or DOWN direction by stepping motor clock pulses on line 96 by deactivating stepping motor gates 92 via an electrical signal on output line 147. In turn, the stepping motor decoder allows the operator to initially place speed adjusting ring 110 to a position that will approximately yield a new desired runner-length. Under such conditions if the approximate angular velocity of the beam section is unknown, the up/down counter 70 would generate a large enough error signal to trigger the fail-safe module if it was not de-energized. Thus the remote control signals to the fail-safe override and stepping motor override modules allow the operator to manually control the knitting machine so as to position the speed adjusting ring 110 to the position on speed adjusting cone 112 in order to obtain the approximate desired yarn runner-length. Once this initial setup is completed the override modules are deactivated allowing the yarn runner-length controller to automatically control the actual yarn runner-length. At this time the START line 127 is activated.
A mode selector 146 is provided in the present invention to allow the use of the invention in modes other than a continuous preset desired runner-length. More particularly, if the knitting operation calls for two partial runner-lengths to be used per rack of knitted cloth, the mode selector is set to allow the one with the greater number of courses to be controlled by the present invention. When switching to the other partial runner-lengthh control, the ring 110 is in the proper position, and no significant error can accumulate during the few courses during which the controller is inactivated. Whatever minor error develops is rapidly compensated the moment the controller is reactivated. It is for this reason that the knitting machine is activated for the partial runner-length with the greater number of courses. The mode selector during this other period of time generates an output signal on output line 150 so as to cause inhibitor 38 to prevent the generation of electrical pulses by rate multiplier 28 and sense rotational decoder 46.
Another permissible mode of operation of the beam section controlled by the present invention is to have the beam section stopped during part of the time when one rack of knitted cloth is being knitted. In such a situation, other beams of the warp beam kintting machine are still being controlled while the yarn on the beam section where this particular condition exists is stopped. This mode of operation causes pattern effects in the knitted fabric. A mode selector position is chosen that will energize the inhibitor 38 during the periods of time when beam section 118 is to be de-energized. It must be understood that the controller section described applies to one bar. Actually, there is an independent controller for each bar of the knitting machine. Each bar is thus independently controlled.
Thus as may readily be seen, multiple devices of the present invention may be used on several beam sections of a warp beam knitting machine where each yarn runner-length controller 20 controls the runner-length of that particular beam section of the knitting machine. As best seen in FIG. 7, in such a configuration the output lines 122 of each fail-safe module 120 are logically "ored" so as to cause a shut-down relay 152 to be energized when any fail-safe output line is energized. The knitting operation is therefore terminated when any beam section of the knitting machine generates an error signal large enough to energize its fail-safe output line.
Operation of the Yarn Runner-Length Controller
The operation of a yarn runner-length controller 20 of the present invention is both fast and efficient.
As best seen in FIGS. 1 and 2, the mode of operation of the knitting machine is chosen on the mode selector 148. If a continuous yarn runner-length is desired, rotary switch 154 is set at the "NORMAL" position. In this position the controller will continuously control the yarn runner-length.
As seen in FIGS. 1 and 3, the BCD switches 30 are then set to the desired yarn runner-length. This desired runner-length has a resolution of one tenth of one inch.
As best seen in FIGS. 1 and 8, following the selection of the desired runner-length, the reset module 73 is activated by energizing "START" line 71 via pushbutton switch 75 located on the knitting machine. Reset module 73 then causes rate multiplier 28, fail-safe module 120, runner-length counter 124, and error counter 132 to be set to their zero bias position. Sampling rate clock 78 automatically resets up/down counter 70. At the time pushbutton 75 is depressed, fail-safe module 120, runner-length counter 124, and error counter 132 are automatically reset without any further manual activation.
Next, as best seen in FIGS. 1, 6 and 7, the fail-safe override module 140 and the stepping motor override module 142 are activated by switches 141 and 143 respectively so as to allow the operator to manually set speed adjusting ring 110 to the position that will yield the approximate desired yarn runner-length. Once the ring has been positioned the override modules are de-activated causing the yarn runner-length controller to begin the automatic control of the yarn runner-length.
This automatic control of the yarn runner-length will continue until the load selector switch 154 is placed in the OFF position or until the fail-safe module 120 terminates the knitting operation.
If the desired knitting operation requires two partial yarn runner-lengths per rack of knitted cloth, the present invention can only control one of the two partial runner-lengths. The mode selector switch 154 is then placed in either the "HIGH" position or the "LOW" position depending on whether the longer or shorter partial runner-length is desired to be controlled (see FIG. 2). More particularly, the partial runner-length that is used for the greater percentage of time (greater number of courses) is chosen so as to provide the greater amount of control time to the total knitting operation. During the knitting of the uncontrolled partial runner-length beam inhibit switch 156 closes thus energizing inhibitor 38.
Similarly, in a knitting operation utilizing more than one beam section where a controlled beam section is stopped during a portion of the knitting operation, the mode control switch 154 is placed in the NORMAL-HIGH position where beam inhibit switch 156 activates inhibitor 38 (see FIG. 1) when the beam is stopped.
The Functional Blocks
The functional blocks of the present invention primarily consist of integrated circuit chips that perform various electronic functions including clocking, counting, electrical pulse shaping and timing, as well as various logic operations. As best seen in FIG. 2, the mode selector 148 comprises a switch 154 that operates in conjunction with a "nand" gate 158 and a beam inhibit switch 156 to provide the desired modes of operation of the present invention.
Inhibitor 38 utilizes an inhibit switch 160 for preventing pulses generated by the main shaft tachometer 22 and the beam tachometer 40 (see FIG. 1) from entering the rate multiplier 28 and the sense rotational decoder 46 respectively. The mode selector and inhibitor although comprising two functional blocks as shown in FIG. 1 are actually interrelated since the mode selector causes the rate multiplier and sense rotational decoder to be deactivated when beam inhibit switch 156 is closed or when switch 154 is in the OFF position.
As best seen in FIG. 3, the binary coded decimal switches 30 comprise four BCD switches 162, 163, 164 and 165. Each switch has four output lines which code the chosen decimal number into a binary coded decimal number. Each switch also displays the chosen decimal number. A typical desired runner-length of 78.2 inches is displayed by the switches shown in FIG. 3.
Rate multiplier 28 comprises a nand gate 166 that allows electrical pulses 26 generated by main shaft tachometer 22 to be transferred to the clock inputs of the rate multipliers if the inhibitor output lines 36 are not at a ground state. Four integrated circuit chips 168, 169, 170, and 172 (Texas Instruments, Part No. SN 74167N) and two nand gates 172 and 173 are utilized to multiply the desired runner-length by a factor of 100 per every 100,000 main shaft tachometer electrical pulses 26.
Similarly, as best shown in FIGS. 1 and 4, sense rotational decoder 46 utilizes two nand gates 175 and 176 to allow electrical pulses generated by wrap beam tachometer 40 to reach the remainder of the decoder if neither output lines 36 are at a ground condition. Nand gates 177 and 178, one-shot multivibrators 179 and 180 (Texas Instruments, Part No. SN74121N), "and" gates 181, 182, 183, 184, and "nor" gates 185 and 186 are utilized to insure that the signals generated by tachometer 40 will be properly decoded on output lines 48 and 50 respectively.
As best seen in FIG. 2, synchronizer clock 54 utilizes a 20 microsecond clock 188 (Texas Instruments, Part No. SN7402), J-K flip-flops 189 and 190 (Texas Instruments, Part No. SN7473), and nand gate 191 to generate three staggered clocking signals used by main shaft shaper-synchronizer 56, beam DOWN shaper-synchronizer 58 and beam UP shaper-synchronizer 60. These clocking signals cause the various electrical pulses to arrive at up/down gate 62 and up/down counter 70 in a staggered fashion that prevents these pulses from being improperly acted upon.
As best seen in FIGS. 1, 2 and 3, the main shaft shaper-synchronizer 56 shapes and synchronizes the electrical pulses from output line 34 with clocking signals from synchronizer clock 54. The shaper-synchronizer utilizes nand gates 193, 194, 195 and 196 and J-K flip-flops 197 and 198 (Texas Instruments, Part No. SN7473) to generate properly shaped and synchronized electrical pulses on output line 66.
Similarly, as best seen in FIGS. 1, 4 and 5, beam DOWN shaper-synchronizer 58 and beam UP shaper-synchronizer 60 shape and synchronize the incoming electrical pulses on output lines 48 and 50 respectively. More particularly, the DOWN shaper-synchronizer utilizes nand gates 200 and 201 and 202 along with J-K flip-flops 203, 204, and 205 (Texas Instruments, Part No. SN7473) to produce electrical pulses on output line 64. Likewise, the UP shaper-synchronizer utilizes nand gates 207, 208, and 209 and J-K flip-flops 210, 211, and 212 to generate the proper electrical pulses on output line 72.
As best seen in FIGS. 1 and 2, the up/down gate 62 merely consists of an "exclusive nor" gate 214 (Texas Instruments, Part No. SN7486) that receives electrical pulses on output lines 64 and 66 and generates electrical pulses on output line 68.
As can be seen in FIG. 8, reset module 127 generates two output reset signals via one-shot multivibrator 216. A start switch 133 in conjunction with nand gates 218, 219, 220 and 221 and one-shot multivibrator 222 provide an electrical pulse to one-shot 216 when switch 133 is momentarily closed. A manual reset switch 223 is provided to allow the yarn runner-length controller to be reset without re-starting the controller.
As can best be seen in FIGS 1 and 5, the up/down counter 70 receives electrical signals on output lines 68 and 72 and counts these signals in a DOWN and UP direction by use of nand gates 225 and 226, invertor 227, and up/down counters 228 and 229 (Texas Instruments, Part No. SN74193). The binary number contained in up/down counters 228 and 229 is reset every 0.3 seconds by an electrical pulse generated by sampling rate clock 78 along output line 76. At such times the zero bias 74 causes the up/down counters to be set to binary number 10,000,000 due to the biasing conditions on input lines 1A, 1B, 1C, and 1D of each counter.
The sampling rate clock 78 generates the electrical pulses on output line 76 via a clock 231 and a one-shot multivibrator 232 (Texas Instruments. Part No. SN74121).
The electrical states of output lines OA, OB, OC, OD, of counters 228 and 229 are transferred into counter register 78 when sampling rate clock line 82 is energized. The counter register consists of two preset up/down counters 234 and 235 (Texas Instruments, Part No. SN74193). The received binary number is then altered by electrical pulses on output lines 101 and 103 from stepping motor gates 92. This altered binary number is retrievable on output lines OA, OB, OC, and OD of counters 234 and 235.
As seen in FIGS. 1 and 6, magnitude comparator 82 comprises two magnitude comparator chips 237 and 238 (Texas Instruments, Part No. 7485) where the outputs 83 of counter register 78 are applied to inputs AA, AB, AC, and AD, of each chip and compared to the binary number 10,000,000 generated on inputs BA, BB, BC, and BD, of each counter via zero bias 84. Output lines 86, 87, and 88 are individually set at an ON state depending on whether the binary number on output line 83 is greater than, equal to, or less than the zero bias binary number.
Stepping motor gates 92 utilize nand gates 239, 240, 241, 242, 243, 244, 245, 246, 247, and 248 to produce electrical pulses on output lines 100, 101, 102, and 103. These electrical pulses are generated in accordance with the electrical pulses generated by stepping motor clock 94 and the conditions of output lines 86, 88, and 90. Output lines 100 and 102 of the stepping motor gates are de-activated if stepping motor override output lines 147 are energized or when A equals B.
As also seen in FIGS. 1 and 6, stepping motor decoder 104 generates buffered electrical output signals on output line 108 to drive stepping motor 106 in accordance with electrical pulses on output lines 100 and 102. The decoder utilizes a preset up/down counter 250 (Texas Instruments, Part No. SN74193) as well as nand gates 251 and 252, "exclusive nor" gates 253 and 254, and inverters 255, 256, 257 and 258. If output line 123 from fail-safe module 120 is energized. the up/down counter 250 is prevented from generating additional output signals to drive the logic components.
As best seen in FIGS. 1 and 8, runner-length counter 124 performs the electrical counting of 100,000 electrical pulses generated by main shaft tachometer 22 by use of decade-counters 260, 261, 262, 263, and 264 (Texas Instruments, Part No. SN7490N). The output of decade-counter 264 generates one electrical pulse per 100,000 electrical pulses received by decade-counter 260. The output of decade-counter 264 drives nand gate 265 and 266 which in turn drives nand gate 267 and 268. The outputs of nand gate 267 and 268 are used to reset the binary coded decimal numbers stored in fail-safe module 120 and error counter 132
As best seen in FIGS. 1 and 7, fail-safe module receives error unit information from up/down counter 70 via output lines 77 and 79 and transfers this information via inverters 270, 271, 272, and 273, and nand gates 274 and 275. The output signals of nand gates 274 and 275 are then transferred by nand gates 276 and 277 where the information is transferred to BCD up/down counter 278 (Texas Instruments, Part. No. SN74192). A preset up/down counter 279 receives the output from the BCD counter and generates output signals that drive nor gate 280 and nand gate 281. These gates in turn drive nand gates 282, 283, 284 and 285. Nand gate 285 clocks J-K flip-flop 286 (Texas Instruments, Part No. SN7473) which in turn drives NPN transistor 287 causing indicator light 288 to be energized. The energization of light 288 indicates that the fail-safe system has been activated and that the knitting machine is shut-down. Flip-flop 286 also drives nand gates 290, 291 and 292 which in turn activate output line 123, preventing stepping motor decoder 104 from activating stepping motor 106. In addition flip-flop 286 drives J-K flip-flop 293 which in turn drives nand gate 294 and 295. The output of nand gate 295 is logically ored with the fail-safe outputs of other beam sections of the knitting machine via nor gate 296. The output of nor gate 296 drives nand gate 297 which in turn drives one-shot multivibrator 298 (Texas Instruments, Part No. SN74121). The one-shot then drives Darlington transistor pair 299 and 300 that energize shut-down relay 152; causing the knitting machine to be stopped.
The binary numbers stored in BCD up/down counter 278 and preset up/down counter 279 are reset to binary numbers 0000 and 1000 respectively whenever an output signal is received from runner-length counter 124 via output line 138. This reset signal is buffered by nand gate 302 which in turn drives one-shot multivibrator 303. The output of this one-shot drives another one-shot multivibrator 304 causing counters 278 and 279 to be reset. Another output of one-shot multivibrator 303 drives nand gate 305 which in turn resets flip-flops 286 and 293.
As also seen in FIGS. 1 and 7, the fail-safe override module 140 merely consists of a single-pole single-throw switch 141 which when closed, prevents nand gates 292 and 294 of fail-safe module 120 from generating energized outputs.
As shown in FIGS 1 and 6, the stepping motor override module 142 utilizes clocking information from stepping motor clock 94 and the position of external switch 143 to drive nand gates 310, 311, 312, 313, 314 and 315. The outputs of nand gates 310 and 311 drives gates 241 and 246 respectively of the stepping motor gates 92. These gates in turn drive the stepping motor decoder 104. The outputs of nand gates 314 and 315 drive nand gate 248 of the stepping motor gate 92.
Thus what has been described is a novel yarn runner-length controller which provides for the automatic control of the length of yarn used by a beam section of a warp beam knitting machine. The present invention allows the operator to "dial-in" the desired yarn runner-length whereby the controller maintains an actual runner-length nearly equal to this desired length throughout the entire knitting operation. The invention also displays any error between the desired and actual runner-length and includes a fail-safe system for shutting-down the knitting machine when the beam section is not properly operating. In addition, it is possible to directly display the actual runner-length. Furthermore, the information generated by the invention is available at output connectors where the error display system interconnects in order to be fed into a data acquisition system allowing remote supervision of a large number of knitting machines. The knitted fabric produced by knitting machines using the present invention has been found to be very high quality with uniform course density throughout.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above apparatus without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings will be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
|
A yarn runner-length controller for warp beam knitting machines utilizes information of the yarn unwinding rate from a warp beam section and continuously compares this information to a signal related to the desired runner-length of the yarn. This continuous comparison yields an error signal with a magnitude proportional to the difference between the desired runner-length and the actual runner-length. The error signal is sampled and this sampled error signal activates a control device operating on the angular velocity of the warp beam section so as to adjust this velocity in the direction that reduces the difference between the actual runner-length and the desired runner-length. The magnitude of the sampled error signal is reduced to zero before the next sampled error signal is received by means of a signal from the control device related to the amount of adjustment made to the beam section's angular velocity. When the sampled error signal is reduced to zero, the control device maintains the beam section's angular velocity to the last adjusted value. The continued sampling of the error signal thus maintains the actual runner-length to within close tolerances of the desired runner-length throughout the duration of the knitting process.
An error display panel indicates any deviation between the actual and desired runner-lengths. A fail-safe module shuts down the knitting machine if the deviation between the actual and desired runner-lengths is greater than a predetermined amount.
In addition, data acquisition means are included which can monitor such conditions as actual and desired runner-lengths, error between actual and desired runner-lengths, number of knitting interruptions, and duration of knitting interruptions.
| 3
|
This is a continuation of application Ser. No. 08/115,606, filed Sep. 3, 1993, now U.S. Pat. No. 5,374,783 which was a continuation of application Ser. No. 07/904,116, filed Jun. 25, 1992, now U.S. Pat. No. 5,243,137, issued Sep. 7, 1993.
TECHNICAL FIELD
The present invention relates to electrical overhead transmission conductors, and especially a steel supported aluminum overhead transmission conductor, or cable. More particularly, the present invention is directed to a method of manufacturing an improved steel supported aluminum overhead transmission conductor cable with unexpectedly improved conductivity and increased current carrying capacity (ampacity), as well as improved self-damping characteristics, and to the aluminum overhead conductor cable manufactured thereby. Both round and trapezoidal wire cross section configurations are disclosed. Better corrosion resistance and high-temperature operation performance is accompanied by improved thermal-related sag, reduced tension creep, and increased fatigue resistance characteristics arising from the disclosed method of manufacture. Certain characteristics of the overhead transmission conductor are enhanced when the aluminum wire strands are of trapezoidal cross section.
BACKGROUND OF THE INVENTION
Steel reinforced aluminum cable (ACSR) for use as an overhead transmission conductor usually comprises a plurality of aluminum wires helically wound around a steel core, which is also typically formed of a plurality of usually round steel wires stranded together. A plurality of layers of aluminum strands are often used. The electrical strands are of electrical grade ("EC") aluminum, one or more aluminum alloys, or a combination of these, tempered to provide sufficient tensile strength to carry a portion of the suspended cable load.
High-voltage transmission companies face numerous problems in reducing costs and ensuring reliable power transmission to their customers. Among these are enormous losses of power due to electrical line losses, extremely expensive maintenance and replacement costs due to broken wires damaged by vibration and oscillation, and the ability to subject the transmission cables to increased loads beyond those for which the cable system may have been designed, if only temporarily, as occurs during peak load conditions or when used to carry the load of a companion circuit that has been temporarily removed from service for maintenance, etc. The known cable standards and constructions represent a compromise among many competing service requirements, thus selection of cable presents an engineering problem of both considerable difficulty and long-term economic importance. The present invention reduces the complexity of the problem by providing in a single overhead transmission conductor a cable with superior conductivity, lower power losses, and greater ampacity for a given cable cross section, and very desirable service characteristics.
Standard ACSR overhead transmission conductor cable utilizes round electrically conductive wire strands. A portion of the tension resulting from the suspended weight of the cable is normally borne by the conventional ACSR aluminum electrical conductors under normal conditions. Under high temperature or high current-carrying operating conditions which soften aluminum wires, however, the steel strand may carry the entire mechanical tension load; the cable thus stretches and sags. ACSR cable is available in the conventional configuration with round conductor strands, and in reduced diameter to meet a "compact" specification. "Compact ACSR" is commonly found in one of two forms.
In one form, at least one layer of the electrical conductor is die-compacted following the stranding operation to reduce the cable cross-sectional area. U.S. Pat. Nos. 1,943,087 and 3,760,093 teach such processes. In another form, the individual strands used for at least one layer of aluminum conductors are shaped into a more compactly fitting cross section, a plurality of which are then fitted together to form the conductor layer or layers. The preferred cross-sectional shape for one embodiment of the invention is called trapezoidal wire. It is shaped before stranding to form the cable. Each compact cable construction relies on different manufacturing steps, and results in differing finished cable characteristics.
Die-compacted ACSR undergoes shaping forces during the compacting process which result in sharp corners or edges. These are susceptible to arcing or corona formation at higher voltage levels, and thus limit use of the configuration to lower voltage levels.
Trapezoidal wire ACSR is formed by "building up" preshaped conductors, resulting in a very dense structure without the mechanical rigidity of die-compacted ACSR. This cable construction can improve the resistance of the wire to aeolian oscillation and galloping, to which such conductors are subjected. Aeolian oscillation is a low amplitude, high frequency vibration that normally occurs due to relatively low wind velocities under 25 kilometers per hour. Galloping, conversely, is a low frequency, large amplitude phenomena. Both galloping and aeolian oscillation can contribute to fatigue and early failure of the conductors in conventional ACSR cable.
As noted, a portion of the tension force is normally carried by the aluminum conductor in ordinary ACSR. However, a condition known as "tension creep" elongation is known to occur, in which the aluminum conductor portion of the overhead cable stretches over time and permits a degree of conductor sag which may be undesirable. This can increase the load on the steel strand core since the tension force carried by the aluminum conductor is reduced without a reduction in the weight of the aluminum conductor.
Electrically conductive metals used for conductor cables are subjected to complex mechanical and heat treatments in order to arrive at desirable mechanical and electrical characteristics. As is well known, the interaction of the mechanical and heat treatments and the electrical characteristics is extremely complex; this complexity is vastly increased when the metal strands are subjected to the manufacturing process conditions necessary to produce a finished cable, installed for use. Tensioning, bending, and frictional heating of the aluminum conductor strands alter the electrical conductivity and temper thereof, often contrary to the finished effect desired.
U.S. Pat. Nos. 3,813,481 and 3,813,772 ("'481" and "'772") disclose known overhead transmission conductor cable designs in which the aluminum wires are at nearly dead soft temper and the stranded steel core carries substantially all of the tension load. This cable is denominated steel supported aluminum conductor, or SSAC. The '481 patent is believed to represent more recent improvements in overhead transmission conductor cable designs. In the design illustrated in that patent, the aluminum conductor wires are annealed to soft condition such that the stranded steel core carries the tensile load.
The manufacturing process for the SSAC product 100 disclosed in the '481 patent is illustrated in FIG. 4. Conventional 61% IACS aluminum rod 102 is drawn conventionally to wire form in a drawing step 104, then the drawn wire 106 is fully annealed in step 108. This drawn, fully annealed wire 110 is soft and easily subject to damage and must be handled carefully. This careful processing requirement extends to the special stranding step 112, where the conductor wires 110 are overlaid around the steel strand core 114.
Strain and work hardening as ordinarily and inherently occur in the stranding process must be minimized to avoid increasing the temper of the wires unnecessarily, as the finished overhead transmission conductor cable wires are specified as having less than 8500 pounds per square inch (psi) yield strength for 1 percent elongation and must provide at least 61% IACS conductivity in the final product. Therefore, the stranding step 112 described in the '481 patent includes numerous special processing condition requirements which necessitate extraordinary adjustments to the stranding apparatus and significantly slower processing speeds.
These special stranding step 112 requirements include, but are not limited to: applying a lubricant to the surface of the fully annealed aluminum wires, reducing the back-tension on the aluminum wires through the stranding machine, reducing the operating speed of the stranding machine, modifying the wire guides to minimize scuffing (which can cause scratches), enlarging the closure dies which press the annealed stranded wires against the steel core, and reducing the pressure of the closing dies. Even with these special stranding precautions, a degree of hardness is imparted to the aluminum conductor wires which requires careful attention, as the upper limits of the yield strength are prescribed at 8500 psi.
In addition to these uneconomical and difficult requirements and adjustments, extreme care must be exercised to protect the fully annealed wire 106 during the stranding step 108. That is, since the wire is dead soft, the surface is easily scratched or damaged; such scratches are an important cause of arcing and corona in the finished overhead transmission conductor cable. Special care and selection is required for overhead transmission cable intended for higher voltage service.
Of particular interest among the teachings of the '481 patent is that the product is to be subjected to only a single annealing step throughout the cable manufacturing process disclosed. The full anneal is to take place within the time frame illustrated at T11 of FIG. 4; i.e., after the drawing step 104 and before string-up 116 of the finished product is completed by placing it in regular service. Due to the deleterious effects of the high temperatures of the annealing process on the steel strand, the '481 patent teaches that the annealing step 108 is preferably performed within the time frame illustrated at T12 of FIG. 4, that is, after the drawing step 104 and before the special stranding step 112. It will be appreciated by those of ordinary skill in the art that a normal anneal occurring after stranding will negatively affect the performance characteristics of the steel strand.
These special manufacturing requirements add significantly to the cost of manufacturing this SSAC cable. No improvements in conductivity of the completed product are disclosed.
PRIOR ART EXAMPLES
Two samples of SSAC cable representing the prior art, as manufactured by the assignee of the '481, patent were obtained and submitted for analysis. One sample was SSAC 397 MCM (thousand circular mils) cross-sectional area and the other was SSAC 636 MCM cross-sectional area.
Several important standard characteristics of the conductor wires of each prior art cable sample were tested in accordance with accepted industry practice, including ultimate tensile strength, percent elongation, and conductivity. Several important characteristics of the steel strand core from the same SSAC prior art samples were also tested according to industry practices, including ultimate tensile strength, stress at 1 percent elongation, and percent elongation. The steel strands from both SSAC prior art sample cables conformed to ASTM Spec. B 606-79 for high strength steel core wire.
The 397 MCM sample was composed of six steel wires stranded over a single steel wire, a first inner layer of 8 round aluminum conductors, and a second layer of 14 round aluminum conductors. The conductor wire properties of the 397 MCM SSAC prior art example are given in Table I. Average values for the outer and inner layers of conductor wires are given, along with an average value of all 22 conductor wires. The electrical conductivity of each conductor wires was measured; the lowest- and highest-conductivity wires were both found in the outer layer, at 63.54% IACS to 63.92% IACS, respectively. Thus, the range of electrical conductivity variation among all conductor wires in the 397 MCM overhead transmission conductor cable was from 63.54% IACS to 63.92% IACS, or 0.38%.
The 397 MCM SSAC prior art sample steel strand wire properties are given in Table II; an average value for the steel strand outer layers is given as well as the inner strand value, along with an average of all 7 strands in the core.
The 636 MCM sample was composed of six steel wires stranded over a single steel wire, a first inner layer of 10 round aluminum conductors, and a second layer of 16 round aluminum conductors. The conductor and steel strand wire properties of the 636 MCM SSAC prior art sample are given in Tables III and IV, respectively. Average values for the outer and inner layers of conductor wires are given, along with an average value of all 26 conductor wires. The electrical conductivity of each conductor wires was measured; the lowest-conductivity wire was found in the inner layer, and the highest-conductivity wire was found in the outer layer, at 63.49% IACS to 63.74% IACS, respectively. Thus, the range of electrical conductivity variation among all conductor wires in the 636 MCM overhead transmission conductor cable was from 63.49% IACS to 63.74% IACS, or 0.25%.
TABLE I______________________________________SSAC 397 MCM Strand UTS.sup.2 % Elong'n ConductivityLayer Diameter.sup.1 (KSI) (10" Gage) (% IACS)______________________________________Outer (avg) 0.135 9.0 31.8 63.7Inner (avg) 0.135 8.9 28.4 63.8Overall (avg) 0.135 8.9 31.3 63.7______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE II______________________________________ Strand UTS.sup.2 Stress @ 1% % Elong'nLayer Diameter.sup.1 (KSI) Elong'n (KSI) (10" Gage)______________________________________Outer (avg) 0.074 245.1 231.2 4.5Core (avg) 0.074 246.2 230.3 4.3Overall (avg) 0.074 245.3 231.2 4.5______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE III______________________________________SSAC 636 MCM Strand UTS.sup.2 % Elong'nLayer Diameter.sup.1 (KSI) (10" Gage) (% IACS)______________________________________Outer (avg) 0.158 8.7 33.5 63.6Inner (avg) 0.158 8.6 33.3 63.6Overall (avg) 0.158 8.7 33.4 63.6______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE IV______________________________________ Strand UTS.sup.2 Stress @ 1% % Elong'nLayer Diameter.sup.1 (KSI) Elong'n (KSI) (10" Gage)______________________________________Outer (avg) 0.121 235.8 218.7 4.6Core (avg) 0.121 238.5 220.3 5.0Overall (avg) 0.121 236.2 218.9 4.6______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
The '481 patent recognizes that it is necessary to use fully annealed conductors in SSAC to permit high temperature operation, and also recognizes that a normal anneal occurring after the stranding process subjects the steel strand core to high temperatures known to negatively affect the service properties of the steel strand core. Therefore, the '481 patent teaches that the annealing step is preferably performed after drawing and before stranding, and that the stranding be carefully performed to avoid undesirable work hardening in the conductor wires.
It is therefore a primary object of this invention to provide an overhead transmission conductor cable that exhibits improved electrical conductivity and meets or exceeds the product characteristics for overhead transmission conductor cables without requiring the extraordinary stranding apparatus adjustments of the prior art manufacturing processes, thereby reducing manufacturing costs.
It is an object of the present invention to provide an improved aluminum overhead transmission conductor cable which exhibits surprising improved conductivity in combination with superior performance characteristics.
A further object of the present invention is to provide a method of manufacturing the improved overhead transmission conductor cable.
It is also an object of the present invention to provide a method of manufacturing the improved aluminum overhead transmission conductor cable without extraordinary, slow, and expensive processing requirements.
A feature of the cable of this invention is that it may easily be manufactured on conventional equipment at normal operating speeds, reducing costs.
Other characteristics of the cable produced according to this invention include improved self-damping, corrosion resistance, reduced electrical losses and greater current capacity for a given cable cross section, high temperature operation, reduced tension creep, and improved thermal-related sag resistance characteristics. An advantage of the present invention is significant material cost savings, consistent with a high quality cable product.
Another advantage of the present invention is that the novel overhead transmission conductor cable can be readily manufactured on conventional cable manufacturing equipment, requiring only the addition of a stress-relief/anneal step and equipment after the stranding operation is completed, which may be simply bypassed and not used when manufacturing other cable configurations on the same equipment line.
SUMMARY OF THE INVENTION
According to the present invention, an overhead transmission conductor cable is manufactured using essentially conventional process steps in order to produce a cable product of improved characteristics, and especially an unexpectedly improved high conductivity level.
Prior art SSAL overhead transmission conductor cables have a conductivity level of about 63% International Annealed Copper Standard (IACS). Overhead transmission conductor cable according to the present invention exhibits superior conductivity, generally exceeding 64% IACS. This conductivity level more closely approaches the theoretical aluminum conductivity limit of about 65% IACS. Because the conductivity is so nearly that of the theoretical maximum value attainable, the variation in conductivity values between individual wires is reduced compared to that of prior art cables of lower conductivity, thus providing improved uniformity among the conductor wires.
The improved high conductivity overhead transmission conductor cable manufacturing process generally includes the preliminary step of supplying a stranded steel core which meets applicable standards. The steel core strands may be covered with a protective coating, such as aluminum or zinc, in order to prevent undesirable deterioration of the steel core in the operating environment. An aluminum coating is preferred for reducing hysteresis losses and for improved higher temperature performance, especially in the heat-treating stages of manufacture.
Manufacture of the aluminum strands which overlie the steel core is accomplished as follows. First, 99.8% purity aluminum is selected to maximize the conductivity in the finished product. Raw aluminum metal of this purity is normally chosen to make electrical conductor grade products of, for example, only 62% IACS conductivity; since this material is readily available, it is selected for manufacture of the aluminum rod product from which the present conductor strands are to be made. The rod is preferably continuously cast and rolled normally to form a rolled rod product. The aluminum rod product is then fully annealed by conventional methods at an elevated temperature for a time period sufficient to assure recrystallization resulting in a reduction of the tensile strength to approximately 9.0 kilopounds per square inch (ksi).
The annealed rod is next formed to the desired size. It may, for example, be drawn to the desired size which introduces strain hardening, of a strength in the range of 20.0 ksi. The overhead conductor is formed of layers of wire which may have either a round or other cross section, including a trapezoidal cross section. When the conductor wires are formed of a trapezoidal cross section, the resulting cable diameter can be reduced for a given current capacity rating, increasing the ampacity rating of the overhead transmission conductor cable. Trapezoidal cross section wires have also been found to improve other service characteristics of the finished cable, including self-damping resistance to aeolian vibration and galloping, and creep.
Trapezoidal shaped wires may be formed by drawing or by preshaping round wire or rod with rollers in one or more reshaping steps. This reshaping may be performed in addition to cross section reduction by drawing. Such shaping operations normally take place prior to the stranding operation, but may be performed as a step relating to the stranding operation.
The stranding operation forms the aluminum conductor wires into at least one layer having a spiral twist, or lay, over the stranded steel cable which forms the core. One or more additional layers may be added until the cable construction is completed. The normal stranding operation adds a slight degree of work hardening due to the tensions and mechanical forces inherent in the stranding operation. Stranding is completed before the product is subjected to heat treatment.
As a result of hardening occurring before and during the drawing and stranding processes, the aluminum components of the cable are not at the desired "O" temper or dead soft condition following stranding. The overhead transmission conductor is therefore subjected to a stress-relieving/annealing heat treatment to produce a dead soft condition in the aluminum components. This must be accomplished without undesirably affecting the steel strand core or its protective coating.
Properly performed, these process steps will produce an aluminum overhead cable having a surprisingly high conductivity of about 64% IACS or greater, improved self damping, better corrosion resistance and high-temperature operation performance, accompanied by improved thermal-related sag, reduced tension creep, and increased fatigue resistance characteristics. Conductor wires produced accordingly exhibit more consistent conductivity levels with little variation among individual conductor wires.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present improved overhead transmission conductor cable will be more clearly appreciated from the following description of the preferred embodiment of the invention taken in conjunction with the accompanying drawing figures, in which like reference numerals indicate like elements, and wherein:
FIG. 1 is a perspective view of an overhead transmission conductor cable having round wire strands to illustrate a cable construction according to this invention, in which the outer conductor layers are selectively removed to show the cable structure;
FIG. 2 is a cross section view of another, similar overhead transmission conductor cable which has trapezoidal wire strands, illustrating a cable construction according to this invention;
FIG. 3 is a diagram which illustrates the processing step sequence of the present invention;
FIG. 4 is a diagram which illustrates the processing step sequence of a prior art process;
FIG. 5 is a diagram showing the conductor wire characteristics for the cable of the present invention with respect to stress relief time; and
FIG. 6 is a diagram showing the steel strand core wire characteristics for the cable of the present invention with respect to stress relief/anneal time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An overhead transmission conductor cable 10 of round wire is shown in FIG. 1 and an overhead transmission conductor cable 12 of trapezoidal wire is shown in FIG. 2. Except for the individual wire cross sections and the finished product ampacity characteristics, the processing steps are substantially identical. For clarity, both configurations are shown with round steel core wire strands; however, other steel core wire strand cross sections may be substituted as desired.
A stranded steel core 14 is required for support of the overhead transmission conductor cable 10, 12. The individual steel core strands may be covered with a protective coating 16, such as aluminum or zinc, in order to prevent undesirable deterioration of the steel core 14 in the intended operating environment. A common overhead transmission conductor configuration uses a central strand 18 and six peripheral strands (here illustrated generally as strand 20) of high tensile strength steel wire strand. For purposes of example only, when manufacturing 795 MCM overhead transmission conductor cable according to the present invention, a first strand 18 of aluminum or zinc coated steel wire having a diameter of about 0.135 inches, an ultimate tensile strength of at least 225 ksi exhibiting about 200 ksi at 1% elongation and about 3 to about 5 percent elongation (10-inch gage) may be used. Similar steel wires comprise the remaining strands 20, which are stranded with a twist along the length thereof as is known.
The electrically conductive aluminum portions of the overhead transmission conductor 10, 12 are formed from an aluminum or aluminum alloy rod 22. Such rod is preferably continuously cast and rolled in the known manner to form a rolled rod intermediate product of a size in the range of about 3/8-inch (10 millimeters) to about 1-inch (25 millimeters) in cross-sectional diameter. Continuously cast and rolled rod and the manufacturing processes therefore are well known. The aluminum metal raw material for the rolled rod is selected to ensure sufficient conductivity in the finished overhead transmission conductor cable products according to this invention, and especially for products characterized by high conductivity of 64% International Annealed Copper Standard (IACS) minimum conductivity specification. This rod 22 may be produced from ingots having an analysis according to TABLE V:
TABLE V______________________________________ELEMENT WEIGHT PERCENT (MAXIMUM)______________________________________Iron 0.13Silicon 0.06Manganese.sup.1 0.003Titanium.sup.1 0.005Vanadium.sup.1 0.008Zinc 0.03Gallium 0.03Copper 0.002Chromium.sup.1 0.002Nickel 0.003Aluminum.sup.2 99.80______________________________________ .sup.1 Total of manganese, titanium, vanadium, and chromium not to exceed 0.015 weight percent. Total of all trace elements other than silicon, iron, and nickel not to exceed 0.08 weight percent. .sup.2 Minimum weight percent.
Deviations from the analysis presented in Table V may be tolerated and still produce an acceptable conductivity level in the finished rod product; however, it is preferred that the ingot analysis be restricted to the above analysis.
The finished aluminum rod product 22 is then annealed at step 24 by conventional methods at an elevated temperature for a time period sufficient to assure recrystallization resulting in a reduction of the tensile strength to approximately 90 ksi or less in the annealed rod 26. The rod is to be fully annealed, or dead soft. The annealing step 24 occurs within the time frame identified as T1 in FIG. 3; that is, before drawing in step 28.
The annealed rod 26 is next drawn to a desired size in a drawing process step 28 to introduce strain hardening in the wire, producing a wire 30 of a strength in the range of about 20 ksi. The preferred drawing process step may include multiple individual steps of drawing the wire to the desired size; these individual drawing steps are collectively called the "drawing step" 28 herein. Either round conductor wires 32 or trapezoidal conductor wires 34 may be used, as desired.
When the overhead conductor 12 is formed of one or more layers of wire having a trapezoidal cross section as in FIG. 2, shaping must occur in addition to cross section reduction by the drawing process step 28. This shaping operation normally takes place in conjunction with the drawing step 28 prior to the stranding operation. However, trapezoidal wire 34 may also be formed in a separate rolling step (not shown), or as an initial step 36 of the stranding operation by rolling.
In the stranding operation at step 36, the conductor wires 30, which can be in the shape of either round or trapezoidal conductor wires 32, 34 (respectively) are formed into at least one layer 38 having a spiral twist, or lay, over the stranded steel cable 14 which forms the core. One or more additional layers 40 et cetera are added until the full overhead transmission conductor cable 10, 12 construction is completed.
It will be appreciated by those of ordinary skill in the art that the cross-sectional width and side to bottom angles of the trapezoidal wires 34 are closely related to the inner and outer diameters of the lays.
Subjecting the conductor wires 32, 34 to the stranding step 36 adds a slight degree of strain-hardening due to the tensions inherently induced by and necessary in the normal stranding operation, and to any work hardening resulting therefrom. Stranding is completed before adjusting the conductors to their final condition of temper.
As a result of hardening occurring before and during the stranding process step 36, it is necessary to subject the aluminum components of the cable 10, 12 to a stress-relieving/annealing heat treatment (step 42) at moderate temperatures to produce a "O" temper, dead-soft condition in the aluminum components. Since the aluminum components enclose the steel strand core 14, this step must be accomplished at temperatures which do not undesirably affect the steel strand core 14 or its protective coating 16.
Applicants prefer that the stress-relieving/annealing treatment step 42 be performed at about 600 degrees F. for zinc coated steel strand for a period of about six to about 14 hours, and preferably from about 6 to about 10 hours. The stress-relief/anneal treatment 42 can be performed at a temperature as high as about 800 degrees F. for the same periods for aluminum coated steel strand. Exercise of due care is necessary to avoid deleterious effects of these high temperatures on the steel material or the steel coatings. The stress-relieving/annealing step 42 must be performed within the time frame T2 (FIG. 4) between stranding 36 and string-up 44, and may be performed before a reeling or coiling step as occurs in preparing the 35 product for shipment.
The present invention comprehends a lower temperature stress-relieving/annealing heat treatment at this stage, rather than performing a full, higher temperature annealing step at this time, as is taught by the prior art.
After the overhead transmission conductor cable 10, 12 is successfully heat treated, it may be delivered to the field on reels (not shown) ready for the stringing up step, 44.
Properly performed, these process steps will produce an aluminum overhead transmission conductor cable 10, 12 having a surprisingly high conductivity of about 64% IACS or greater. Other characteristics of the cable 10, 12 produced according to the invention disclosed include improved corrosion resistance, reduced electrical losses and greater current capacity for a given cable cross section, high temperature operation, reduced tension creep, improved thermal-related sag, self-damping, and fatigue resistance characteristics.
TEST SAMPLES
Samples of a 795 MCM overhead transmission conductor cable made according to the present invention were submitted for testing. The conductor wires of the respective cable samples were drawn from annealed rod and stranded thereafter. Round conductor wires were used in the manufacture, and stranded under normal circumstances before being subjected to a stress-relieving/annealing heat treatment. In this first example, the overhead transmission conductor cable was subjected to a stress-relieving/annealing heat treatment The 795 MCM samples were identical except for heat treatment processes to which they were subjected. The sample were composed of six steel wires stranded over a single steel wire, a first inner layer of 10 round aluminum conductors, and a second layer of 16 round aluminum conductors. The conductor wire properties of the cables are discussed below.
The 795 MCM overhead transmission conductor cable sample steel strand wire properties are also given below. An average value for the steel strand outer layers is given as well as the inner strand value, along with an average of all 7 strands in the core.
EXAMPLE 1
A first sample of 795 MCM cable made according to the present invention was submitted for analysis according to accepted industry practices. Several important characteristics of the conductor wires were tested, including ultimate tensile strength, percent elongation, and conductivity. Important characteristics of the steel strand core were tested according to industry practices as well, including ultimate tensile strength, stress at 1 percent elongation, and percent elongation.
In this first example, the overhead transmission conductor cable was subjected to a stress-relieving/annealing heat treatment at 600 degrees F. for a period of 6 hours.
The aluminum conductor strands of the as-stranded cable exhibited properties consistent with wire drawn from annealed rod. The conductor wires were fully annealed. Electrical conductivity was determined for each of the conductor wires; the range of variation in electrical conductivity among all conductor wires in the sample was extremely small: from 64.0% IACS to 64.1% IACS, or 0.1%. The conductor wire properties of this first example are given in Table VI. Average values for the outer and inner layers of conductor wires are given separately, along with an overall average value of all the conductor wires. Similarly, the steel strand wire properties are given in Table VII.
TABLE VI______________________________________ Strand UTS.sup.2 % Elong'n ConductivityLayer Diameter.sup.1 (KSI) (10" Gage) (% IACS)______________________________________Outer (avg) 0.174 8.9 33.5 64.1Inner (avg) 0.174 8.9 33.3 64.1Overall (avg) 0.174 8.9 33.4 64.1______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE VII______________________________________ Strand UTS.sup.2 Stress @ 1% % Elong'nLayer Diameter.sup.1 (KSI) Elong'n (KSI) (10" Gage)______________________________________Outer (avg) 0.135 240.6 217.1 4.8Core (avg) 0.135 237.1 214.4 4.5Overall (avg) 0.135 240.1 216.7 4.8______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
EXAMPLE 2
A second sample of the same 795 MCM overhead transmission conductor cable material made according to the present invention was subjected to a heat treatment at 600 degrees F. for a period of 10 hours, and submitted for standard analysis. The same important characteristics of the conductor wires and of the steel strand core were tested in the second sample as well.
The aluminum conductor strands of the as-stranded cable exhibited properties consistent with wire drawn from annealed rod in the second sample as well; the conductor wires were fully annealed. Electrical conductivity was again determined for each of the conductor wires; the range of variation in conductivity among all conductor wires in the sample was again extremely small: from 64.0% IACS to 64.1% IACS, or a range of only 0.1%. The conductor wire properties of this second sample are given in Table VIII. Average values for the outer and inner layers of conductor wires are given separately, along with an overall average value of all the conductor wires. Similarly, the steel strand wire properties are given in Table IX.
TABLE VIII______________________________________ Strand UTS.sup.2 % Elong'n ConductivityLayer Diameter.sup.1 (KSI) (10" Gage) (% IACS)______________________________________Outer (avg) 0.174 8.9 33.1 64.1Inner (avg) 0.174 8.8 34.1 64.1Overall (avg) 0.174 8.8 33.5 64.1______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE IX______________________________________ Strand UTS.sup.2 Stress @ 1% % Elong'nLayer Diameter.sup.1 (KSI) Elong'n (KSI) (10" Gage)______________________________________Outer (avg) 0.135 239.0 215.3 5.0Core (avg) 0.135 237.0 212.7 5.0Overall (avg) 0.135 238.7 215.0 5.0______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
EXAMPLE 3
A third sample of 795 MCM overhead transmission cable made according to the present invention was subjected to a heat treatment at 600 degrees F. for a period of 14 hours, and submitted for standard analysis. The same important characteristics of the conductor wires and of the steel strand core were tested.
The aluminum conductor strands of the third sample of as-stranded cable exhibited properties consistent with wire drawn from annealed rod as in the first and second samples; the conductor wires were fully annealed. Electrical conductivity was determined for each of the conductor wires; the range of variation was again extremely small; from 64.0% IACS to 64.1% IACS, or a range of only 0.1%. The conductor wire properties of this third sample are given in Table X. Average values for the outer and inner layers of conductor wires is given separately, along with an overall average value of all the conductor wires. Similarly, the steel strand wire properties are given in Table XI.
TABLE X______________________________________ Strand UTS.sup.2 % Elong'n ConductivityLayer Diameter.sup.1 (KSI) (10" Gage) (% IACS)______________________________________Outer (avg) 0.174 8.9 33.1 64.1Inner (avg) 0.174 8.9 34.9 64.1Overall (avg) 0.174 8.9 33.8 64.1______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
TABLE XI______________________________________ Strand UTS.sup.2 Stress @ 1% % Elong'nLayer Diameter.sup.1 (KSI) Elong'n (KSI) (10" Gage)______________________________________Outer (avg) 0.135 241.2 217.1 4.9Core (avg) 0.135 237.2 213.1 5.5Overall (avg) 0.135 240.7 216.5 5.0______________________________________ Notes: .sup.1 Diameter in inches. .sup.2 Ultimate tensile strength.
FIGS. 5 and 6 reflect the data derived from testing of the above-three samples, illustrating the effects of the stress-relief/anneal heat treatment on the conductor wires and the steel strands of the core.
FIG. 5 shows that the conductors wires of all three samples substantially fully reached their respective end values at the six-hour point according to Examples 1-3, with little or no change through a 14-hour stress-relief/anneal heat treatment. The conductor wires reached the 64.1% IACS conductivity level and retained this level after the full stress-relief/anneal period prescribed, i.e., 14 hours. FIG. 5 also reveals that all three samples were substantially unaffected in their ultimate tensile strength when subjected to a stress-relief/anneal heat treatment of from about six to about 14 hours.
FIG. 6 shows that the steel strands varied insubstantially in ultimate tensile strength and stress at 1 percent elongation, while elongation percentage increased slightly depending on the duration of the stress relief treatment.
Although only preferred embodiments are specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention.
|
An electrical overhead transmission conductor cable having a steel reinforcing core which exhibits improved characteristics and unexpected conductivity above about 64% IACS is manufactured of a steel core covered by at least one stranding layer which is formed of round or trapezoidal shaped wire strands subjected to annealing before heat treatment and drawn and stress-relieved/annealed after stranding is completed, to provide a finished cable which includes an aluminum conductive portion which is dead soft, or "O" temper. The steel core of the cable carries substantially the entire tension load of both the core and conductors when suspended between vertical towers. The overhead transmission cable may be formed of trapezoidal cross section conductors wires for improved vibration performance characteristics.
| 8
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a color mask for an image sensor of a vehicle camera.
[0003] 2. Description of Related Art
[0004] For switching between low beam and high beam of a vehicle, automatic switching systems are known in which a vehicle camera detects whether other vehicles or road users are present in a relevant range ahead of the vehicle and the headlights are automatically switched between high beam and low beam as a function of this detection. The cameras generally have sensors including a color mask which enable a color differentiation, in particular a red/white differentiation, in order to detect the generally red taillights and the generally white low beams and high beams of other vehicles and to differentiate between them. For example, it should be possible to distinguish a low red light from a white reflection on another object, e.g., a traffic sign.
[0005] One of the greatest difficulties in implementing the red/white differentiation is the size of the light sources, since the light sources are generally only displayed on one sensor pixel. Due to the color mask, one is thus reliant on a moving light source for implementation, which illuminates different pixels with different colors based on the movement.
[0006] Standard Bayer pattern masks are generally used as color masks in which every second filter pixel of the color mask is green, these green filter pixels being situated distributed alternatingly in a chessboard pattern across the matrix arrangement of the filter pixels. Blue and red filter pixels are situated in the other matrix areas, with rows having green and blue pixels and rows having red and green pixels alternating. This standard Bayer pattern mask enables a complete color differentiation, i.e., interpretation into the colors red, blue, and green. However, the reduction of the high-sensitivity resolution by the factor 2 as opposed to that of a monochrome image sensor is disadvantageous. Moreover, reduced filter masks are known in which some color pixels of this standard Bayer pattern are omitted and thus transparent pixels remain in their place, thereby increasing the high-sensitivity resolution.
[0007] Japanese patent document JP 2004304706 A shows a color filter having green, white, red, and blue color filter segments, of which the white segments, used for a luminescence signal, occupy every other matrix area in a chessboard pattern and the color segments occupy the remaining half of the matrix areas. Rows having white and green segments and rows having white, red, and blue segments alternate, so that two blue segments and two red segments are situated diagonally opposite on the corners of each green segment. Moreover, an interpolation method for analyzing the image signals, which are recorded using such a color mask, is described.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is based on the idea of providing a color mask or filter mask having only two different filter pixels which are offset to each other in the rows and/or columns of the matrix arrangement.
[0009] In a specific example embodiment, the first filter pixels have a red transmission characteristic and the second filter pixels have a broader transmission characteristic including the red spectral range and additional spectral ranges. In this case, the second filter pixels may be completely transparent, in particular in the optical range.
[0010] According to the present invention, a filter pixel or filter segment is referred to as a red filter pixel which is transparent to light in the red wavelength range and essentially non-transparent to other wavelength ranges. A filter pixel or filter segment is referred to as a transparent filter pixel which is transparent to light in a wider wavelength range and thus essentially appears transparent or white in the optical range; it therefore allows a luminescence signal in which the total luminosity is measured. When applying the color mask, the mask for the transparent filter pixels may thus be omitted, so that a process step is not necessary here and complete transparency is achieved.
[0011] By providing only transparent and red filter pixels according to the present invention, the filter pixels to be used for detecting a low beam or a high beam or a taillight may have a high-sensitivity resolution as opposed to an image sensor without a color mask having a resolution reduction of only approximately 1.5, for example.
[0012] According to the present invention, this is based on the findings that pitching motions in particular, i.e., pivoting motions (rotations) about the transverse axis, as well as yawing motions, i.e., pivoting motions (rotations) about the vertical axis, occur in a vehicle. Pitching motions occur in particular during braking and accelerating processes and due to road bumps; yawing motions occur in particular due to greater or also smaller steering actions. In particular, the relative motion between the vehicle having the camera according to the present invention and the object to be detected is relevant here, so that a relative yawing motion may also occur during straight-line driving with respect to an object situated offset to the lane of the vehicle, e.g., a vehicle traveling in the oncoming lane.
[0013] In this case, pitching motions correspond to a migration of the detected light source in the vertical direction on the matrix arrangement, i.e., along the columns. A yawing motion corresponds to the migration of the dot along a horizontal row of the matrix arrangement. An optical system, situated in the camera in front of the sensor, possibly generates an inversion of the directions, i.e., right and left as well as up and down; however, this is not relevant for the principle of the present invention to detect horizontal yawing motions and vertical pitching motions.
[0014] As a typical case, the occurrence of pure pitching motions is detected in the vehicle. For this purpose, a matrix arrangement is created in which red filter pixels are situated in each column, e.g., as each fourth pixel in each column, consecutive columns being preferably offset to one another. Purely transparent rows may similarly also result here, since they are irrelevant for detecting a pitching motion. A pitching motion may thus be relatively reliably detected, even in the event of a relatively small number of red color pixels.
[0015] According to a further embodiment, pure yawing motions may be detected, for which the red filter pixels are situated in all rows, preferably again offset to one another, i.e., in consecutive rows at spots offset to one another.
[0016] For detecting yawing motions as well as pitching motions, an offset of the red filter pixels by rows and columns may take place, so that, for example, a chessboard-pattern of red and transparent pixels may result in which transparent and red pixels, alternating in the columns direction and the rows direction, are provided; however, a resolution loss by a factor of 2 may occur as opposed to an image sensor without a color mask. A lesser number of red pixels may correspondingly be provided in this specific embodiment.
[0017] According to the present invention, other embodiments than red/transparent may basically also be selected. In particular, a narrower transmission spectrum, i.e., a colored filter pixel such as also blue, yellow or green or mixed colors, may be combined with a broader transmission spectrum, transparent in particular. Furthermore, two spectral ranges, which overlap only partially or not at all, may also be selected.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0018] FIG. 1 shows a top view onto a road scene of a vehicle having a camera.
[0019] FIG. 2 shows a camera system in the vehicle having an image sensor and a color mask in a side view and a lateral section.
[0020] FIG. 3 shows a color mask according to a first example embodiment for detecting pitching motions in particular.
[0021] FIG. 4 shows a color mask according to a second example embodiment for detecting yawing motions in particular.
[0022] FIG. 5 shows a color mask according to a third example embodiment for detecting different motions.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A vehicle 1 having a camera 2 travels on a lane 3 . In detection range 4 of camera 2 , different objects O 1 , O 2 , O 3 situated on and outside lane 3 are detected. According to FIG. 2 , camera 2 is installed behind a window 5 of vehicle 1 , in particular windshield 5 and has, in addition to optics 6 (not shown in detail), an image sensor 7 having a matrix arrangement of sensor pixels and a color mask (filter mask) 8 , attached to image sensor 7 , of which different specific embodiments are shown in FIGS. 3 through 5 . Image sensor 7 gathers the optical light incident through color mask 8 and outputs image signals S 1 to control and analyzer device 9 which is then able to carry out an analysis in appropriate high-sensitivity resolution, whereupon appropriate warning messages may be issued if needed or also direct interventions in the vehicle management system may take place.
[0024] Color mask 8 has a matrix arrangement of filter pixels m ij with i=1, 2, . . . and j=1, 2, . . . , a 4×7 matrix being shown in FIGS. 3 through 5 for the sake of simplifying the illustration. Filter pixels m ij filter the incident light and let light in a predefined wavelength range pass. According to the shown specific embodiments, filter pixels m ij are either completely (or essentially completely) transparent for optical light; such filter pixels m ij are indicated as C (clear) and are thus transparent or “white,” or, as red filter pixels, let essentially only red light pass and are indicated by R.
[0025] Each filter pixel m ij is placed, e.g., glued, directly in front of an image sensor pixel; the distance between image sensor 7 and color mask 8 in FIG. 2 is only shown for the sake of clarity. Matrix arrangement m ij has horizontal rows l 1 , l 2 , l 3 , l 4 and vertical columns k 1 , k 2 , k 3 , . . . . The horizontal direction of rows li thus corresponds to horizontal direction h in FIG. 1 ; the direction of vertical columns k j corresponds to vertical direction v in FIG. 2 .
[0026] According to the present invention, small light sources of objects O 1 , O 2 , O 3 are also taken into account which are displayed on only one image sensor pixel. Due to the motion of vehicle 1 and/or objects O 1 , O 2 , O 3 , the respective light source sweeps over multiple pixels on the image sensor matrix and the attached color matrix m ij . During a pitching motion of vehicle 1 , i.e., a rotation about its transverse axis, camera 2 is panned in vertical direction v, so that object O 1 , O 2 , O 3 , recognized as a light source, moves in the direction of columns kj; during a yawing motion, i.e., a rotation of the vehicle about its vertical axis (yaw axis), i.e., parallel to lane 3 in horizontal direction h in FIG. 1 , the light source signal of objects O 1 , O 2 , O 3 thus moves in the horizontal direction, i.e., along a row li.
[0027] The specific embodiment in FIG. 3 shows a color matrix arrangement in which three of four pixels are transparent and each fourth pixel is red, red filter pixels R being situated in all columns kj. Purely transparent rows 11 , 13 preferably alternate here whose filter pixels M 1 j and m 3 j are for all j=1, 2, 3 . . . C, and rows l 2 , l 4 , lying in between, in which red and transparent filter pixels alternate, i.e., m 21 =m 23 =m 25 =m 27 =R and m 22 =m 24 =m 26 =C, for example.
[0028] The specific embodiment in FIG. 3 is particularly suitable for covering pure pitching motions of vehicle 1 , i.e., a motion of camera 2 in the vertical direction or columns direction. Since vehicles typically experience pitching motions, in particular during accelerating and braking, as well as due to road bumps, the respective object O 1 , O 2 , O 3 will sweep over multiple sequential filter pixels mij and thus also over one red filter pixel R even when displayed only on one pixel in the respective column kj.
[0029] In contrast to a reduced Bayer pattern color matrix, which has purely transparent columns, it is possible, at the same high-sensitivity resolution using a surprisingly simple measure—namely the offset placement of red filter pixels R—to increase substantially in typical pitching motions the reliability of distinguishing a red light from a white reflection. In contrast to a full RGB Bayer pattern, only a resolution reduction by a factor of approximately 1.5 occurs.
[0030] In the specific embodiment in FIG. 4 , red filter pixels R are provided in all rows ki. Purely transparent columns k 9 , k 11 , k 13 preferably alternate here with combined, i.e., transparent/red columns k 8 , k 10 , k 12 , k 14 in which a red filter pixel R and a transparent filter pixel C are situated in an alternating manner. Here again, three out of four pixels are transparent and each fourth pixel is red, i.e., at the same physical high-sensitivity resolution as in FIG. 3 .
[0031] During a yawing motion in which the camera pans in horizontal direction h, also a small light source is detected by transparent as well as red pixels.
[0032] FIG. 5 shows a combined specific embodiment in which red filter pixels R and transparent pixels C alternate in the columns and the rows direction, so that a chessboard pattern of R and C results. This pattern may cover pure yawing and pitching motions, as well as combined motions; however, a resolution lost by the factor 2 occurs compared to a sensor 7 without a color mask.
[0033] Control and analyzer device 9 may thus compare the intensities of image signals S 1 with transparent filter pixels (luminescence signal) and red filter pixels and ascertain from the result whether the image of a light source moving across the matrix arrangement has white or red light.
|
A color mask for an image sensor of a vehicle camera has a matrix arrangement made up of first filter pixels and second filter pixels. In every horizontal row and/or every vertical column, first filter pixels and second filter pixels are situated, the first filter pixels and the second filter pixels having different transmission behaviors. The second filter pixels have a more comprehensive transmission behavior, e.g., completely transparent to optical light. The first filter pixels are preferably red.
| 7
|
FIELD OF THE INVENTION
The present invention relates to diaminopyridine dyes for cellulose-containing fibers, and more particularly, to reactive diaminopyridine dyes for dyeing cellulose-containing fibers, particularly cellulose fibers and polyester-cellulose fibers in from orange to bluish red having excellent fastness to light, etc.
SUMMARY OF THE INVENTION
The present invention relates to diamino-pyridine dyes for cellulose-containing fibers, represented by the general formula (I): ##STR2##
X is hydrogen or a halogen atom;
Y is an alkoxy group containing from 1 to 5 carbon atoms, --O--R 10 --O--R 11 , or a phenoxy; and
n is 2 or 3 (wherein R 1 is a nitro group, a cyano group, a methylsulfonyl group, a phenylsulfonyl group, a mono- or dilower alkylaminosulfonyl group, an acetyl group, or a benzoyl group; R 2 and R 3 are each a hydrogen atom, a trifluoromethyl group, a halogen atom, or a cyano group; R 4 is a hydrogen atom, a lower alkyl group, a mono or dilower alkylaminosulfonyl group, a mono- or di-lower alkylcarbamoyl group, or an acetylamino group; R 5 and R 6 are each a hydrogen atom, a halogen atom, or a lower alkyl group; R 7 is a lower alkyl group; R 8 is a trifluoromethyl group, or a halogen atom; R 9 is a hydrogen atom, or a halogen atom; R 10 is an ethylene group, or a propylene group; and R 11 is a methyl group, or an ethyl group).
DETAILED DESCRIPTION OF THE INVENTION
The dyes represented by the general formula (I) can be easily prepared, for example, by reacting the compounds represented by the general formula (IV): ##STR3## (wherein D, X and n are the same as described for the general formula (I)) with the compounds represented by the general formula (V): ##STR4## (wherein Y is the same as described for the general formula (I)) in N-methyl-2-pyrrolidone.
Halogen atoms indicated by X, R 2 , R 3 , R 5 , R 6 , R 8 and R 9 in the general formulae (I) and (IV) include a fluorine atom, a chlorine atom, and a bromine atom.
Lower alkyl groups indicated by R 4 , R 5 , R 6 and R 7 include a methyl group, an ethyl group, and straight or branched alkyl groups containing from 3 to 4 carbon atoms.
Mono- or di-lower alkylaminosulfonyl groups indicated by R 1 and R 4 include a methylaminosulfonyl group, an ethylaminosulfonyl group, an isopropylaminosulfonyl group, an isopropylaminosulfonyl group, an n-propylaminosulfonyl group, an n-butylaminosulfonyl group, a sec-pentylaminosulfonyl group, an n-hexylaminosulfonyl group, a dimethylaminosulfonyl group, a diethylamino-sulfonyl group, and a di(n-propyl)aminosulfonyl group.
Mono- or di-lower alkylcarbamoyl groups indicated by R 4 include a methylcarbamoyl group, an ethylcarbamoyl group, an isopropylcarbamoyl group, an n-butylcarbamoyl group, an n-propylcarbamoyl group, a sec-pentylacarbamoyl group, an n-hexylcarbamoyl group, a dimethylcarbamoyl group, and a di(n-propyl)carbamoyl group.
In preparing the diaminopyridine dyes represented by the general formula (I), the azo compounds represented by the general formula (IV) are reacted with the difluorotriazines represented by the general formula (V), the molar ratio of the difluorotriazine to the azo compound being from 1.0 to 1.2, in an organic solvent, e.g., acetone, methyl ethyl ketone, dioxane, N,N-dimethylformamide, N-methyl-2-pyrrolidone, and dimethyl sulfoxide, at a temperature of from 0° C. to room temperature.
In this case, if necessary, a tertiary amine, e.g., triethylamine and tributylamine, can be used as an acid binding agent.
A precipitate formed on discharging the above obtained reaction solution into water is separated by a technique, such as filtration and centrifugal separation. Thus, the diaminopyridine dyes of the general formula (I) can be obtained.
Cellulose-containing fibers which are dyed by the diaminopyridines of the invention include natural fibers, e.g., cotton and jute, semi-synthetic fibers, e.g., viscose rayon and copper-ammonia rayon, partially aminated or acylated cellulsoe fibers, and their fabrics, e.g., woven fabrics and unwoven fabrics, and so forth.
In addition, mixed fibers of the above described fibers with other fibers such as polyester fibers, cation dyeable polyester fibers, anion dyeable polyester fibers, polyamide fibers, wool, acryl fibers, urethane fibers, diacetate fibers, and triacetate fibers, and their fabrics can be dyed. Of the above described fibers and fabrics, cellulose fibers, mixed fibers of cellulose fibers and polyester fibers, and their fabrics are particularly suitable for dyeing with the diaminopyridine dyes of the invention.
In the practice of dyeing using the diaminopyridine dyes of the invention, it is preferred for the dyes to be finely dispersed in a medium to the extent that the particle size is from about 0.5 to 2μ. This can be achieved by various techniques such as a method in which a water-soluble dispersant, such as a nonionic, e.g., Pluronic, surface active agent, or an anionic dispersant, e.g., sodium ligninsulfonate, and a sodium salt of a naphthalenesulfonic acid-formalin condensate, is used and the dye is dispersed finely in water by the use of a grinder, such as a sand grinder and a mill; a method in which a water sparingly soluble or water-insoluble dispersant, e.g., compounds derived by addition of small moles of ethylene oxide to sulfosuccinic acid esters, nonylphenol or the like, is used, and the dye is dispersed in a solvent other than water, such as alcohols, e.g., ethyl alcohol, isopropyl alcohol, and polyethylene glycol, ketones, e.g., acetone, and methyl ethyl ketone, hydrocarbons, e.g., n-hexane, toluene, xylene, and mineral turpentine, halogenated hydrocarbons, e.g., tetrachloroethylene, esters, e.g., ethyl acetate and butyl acetate, ethers, e.g., dioxane, and tetraethylene glycol dimethyl ether, or mixtures thereof; and a method in which the dye is dispersed finely in a mixed solvent of water and a solvent compatible with water in any proportion, selected from the above described solvents.
At the step of finely dispersing the diaminopyridine dyes of the invention, polymeric compounds soluble in the dispersants, surface active agents which have mainly functions other than the dispersion action, and so forth can be added.
This fine dye dispersion can be used as such as a padding bath for use in a padding dyeing method, or as a printing color paste for use in a printing method. In practical use, however, the fine dye dispersion is diluted with water, a mixed solvent of water and a solvent compatible with water in any proportions, or an o/w type emulsion or w/o type emulsion in which the oil phase is a petroleum hydrocarbon, e.g., mineral turpentine, or a halogenated hydrocarbon, e.g., tetrachloroethylene, to the desired level determined depending on the desired dyeing concentration and, thereafter, is used as a padding bath or a printing color paste.
In the preparation of such padding baths and printing color pastes, it is possible to add cellulose fiber swelling agents in order to advantageously perform dyeing, or to add alkali metallic compounds, organic epoxy compounds, organic vinyl compounds, etc., as acid binding agent for the purpose of accelerating the reaction between the dyes and the cellulose fibers.
Alkali metallic compounds which can be used include alkali metal carbonic acid salts and, additionally, alkali metal aliphatic acid salts, such as alkali metal hydrocarbonic acid salts, alkali metal phosphoric acid salts, alkali metal boric acid salts, alkali metal silicic acid salts, alkali metal hydroxides, and alkali metal acetic acid salts, and alkali precursor compounds, such as sodium trichloroacetate and sodium acetoacetate, which release alkalis when heated in the presence of water.
The amount of the alkali metallic compound being used is usually sufficient to be such that the pH of the padding bath or printing color paste becomes from 7.5 to 8.5. Organic epoxy compounds which can be used include ethylene glycol diglycidyl ether, and polyethylene glycol diglycidyl ether having an average molecular weight of from 150 to 400. Organic vinyl compounds which can be used include ethylene glycol diacrylate, and polyethylene glycol diacrylate or dimethacrylate having an average molecular weight of from 150 to 400. The amount of the organic epoxy compound or organic vinyl compound used is from about 3 to 6% by weight based on the padding bath or printing color paste.
In order to prevent dry migration in the course of padding dyeing, or to regulate the color paste viscosity to the optimum level in each printing method, a tackifier, such as a water-soluble polymer, e.g., sodium alginate, may be added.
The preparation of the padding bath or printing color paste is not limited to the above described procedure. Also, it is not always required for the cellulose swelling agent or acid binding agent to be present in the padding bath or printing color paste, and the cellulose swelling agent or acid binding agent may be incorporated into the fibers in advance.
Any cellulose fiber swelling agents can be used as long as they have a boiling point of at least 150° C. and have the effect of swelling the cellulose fibers. Examples of such cellulose fiber swelling agents include ureas such as N,N,N',N'-tetramethylurea, polyhydric alcohols such as polyethylene glycol and polypropylene glycol, and their derivatives. Of these compounds, polyhydric alcohol derivatives which are prepared by dimethylating or diacetylating both terminal hydroxy groups of polyethylene glycol, polypropylene glycol, or the like having an average molecular weight of from about 200 to 500 and which are inactive with reactive groups of dye are particularly preferred as cellulose fiber swelling agents.
The amount of the cellulose fiber swelling agent being used is appropriately from about 5 to 25% by weight, preferably from about 8 to 15% by weight, based on the padding bath or printing color paste.
Dyeing of the above-described cellulose-containing fibers using the diaminopyridine dyes of the invention can be performed by the usual techniques. For example, a cellulose-containing fiber material is impregnated or printed with a padding bath or printing color paste as prepared by the above described method and dried and, thereafter, it is heat-treated with hot air or superheated vapor maintained at 160 to 220° C. for 30 seconds to 10 minutes, or in high pressure saturated steam maintained at 120° to 150° C. for 3 to 30 minutes, and washed with hot water containing a surface active agent, or an o/w or w/o type emulsion washing bath in which the oil phase is a halongenated hydrocarbon, such as tetrachloroethylene, or by a usual dry cleaning method.
Thus there can be obtained dyed products which are dyed sharply and uniformly, and which have good light fastness and wet color fastness.
The following examples are given to illustrate the invention in greater detail. All parts are by weight.
EXAMPLE 1
A dye composition consisting of 15 parts of disazo dye represented by the formula: ##STR5## 15 parts of a naphthalenesulfonic acid-formaldehyde condensate, and 70 parts of water was processed by the use of a paint shaker as a finely dispersing apparatus to prepare a dye dispersion.
The dye dispersion thus prepared was used to prepare a printing color paste having the following composition.
______________________________________ parts______________________________________Dye dispersion 6.55% Aqueous solution of sodium alginate 55Polyethylene glycol dimethyl ether 9having an average molecular weightof 400Water 29.5 100 (pH 8.0)______________________________________
The printing color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printing machine, was subjected to preliminarily drying at 80° C. for 3 minutes and then, was fixed by dry heating at 215° C. for 90 seconds. After being washed with water, the printed cloth was subjected to soaping using a washing solution containing 2 g/liter of a nonionic surface active agent (Scourol #900 (trade name, produced by Kao Soap Co., Ltd.) at a bath ratio of 1:30 at 80° C. for 20 minutes, and there was thus obtained a dyed product which was yellowish red having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows:
4-Aminoazobenzene was diazonated by the usual method and coupled to 2-anilino-3-cyano-4-methyl-6-(β-aminoethylamino)pyridine to prepare a dye. Then, 4.75 g of the dye was dissolved in 80 ml of N-methyl-2-pyrrolidone, and 1.9 g of 2,4-difluoro-6-methoxytriazine and 1.2 g of triethylamine were added thereto and stirred at 0° to 5° C. for 3 hours. The reaction solution was added dropwise to 1,500 ml of water, and the thus obtained precipitate was separated by filtration and dried under reduced pressure to obtain 5.9 g of yellow red powdery compound represented by the above-described formula. For this dye, λ max (acetone) was 490 nm.
EXAMPLE 2
A dye composition consisting of 15 parts of monoazo dye represented by the formula: ##STR6## 10 parts of Pluronic surface active agent (Pluronic L 64 (trade name), produced by Asahi Denka Co., Ltd.), and 75 parts of water was processed by the use of a sand grinder as a finely dispersing apparatus to prepare a dye dispersion. The dye dispersion thus prepared was used to prepare a printing color paste having the following composition:
______________________________________ parts______________________________________Dye dispersion 75% Aqueous solution of sodium alginate 55Polyethylene glycol diacetate having 10an average molecular weight of 300Polyethylene glycol diglycidyl ether 3having an average molecular weightof 200Water 25 100 (pH 6.5)______________________________________
The thus prepared printing color paste was printed on a cotton broad cloth (cotton yarn number: 40) which has been subjected to a silket processing, by the use of a screen printing machine, was subjected to preliminarily drying at 80° C. for 3 minutes, and was processed using superheated steam at 185° C. for 7 minutes.
Thereafter, the same washing processing as in Example 1 was performed, and there was thus obtained a reddish brown dyed product having excellent light fastness and wet color fastness.
The dye used in this example was prepared as follows:
1-Aminoanthraquinone was diazonated by the usual method and coupled to 2-anilino-3-cyano-3-cyano-4-methyl-6-(β-aminoethylamino)pyridine to prepare a dye. The thus prepared dye was then reacted with 2,4-difluoro-6-methoxytriazine by the use of tri-n-butylamine as an acid binding agent in N-methyl-2-pyrrolidone to obtain the desired dye. For this dye, λ max (acetone) was 485 nm.
EXAMPLE 3
A dye composition consisting of 10 parts of monoazo dye represented by the formula: ##STR7## 2 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 8.9), and 88 parts of diethylene glycol diacetate was ground by the use of a paint conditioner as a finely dispersing apparatus to prepare a dye ink.
A mixture of 10 parts of the dye ink and 55 parts of mineral turpentine was gradually added to 35 parts of an aqueous solution having the composition as shown hereinafter while stirring with a homomixer (5,000 to 7,000 rpm) until a uniform solution was obtained, and there was thus prepared a viscous o/w type emulsion color paste.
______________________________________Composition of Aqueous Solution parts______________________________________Water 31Repitol G (special nonionic surface 3.8active agent (trade name), producedby Dai-ichi Kogyo Seiyaku Co., Ltd.)Sodium trichloroacetate 0.1 34.9______________________________________
The thus prepared color paste was printed on a polyester/cotton mixed cloth (mixing ratio: 65/35) by the use of a screen printing machine, dried at 100° C. for 2 minutes, and then, processed with superheated steam at 175° C. for 7 minutes. Thereafter, the printed cloth was washed with a heated tetrachloroethylene bath containing a small amount of water and dried, and there was thus obtained a golden dyed product which had excellent light fastness and wet color fastness, and was free from staining in the white background.
The dye used in this example was prepared as follows:
2-Chloro-4-methylcarbonylaniline was diazonated by the usual method and coupled to 2-anilino-3-cyano-4-methyl-6-(γ-aminopropylamino)pyrridine to prepare a dye. The dye thus prepared was then reacted with 2,4-difluoro-6-methoxyethoxytriazine in dimethyl sulfoxide by the use of triethylamine as a deoxidizing agent to obtain the desired dye. For this dye, λ max (acetone) was 467 nm.
EXAMPLE 4
A dye composition consisting of 16 parts of disazo dye represented by the formula: ##STR8## 7 parts of polyoxyethylene glycol nonylphenyl ether (HLB: 13.3), 3 parts of a naphthalenesulfonic acidformaldehyde condensate, and 74 parts of water was finely dispersed by the use of a sand grinder to prepare a dye dispersion.
The dye dispersion was then used to prepare a padding solution having the following composition:
______________________________________ parts______________________________________Dye dispersion 6Tetraethylene glycol dimethyl ether 15Water 79 100 (pH 8.0)______________________________________
A polyester/cotton mixed cloth (mixing ratio: 65/35) was impregnated with the above prepared padding bath and squeezed at a squeezing ratio of 45% and, thereafter, was dried at 100° C. for 2 minutes and fixed by dry heating at 200° C. for 1 minute. The cloth was then washed with a heated ethanol bath, and there was thus obtained a red dyed product having excellent light fastness and wet color fastness.
The dye used in this example was prepared in the same manner as in Example 1. For this dye, λ max (acetone) was 503 nm.
EXAMPLE 5
Printing was performed in the same manner as in Example 1 except that a nylon/rayon mixed cloth (mixing ratio: 50/50) was used and the dry heating fixing temperature was 185° C., whereby there was obtained a red dyed product having good wet color fastness and light fastness.
EXAMPLE 6
Using the azo dyes shown in Table 1, printing was performed in the same manner as in Example 1. All dyed products had good light fastness and wet color fastness. The hue of dyed cloth and λ max (acetone) of each dye are shown in Tables 1 and 2.
TABLE 1__________________________________________________________________________ ##STR9## λ.sub.max 1 Hue of (acetone)No. D G n Y Dyed Cloth (nm)__________________________________________________________________________##STR10## CN 2 OC.sub.2 H.sub.4 OC.sub.2 reddish 485wn 2 " " 3 OC.sub.3 H.sub.7 (n) " 487 3 " " 3 ##STR11## " 488 4##STR12## " 2 OCH.sub.3 reddish 470nge 5 " " 3 OC.sub.2 H.sub.4 OCH.sub.3 " 4726 " CONH.sub.2 2 OC.sub.4 H.sub.9 (n) red 487 7##STR13## CN 2 ##STR14## " 486 8 " CONH.sub.2 2 OC.sub.3 H.sub.6 OCH.sub.3 deep red 501 9##STR15## CN 2 OCH.sub.3 " 512 10 " " 3 OC.sub.2 H.sub.5 " 514 11##STR16## " 3 OCH.sub.3 bluish 514 12 " " 3 OC.sub.3 H.sub.6 OC.sub.2 ".sub.5 51413 " CONH.sub.2 2 " " 528 14##STR17## CN 2 OCH.sub.3 reddish 492wn 15 " " 2 OC.sub.3 H.sub.7 (i) " 492 16##STR18## " 2 OCH.sub.3 reddish 473nge 17 " " 3 " " 475 18##STR19## " 3 OC.sub.2 H.sub.5 yellowish 493 19 " CONH.sub.2 3 " bluish 505 20##STR20## " 3 " orange 470 21##STR21## CN 2 OCH.sub.3 " 472 22 " " 2 ##STR22## " 472 23##STR23## " 2 OC.sub.2 H.sub. " 476 24 " CONH.sub.2 2 OC.sub.2 H.sub.4 OC.sub.2 yellowish 487 25##STR24## CN 2 OCH.sub.3 golden 471 26 " " 3 ##STR25## " 472 27##STR26## " 3 OC.sub.4 H.sub.9 (sec) red 491 28##STR27## " 3 OC.sub.2 H.sub.5 orange 473 29 " CONH.sub.2 2 OCH.sub.3 yellowish 484 30##STR28## CN 2 " orange 468 31##STR29## CONH.sub.2 2 " red 502 32 " " 2 OC.sub.2 H.sub.5 " 502 33##STR30## CN 2 OCH.sub.3 orange 471 34 " " 2 OC.sub.2 H.sub.4 OC.sub.2 ".sub.5 471 35##STR31## " 2 OC.sub.2 H.sub.5 yellowish 490 36 " " 2 OC.sub.2 H.sub.4 OCH.sub.3 " 49037 " " 3 OCH.sub.3 " 49038 " " 3 OC.sub.4 H.sub.9 (n) " 49039 " CONH.sub.2 3 OCH.sub.3 red 502 40##STR32## CN 2 " " 502 41 " " 2 ##STR33## " 502 42##STR34## " 2 OC.sub.2 H.sub.5 " 504 43 " CONH.sub.2 3 OCH.sub.3 bluish 514 44##STR35## CN 2 " yellowish 495 45 " CONH.sub.2 2 OC.sub.3 H.sub.7 OC.sub.2 redub.5 507 46##STR36## CN 2 " " 508 47 " " 2 OCH.sub.3 " 508 48##STR37## " 2 " bluish 511 49 " " 3 " " 509 50##STR38## CONH.sub.2 3 OC.sub.3 H.sub.7 (i) " 513 51 " CN 3 OCH.sub.2 red 503 52##STR39## " 2 OCH.sub.3 " 503 53 " " 2 OC.sub.2 H.sub.5 " 503 54##STR40## " 2 OCH.sub.3 " 511 55 " " 2 OC.sub.2 H.sub.4 OCH.sub.3 " 512 56##STR41## " 2 " " 504 57 " CONH.sub.2 3 ##STR42## bluish 519 58 " " 3 OCH.sub.3 " 520 59##STR43## CN 2 " " 518 60 " " 2 OC.sub.2 H.sub.5 " 518 61##STR44## " 2 OCH.sub.3 red 511 62 " " 2 ##STR45## " 512 63##STR46## " 3 OCH.sub.3 " 504 64 " CONH.sub.2 3 " bluish 520 65##STR47## CN 2 " deep red 512 66 " " 2 OC.sub.2 H.sub.5 " 512 67##STR48## " 2 OCH.sub.3 red 503 68 " " 2 OC.sub.5 H.sub.11 (n) " 504 69##STR49## CONH.sub.2 3 OCH.sub.3 bluish 521 70 " " 3 OC.sub.5 H.sub.11 (iso) " 521 71##STR50## CN 2 OCH.sub.3 orange 471 72 " " 3 ##STR51## " 471 73 " CONH.sub.2 3 OCH.sub.3 yellowish 48474 " CN 3 OC.sub.2 H.sub.5 orange 470 75##STR52## " 2 OCH.sub.3 " 474 76 " CONH.sub.2 2 OC.sub.2 H.sub.4 OCH.sub.3 yellowish 485 77##STR53## CN 3 OC.sub.3 H.sub.7 (n) red 494 78 " " 3 OC.sub.3 H.sub.6 OCH.sub.3 " 49479 " CONH.sub.2 3 OCH.sub.3 bluish 511 80##STR54## CN 2 " red 494 81 " " 3 " " 492__________________________________________________________________________
TABLE 2__________________________________________________________________________ ##STR55## No. D m ##STR56## Z Dyed ClothHue (nm)(acetone)λ .sub.max__________________________________________________________________________ ##STR57## 2 ##STR58## OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 reddish brown 483 2 ##STR59## 2 ##STR60## OCH.sub.3 red 485 3" 3 ##STR61## OC.sub.2 H.sub.5 " 487 4 ##STR62## 2 ##STR63## ##STR64## bluish red 512 5" 2 ##STR65## OCH.sub.3 " 512 6 ##STR66## 2 ##STR67## OC.sub.3 H.sub.7 (n) orange 470 7" 3 ##STR68## " " 472 8 ##STR69## 2 ##STR70## OC.sub.2 H.sub.4 OCH.sub.3 golden 469 9 ##STR71## 2 ##STR72## OC.sub.3 H.sub.6 OC.sub.2 H.sub.5 " 461 10 ##STR73## 2 ##STR74## OC.sub.2 H.sub.5 yellowish red 489 11" 3 ##STR75## OC.sub.4 H.sub.9 (t) " 489 12 ##STR76## 2 ##STR77## OCH.sub.3 " 499 13 ##STR78## 2 ##STR79## OCH.sub.3 red 501 14 ##STR80## 2 ##STR81## OC.sub.2 H.sub.5 " 503 15" 3 ##STR82## ##STR83## " 505 16" 2 ##STR84## OCH.sub.3 " 501 17 ##STR85## 2 ##STR86## OC.sub.3 H.sub.7 (n) red 503 18" 2 ##STR87## OC.sub.2 H.sub.4 OCH.sub.3 " 501 19 ##STR88## 2 ##STR89## OCH.sub.3 deep red 505 20 ##STR90## 2 ##STR91## ##STR92## " 505 21" 2 ##STR93## OC.sub.4 H.sub.9 (sec) " 503 22 ##STR94## 2 ##STR95## OC.sub.3 H.sub.7 (i) " 507 23" 3 " OCH.sub.3 " 508 24 ##STR96## 2 " OC.sub.2 H.sub.5 " 505 25" 3 ##STR97## OC.sub.2 H.sub.4 OCH.sub.3 " 506 26 ##STR98## 2 ##STR99## OC.sub.5 H.sub.11 (n) " 507 27 ##STR100## 2 ##STR101## OC.sub.4 H.sub.9 (t) " 507 28" 2 " ##STR102## " 507 29" 3 ##STR103## OC.sub.2 H.sub.4 OC.sub.2 H.sub.5 " 508 30 ##STR104## 2 ##STR105## OC.sub.3 H.sub.6 OCH.sub.3 " 506 31 ##STR106## 3 ##STR107## OCH.sub.3 " 509 32 ##STR108## 2 ##STR109## OC.sub.2 H.sub.5 orange 468 33 ##STR110## 2 ##STR111## OC.sub.3 H.sub.7 " 468 34 ##STR112## 2 ##STR113## OC.sub.2 H.sub.5 red 494 35" 2 ##STR114## OC.sub.2 H.sub.5 " 492 36 ##STR115## 2 ##STR116## OC.sub.5 H.sub.11 (sec) reddish blue 594 37" 3 " OC.sub.2 H.sub.5 " 595 38" 2 ##STR117## OC.sub.3 H.sub.7 (i) " 592 39" 3 ##STR118## OC.sub.4 H.sub.9 (sec) " 593__________________________________________________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
|
Diaminopyridine dyes for dyeing cellulose-containing fibers, particularly cellulose fibers and polyester-cellulose fibers in from orange to bluish red, with excellent fastness to light. The dyes are represented by the formula (I): ##STR1## X is a hydrogen atom, or a halogen atom; Y is an alkoxy group containing from 1 to 5 carbon atoms, --O--R 10 --O--R 11 , or a phenoxy group; and
n is 2 or 3, and wherein R 1 is a nitro group, a cyano group, a methylsulfonyl group, a phenylsulfonyl group, a mono- or di-lower alkylaminosulfonyl group, an acetyl group, or a benzoyl group; R 2 and R 3 are each a hydrogen atom, a trifluoromethyl group, a halogen atom, or a cyano group; R 4 is a hydrogen atom, a lower alkyl group, a mono- or di-lower alkylaminosulfonyl group, a mono- or di-lower alkylcarbamoyl group, or an acetylamino group; R 5 and R 6 are each a hydrogen atom, a halogen atom, or a lower alkyl group; R 7 is a lower alkyl group; R 8 is a hydrogen atom or a halogen atom; R 10 is an ethylene group, or a propylene group; and R 11 is a methyl group, or an ethyl group.
| 2
|
This is a continuation of application Ser. No. 07/722,118 filed on Jun. 26, 1991, now abandoned.
BACKGROUND OF THE PRESENT INVENTION
1. Field of the Invention
This invention relates to the field of magnetic disk files and more specifically to the field of data track misregistration detection.
2. Background Art
In a typical rotating medium as a storage system, data is stored on magnetic or magneto optic disks in a series of concentric "tracks." These tracks are accessed by read/write head that detects variations in the magnetic orientation of the disk surface.
The read/write head moves back and forth, radially or angularly, on a disk under control of a head-positioning servo mechanism so that it can be selectively positioned over a selected one of the tracks. Once in position over a track, the servo mechanism causes the head to trace a path which follows the center line of the selected track.
In a magnetic disk file containing multiple information storage surfaces, at least one recording head is uniquely associated with each surface. It is common for head positioning to consist of a synchronous operation in which all heads are moved in a similar manner by a single apparatus. Such an apparatus is illustrated in FIGS. 7 and 8.
FIGS. 7 and 8 illustrate side views of the head/disk assembly shown in FIG. 1. FIG. 7 shows a single disk system; FIG. 8 exhibits a multiple disk implementation. Data storage disks 1 are aligned on a common spindle axis for rotational purposes. One side of one disk is dedicated to servo information (101); all other surfaces comprise data surfaces 100. All data heads 1B and the single servo head 1D are manipulated simultaneously by positioning apparatus 700, under the control of an actuator (voice-coil motor 3 in FIG. 1).
The apparatus (700) provides for synchronized radial or angular movement of the heads (1B, 1D) across the surfaces (100, 101) of the disks (1). Thus, when one head is seeking a specific track, all heads are simultaneously positioned over the associated track on their respective surfaces.
Servo position reference information stored on at least one disk surface is used to provide position information to the disk drive servo system. Based on the position information, the servo system directs the positioning apparatus to center the heads over the correct tracks.
As track densities increase, misregistration of data heads with their corresponding tracks can become a problem in disk files employing servo position reference information physically separate from the data surfaces, as is the case with a dedicated servo scheme. In a dedicated servo scheme, one surface is entirely devoted to servo information. Data track locations are registered at the associated sites on the servo surface. This scheme provides for continuous position referencing. Positioning of all heads is accomplished in accordance with the servo information extracted from the single servo surface by the servo head.
Static and slowly-varying misregistration can occur due to thermal gradients, mismatch of thermal expansion coefficients of the materials from which the actuator and spindle are fabricated, and slip of bolted joints.
Attempts have been made in the past to compensate for misregistration solely by mechanical means. U.S. Pat. No. 4,860,135 to Cain is an example of this approach. In Cain a magnetic disk memory data storage device has a unitary arm assembly mounted for rotation by an actuator for carrying the transducers and shifting them across the disk surfaces. Due to the presence of multiple heat sources in the device, the assembly is subjected to varying temperature during normal device operation which causes differential rotation of the individual arms and consequent misalignment of them.
To compensate for thermal expansion, a slot is placed in the edge of an arm and a cylinder consisting of a material with a smaller thermal coefficient is placed in the slot in an interference fit. The cylinder tends to counteract the misalignment arising from the temperature change by causing the tension under which the edge of the arm in which the cylinder is placed to decrease as temperature increases and increase as temperature decreases.
Electrical detection of static misregistration is also known in the prior art. Essential to many misregistration detection means is a servo pattern located on every data surface. This servo pattern is accessed to measure the amount of track misregistration that occurs on that surface. U.S. Pat. Nos. 4,530,019 to Penniman and 4,530,020 to Sutton describe suitable servo patterns.
U.S. Pat. No. 4,530,019 to Penniman describes a sector format including, in their respective order, an erase gap, an automatic gain control (AGC) information burst, a first burst of servo control information, a second burst of servo control information, and user data. The first and second servo control information bursts are written alternately off track by one-half of the track separation between the track of interest and the next adjacent tracks to each side thereof. This sectorized servo format enables the apparatus to perform head-to-track alignment checks every sector. This sectorized format unnecessarily restricts the data storage capacity of the disk surface.
U.S. Pat. No. 4,530,020 to Sutton describes a runout correction pattern similar to the pattern described in the patent to Penniman. Sutton, however, produces the servo pattern as an integer number of sequentially recorded erase gaps, AGC bursts and servo bursts along track 0; no data is stored on this track. Decoding of the runout correction patterns by a positionally fixed playback transducer establishes runout correction information which may be provided to control, as a function of rotational angle of the disk, the servo mechanism adjusting the playback transducer position during playback of the data stored on the disk.
The purpose for having alternating servo bursts displaced one-half of the track width to each side is to provide signal amplitudes indicative of the amount of misregistration. An apparatus is used to sense the amplitude of each servo burst. For a head tracking too much to one side of the track, the bursts aligned along the side closest to the head position will read as a stronger signal and the servo bursts aligned on the side away from the head will read as a weaker signal.
There are several patents describing apparatus designed for the purpose of detecting track misregistration utilizing this type of servo pattern. In general, these designs are complex and comprise peak detector, multiple sample-and-hold circuits, multiplexer elements and an analog to digital converter.
U.S. Pat. Nos. 4,814,909 and 4,872,074 to Brown et al. describe a transducer position control system comprising these elements. On the four innermost and outermost tracks of a data surface, the first sector after each track index marker contains servo bursts offset as previously described. A peak detector receives the burst signals as input and provides the peak voltage to two sample-and-hold circuits.
The sample-and-hold circuits are triggered such that one circuit contains the peak value of a first burst and the other circuit contains the peak value of a second burst. On an alternating basis, each of the held burst values is selected by an analog data selector and provided to an analog to digital converter. The converter provides the digital value to the microprocessor which then calculates the amount of misregistration by comparing subsequent bursts. A disadvantage of the invention of Brown is its complexity, requiring double peak detectors, sample-and-hold circuits, and an analog-to-digital converter.
A digitally implemented apparatus is described in the U.S. Pat. No. 4,488,187 assigned to Alaimo. The apparatus of Alaimo comprises a digital demodulator which serves as a servo counter to provide a microprocessor with a binary offset count. The servo pattern used in this apparatus comprises a first group of digital pulses offset towards one side of track center, with each succeeding pulse offset by a decreasing distance, and a second group of digital pulses offset to the other side of track center, with each succeeding pulse offset by an increasing distance. The demodulator counts the number of pulses read by the recording head. The count produced by each group of pulses indicates the amount of misalignment between the data track and recording head. A disadvantage of this digital detection scheme is that the writing of the servo pulses requires a complex servo writing method and apparatus.
U.S. Pat. No. 4,412,165 to Case et al describes a sector servo position control system in which the position signals are derived from the servo samples with the head constrained in the correct on track position. The value of each of these position error signals is then stored as a digital number, forming part of a correcting byte in the data section immediately proceeding the associated faulty sample. The servo loop comprises a demodulator, analog to digital converter, digital controller, timing logic block, digital to analog converter and sample and hold circuitry.
U.S. Pat. No. 4,594, 622 to Wallis describes a track following servo system for a disk file that is improved by the feeding forward of a prediction of track eccentricity into the normal feedback control loop. The eccentricity related function is derived by combining functions of the position error signal and of the input signal to the head position actuator.
U.S. Pat. No. 4,878,135 to Makino et al. describes a head positioning system for use with a magnetic disk with outer, middle and inner servo tracks which are radially separated by data tracks. The circuitry employs a quadratic compensation function for determining the offset correction value.
U.S. Pat. No. 4,890,172 to Watt et al. describes a method for automatically calibrating gain parameters of a servo control. The method generally comprises a step of encoding AB bursts on at least one special calibration track of a disk surface. Servo correction number information is also encoded on the calibration track to compensate for the off-center pattern of the AB burst. A digital signal processing technique is performed on a correction signal derived from the AB burst and servo correction information to detect a residual signal at the preselected frequency of the off-center pattern signal. The gain of the track position detector is adjusted to minimize the magnitude of the residual signal.
U.S. Pat. No. 4,907,109 to Senio describes a magnetic disk drive system having automatic offset and gain adjustment means. The magnetic disk drive includes units that, immediately upon receipt of a power supply and before receipt of a seek command, measure one or more position offset values along one or more cylinders on a magnetic disk. This is done by detecting the control current when the position of the magnetic head is controlled under the fine position control, and calculating one or more offset correction values.
U.S. Pat. No. 4,920,462 to Couse et al. describes a disk drive fine servo velocity control and method for head positioning relative to a disk. During a seek operation, servo velocity control circuitry seeks out the destination track and places the head within the boundaries of that track while the servo position control circuitry, using servo information places the head on the centerline of the destination track. The fine servo control circuitry is provided for communicating the information generated by the servo position control circuitry to the servo velocity circuitry when the head is several tracks from the destination track in order to allow the actuator to smoothly and quickly cause the head to seek within the boundaries of the destination track without overshooting that track.
SUMMARY OF THE PRESENT INVENTION
The apparatus for detecting data track misregistration of the present invention involves the interaction of a microprocessor with a demodulator. Microcode within the microprocessor periodically initiates a misregistration scan of fixed calibration tracks on the data surfaces at selected intervals to generate a calibration offset table that is used to compensate misregistration of data heads during the intervening interval.
Misregistration is detected by reading information bursts in the calibration areas. These bursts are written under the control of an interface controller to overlap three adjacent tracks. A first type of burst overlaps the inside and middle tracks. A second type of burst overlaps the middle and outside tracks. The demodulator of the present invention obtains the peak values of these bursts and outputs a timing pulse proportional to their respective peak voltage values. A timer within the microprocessor measures the time values, and the misregistration displacement is calculated by the comparison of the inner burst and outer burst time values. The calculated displacement is used in the offset table for subsequent disk references. The invention circumvents the need for a dedicated analog-to-digital converter and multiplexing switch.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates the servo environment of the present invention.
FIG. 2 illustrates the preferred embodiment of the servo demodulator of the present invention.
FIG. 3 illustrates signal waveforms within the servo demodulator of the present invention.
FIG. 4 illustrates a misregistration calibration area format for use with the present invention.
FIG. 5 shows a simplified flow chart of the microprocessor's microcode for use in the present invention.
FIG. 6 illustrates a functional diagram of the servo demodulator of the present invention.
FIG. 7 illustrates a side view of the head/disk assembly of the present invention.
FIG. 8 illustrates a side view of a multiple disk embodiment of the head/disk assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A system for data track misregistration detection comprising a demodulator operating in tandem with a microprocessor is described. The invention may be used for thermal misregistration and low-frequency offset correction in disk files employing a dedicated servo surface. In the following description, numerous specific details, such as gain values, specific circuit elements, etc. are described in detail in order to provide a more thorough description of the present invention. It will be apparent, however to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well known features have not been described in detail so as not to obscure the present invention.
In the present invention, a thermal compensation demodulator receives analog information in a differential format from an associated recording channel and provides a binary timing signal to a microprocessor. A software idle loop continually checks for commands on the disk interface while maintaining a timer which governs frequency of access to the misregistration calibration area. At specific intervals (i.e. 5 minutes), or at an interval determined by the expected rate of change of misregistration, an access to the calibration area is made. Each data head is selected sequentially and the demodulator is cycled to measure the misregistration value. A table, indexed by head, is constructed holding misregistration data. When a read or write command to a specific head is received, the table is interrogated. If the misregistration value obtained from the table is within a preset threshold range of the current position of the head, no head position correction is made and the operation proceeds normally. However, if misregistration is outside the threshold boundary, an appropriate position offset is introduced in the servo prior to the execution of the read or write command. Initiation of the offset command may be delayed until the servo has repositioned the head. Separate thresholds can be employed for write and read commands. The use of thresholds permits latency reduction, since it obviates head repositioning when misregistration is small.
Application of the invention to measurement and correction of track misregistration of data heads relative to a calibration track is the subject of FIG. 1. Data storage disks 1 contain surfaces for storage of customer data (100), as well as a servo position-reference surface (not shown) for storing information used by a dedicated servo. Misregistration calibration areas 1A are recorded at appropriate locations on all data surfaces 100. These are typically located in the outer guardband regions of the data surfaces, and are accessed periodically to gauge the amount of track misregistration on each data-surface recording head 1B. The dedicated servo system 4 controls head positioning through voice-coil motor 3 and positioning apparatus 700. Servo system 4 receives commands and presents status to interface controller 6 over a serial communication link on cable 4A. An important capability of the servo system is its ability to offset head position in marginal increments. This capability is utilized both in the initial writing of calibration tracks 1A, and in subsequent head repositionings to restore track misregistration. The servo system also delivers index and sector pulses to interface controller 6 over wires 4B. The number of sectors into which a track is divided may be altered by an appropriate command transmitted on cable 4A.
Record/reproduce channel 2 performs data encoding, detection, and clocking functions of a disk file and communicates with interface controller 6 over cable 2C. Data preamplifier 1C amplifies the signal output of the data surface recording 1B to a level suitable for application to the reproduce channel. The reproduce channel includes an automatic gain control (AGC) hold feature which permits acquisition of a specific gain value, and retention of that value. Wire 2B selects AGC acquisition or hold mode, and is controlled by microprocessor 6B. The AGC hold mode is invoked solely when reading misregistration calibration areas 1A.
Demodulator 5 receives analog reproduce data in a differential format on wires 2A, after this data has been filtered and subjected to AGC control in record channel 2. Comparator output 5B from the demodulator cooperates with event capture timer 6C in microprocessor 6B, and with demodulator mode control signal 5A to permit demodulation of calibration track information.
Interface controller 6, comprising data controller 6A and microprocessor 6B, governs communication between the disk file and a standardized device interface over cable 7. This interface can be, for example of the SCSI or PC/AT type. Use of a high-level interface is essential in implementing track misregistration calibration schemes, as it allows periodic accesses to calibration data, and any necessary recording head offset operations, to be effectively obscured from the customer. The interface controller 6 writes misregistration calibration areas 1A in a special sequence, thereby avoiding the requirement that these tracks be written by an expensive servo writer.
FIG. 5 illustrates the control flow of the microcode within the microprocessor 6B which is responsible for performing correction of track misregistration. FIG. 5 is only representative, other methods of implementing the track misregistration correction are possible. Additionally, means for cancelling low-frequency repetitive effects caused, for example, by loss of disk eccentricity could be contemplated. A software idle loop continually checks for commands on the interface, while maintaining a timer which governs frequency of access to the misregistration calibration area. At predetermined intervals, the calibration areas are accessed. Each head is checked sequentially, the demodulator is cycled to measure the misregistration value, and a table indexed by head is constructed holding misregistration data. When a read or write command to a specific head is received, the table is consulted. If the misregistration is within a preset threshold, no head position correction is made. If the misregistration is outside the threshold bound, an appropriate position offset is commanded in the servo prior to the execution of the read or write command. Formatting of the misregistration calibration areas is accomplished by a special format command.
As shown in FIG. 5, at the beginning of the microcode loop, the microprocessor's internal timer is checked to see if a predetermined interval of time has passed since the last calibration was made (block 510). If the answer is yes, the data heads seek to track K where the servo calibration pattern is located (block 511). Then, all heads are scanned, sequentially, to build an offset table, D(head), based on the detected misregistration of each head (block 512). The loop returns to START.
If the answer is no, hence the predetermined interval has not elapsed since the last calibration, then the microcode checks to see if there is a command request from the interface (block 513). If there is no request, then operation returns to START. If there is a request, then operation proceeds to the command interpreter (block 514).
If the command is a seek command, then microcode executes the seek command (block 515) and returns to START. If the command is a format command, then the microcode commands the operation for formatting the misregistration calibration areas (block 516) and then returns to START. If the command is a read or write command then the microcode branches to a new decision block (517) to determine whether to read or write.
If the command is a write command, then a check of the misregistration calibration table is made (block 521) to see if the misregistration lies within the write threshold (THRW). If the misregistration does lie within the threshold then the write command is executed (block 523) and the microcode returns to START. If the misregistration is not within the threshold region then the microprocessor commands an appropriate offset in the servo (block 522) prior to the execution of the write command. The offset value is taken from the misregistration calibration table, D(head). After the offset is applied, the write command is executed and operation returns to START.
If the command is not a write command, then the misregistration calibration table is checked (block 518) to see if the offset value is within the read threshold value THRR. Note that THRW is normally less than THRR. If the value in D(head) is less than the threshold value, then the read command is executed (block 520) and operation returns to START. If the offset value is outside the threshold value, then the microprocessor commands the servo positioning system to reposition the head according to the offset value (block 519). The read command is then executed and operation returns to the start of the loop.
A misregistration calibration servo format is illustrated in FIG. 4. Misregistration calibration areas 1A are written by interface controller 6 upon receipt of an appropriate command over device interface 7, by appropriate sequencing of recording channel 2 and of servo 4. Use is made, in this operation, of the capability of the interface controller 6 to select varying sector lengths in dedicated servo system 4. Each calibration comprises three adjacent tracks K-1, K, and K+1, each of pitch equal to the data track pitch. The central track of the area is written with an arbitrary number of AGCBURST-ODDBURST-EVENBURST triplets. All bursts are recorded with a constant frequency tone. AGCBURSTs 400 are written with the recording head centered on track K. ODDBURST 401 and EVENBURST 402 position bursts are written with the recording head offset from track K center by nominally 1/2 of track towards the inner and outer diameter of the disk, respectively. Head offset is obtained by issuing an appropriate command to servo system 4.
The misregistration calibration area is d.c. erased by the interface controller prior to recording of the triplets; complete erasure is ensured by performing erasure with the head in both offset and on-track positions of tracksK-1,K, and K+1.
As shown in FIG. 4, each burst of a triplet is demarked by a sector pulse 403; accordingly, prior to recording the misregistration calibration areas, the interface controller commands the servo system to deliver a number (i.e. three: number of triplets per track) of sector pulses per track. This number is not necessarily the same as the number of sector pulses employed on data tracks.
The AGCBURST 400 provides a gain reference to reproduce channel 2; the gain thus established is held constant through the adjacent ODDBURST 401 and EVENBURST 402.
The ODDBURST 401 and EVENBURST 402 fields are used differentially in known fashion to sense the radial position of the recording head 1B; for example, outward displacement of the head 1B results in an increase in amplitude of ODDBURST and reduction in amplitude of EVENBURST. The sum of ODDBURST and EVENBURST amplitudes remain nominally constant for moderate displacement of the recording head from track center of track K, thus permitting the head displacement D to be calculated as, ##EQU1## where constant G is a function of the headwidth of the particular recording head.
A block diagram of the novel demodulator circuit of the present invention is illustrated in FIG. 6. The function of demodulator 5 is to produce a measure of the misregistration of a selected data recording head in reference to its associated misregistration calibration area. The demodulator of the present invention is made up of five stages: A gain stage 630, a full wave rectifier 631, a peak detector and voltage-to-time converter 632, a bias replicator circuit 633, and an analog comparator 216.
The analog read data from line 2A is passed through a gain stage 630, which has a nominal gain of three. The amplified output 215 of the gain stage is provided to full-wave rectifier 631 to supply rectified signal 210 to the peak detector and voltage-to-time converter 632. The peak detector and voltage-to-time converter 632 also receives the Acquire/Discharge signal 5A from the microprocessor 6B and the bias signal 214 from the bias replicator 633. The Acquire/Discharge signal 5A is used to control the voltage-to-time conversion. The bias signal 214 is utilized in clamping circuitry within the peak detector to prevent transistor saturation. The output 212 of the voltage-to-time converter is a voltage signal ramping down from the peak value at a constant rate. The signal 212 is provided to the negative input of comparator 216.
The bias replicator 633 outputs a constant reference voltage signal 214 equivalent to the value that signal 212 would have if the differential input on lines 2A was zero. The reference signal 214 is provided to the positive input f comparator 5F.
Comparator SF produces binary digital output 5B. The falling edge of 5B is triggered as signal 212 rises above bias signal 214. The rising edge of signal 5B is triggered when the falling voltage 212 reaches the bias signal level.
A circuit diagram of the demodulator is shown in FIG. 2. One of the differential input lines of analog read data 2A is coupled through capacitor 200 to the base of transistor Q1, and the other input line is coupled through capacitor 201 to the base of transistor Q2. The base of transistor Q1 and the base of transistor Q2 are coupled to a gain stage biasing voltage through bias resistances RB1 and RB2, respectively. The emitter of transistor Q1 and the emitter of transistor Q2 are coupled together through resistor R4, and the emitters of transistors Q1 and Q2 are also coupled to current sources 202 and 203, respectively. Current sources 202 and 203 are coupled to ground, VSS. The collector for Q1 is coupled to the supply voltage VCC through resistor R1 and is also coupled to the base of transistor Q4. The collector of Q2 is coupled to VCC through resistor R2 and also coupled to the base of transistor Q3.
The collector of transistor Q3 and the collector of transistor Q4 are coupled to VCC. The emitters of transistors Q3, Q4 and Q5 are coupled to node 210 which is in turn coupled through a third current source 204 to VSS.
The base and collector of transistor Q5 are coupled to node 211, as are the base of Q6, the emitter of transistor Q7, and the collector of transistor Q12. Connected between VCC and node 211 is current source 217 with a current value of Ip. The collector of transistor Q6 and the collector of transistor Q7 are coupled to VCC. The emitter of transistor Q6 is coupled through resistor R5 to node 212. Capacitor 213 is coupled between node 212 and VSS. Also coupled to node 212 and VSS is current source 208, which has a current value of I DISCH . Node 212 is coupled to the negative input of comparator 216.
In the bias replicator circuit, the base of transistor Q8 is coupled through current source 205 to VSS and coupled through resistor R3 (R1=R2=R3) to VCC. The collector of transistor Q8 is coupled to VCC. The emitters of Q8 and Q9 are jointly coupled to current source 206, which is coupled to VSS. Current source 206 has a current value equivalent to that of current sources 202-205. The collector and base of transistor Q9 are coupled through current source 218, which has a current value equivalent to that of current source 217, to VCC.
The base of transistor Q10 is coupled to the base and collector of transistor Q9. The collector of Q10 is coupled to VCC and the emitter is coupled to node 214. Node 214 is coupled to the positive input of comparator 216 and to the base of transistor Q7. In addition, current source, 209 having a current value equivalent to that of current source 208, is coupled between node 214 and ground VSS. Note that, to ensure proper bias replication, R1=R2=R3; and Q8, Q9 and Q10 replicate the action of Q3/Q4, Q5 and Q6, respectively.
The emitter of transistor Q11 and the emitter of transistor Q12 are jointly coupled to current source 207 of value Is (Is>I P ), which is coupled to VSS. The base of transistor Q12 is coupled to a reference voltage, and the base of transistor Q11 is coupled to the acquire/discharge signal on line 5A. The collector of transistor Q11 is coupled to VCC.
Transistors Q1, Q2, Q3 and Q4 form a gain stage followed by a full wave rectifier. The gain stage receives a differential signal from the recording channel 2 over wires 2A. The amplified output 34 of the gain stage is taken from the collectors of transistors Q1 and Q2.
Transistors Q5, Q6, Q11 and Q12 comprise a single-gated peak-hold circuit, the state of which is controlled by the acquire/discharge mode logic signal 5A. Transistor Q7 damps the base of transistor Q6 and collector of transistor Q12 to prevent saturation and zenering of the base-emitter junction of transistor Q6. In the acquire mode of the peak-hold circuit, capacitor 213 is allowed to charge up to the signals peaks through transistor Q6, which functions essentially as an emitter follower, with trickle emitter currents set by the I DISCH discharge current source 208. When the peak-hold circuit is set into hold mode, the base-emitter junction of transistor Q6 is forced into reverse-bias, whereupon capacitor 213 commences to discharge linearly under influence of constant-current source 208.
Comparator 216 signals on wire 5B when capacitor 213 has been discharged to a reference level established by transistors Q8, Q9, Q10 and their associated biasing current sources. This transistor network operates as a replica bias circuit which ensures that the potential on the non-inverting input of the comparator closely tracks the potential which capacitor 213 would assume in the absence of an input signal on wires 2A. The output 5B from the comparator 216 is a binary digital waveform.
Shown in FIG. 3 are waveforms pertinent to operation of the demodulator 5. These wave shapes are illustrated for the case of recording head 1D displaced inward relative to track center in the misregistration calibration area. Accordingly, the reproduced ODDBURST 401 is shown of smaller amplitude then the associated EVENBURST 402. Waveform A! illustrates the analog read data appearing on wires 2A when the misregistration calibration is being read. Signal B! toggles high in the AGC field to freeze AGC gain during the subsequent two position burst fields. Signal C! is pulsed high in each position field to control acquisition and discharge of the peak values of the ODDBURST and EVENBURST fields. Shown at D! and E!, respectively, are the potential across capacitor 213 in the demodulator and the logic signal output of comparator 216. Signals B! and C! are generated by microprocessor 6B. Signal E! is applied to the event capture timer 6C of microprocessor 6B.
Microprocessor 6B of FIG. 1 employs event capture timer 6C to measure for each ODDBURST 401 and EVENBURST 402 field the time interval between the switching of demodulator 5 into discharge mode (fall of waveform C!, and completion of discharge as marked by rise of the comparator output 5B (rise of waveform E!).
For a capacitor, I=CdV/dt. When integrated, this provides, in the case of the demodulator,
V PEAKWOOD =T ODD (I DISCH /C) and
V PEAKEVEN =T EVEN (I DISCH /C).
The magnitude of the discharge current, I DISCH , from current source 208, divided by the magnitude of capacitor 213 forms a common multiplying factor of both peak voltage equations. Accordingly, the magnitude of I DISCH and of C are not critical. Substituting these peak voltage equations into the original misregistration equation allows for the (I DISCH /C) term to be cancelled from the expression for D. The position misregistration, D, can be calculated within the microprocessor using the modified formula, ##EQU2## The demodulator 5 thus functions as a voltage-to-time converter in demodulating burst amplitudes.
Thus a means for detection of data track misregistration is described.
|
Apparatus for detecting data track misregistration is described. The present invention involves the interaction of a microprocessor with a demodulator. Microcode within the microprocessor initiates a misregistration scan of all data tracks at specific intervals to generate a calibration offset table that is used to direct the heads during the subsequent interval. A demodulator obtains the peak values of calibration servo bursts, displaced one-half of the track width to either side of a track, and outputs a timing pulse proportional to their respective peak voltage values. A timer within the microprocessor extracts the time values, and the misregistration displacement is calculated by the comparison of the inner burst and outer burst time values. The calculated displacement is used in the offset table for subsequent disk references.
| 6
|
FIELD OF THE DISCLOSURE
The present invention relates to a spectrophotometer in which an interferometer is associated with a dispersive system.
BACKGROUND OF THE DISCLOSURE
Such an interferometer is known, in particular from French patent application 2 858 404 published on Feb. 4, 2005 in the name of the proprietor of the present patent application. It makes it possible to obtain simultaneously an image of a field in which there are light sources, together with spectral analysis of the light emitted by these sources. In particular, when it is combined with a telescope placed in front of the inlet to the spectrophotometer, it can be used for making space or terrestrial observations.
FIG. 1 a shows an example of how the various optical elements can be arranged within such spectrophotometer. For reasons of clarity, the dimensions of the optical elements shown in the figure and the distances between the elements are not proportional to actual dimensions and distances. Furthermore, optical elements that are known to the person skilled in the art are not described in detail below. Indications are merely given concerning their use within the spectrophotometer.
As shown in FIG. 1 a, a Fourier transform interferometer 3 is arranged to receive at its inlet a primary light beam F 2 and to deliver at its output an intermediate light beam F 7 . By way of example, the primary beam F 2 may originate from a source S that is to be observed and that is situated within the inlet field of the interferometer 3 .
In a spectrophotometer for spatial or terrestrial observation, the source S is situated at a great distance from the spectrophotometer. The figure then shows only the direction in which said source S is situated. In the jargon of the person skilled in the art, the source S is said to be “situated at infinity”. An inlet optical unit 2 , which may be of the telescope unit type, produces the primary beam F 2 from an inlet light beam F 1 emitted by the source S. The inlet optical unit 2 forms an image S′ of the source S. It should be understood that the operation principle described in detail herein for a source S situated at infinity can be transposed to a source S situated at a finite distance from the spectrophotometer. How to perform such a transposition is well known and is not specific to the system described.
The Fourier transform interferometer 3 produces an interferogram of the light emitted by the source S. This interferogram extends along a direction D 1 of variation in an optical path length difference that extends perpendicularly to the plane of FIG. 1 a.
The interferometer 3 may in particular be of the Michelson type. It then comprises:
a splitter device 31 that splits the intensity of the primary beam F 2 into two secondary beams F 3 and F 4 propagating in respective directions D 0 ′ and D 0 . D 0 may be the direction along which the primary beam F 2 enters the interferometer 3 , while D 0 ′ is conjugate relative to direction D 0 by the splitter device 31 . By way of example, the splitter device 31 may comprise a planar semi-reflective plate disposed in a plane containing direction D 1 and extending at 45° relative to direction D 0 ;
two mirrors 32 and 33 disposed respectively to reflect the secondary beams F 3 and F 4 so as to form first and second reflected secondary beams F 5 and F 6 ; and
a combiner device disposed to combine the reflected secondary beams F 5 and F 6 so as to form the intermediate beam F 7 . In known manner for Michelson type interferometers, the splitter device 31 also performs the function of combining the reflected secondary beams F 5 and F 6 .
In FIG. 1 a, for reasons of clarity, the beams F 3 -F 6 are represented solely by their respective propagation directions.
Mirrors 32 and 33 may both be planar mirrors. Each exhibits a determined angle respectively relative to the propagation directions of the secondary beams F 3 and F 4 . Mirror 32 is perpendicular to direction D 0 ′, and mirror 33 may be titled about an axis B-B that is perpendicular to directions D 0 and D 1 . The tilt-angle of mirror 33 lies, for example, in the range 0.2° to 5°.
An optical path length difference results from the respective tilt-angles of the mirrors 32 and 33 between two portions of a given light ray of the primary beam F 2 as split by the device 31 . These two light ray portions belong respectively to the secondary beams F 3 and F 4 , and each of them is reflected by the corresponding mirror 32 or 33 . The light ray portions also belong to the reflected secondary beams F 5 and F 6 and they are combined by the device 31 within the intermediate beam F 7 . The intermediate beam F 7 thus corresponds to an interference pattern of the reflected secondary beams F 5 and F 6 . The difference in the optical path lengths traveled by the two light ray portions depends on the locations of the points at which they are respectively reflected on the mirrors 32 and 33 . More specifically, it depends on the locations of the points of reflection measured along the direction D 1 . In other words, this optical path length difference varies during displacement of the points of reflection along the direction D 1 , i.e. during displacement of the source S in a plane perpendicular to that of FIG. 1 a and containing direction D 0 . Direction D 1 is also perpendicular to the propagation direction of the intermediate beam F 7 .
The distance between the interferometer 3 and the inlet optical unit 2 is set in such a manner that the image S′ of the source S is formed inside the interferometer 3 , substantially at the mirrors 32 and 33 . Image S′ then corresponds to the point at which the secondary beam F 4 is reflected on mirror 33 .
A dispersive system 6 is arranged so as to receive at its inlet the intermediate beam F 7 . It may comprise a collimator lens 5 , a prism P, and a focusing lens 7 arranged so that the light from the intermediate beam F 7 passes successively through the collimator lens 5 , the prism P, and then the focusing lens 7 . In FIG. 1 a, the lenses 2 , 5 , and 7 are represented symbolically by respective individual lenses, however each of them could be constituted by a more complex lens assembly. By way of example, collimator 5 is arranged to transform the intermediate beam F 7 into a parallel beam that passes through the prism P. The focusing lens 7 is arranged to form a final image S D (λ) of the source S in a plane conjugated with the mirror 32 . Prism P disperses the light from the intermediate beam F 7 angularly in a direction D 2 that is substantially perpendicular to the propagation direction of the light. A set of images S D (λ) corresponding to different dispersed wavelengths λ are thus formed simultaneously. The images S D (λ) aye offset mutually along a direction D 4 that is conjugate with the dispersion direction D 2 by the focusing lens 7 .
In known manner, the prism P can be replaced by a diffraction grating, without changing the operation of the spectrophotometer.
The interferometer 3 and the dispersive system 6 are oriented relative to each other in such a manner that the dispersion direction D 2 is substantially perpendicular to the direction D 1 in which optical path length difference varies.
Finally, a planar matrix of photodetectors 8 is arranged in the plane that is conjugate with the mirror 32 and that contains the images S D (λ). Consequently, a spectrophotometer of the type considered in the present invention possesses an imaging function: on the matrix 8 of photodetectors, it produces an image of each source S that is situated in the inlet field. As shown in FIG. 1 b, the matrix 8 is composed of photodetectors distributed in columns C and rows L that are perpendicular to the columns. The columns C are parallel to a direction D 3 and the rows of the matrix 8 are parallel to a direction D 4 . Consequently, the direction D 4 is the direction in which the columns C of the matrix 8 are offset relative to one another.
Within the spectrophotometer, the matrix 8 of photodetectors is oriented in such a manner that the direction D 3 of the columns C is conjugate with the direction D 1 in which optical path length difference varies. For a system of the kind shown in FIG. 1 a, direction D 3 is parallel to direction D 1 . Direction D 4 then corresponds to the dispersion direction D 2 .
In a preferred embodiment of such a spectrophotometer, at least one of the two mirrors of the interferometer, e.g. mirror 33 , is of the echelette-grating type. It is constituted by elementary faces perpendicular to direction D 0 , in the form of reflecting planar strips elongate parallel to the axis B-B and offset relative to one another along direction D 0 . The offset of each elementary face in direction D 0 defines the optical path length difference and varies in the direction D 1 . The width of the elementary faces of mirror 33 is also determined in such a manner that the product of this width multiplied by the optical magnification existing between mirror 33 and the matrix 8 of photodetectors is equal to the dimension of the photodetectors of the matrix 8 along direction D 3 . Each elementary face of mirror 33 is thus conjugate with a respective row L of photodetectors. Under such circumstances, the number of photodetectors in a column C of matrix 8 is preferably not less than the number of elementary faces of the mirror 33 .
Mirrors 32 and 33 may also be both of the echelette-grating type. Under such circumstances, the optical path length difference results from the offsets between the elementary faces of the two mirrors. In particular, the mirrors can be arranged in such a manner that the elementary optical faces of each of them are conjugate optically with respective faces of the other mirror by the splitter device 31 .
An intermediate optical unit 10 may also be placed on the path of the intermediate beam F 7 so as to produce an intermediate image S″ of the source S. A rectangular slit 4 is placed level with the image S″, in a plane substantially perpendicular to the propagation direction of the intermediate beam F 7 . The slit 4 is long parallel to direction D 1 and presents a width l parallel to direction D 0 . In conventional manner, the slit 4 acts as an inlet slit for the dispersive device 6 , and each column C of photodetectors in the matrix 8 performs an outlet slit function for the dispersive system 6 .
Optionally, a two-axis optical scanner device 1 can also be arranged on the path of the inlet beam F 1 . The first axis of rotation of the scanner device 1 is perpendicular to directions D 0 and D 0 ′, and is denoted Z-Z. The second axis of rotation of the device 1 , denoted A-A, is perpendicular to the axis Z-Z and can turn thereabout. An inlet aperture of the scanner device 1 then sweeps over an observation field in which the light source S is located, so that the inlet beam F 1 possesses, at the outlet from the scanner device 1 , a propagation direction that is unchanging relative to the spectrophotometer and substantially parallel to the direction D 0 . During rotation of the scanner device 1 about axis Z-Z, the image S′ of the source S moves parallel to the axis B-B. During rotation of the scanner device 1 about the axis A-A, the image S′ of the source S moves parallel to the direction D 1 .
The operation of such a spectrophotometer is described below. Images S D (λ i ) of a given light source S are formed on each column C of the matrix 8 of photodetectors. The dispersed wavelength λ i is defined by the offset in the direction D 4 of the column C in question. It is in fact a mean value which corresponds substantially to the middle position of the column C in question in the direction D 4 .
Simultaneously, during rotation of the scanner device 1 about the axis A-A, the photodetectors in each column C of the matrix 8 record an interferogram of the light of the inlet beam F 1 . Direction D 3 is thus simultaneously an interferogram direction and a spatial displacement direction in the image that the spectrophotometer forms of sources situated in the inlet field By means of a Fourier transform of the light energy received by the photodetectors in the column C corresponding to the wavelength λ i , it is possible to calculate precisely the spectral distribution of energy over a range centered around λ i .
The term spatial resolution in the direction D 3 or the direction D 4 is used to designate the minimum separation distance between two light sources having images on the matrix 8 that are offset in the direction D 3 or D 4 , respectively. For light sources situated at infinity, the distance between the light sources is an angular distance. The spatial resolution in the direction D 3 is determined by the dimension of a photodetector of the matrix 8 in said direction. The spatial resolution in the direction D 4 is determined by the width l of the slit 4 .
The term spectral resolution is used to designate the minimum difference between two wavelengths for which the respective light intensities can be measured or deduced separately from each other. In known manner, the spectral resolution of the interferometer 3 , which appears along direction D 3 , is associated with the number of detectors in a column C of the matrix 8 . The spectral resolution of the dispersive system 6 which appears along direction D 4 results from the width l of the slit 4 and from the dimension of the photodetectors in the matrix 8 along direction D 4 .
Below, Y denotes a displacement axis in the image that the spectrophotometer forms of light sources situated in the inlet field, and corresponding to direction D 4 . Similarly, DS designates a wavelength variation axis of the light that is detected during a displacement over the matrix 8 parallel to the direction D 4 . DS is referred to as the spectral dispersion axis and corresponds to the dispersion function of the system 6 .
FIG. 2 a shows the origins of the contributions to the light energy detected along a row of the matrix 8 , in a chart identified by axes DS and Y. The spectral dispersion axis DS is shown as the abscissa and the displacement axis Y as the ordinate. A central point in this diagram corresponds to the wavelength λ 0 which is taken as the origin for the dispersion generated by the system 6 .
The spatial and spectral resolutions discussed below are displayed by equivalence in this diagram. The two opposite edges of the slit 4 correspond to respective images on the matrix 8 which are separated by a distance δy s along direction Y (s index denoting “slit”). The distance δy s is equal to the width l of the slit 4 multiplied by the optical magnification G generated by the portion of the spectrophotometer present between the plane of the slit 4 and the plane of the matrix 8 of photodetectors (δy s =l×G). The points on the row of the matrix 8 that correspond to the images of the two edges of the slit 4 can also correspond to light-intensities detected respectively for wavelengths λ 0 -δλ s /2 and λ 0 +δλ s /2, where δλ s is a first contribution to the spectral resolution of the dispersive system 6 generated by the slit 4 .
Finally, the dimension of each detector of the matrix 8 , measured along direction D 4 , generates a second contribution to the spectral resolution of the dispersive system. This second contribution is denoted δλ d and is also referred to as the spectral sampling internal of the photodetectors. It is equal to the dimension d of the photodetectors along direction D 4 divided by a linear dispersion coefficient Γ of the system 6 (δλ d =d/Γ).
The area of the shading A provides a measure of the light energy that is detected by the photodetectors of a row L of the matrix 8 , and that can be attributed to the central wavelength λ 0 .
The diagram of FIG. 2 a shows that the distance denoted δy s is the spatial resolution along direction D 4 . Indeed, the light energies that are detected respectively at two points along a row L of the matrix 8 that are separated by a distance that is less than δy s can correspond to light rays having different wavelengths and that originate from the same light source S.
To improve spatial resolution along direction D 4 , it is therefore common practice to reduce the width l of the slit 4 so that the distance δy s on the matrix 8 corresponds to the dimension of the photodetectors along direction D 4 . In other words, the width l of the slit 4 is usually set in such a manner that the width of the image of the slit 4 on the matrix 8 is equal to the thickness of one column C of photodetectors: l=d/G, such that δy s =d. The inlet field of the spectrophotometer for which an image is formed on the matrix 8 during a given exposure is then a very narrow strip, having a width in the image that corresponds to the width of a single column of photodetectors. This inlet field that is viewed by the spectrophotometer during a single exposure is thus very narrow.
Consequently, when the spectrophotometer is combined with the scanner system 1 , scanning by rotation about the axis Z-Z must be performed with a very short pitch in order to obtain recordings that correspond to contiguous strips in the observation field. The duration of the resulting scan is then very long.
FIG. 2 b shows the spectral response function of the spectrophotometer, denoted Rep, along a row L of the matrix 8 of photodetectors.
An object of the present invention thus consists in proposing a spectrophotometer of the type described above, which exhibits an inlet field that is wider along direction Y without impairing resolution.
SUMMARY OF THE DISCLOSURE
To this end, the invention provides a spectrophotometer that comprises:
a matrix of photodetectors distributed in columns and rows along two perpendicular directions, this matrix of photodetectors being placed in an image plane of the spectrophotometer;
an interferometer arranged to produce, on a column of the matrix of photodetectors, an interferogram of a light source situated in an inlet field of the spectrophotometer;
a dispersive system arranged on the path of the light beams passing through the interferometer, and arranged to disperse light parallel to the rows of the matrix of photodetectors; and
a slit arranged in an intermediate image plane between the inlet of the spectrophotometer and the matrix of photodetectors, the slit having a width direction conjugated with the row direction of the matrix of photodetectors.
According to the invention, the interferometer has a spectral resolution less than the spectral sampling interval of the photodetectors along the row direction of the matrix. And also the width of the slit is adapted so that a spectral resolution of the dispersive system generated by the slit is greater than the spectral sampling interval of the photodetectors along the row direction of the matrix.
The slit then makes it possible in a single exposure to form on the matrix of photodetectors an image of a broad strip in the inlet field. Thanks to the invention, two points that emit light and that are in alignment along the width direction of the strip can be distinguished from each other in the information extracted from the detected light energies. A scan of an observation field in a direction corresponding to the rows of the matrix of photodetectors can then be performed with a large pitch, while nevertheless obtaining complete coverage made up of contiguous strips in the inlet field. The number of exposures needed to cover an entire observation field is then small, and the total duration of scanning is compatible with using the spectrophotometer on board a satellite.
In addition, by means of the invention, effective spatial resolution is obtained for the spectrophotometer along the row direction of the matrix of photodetectors that is smaller than the resolution that would result solely from the width of the slit. This improvement in resolution is obtained by transferring light energy measurements sensed along the column direction of the matrix of photodetectors into measurements sensed along the row direction of the matrix.
In a preferred embodiment of the invention, the width of the slit is also adapted so that a dimension of the image of the slit on the matrix of photodetectors is equal to the dimension of the photodetectors multiplied by R, said dimensions of the image of the slit and of the photodetectors being measured along the row direction of the matrix of photodetectors, where R is the quotient of the spectral sampling interval of the photodetectors along the row direction of the matrix divided by the spectral resolution of the interferometer. The interferometer is then used in optimal manner for improving spatial resolution along the row direction of the matrix of photodetectors.
Advantageously, the interferometer includes a Michelson apparatus. The Michelson apparatus is itself provided with a planar mirror and an echelette-grating mirror disposed to reflect respective portions of the light beam emitted by a source situated in the inlet field of the spectrophotometer. Alternatively, both mirrors of the Michelson apparatus may be echelette-grating mirrors. Spatial and spectral measurements of light sources can then be obtained that are particularly accurate.
The spectrophotometer may also include a scanner device that is placed at the inlet of the spectrophotometer, and that has two scanning directions conjugated respectively with the column direction and with the row direction of the matrix of photodetectors. A large field of observation can then be covered quickly by successive exposures in automatic manner.
Finally, the invention provides a satellite including an on-board spectrophotometer in accordance with the invention. Such a satellite can be used for making spatial or terrestrial observations while it is orbiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will appear from the following description of non-limiting embodiments, given with reference to the accompanying drawings, in which:
FIG. 1 a is an optical diagram showing the principle of a prior art spectrophotometer to which the invention can be applied;
FIG. 1 b shows a matrix of photodetectors suitable for use in the spectrophotometer of FIG. 1 a;
FIG. 2 a is a diagram showing the light energy contribution measured along the rows of the FIG. 1 a matrix of photodetectors for a spectrophotometer in accordance with FIG. 1 a;
FIG. 2 b shows the response function of the spectrophotometer shown in FIG. 2 a, along the row direction of the matrix of photodetectors;
FIG. 3 a corresponds to FIG. 2 a for a spectrophotometer of the invention; and
FIG. 3 b corresponds to FIG. 2 b for the spectrophotometer of the invention as shown in FIG. 3 a.
DETAILED DESCRIPTION
FIGS. 1 a, 1 b, 2 a, and 2 b, relating to the known prior art, have been described in detail above.
There follows a description of a particular embodiment of the invention. A spectrophotometer of the invention can possess a structure identical to that described with reference to FIGS. 1 a and 1 b. The echelette-grating mirror 33 possesses N elementary reflecting faces offset at a pitch p. Each column C of the matrix 8 has N photodetectors, and the length of the slit 4 along direction D 1 is sufficient for an image of a complete slice of the mirror 33 parallel to the direction D 1 to be formed on the matrix 8 . The rows of the matrix 8 are then optically conjugated with respective elementary reflecting faces of the mirror 33 . This corresponds to an interferometer model for which the relative positions of the mirrors 32 and 33 along direction D 0 and D 0 ′ is known initially with accuracy.
According to the first characteristic of the invention, the number N is selected so that the spectral resolution δλ i of the interferometer 3 is smaller than the contribution δλ d to the spectral resolution of the dispersion system 6 that is due to the dimension d of the photodetectors. Use is made of the quotient R that is equal to the spectral sampling interval of the photodetectors along direction D 4 divided by the spectral resolution of the interferometer 3 . R=δλ d /δλ i . R is greater than 1. By way of example, N may be equal to 64 or 128.
The spectral resolution δλ s of the dispersive system 6 that is associated with the slit 4 is proportional to the width δy s of the image thereof on the matrix 8 of photodetectors along the direction D 4 : δλ s =δy s /Γ=l×G/Γ.
According to the second characteristic of the invention, the width l of the slit 4 is selected so that δλ s is greater than the spectral sampling interval δλ d of the photodetectors along the row direction L of the matrix. To this end, the width l must be greater than d/G.
FIG. 3 a corresponds to FIG. 2 a when the characteristics of the invention are implemented, i.e. when δλ i <δλ d <δλ s . By transferring the spectral resolution δλ i of the interferometer 3 onto the spectral direction DS associated with direction D 4 , wavelength variation along each row L is divided into elementary intervals, for each of which the light energy spectral distribution can be deduced from the light energies detected on one of the columns C of the matrix 8 . There then appears a new spatial resolution associated with direction D 4 , which is denoted δy i . This spatial resolution δy i results from the spectral resolution δλ i and the slope visible in the diagram of FIG. 3 a of the contributions to the detected light energy. From FIG. 3 a: δy i =δy s ×δλ i /δλ s . The spectral resolution δy i that is obtained is thus less than the spatial resolution δy s that would result solely from the width of the slit 4 . The following obtains: δy i =Γ×δλ i , whence: δy i <d. In other words, the spatial resolution along direction D 4 that results from the combination of the invention whereby measurements performed using the dispersive system 6 are combined with measurements performed using the interferometer 3 is smaller than the resolution that results from the dimension of the slit. This spatial resolution is obtained even through the width of the inlet field strip that is viewed in a single exposure is increased.
Preferably, the width of the slit 4 is selected so that the dimension of the image of the slit 4 on the matrix 8 of photodetectors is equal to the dimension of the photodetectors multiplied by N, these dimensions being considered along direction D 4 . In other words, δy s =N×d. For this purpose, l=N×d/G. The strip width in the inlet field that is viewed in a single shot is thus increased by a factor N, while allowing optimum use of the measurements performed by means of the interferometer 3 for obtaining small spatial resolution along direction D 4 .
If the relative position of the mirrors 32 and 33 is unknown initially, it can be determined by comparing the light energies detected for positive and negative values of the optical path length difference. The offsets of the elementary reflecting faces of the mirror 33 are then corrected by a fixed quantity so as to obtain a detected light energy distribution that is symmetrical between opposite values of the optical path length difference.
The slit 4 enables an observation field of the spectrophotometer to be scanned by the device 1 rotating about axis A-A, using strips of large width, corresponding to the distance δy s on the matrix 8 . The scanning speed of the device 1 about the axis Z-Z can then be increased by the ratio δy s /δy i =δλ s /(δλ d +δλ i ).
Furthermore, as shown in FIG. 3 b, the response function Rep is more uniform along a row of photodetectors L. As a result, operating conditions for the spectrophotometer are obtained, which lead to better precision in the imaging result and in the spectral analysis.
Finally, another advantage of such a spectrophotometer results from the fact that the effective spatial resolution and spectral resolution are determined by the structure of the echelette-grating mirror 33 . Given that the entire spectrophotometer is static, i.e., does not have any moving parts, measurements, both spatial measurements and spectral measurements, can be very accurate provided the mirror 33 is initially calibrated with precision and provided it is made out of a material that is thermally stable and relatively undeformable.
Naturally, the principle of the invention can be applied identically to a spectrophotometer in which some of the optical elements described are arranged in a different order along the path of the light beams. This applies in particular to the slit 4 which can be placed in equivalent manner at a plurality of locations in the spectrophotometer. Similarly, the invention can be applied to a spectrophotometer that is adapted to operate on light emitted by sources situated at a finite distance from the spectrophotometer inlet.
Although the invention is described using an intermediate lens 10 disposed at the outlet of the interferometer 3 , such an intermediate lens is not essential for implementing the invention. It can therefore be omitted, in particular in order to obtain a spectrophotometer that is lighter in weight and more compact. Under such circumstances, the slit 4 is located within the interferometer 3 , e g. on the mirrors 32 and/or 33 .
Finally, although the invention has been described in detail for a spectrophotometer that includes a Fourier transform interferometer, it should be understood that it could be applied to a spectrophotometer including an interferometer of some other type. To do this, it suffices that the interferometer is arranged to produce interferograms from an inlet light beam.
|
A spectrophotometer incorporating an interferometer and a dispersive system is adapted to have an enlarged inlet field without degrading its spatial resolution. To this end, spectral data deduced horn measurements performed by means of the interferometer are transferred into spectral data deduced from measurements per formed by means of the dispersive system. Such spectrophotometer makes it possible to scan an observation field quickly, and is compatible with use on board a satellite.
| 6
|
BACKGROUND
The present invention relates to methods of and apparatus for making a history or record, particularly, but not exclusively, of medical treatments or procedures, and to methods of and apparatus for using the history or record. More particularly, it relates to producing and digitizing a number of images to create a digital library of images, producing and providing a digital library of texts corresponding to the images in the library of images, providing an image from outside the digital library, digitizing it and comparing it to the digital images in the digital library, and selecting from the digital library of texts a text which corresponds to the outside image, and using the selected text to produce at least a portion of a record.
In many fields and technologies it is important to create and maintain a record, or history or narrative, of situations, facts, operations or procedures. Such records are important for achieving repeatability and accuracy, for educational or evaluative purposes, and/or for reconstructive purposes. For example, in industrial production, they may be used to detect deviations from specifications and production standards, and/or they may be used to create a “standard operating procedure” (“SOP”). In the legal field, transcripts or records of legal proceedings may be used to revisit or review the propriety of proceedings and decisions. In research or experimental science, laboratory notebooks or journals may reflect and/or evidence results of chemical combinations or hypothesis. In medicine, medical records and transcripts of surgical procedures may be used for diagnosis, to determine subsequent treatments, and/or to determine or assess prognoses. In each of these examples, and in many other instances and fields, records provide a database or library of knowledge, teach, instruct or inform about past practices or products, and/or aid in the detection and elimination of anomalies and inaccuracies.
Making and keeping a record has been, and is, a painstaking process. Typically, it has involved an individual hand writing a description or narrative, which may then be archived or preserved for reference by the individual who created it, or others. Developments in recording technologies, e.g., photography, sound and voice recording and storage, digital storage of information, etc., have somewhat eased the burden of creating a record, but there is room for further improvement.
Turning to the field of medicine, in which the present invention finds particular, but not exclusive, applicability, medical records were typically produced by the care giver writing by hand, for example, in a patient's chart. More recently, a care giver or physician may speak into a sound recording machine, or dictate, a description of a treatment or procedure. The recording or “tape” is then transcribed by others into a written record or chart. Also more recently, photographic records may be used. For example, a surgical procedure may be filmed, and the film may be accompanied by a verbal description dictated or spoken by the surgeon or attending physician while the procedure is taking place. Notwithstanding these advances, problems and inefficiencies remain.
One problem stems from outsourcing dictated medical records, even when such outsourcing is to organizations or people specializing in the transcription of medical records. The dictated item must be communicated to the transcriptionist, and back, and physicians and care givers must review and edit the transcription, leading to inefficiencies in time and handling, and increased costs. Another problem is the time interval or delay between the procedure and the availability of the transcript. This is true even when a physician dictates during a procedure, which itself may interfere with the concentration or performance of the physician. Typically, current medical record procedures still require a physician or surgeon to go to a workstation to dictate a description of a procedure or treatment after it is completed, at least to review a transcript, but in most instances, to dictate a description as well.
There are some attempts to improve the efficiency of producing medical records. For example, there are service providers, e.g., Speech Machines, Inc. and MedQuist, Inc., which specialize in transcribing dictated descriptions of medical treatments. They may use voice or term recognition systems (e.g., Dragon System's “Naturally Speaking,” IBM's “ViaVoice” and Lernout & Hauspie's “VoiceXpress”) wherein a vocal term or phrase is recognized by a computer which then converts it into a word-processing result. U.S. Pat. No. 6,031,526 discloses a system wherein generating electronic and printed medical records provides automatic integration of captured video still images and voice dictated information concerning the image, and wherein a voice recognition module allows the system to respond to voice commands and automatically transcribe the dictated text into a word processing document. Another, generally similar example of such systems is that provided by cMore Medical Solutions, Inc. of Minneapolis, Minn. Although efficiency of making a record may be increased, there are still transmission and handling delays, even when use is made of browser or internet-based systems.
One way to relieve physicians' dictation burden would be to film or photograph a treatment or surgical procedure and use the recorded images to trigger a descriptive text. Such a solution would likely involve a computer or computers. U.S. Pat. No. 4,996,707 (O'Malley et al.) discloses a computer system having the capability to receive and store graphic images which might be useful in such a solution. The system includes software that can digitize images, enabling them to be stored in memory and then accessed and used for various purposes, including identification, printing, or converting the digitized images to speech using a “text-to-speech” module. There is no disclosure or suggestion of digitizing a large number of images to create a digital library of images, providing an image from outside the digital library, digitizing it and comparing it to the digital images in the digital library, and providing for the production of a descriptive text associated with the image from outside the digital library.
Computers and storage and manipulation of data using computers hold promise for improving medical record creation, record keeping and use of stored medical records. For example, U.S. Pat. No. 5,050,220 involves an optical fingerprint correlator wherein a fingerprint is digitized, and then may be compared to a database of fingerprints to try to find a match. Such a correlator could be adapted to identify a patient, pull up the patient's medical record, and compare a current or recent diagnostic image (e.g., an MRI image) to the record. U.S. Pat. No. 5,031,228 discloses another image recognition system and method for identifying a pattern in images, and U.S. Pat. No. 5,668,897 discloses a method and apparatus for imaging and image processing, including digitizing an image and comparing the digitized image against a codebook of stored digital images. None of these patents discloses using an image to select or create a text describing an image.
The use of microprocessors, computers and computer management of data, including images, in the field of medicine is reflected in U.S. Pat. Nos. 5,241,472; 5,261,404; 5,740,802; 5,951,571; 5,961,456 and 6,024,695, the disclosures of which patents are incorporated herein by reference. Typically, the systems and methods disclosed in these patents involve obtaining images, digitizing the images and storing and/or manipulating or using the images, e.g., in U.S. Pat. No. 5,241,472 to create a text file. In U.S. Pat. No. 5,951,571 a computer is used to access a data storage unit containing previously acquired and digitally stored images of a patient. U.S. Pat. No. 5,961,456 is directed to a system and method for using current actual images and computer generated reference images, and the U.S. Pat. Nos. 5,261,404 and 6,024,695 patents use computer technologies to use images to position or guide surgical procedures. The U.S. Pat. No. 5,740,802 patent involves interactive computer generated models obtained from medical diagnostic imaging data to allow a surgeon to view internal and external patient structures and their relation to adjust the surgery accordingly. None of these patents discloses or suggests the use of the disclosed technologies to facilitate dictation, i.e., to help a physician create a medical record describing an administered treatment or procedure by using an image drawn from the treatment or procedure to trigger or select a text descriptive of the image, wherein the text then becomes at least part of a medical record.
U.S. Pat. Nos. 5,704,371 and 6,026,363 disclose a medical history documentation system and method which may involve a microprocessor to collect data and down load it to a computer which may store and process the data to provide a patient history text. There is no disclosure of using images to provoke the selection of a text corresponding to the image, wherein the selected text may become the record, or portion of the record, of a medical treatment or surgical procedure.
Notwithstanding the advances represented by the above mentioned technology and patents, it would be advantageous if there were a method and apparatus for more efficiently and accurately making a history or record, particularly, but not exclusively, a medical record.
SUMMARY
In one embodiment, the present invention provides methods and apparatus for making a history or record, particularly, but not exclusively, of a medical treatment or surgical procedure.
In one embodiment, the present invention relates to producing and digitizing a number of images to create a digital library of images, providing an image from outside the digital library, digitizing it and comparing it to the digital images in the digital library, and producing a text associated with the image from outside the digital library.
In one embodiment, the present invention comprises a visual input device, a processor, a visual output device, and a transmission system linking the input device, the processor and the output device.
In one embodiment, the present invention relates to the capture, recognition and manipulation of data.
In one embodiment, the present invention relates to the capture, recognition and manipulation of data, particularly data concerning medical treatment, wherein the treatment may be broken down into a series of steps, and wherein each step may be described by standard language understood by one skilled in the art. This feature of the present invention is well-suited to use in surgical procedures, wherein any one procedure may be accomplished in one of usually several or so standard or routine ways, wherein any one procedure may be broken down into steps or milestones, and wherein any one procedure usually involves encountering the same or similar physical structures.
An advantage of the present invention is that it facilitates creating a record, particularly, but not exclusively, a medical record.
In one embodiment, the present invention relates to producing and digitizing a number of images, related to a medical treatment, particularly a surgical procedure, to create a digital library of images, providing an image from outside the digital library, digitizing it and comparing it to the digital images in the digital library, and producing a text associated with the image from outside the digital library. In some embodiments, an image of an unusual, a typical and/or anomalous medical condition or situation may provoke, trigger or provide a “blank” text to be filled in later by the treating person. An advantage is better coordination of procedures and respective outcomes, as well as improving the time it takes for comparative or analytical information to become available. In some embodiments, the image from outside the digital library may be a real time image.
A feature of the present invention is image recognition, wherein a collection of images is available, each having an associated descriptive text, and wherein an image not in the collection is compared to images in the collection to find a comparable or matching image, and associated text. The collection of images may be created by accumulating images originally not in the collection.
Another feature of the present invention is providing a library of descriptions or texts, each associated, related to and/or describing a structure, step or quality depicted or captured as an image. In some embodiments, the structure, step or quality is an aspect of a medical treatment or surgical procedure.
Another feature of the present invention is providing coordination of procedures and outcomes, e.g., the outcome of a medical treatment may be compared to outcomes of similar procedures, anomalies or abnormalities may be compared and/or identified, a record of a procedure may be available for consideration more quickly, etc.
In one embodiment of the method and apparatus of the present invention, a live or real-time image obtained during a surgical procedure is compared to stored images of previous surgical procedures to find a stored image similar or substantially identical to the live image, whereupon a script or text describing the live image is produced.
In some embodiments, the method of the present invention involves creating a collection or library of images drawn from surgical procedures, e.g., laparoscopic gallbladder procedures, cholecystectomy, hernia procedures, etc., wherein the individual images comprise pictorial representations of anatomy or structures encountered and steps undertaken during the procedures. In some embodiments, the collection of images may be sorted or indexed into sets or groups, wherein a set or group may be comprised of any number of generally similar images depicting a step or action which is typically common to a selected procedure, e.g., a step in a laparoscopic gallbladder procedure.
In one embodiment, the present invention encompasses breaking a surgical procedure into a series of steps, capturing or representing each step in an image, each image depicting the step and structures and qualities associated with the step, digitizing the images, and creating a text respectively descriptive of a step and images of that step, wherein the text comprises standard language understood by one skilled in the art, and may be selected, without substantial change, to describe the similar step of another generally similar surgical procedure, the text selection being accomplished on the basis of comparing images from the generally similar surgical procedure to the previously acquired images.
In one embodiment, the present invention relates to producing a number of digital images to create a digital library of images, providing an image from outside the digital library, digitizing it (if it is not already digital) and comparing it to the digital images in the digital library, and producing a text associated with the image from outside the digital library, wherein the digital images and text may be considered data and may be analyzed and/or manipulated to provide likely or actual: diagnostic outcome information; a classification or sort of procedures by type; possible therapeutic, corrective or repair steps; and a recommendation of optional, and/or the optimal, therapeutic, corrective or repair steps. In one embodiment, the present invention may provide for statistical analysis of subject procedures and outcomes, for example, surgical procedures, whereby the optimum or best step or action within a given procedure may be identified.
In one embodiment of the present invention, data may be accumulated, analyzed and reported.
In one embodiment, the present invention relates to methods and apparatus for viewing and taking an image or picture of a number of objects or situations, processing the images, including digitizing and storing them and creating a text describing each of them, viewing and taking another image or picture, processing the another image, including digitizing and storing it, and selecting one of the texts which corresponds to the another image.
An advantage of the present invention is the creation and use of a world-wide network of procedural information, including, but not limited to medical and/or surgical information, wherein the information may be accessed by those engaged in similar procedures and/or wherein the information may evolve, e.g., the data comprising the information may increase, both in number and sophistication.
Another advantage of the methods and apparatus of the present invention is that they may be used to create an “early warning” system wherein a real-time image is compared to a library of images which includes images of anomalous, abnormal and/or dangerous structures, situations and/or qualities and, if a similarity is detected, a warning or alert is provided. In one embodiment, the present invention takes advantage of the routine, repetitive or common steps typical of a given procedure, for example, a surgical procedure, to provide for the early warning system, and/or to provide for a predictive and/or educational system, wherein a accessible and/or searchable database comprising a collection of images and texts to provided for consideration before undertaking a procedure.
Other features and advantages of methods and apparatus of the present invention will become more fully apparent and understood with reference to the accompanying description, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
This patent and/or patent application file contains photographs executed in color. Copies of this patent or patent application publication with color photographs will be provided by the Office upon request and payment of the necessary fee.
FIG. 1, including FIGS. 1 a - 1 e , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 2, including FIGS. 2 a - 2 c , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 3, including FIGS. 3 a - 3 d , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 4, including FIGS. 4 a - 4 i , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 5, including FIGS. 5 a - 5 f , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 6, including FIGS. 6 a - 6 c , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 7, including FIGS. 7 a - 7 g , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 8, including FIGS. 8 a - 8 b , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 9, including FIGS. 9 a - 9 c , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 10, including FIGS. 10 a - 10 i , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 11, including FIGS. 11 a - 11 e , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 12, including FIGS. 12 a - 12 e , comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 13, including FIGS. 13 a - 13 j comprises representative images exemplifying images for use in embodiments of the present invention.
FIG. 14 depicts one embodiment of a computer or processing system of the present invention.
FIG. 15 depicts an embodiment of the process or method of the present invention.
FIG. 16 depicts another embodiment of the present invention.
FIG. 17 depicts another embodiment of the present invention.
DETAILED DESCRIPTION
The accompanying figures and this description depict and describe embodiments of a process or method and apparatus in accordance with the present invention, and features, steps and components thereof. As used herein, the terms “medical treatment”, “surgery” and “surgical procedure” are intended to encompass any medical care giver/patient interaction, including, but not limited to office examinations, surgical procedures, physical therapy, administration of medication, consults, diagnostic procedures, etc. In some embodiments, the methods and apparatus of the present invention may comprise integrated structures or features, such as a network of microprocessors, communication links and the like, at various locations, including a central station, and the steps may be performed at various locations. Although electronic, e.g., digital, apparatus and methods are contemplated, the present invention is also intended to encompass “hard copy,” e.g., video images, photographs, printed documents, including directories or indices, and the like.
Unless specifically disclosed or taught, any suitable electronic devices and coupling or linking methods and apparatus may be used in the present invention, for example, the present invention may incorporate appropriate microprocessors, integrated circuits, chips, memory structures, wireless links, internet links, telephony, optical fiber technology, data storage technology, etc.
Any references to positional and/or temporal locations, e.g., the location of microprocessors and/or the order of processing or steps, are intended for convenience of description, not to limit the present invention to any one positional or temporal orientation.
Although the microprocessor or controller, or microprocessors, for the present invention can be any controller or microprocessor-based system, and more than one may be involved, in one embodiment of the invention, the controller comprises a suitable central processing unit and suitable peripheral devices. In one embodiment, a suitable peripheral device may be a field programmable micro-controller peripheral device that includes, like the processing unit, programmable logic devices, EPROMs, and input-output ports. Typically, instructions are stored in the controller as program logic, which might be found as RAM or ROM hardware in the processing unit or peripheral device. (Since the processing unit may have some memory capacity, it is possible that some of the instructions are stored in the processing unit.) As one skilled in the art will recognize, various implementations of program logic are possible. The program logic could be either hardware, software, or a combination of both. Hardware implementations might involve hardwired controller logic or instructions stored in a ROM or RAM device. Software implementations would involve instructions stored on a magnetic, optical, or other media that can be accessed by the processing unit. Communication implementations may be wired, optical or wireless.
FIG. 14 depicts one embodiment of the processing system of the present invention where an apparatus 100 is used to process the images received from inputs 112 and generate text output also depicted at block 112 and which may be stored in a text library. A central processing unit or CPU 102 utilizes appropriate software to operate the system. The image library 107 contains the images and is stored in the memory 106 . The image recognition device 108 compares a newly acquired image to the images in the library. Once the image is recognized the computer will select the text corresponding to the recognized image. The apparatus 100 can be connected to appropriate interfaces 104 and/or to a remote computer or interface 114 and/or other suitable remotes or peripherals 116 .
The following examples reflect one embodiment of the present invention wherein at least a portion of a dictation record regarding a surgical procedure corresponds to an image captured during that procedure and during other similar procedures. In other words, each of the following examples of dictation records concerning actual surgical procedures includes certain steps or elements in common, and those elements or steps, and the entire procedure, may be photographed during the procedures of the examples. The examples are generally typical of such procedures and, thus, the pictures of common elements or steps will be generally typical. The pictures may be digitized using a suitable method, and stored in a digital library. Pictures taken during another (e.g., real time) procedure, not one of the examples, but another similar procedure, may be digitized and compared to the pictures in the digital library. Because the another procedure is similar to the procedures already represented in the digital library, pictures of steps from it will correspond or match closely pictures of steps from the previous similar procedures. The corresponding or matching picture(s) in the digital library may be used to trigger a text descriptive of the picture(s) which will also be descriptive of the step of the another (or real time) procedure.
FIGS. 1-13, including FIGS. 1 a - 1 e , 2 a - 2 c , 3 a - 3 d , 4 a - 4 i , 5 a - 5 f , 6 a - 6 c , 7 a - 7 g , and 8 a - 8 b , 9 a - 9 c , 10 a - 10 i , 11 a - 11 e , 12 a - 12 e , and 13 a - 13 j , are actual images taken from the procedures of the following Examples 1-6 (gallbladder) and Examples 1-4 (hernia) or from generally similar procedures. Any surgical procedure, including those of the examples, may be imagined as a film or movie, i.e., a continuous series of images, and FIGS. 1-13 comprise selected stills or individual images clipped or selected from the film. Images identified as Figures corresponding to the steps of the procedures of Examples 1-6 (gallbladder) and Examples 1-4 (hernia) have been referenced in the dictation text of those examples. It should be appreciated that other and/or additional common, routine and/or similar steps, dictation portions and images may be identified. In the following examples, grammatical and typographical errors from the original transcribed dictation record have been corrected.
The following six examples are actual dictated records of gallbladder procedures. It should be understood that an advantage of the present invention derives from the fact that surgical procedures are repetitive in terms of what is seen, and the words used to describe what is seen. Indeed, routinization in procedures is important to surgeons and patients because anatomy usually conforms from patient to patient. Although a surgeon may slightly vary steps and/or the order of steps in a procedure, and although there may be some slight variations in the angle of vision, color, etc., there will be steps and images which are substantially similar from procedure to procedure. Again, the parenthetical reference to a figure or figures following each step is to link the step with various corresponding sample figures and are outlined by bold lettering.
EXAMPLE 1
Gallbladder
Operative Procedure: Laparoscopic Cholecystectomy, Cholangiography.
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained the patient's abdomen was prepped and draped in the usual fashion. A CO2 pneumoperitoneum was instilled through a 10 mm trocar placed cephalad to the umbilicus at 4 liters per minute of flow pressure equal to or less than 17 mmHg to a total of 4.5 liters. A 45° angle laparoscope was introduced. Examination of the abdomen was unremarkable except for the gallbladder which showed multiple adhesions. These were of a chronic type. Under direct vision a 5 mm trocar was placed along the right anterior axillary line.
Step 1: Fundus of the gallbladder was grasped. (FIGS. 1, 1 a - 1 e )
Step 2: A # 17 gauge pericardial needle was passed percutaneously into the gallbladder. Then 30 cc of bile was aspirated and replaced with 60 cc of 50 percent Hypaque and two separate aliquots of 50 and 10 cc each with x-rays taken at the conclusion of infusion of each aliquot. After x-rays were taken and examined excess Hypaque was aspirated and the needle removed under direct vision. (FIGS. 2, 2 a - 2 c )
Step 3: Two 5 mm and a 12 mm trocars were placed in the right mid abdomen. The patient was placed in reversed Trendelenburg's position. (FIGS. 3, 3 a - 3 d )
Step 4: The neck of the gallbladder was grasped and dissected out from surrounding tissue. The junction of the cystic duct, common duct, and common hepatic duct was visualized. (FIGS. 4, 4 a - 4 i )
Step 5: The cystic duct was dissected free, clipped proximally and distally, divided. (FIGS. 5, 5 a - 5 f )
Step 6: The cystic artery was electrocoagulated with bipolar cautery. (FIGS. 6, 6 a - 6 c )
Step 7: The gallbladder was removed off the liver bed with bipolar cautery in retrograde fashion. (FIGS. 7, 7 a - 7 g )
Step 8: The gallbladder was led out of the abdomen through the 12 mm trocar. (FIGS. 8, 8 a - 8 b )
Conclusion
The abdomen was irrigated with saline and the irrigant suctioned out. Trocars were removed. The deep tissue was closed with interrupted #2 Vicryl to the fascia, continuous running #4 Vicryl subcuticular to reapproximate the skin. Closure was reinforced with Steri-Strips. Gauze bandage and paper tape with dressings were applied. Blood loss was negligible. She left the Operating Room in satisfactory condition. (End of Example 1)
EXAMPLE 2
Gallbladder
Operative Procedure:
1. Laparoscopic cholecystectomy with cholecyst cholangiography.
2. Excision of chronic infected, nonhealing cyst of the back with conversion from transverse to oblique orientation using Z-plasty technique.
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion, after which CO2 pneumoperitoneum instilled through a 10 mm Innerdyne trocar placed cephalad to the umbilicus and 4 L/min flow, pressures equal to or less than 17 mm Hg to a total of 5 L. A 45-degree angle laparoscope introduced. Thorough examination of the abdomen revealed a right inguinal hernia. Otherwise, there were a few adhesions to the gallbladder, a few stones in the gallbladder of cholesterol origin, and at the time of cholangiography, one was able to see a normal anatomical pattern. No defects in the common duct with dye entering freely into the duodenum. Under direct vision, a 5 mm trocar placed along the right anterior axillary line.
Step 1: Bi-toothed biopsy forceps used to grab the fundus of the gallbladder for upward retraction. (FIGS. 1, 1 a - 1 e )
Step 2: A 17 gauge pericardial needle passed percutaneously into the gallbladder, excess bile aspirated, replaced with 60 cc of 50% Hypaque, delivered in two aliquots of 50 and 10 cc each. At the end of infusion of each aliquot, x-rays were taken. These were examined. Findings as listed above. Excess dye was then aspirated, the needle removed. (FIGS. 2, 2 a - 2 c )
Step 3: Additional 5 mm and 12 mm trocar placed in the right mid abdomen. Patient placed in reversed Trendelenburg position. (FIGS. 3, 3 a - 3 d )
Step 4: The neck of the gallbladder was elevated, the cystic duct dissected from the gallbladder to junction with the common bile duct, cystic artery identified along with the lymph node of Calot. (FIGS. 4, 4 a - 4 i )
Step 5: The cystic duct was clipped ×3 proximally, distally, the cystic duct divided. (FIGS. 5, 5 a - 5 f )
Step 7: The gallbladder dissected off the liver bed with bipolar cautery. (FIGS. 7, 7 a - 7 g )
Step 6: The cystic artery was electrocoagulated with bipolar cautery. (FIGS. 6, 6 a - 6 c )
Step 8: The gallbladder was then delivered out of the abdomen through the leading edge of the 12 mm trocar. (FIGS. 8, 8 a - 8 b )
Conclusion
The stones were removed before the entire gallbladder could be removed from the abdominal cavity. Once done, the 12 mm trocar was replaced, the right upper quadrant irrigated with saline until clear. No bile or blood was noted. Irrigant suctioned out along the right lateral sulcus of the liver. Instruments removed, CO2 let out through open valves and external massage. Trocars removed, deep tissue closed with 2-0 Vicryl, skin with continuous running 4-0 Vicryl and ½ inch Steri-Strips. Tegaderm dressings applied. Tolerated well. At that point, we placed the patient prone. The lesion in the upper mid back measured approximately ¾ to 1 inch in transverse diameter. The cyst was partially filled with material. It was opened and chronically fistulized to the skin. Actually, the cyst traveled cephalad a fair distance underneath the skin. The area was locally infiltrated with 0.25% Marcaine with epinephrine as were the previous sites of the gallbladder trocars. A Z-plasty was marked on the skin. The mass itself was first excised. Z-plasty flaps were dissected out. Bleeding controlled with electrocoagulation. After the flaps were completed, they were placed in the proper orientation, allowing a central vertical incision and two adjacent oblique incisions. The closure was completed with interrupted 4-0 Vicryl to the subcutaneous tissue. It should be mentioned a #7 round Jackson-Pratt drain was placed into the depths of the incision, brought out through a lateral stab wound, tied to the skin with 2-0 silk. After stabilization of the flaps, the skin was reapproximated with continuous running 5-0 Vicryl. Sterile compressive dressing applied. Tolerated well. Blood loss negligible. Left the operating room now in satisfactory condition. (End of Example 2)
EXAMPLE 3
Gallbladder
Operative Procedure: Laparoscopic Cholecystectomy with Cholecyst Cholangiography.
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion after which CO2 pneumoperitoneum instilled with a Veress needle placed cephalad to the umbilicus at 2.5 L full to pressures equal to or less than 16 mmHg to a total of 6 L. The Veress needle then removed and replaced with a 10-mm InnerDyne trocar. A 45-degree-angle laparoscope introduced. General examination of the abdomen. Findings as listed above. No adhesions were present to the gallbladder. The gallbladder appeared gray in color. Under direct vision, a 5-mm trocar was placed along the right anterior axillary line.
Step 1: The bitoothed biopsy forceps were used to grab the fundus of the gallbladder with upward retraction. (FIGS. 1, 1 a - 1 e )
Step 2: A 17-gauge pericardial needle passed percutaneously into the gallbladder. Approximately 30 cc of dark brown bile was aspirated and 60 cc of 50% Hypaque instilled in two separate aliquots of 50 and 10 cc each. At the end of the infusion of each of the two aliquots, x-rays were taken and examined in the operating room, with the findings as listed above. The excess Hypaque was then aspirated, the needle removed. (FIGS. 2, 2 a - 2 c )
Step 3: Under direct vision a 5-mm and 12-mm trocar were placed in the right midabdomen. (FIGS. 3, 3 a - 3 d )
Step 4: Bitooth biopsy forceps used to place the neck of the gallbladder on stretch after placing the patient in reverse Trendelenburg position. Everest Medical bipolar curved scissors and forceps used to uncover the cystic duct and the cystic artery. The cystic duct was followed to its junction with the common bile duct. (FIGS. 4, 4 a - 4 i )
Step 5: The cystic duct was clipped times 2 proximally and once distally, divided. (FIGS. 5, 5 a - 5 f )
Step 6: The cystic artery electrocoagulated with bipolar cautery. (FIGS. 6, 6 a - 6 c )
Step 7: Gallbladder dissected off the liver bed with bipolar cautery aided by bipolar scissors dissection. (FIGS. 7, 7 a - 7 g )
Step 8: After removal of the gallbladder from the liver, the gallbladder fossa was examined for bile or blood. There was none. The gallbladder then placed into a bag which was then brought out half way through the abdomen and ring forceps used to extract whatever was left of the gallbladder itself and the bag as well. (FIGS. 8, 8 a - 8 b )
Conclusion
With all of this removed, the 12-mm trocar was placed back into the abdomen, the right upper quadrant irrigated with saline until clear, and the instruments then removed. CO2 let out through external massage. The trocars were removed. The deep tissue was closed with 2-0 Vicryl, the skin with continuous running 4-0 Vicryl, with ½ inch Steri-Strips. Each puncture site was locally infiltrated with 0.25% Marcaine with epinephrine for postoperative pain relief. A Tagaderm dressing was applied. Tolerated well. Blood loss negligible. (End of Example 3)
EXAMPLE 4
Gallbladder
Operative Procedure: Laparoscopic Cholecystectomy
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion, after which CO2 pneumoperitoneum was instilled through a 10-mm InnerDyne trocar placed cephalad to the umbilicus at 4 L per minute flow pressures equal to or less than 16 mmHg to a total of 5 L. A 45-degree-angle laparoscope was introduced. Sterile examination of the abdomen and findings as listed above.
Step 3: Under direct vision, 5-mm trocars times two were placed in the right midabdomen along with the 12-mm InerDyne trocar. (FIGS. 3, 3 a - 3 d )
Multiple adhesions were present on the gallbladder. These were taken down with bipolar cautery. The gallbladder was then elevated out of the wound after being freed of adhesions.
Step 4: Careful dissection of the gallbladder as it narrowed down into the cystic duct was noted. Medial dissection was unremarkable. (FIGS. 4, 4 a - 4 i )
Step 5: Once the dissection was completed, the clips were placed proximally on the cystic duct times three, one distally, the cystic duct divided. (FIGS. 5, 5 a - 5 f )
Then dissected off in a retrograde fashion using bipolar cautery. The gallbladder represented an intrahepatic gallbladder as well as subacute. The dissection went very smoothly without any bleeding.
Step 6: The cystic artery had been identified and electrocoagulated. (FIGS. 6, 6 a - 6 c )
Step 7: We located the anterior cystic artery. The dissection continued smoothly off the liver bed. (FIGS. 7, 7 a - 7 g )
The liver bed was then inspected for any residual bleeding or bile staining and none was evident except some bleeding, a very minimal amount, toward the bottom of the liver bed, and a piece of Surgicel was placed here for control. This was then re-examined after total removal of the gallbladder and again no blood or bile was now present.
Step 8: The gallbladder after being removed was then led partially out of the abdomen through the 12-mm trocar and grabbed with clamps, incised, the bile suctioned out, and small stones were then removed with a ring forceps until the gallbladder was small enough in size to pop through the opening. (FIGS. 8, 8 a - 8 b )
Conclusion
The trocar was then replaced, the right upper quadrant irrigated with saline, some irrigant suctioned off, and the procedure terminated with removal of instruments. Open valves on the trocars. External massage to remove CO2 gas. The trocars were removed and the tissue closed with interrupted 2-0 Vicryl sutures, the skin with continuous running 4-0 Vicryl and ½ -inch Steri-Strips. Tegaderm dressing was applied. Tolerated well. Left the operating room in satisfactory condition. (End of Example 4)
EXAMPLE 5
Gallbladder
Operative Procedure: Laparoscopic Cholecystectomy and Cholecyst-Cholangiography.
Description of Procedure:
Introduction
After satisfactory endotracheal inhalation anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion, after which CO2 pneumoperitoneum was instilled through a 10 mm Innerdyne trocar placed cephalad to the umbilicus at a 4 L/min flow with pressures equal to or less than 17 mmHg to a total of five liters. A 45 degree angle laparoscope was introduced into the abdomen and general examination of the abdomen unremarkable except for findings as listed above. Under direct vision, a 5 mm trocar was placed along the right anterior axillary line.
Step 1: Bi-toothed biopsy forceps grasped the fundus of the gallbladder with upward retraction. (FIGS. 1, 1 a - 1 e )
Step 2: A 17 gauge pericardial needle was passed percutaneously into the gallbladder, excess bile aspirated and 60 cc of 50% Hypaque introduced in 50 and 10 cc aliquots. At the end of each aliquot x-rays were taken and cystic duct obstruction was noted. Excess dye was then removed, the needle removed. (FIGS. 2, 2 a - 2 c )
Step 3: A 5 mm and 12 mm trocars placed in the right mid abdomen under direct vision. The patient was placed in reverse Trendelenburg position. (FIGS. 3, 3 a - 3 d )
Step 4: The gallbladder was then grabbed just above the stone which was impacted in the neck. The cystic duct was fully dissected away from the gallbladder and the anterior and posterior cystic artery noted. (FIGS. 4, 4 a - 4 i )
Step 5: After all three structures were identified clearly, they were clipped, appropriately divided. (FIGS. 5, 5 a - 5 f )
Step 7: The gallbladder then dissected off the liver bed with bipolar cautery and scissors. (FIGS. 7, 7 a - 7 g )
Step 8: It was then put into an extraction bag, brought half way out of the abdomen through the 12 mm trocar and piecemeal we were able to remove the gallbladder bag intact. (FIGS. 8, 8 a - 8 b )
Conclusion
The puncture site was irrigated with saline. The abdomen was copiously irrigated until clear. No drains were placed. The trocars were removed, the deep tissue closed with interrupted 2-0 Vicryl and the skin with continuous running 4-0 Vicryl subcuticular. Half inch Steri-Strips were applied, Tegaderm dressings applied, the wounds locally infiltrated with 0.25% Marcaine with epinephrine for postoperative pain relief and the procedure terminated. The patient tolerated it well and left the operating room in satisfactory condition. (End of Example 5)
EXAMPLE 6
Gallbladder
Operative Procedure: Laparoscopic Cholecystectomy, Cholangiography.
Description of Procedure:
Introduction
After a satisfactory endotracheal anesthesia was obtained the abdomen was prepped and draped in the usual fashion. A CO2 pneumoperitoneum was instilled through a 10 mm innerdyne trocar placed cephalad to the umbilicus at four liters per minute flow. Flow pressures were equal to or less than 17 mmHg to a total of five liters. The 45° angle laparoscope was introduced. General examination of the abdomen showed findings as described above.
Step 3: Under direct vision a 5 mm and 12 mm disposable trocar was placed in the right upper quadrant along with a third trocar, 5 mm. (FIGS. 3, 3 a - 3 d )
Step 1: Bitooth biopsy forceps were used to grasp the fundus of the gallbladder. (FIGS. 1, 1 a - 1 e )
Step 2: A #17 gauge pericardial needle was passed percutaneously into the gallbladder and 30 cc of dark bile was aspirated. Then 60 of 50% Hypaque was instilled through separate aliquots, and 50 and 10 cc each. X-rays were taken at the conclusion of each aliquot infusion. Findings are as noted above. Excess Hypaque was aspirated and the needle removed. The patient was placed in reversed Trendelenburg position. (FIGS. 2, 2 a - 2 c )
Step 4: The gallbladder was grasped at the neck. Moderate amount of inflammation was noted in the wall with edema. The lymph node of Calot was identified and stripped off the gallbladder. The gallbladder junction with the cystic duct was identified which was then traced down to the common bile duct. The cystic artery was identified and all these structures lay in normal anatomic position. The cystic duct was dissected free of surrounding tissue. (FIGS. 4, 4 a - 4 i )
Step 5: Two clips were then placed proximally and two distally. The duct was divided. (FIGS. 5, 5 a - 5 f )
Step 6: The cystic artery was electrocoagulated with bipolar cautery and divided. (FIGS. 6, 6 a - 6 c )
Step 7: The gallbladder was then dissected off the liver bed with bipolar cautery in a retrograde fashion until it was free from the liver. (FIGS. 7, 7 a - 7 g )
Step 8: It was then brought partially out of the abdomen through the 12 mm trocar. (FIGS. 8, 8 a - 8 b )
Conclusion
The instrument was then placed within the gallbladder to crush the stone into multiple small pieces which were then removed piecemeal until the gallgladder popped through the hole. Some fragments got loose but were retrieved both intra-abdominal with a pelviscopic scoop and within the wound itself while pulling the gallbladder through the wound with pickups. The whole tract was irrigated copiously with saline until all fragments were cleaned up. The inside of the abdomen was irrigated with saline, especially the gallbladder fossa and along the right lateral sulcus of the liver, all of which was aspirated. No evidence of any bleeding, bile leakage was noted. Instruments were removed. Trocars were removed after expelling co2 gas with external massage. After removal of the trocars the deeper tissue was reapproximated with #2-0 Vicryl and skin with continuous running #4 Vicryl. Half-inch Steri-Strips were placed. Tegaderm dressing was applied. The patient tolerated the procedure well. Blood loss was negligible. No complications were apparent. (End of Example 6)
The present invention can be used for various types of procedures in addition to the prior 6 examples just discussed. Another example is for use in hernia procedures. The following four examples are dictation records from left inguinal hernia repair procedures. References have been inserted in each example to refer to FIG. 1 and FIGS. 9-13, including FIGS. 1 a - 1 e , 9 a - 9 c , 10 a - 10 i , 11 a - 11 e , 12 a - 12 e , 13 a - 13 j which comprise images actually captured during the procedure of Example 1-4 (hernia).
EXAMPLE 1
Hernia
Operative Procedure: Laparoscopic Repair of Left Inguinal Hernia with Polypropylene Mesh
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained, patient's abdomen was prepped and draped in the usual fashion after which CO2 peritoneum instilled through a 10 mm trocar placed cephalad to the umbilicus at 4 liters/minute flow of pressures equal to or less than 16 mmHg to a total of 5 liters. The 45 degree angle laparoscope introduced. General examination of the abdomen with findings as listed above.
Step 1: Under direct vision, a 5 mm and 12 mm trocar placed in right and left mid abdomen respectively. (FIGS. 1, 1 a - 1 e )
Step 2: Patient placed in Trendelenburg position. Everest medical curved scissors and bitooth biopsy forceps used to develop a left curvilinear peritoneal flap directed posteriorly which allowed entry into the preperitoneal space. (FIGS. 9, 9 a - 9 c )
Step 3: Dissection of the space curved from the line of Douglas above to Cooper's ligament below beyond the midline and lateral to the internal ring. (FIGS. 10, 10 a - 10 i )
Step 4: Direct space hernia was evident. A very small amount of fat was contained within the internal ring which was essentially normal in size and this was not reduced. A piece of polypropylene mesh measuring 6×5 inches was tightly rolled up into {fraction (10/11)} mm trocar, placed on the 12 mm trocar and popped into the preperitoneal space on the left. This was unfurled, covered with the inguinal femoral area. (FIGS. 11, 11 a - 11 e )
Step 5: Stapled in place. (FIGS. 12, 12 a - 12 e )
Step 6: Pressure was then reduced to 5-6 mmHg, the leaves of peritoneum then reapproximated with closely placed staples. (FIGS. 13, 13 a - 13 j )
Conclusion
When complete, instruments were removed, CO2 let out through open valves and external massage. Trocar was removed, deep tissue closed with interrupted 2-0 Vicryl, skin with continuous running 4-0 Vicryl, Steri-Strips applied, Tegaderm placed. Tolerated well. Blood loss negligible. Left the operating room in satisfactory condition. (End of Example 1)
EXAMPLE 2
Hernia
Operative Procedure: Laparoscopic Repair of Recurrent Left Inguinal Hernia with Polypropylene Mesh
Description of Procedure:
Introduction
After satisfactory general endotracheal anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion after which CO2 pneumoperitoneum was instilled through a 10 mm Interdyne trocar placed cephalad to the umbilicus, 4 liters/minute flow and pressures equal to or less than 16 mmHg to a total of 4 liters. A 25 degree angle laparoscope was introduced and examination of the abdomen was unremarkable. A left inguinal hernia was noted. There is minimal weakness on the right and no additional surgery was done for that.
Step 1: Under direct vision, a 5 mm and 12 mm trocars were placed in right and left midabdomen, respectively. (FIGS. 1, 1 a - 1 e )
Step 2: The patient was placed in Trendelenburg position and a bitooth biopsy forceps and Everest Medical curved forceps and scissors used to develop a left curvilinear peritoneal flap directed posteriorly allowing entry into the preperitoneal space. (FIGS. 9, 9 a - 9 c )
Step 3: The space was dissected completely beyond the midline to the line of Douglas above to Cooper's ligament below. (FIGS. 10, 10 a - 10 i )
The hernia could be seen in the direct space constituting herniated fat, which was then reduced out of the hole, which could clearly be seen. The dissection carried well beyond the internal ring. A search for lipoma was negative. With the flap nicely developed.
Step 4: A piece of polypropylene mesh measuring 15×11.5 cm was placed into the preperitoneal space and used to cover the inguinal femoral area. (FIGS. 11, 11 a - 11 e )
Step 5: Staples were placed at all but the volar inferior portion mesh because of underlying nerve tissue in this region. (FIGS. 12, 12 a - 12 e )
Step 6: Pressure then reduced to 8 mmHg and leaves of peritoneum reapproximated with closely placed staples. (FIGS. 13, 13 a - 13 j )
Conclusion
Instruments were removed and CO2 removed through open valves. Trocars were removed. Deep tissue was closed with interrupted #2-0 Vicryl and skin with running #4-0 Vicryl and ½ inch Steri-Strips. Tegaderm dressings applied. Marcaine 0.25% with epinephrine was instilled in puncture sites for postoperative pain relief. Blood loss was minimal. The patient tolerated the procedure well and left the operating room in satisfactory condition. (End of Example 2)
EXAMPLE 3
Hernia
Operative Procedure: Laparoscopic Repair of Left Direct Space Weakness with Excision of Left Inguinal Lipoma Using Polypropylene Mesh.
Description of Procedure:
Introduction
After satisfactory endotracheal anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion after which CO2 pneumoperitoneum was instilled through a 10-mm InnerDyne trocar placed cephalad to the umbilicus at 4 L per minute flow pressures equal to less than 16 mmHg. A 45-degree angle laparoscope introduced into the abdomen. The left inguinal hernia and weakness were noted, primarily over the direct space. The right inguinal area was unremarkable.
Step 1: Under direct vision, a 5-mm and 12-mm trocar was placed in the right and left midabdomen respectively. (FIGS. 1, 1 a - 1 e )
Step 2: The patient placed in Trendelenburg position and a 45-degree-angle laparoscope introduced. General examination of the abdomen as noted above. Using a bitooth biopsy forceps, the Everett Medical curved scissors and Kleptinger bipolar cautery, a left curvilinear peritoneal flap was directed posteriorly. (FIGS. 9, 9 a - 9 c )
Step 3: The preperitoneal space dissected thoroughly from beyond the midline to below. (FIGS. 10, 10 a - 10 i )
An extremely weak posterior space was noted. A lipoma of the cord was noted. In addition, there were multiple and enlarged lymph nodes present at the mouth of the slightly dilated internal ring. This site is considered to be unusual and is not customarily found, although such nodes are found in the region of the femoral ring. For that reason, a biopsy was taken of one of these nodes and sent for pathologic examination.
Step 4: After thorough dissection of the preperitoneal space, polypropylene mesh measuring 15×11.5 was rolled up in a 10-11 trocar placed down a 12-mm trocar and placed into the preperitoneal space. This was unfurled over the inguinal femoral area. (FIGS. 11, 11 a - 11 e )
Step 5: Held in place with staples. (FIGS. 12, 12 a - 12 e )
Step 6: The pressure was then reduced to 8 mmHg and the leaves of peritoneum reapproximated with closely placed staples. (FIGS. 13, 13 a - 13 j )
Conclusion
The instruments were removed and CO2 let out through open valves and external massage. The trocar was removed. The deep tissue was closed with interrupted 2-0 Vicryl, the skin with continuous running 4-0 Vicryl, with ½ inch Steri-Strips. A Tegaderm dressing was applied. Tolerated well. Blood loss negligible. Left the operating room in satisfactory condition. (End of Example 3)
EXAMPLE 4
Hernia
Operative Procedure: Laparoscopic Repair of Indirect Right Inguinal Hernia with Polypropylene Mesh
Description of Procedure:
Introduction
After satisfactory endotracheal inhalation anesthesia was obtained, the patient's abdomen was prepped and draped in the usual fashion, after which CO2 pneumoperitoneum was instilled through a 10 mm Innerdyne trocar placed cephalad to the umbilicus at 4 L/min flow with pressures equal to or less than 17 mmHg to a total of 4.5 liters. A 45 degree angle laparoscope was introduced. General examination of the abdomen revealed findings as listed above.
Step 1: Under direct vision, 5 mm and 12 mm trocars were placed in the right and left mid abdomen respectively. (FIGS. 1, 1 a - 1 e )
Step 2: The patient was placed in Trendelenburg position. A curvilinear flap was developed in the right inguinal area using Everest Medical bipolar curved scissors and forceps and bi-toothed biopsy forceps. (FIGS. 9, 9 a - 9 c )
Step 3: As the flap was developed it allowed entry into the preperitoneal space, which was dissected from the line of Douglas above to Cooper's ligament below lateral to the internal ring and medial to the midline. (FIGS. 10, 10 a - 10 i )
Step 4: Once fully developed and the extraneous sac removed from the internal ring, a piece of polypropylene mesh measuring 6×5 inches was rolled up into a 10-11 mm trocar, popped down the 12 mm trocar and then into the preperitoneal space. This was unfurled over the inguinal-femoral area. (FIGS. 11, 11 a - 11 e )
Step 5: Held in place with staples. (FIGS. 12, 12 a - 12 e )
Step 6: Pressure was then reduced to 6 mmHg and the leaves of peritoneum reapproximated with closely placed staples. (FIGS. 13, 13 a - 13 j )
Conclusion
When this was completed, instruments were removed, the CO2 let out through open valves and external massage, the trocars removed, the deep tissue closed with interrupted 2-0 Vicryl suture to the fascia and subcutaneous tissue, the skin closed with continuous running 4-0 Vicryl with half inch Steri-Strips. Tegaderm dressings were applied, 0.25% Marcaine with epinephrine instilled in the puncture sites for postop pain relief and the procedure terminated. (End of Example 4)
The preceding examples are intended to be exemplary, and the present invention is not limited to the preceding examples.
FIG. 15 depicts one embodiment of the method, process and/or functional flow of the present invention. The images are obtained and stored in the image library, 200 . First the image is obtained, 202 , and then appropriately digitized, 204 . The digitized images are then added to the image library 206 and compared to the images in the library, 208 . Corresponding to the images or to groups of similar images (e.g. Figures) is the respective text descriptions of the steps and/or of the image, 400 . The text is created, 402 , and then added to a text library 404 . Text creation, editing, and storage can be either a separate or concurrent function of the image processing.
The text and the images are combined together, 600 , after the obtained image is compared to images from the image library 602 . Similar images in the image library may be grouped together with a descriptive text associated with each grouping. Subgroups of the grouped images may be created to provide further descriptive detail to the step (e.g., the color of organ, the position of the organ, etc.). After the comparison of the images has been made and the obtained image is associated with a group and/or related subgroup, the obtained image is labeled with the corresponding text from the text library 604 . The text that is selected from the text library is used to create a record 606 or part of a record. The record or portion there of that is created can then be communicated, displayed, or manipulated, 608 .
The following are “stylized” descriptive texts based on the steps and images from the above examples. These stylized texts are examples of language which may be descriptive of the various steps, procedures, functions, physiology, physiological conditions, and the like generally typical of gallbladder and hernia procedures, respectively. The process outlined in FIG. 15 may be used to create a record comprising the following stylized steps. The text for the steps of the procedure may be set or read only; however, a doctor or other person creating a record may insert patient specific details in the introduction and conclusion of the record to account for problems, deviations or additions to the set-up or closing procedures.
Gallbladder (Stylized Text)
Step 1: The bitoothed biopsy forceps were used to grab the fundus of the gallbladder with upward retraction. (FIGS. 1, 1 a - 1 e )
Step 2: A 17 gauge pericardial needle was passed percutaneously into the gallbladder. Excess bile was aspirated and replaced with 60 cc of 50% Hypaque instilled in two separate aliquots of 50 and 10 cc each. At the end of the infusion of each of the two aliquots, x-rays were taken and examined in the operating room with the findings as listed above. The excess Hypaque was aspirated and the needle removed under direct vision. (FIGS. 2, 2 a - 2 c )
Step 3: A 5-mm and 12-mm trocar were placed in the right mid-abdomen. The patient was placed in reversed Trendelenburg position. (FIGS. 3, 3 a - 3 d )
Step 4: The gallbladder was grasped at the neck and dissected out from surrounding tissue. The gallbladder junction with the cystic duct was identified. The cystic duct was fully dissected away from the gallbladder and the cystic artery noted. (FIGS. 4, 4 a - 4 i )
Step 5: The cystic duct was dissected free, and clipped proximally and distally, divided. (FIGS. 5, 5 a - 5 f )
Step 6: The cystic artery was electrocoagulated with bipolar cautery. (FIGS. 6, 6 a - 6 c )
Step 7: The gallbladder was dissected off the liver bed with bipolar cautery. (FIGS. 7, 7 a - 7 g )
Step 8: The gallbladder was led out of the abdomen through the 12-mm trocar. (FIGS. 8, 8 a - 8 b )
Hernia (Stylized Text)
Step 1: Under direct vision, 5-mm and 12-mm trocars were placed in the right and left midabdomen, respectively. (FIGS. 1, 1 a - 1 e )
Step 2: The patient was placed in the Trendelenburg position. A curvilinear flap was developed using Everest Medical curved scissors and forceps and bitoothed biopsy forceps. (FIGS. 9, 9 a - 9 c )
Step 3: The space was dissected from the line of Douglas above to Cooper's ligament below. (FIGS. 10, 10 a - 10 i )
Step 4: A piece of polypropylene mesh was tightly rolled up and placed into the preperitoneal space. This was unfurled over the inguinal femoral area. (FIGS. 11, 11 a - 11 e )
Step 5: The mesh was stapled in place. (FIGS. 12, 12 a - 12 e )
Step 6: Pressure was then reduced and the leaves of the peritoneum then reapproximated with closely placed staples. (FIGS. 13, 13 a - 13 j )
In one embodiment, the apparatus of the present invention may further comprise an input/output device 112 located in or just outside an operating room. In this example, a surgeon could perform a procedure while it is being filmed and while the film (image) is processed to produce a record in accordance with the present invention. Upon finishing the procedure and leaving the operating room, the record could be accessed in hard or electronic form by the surgeon, e.g., at a terminal 112 outside the operating room. The surgeon could then immediately review the text, edit it if desirable or necessary and sign it. In some embodiments, the signature may be electronic, and the record may be immediately placed in an electronic chart or patient record.
One example of using the apparatus and methods of the present invention in fields other than medicine is their use in mass or batch manufacturing or production of parts. In this example, the parts are typically subjected to a number of steps or processes to provide a raw, or stock, material with selected features. Images of the steps, and the part during and/or after the steps, can be captured. These images, which may be digital initially or digitized, may be stored in a library of images, and/or may be immediately or at a later time compared to other images in the library or to real time images or the process as it occurs. This comparison could be used, for example, to assess the repeatability of the process, and/or that the finished parts meet required tolerances. Stored images from the library could be used for educational purposes, e.g., to train production line workers, and/or for assessments of the cost and/or time efficiency of the process. The images also could be used to create a record of production, required tolerances, standard operation procedure and/or testing. For example, images could be compared to assess tolerances of finished parts and, if an “out-of-tolerance” part or feature is detected, a warning message or text could be produced and recorded and/or sent to a monitoring location; the images of the steps could be used to trigger a written standard operating procedure and/or portions thereof; and/or the images could be used to trigger a written or textual production and/or quality control record. Similarly, the methods and apparatus of the present invention could be used in assembly line settings, wherein a final product is built or assembled.
Another example of using the apparatus and methods of the present invention in fields other than medicine is their use in athletic or sports training in improving techniques, for example, in improving a golf swing. A golf swing involves various body and club positions and movements. A person trying to improve his or her golf swing may stand at a tee with his club and swing at a ball while a camera, video camera or the like photographs the golfer. The camera obtains images of various parts and aspects of the golfer's swing, positioning, and movement. Such images may be saved or stored in an image library, which may thus comprise images and/or groups of similar images of the various golfers and/or images of various golf swings, including stylized or ideal golf swings. A processing unit could digitize the obtained images from the golfer's swing and compare the images obtained to the images in the library, for example, to the ideal swing images. The obtained images may then identified, and/or added to the images library, and a text from a text library, may be added to create a report identifying, for example, what is incorrect with the golfer's swing and suggestions on how to correct it.
Referring to FIGS. 16 and 17, one example would be that the camera could focus on the position of the club head on the golfer's back swing. The images in the library would have various images of an “open” and “closed” back swing as depicted by the possible representative images in FIG. 16 . The obtained image would be compared to the images in the image library and identified as either “open” or “closed”. FIG. 17 shows representative figures of possible images for the library of images. If the back swing is “closed” a text statement would be added to the report identifying the golfer's back swing as “closed”, stating the problems of having a “closed” back swing, stating how to change the back swing to “open”, and how an “open” back swing should improve their swing. The report may be available in hard or electronic form, and may be available to the golfer and/or a teaching pro.
The methods and apparatus of the present invention may be used for any medical treatment or surgical procedure, and may be used in fields other than medicine. Suitable computer and/or microprocessing equipment and systems, including suitable software, may be used to accomplish the methods of the present invention, along or in conjunction with suitable image capturing and processing equipment or systems and communication systems. In some embodiments, the present invention may comprise a dispersed library of information, i.e., there is no “central station,” central library, central server or central repository, but rather a substantially instantaneous communication or flow of information over the internet or the like. The present invention encompasses taking, transmitting and processing digital images, wherein the digital images can be placed into a digital library of images directly. It encompasses a digital library of digital or digitized images and texts, wherein the digital library may be accessed and/or manipulated from a central and/or one or more remote locations.
The present invention may be embodied in other specific forms without departing from the essential spirit or attributes thereof, and it may be used in applications outside the medical field. Described embodiments should be considered in all respects as illustrative, not restrictive.
|
The present invention relates to methods of and apparatus for producing and digitizing a number of images to create a digital library of images, providing an image from outside the digital library, digitizing it and comparing it to the digital images in the digital library, and providing a text descriptive of the image from outside the digital library.
| 6
|
TECHNICAL FIELD
The present invention relates to a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, and more particularly, to a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, which prevents an external object from entering a clearance space under a pedal arm and a pedal when the vehicle is running, thereby preventing fatal traffic accidents.
BACKGROUND ART
FIG. 1 illustrates an example of a foot pedal unit 1 of a general vehicle. In some cases, an external object E such as a solid and bulky thing, for example, a can, a drinking container, a water bottle, etc. or a floor mat used in a vehicle may freely move while the vehicle is running and during an acceleration motion, sudden stop, veering, etc., may enter a clearance space 6 provided for an operation of the foot pedal unit 1 including a clutch, a brake, and an accelerator, that is, a space formed between a lower surface 4 of the foot pedal unit 1 and an indoor floor surface 5 of the vehicle.
According to research reports of the National Police Agency and the Road Traffic Safety Authority, in a physical situation such as an acceleration, sudden stop, veering, etc. when a vehicle is running, an external object such as a solid and bulky thing, for example, a can, a drinking container, a water bottle, etc., having a rod or cylindrical shape, or a floor mat used in a vehicle may enter a gap formed between the foot pedal unit, particularly a lower part of the brake, and an upper surface of the floor surface of a vehicle. In this case, even when a driver pushes the brake, the vehicle does not stop as intended so that uncontrollable and severe accidents may often occur. Regarding the clutch and accelerator, when a driver tries to push the clutch or accelerator to change the speed of a vehicle or accelerate to pass other vehicles on a highway or motorway, if an external object enters a space under a pedal, the intended acceleration is not obtained and the vehicle may be hit by a vehicle behind.
A vehicle may perform a sudden start, sudden stop, sudden veering, ascending, descending, etc. according to road conditions or unexpected situations. In this state, when an external object used or provided in a vehicle enters a clearance space provided for the operation of a foot pedal unit and then a driver, who is not aware of this situation, pushes a pedal to accelerate or stop the vehicle according to a driving situation, the pedal does not work, and thus, the vehicle enters an uncontrollable state and a rear-end collision or other collisions may occur.
Recently, foot pedal unit accidents due to the insertion of an external object have been reported by many broadcasting companies in prime time news.
As an example of a conventional technology, Korean Patent Publication No. 2007-0067658 (2007.6.28) discloses an object prevention device main body 60 that is provided at a lower side of a pedal 3 . However, an external object may enter a space under a pedal arm 2 by passing around the rear side of the object prevention device main body 60 , and thus, the object is trapped by the object prevention device main body 60 , which may be more dangerous than a case when no object prevention device main body 60 is used. Thus, since accidents may be insufficiently prevented and installation of products is not easy, the conventional technology is not widely employed, although it is one of the necessary safety devices for a driver.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problem
The present invention provides a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, the device having an improved structure to prevent the external object from entering a clearance space under a pedal arm and a pedal when the vehicle is running, thereby preventing traffic accidents.
Technical Solution
According to an aspect of the present invention, there is provided a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, the foot pedal unit comprising a pedal arm and a pedal coupled to an end portion of the pedal arm, the device including a main body formed of an elastic member that is elastically deformable, arranged between a lower surface of the foot pedal unit and an indoor floor surface of the vehicle, and coupled to at least one of the foot pedal unit and the indoor floor surface, in which the main body is formed to prevent the external object from entering a space under the pedal arm and the pedal.
The main body may be coupled to the indoor floor surface of the vehicle.
The main body may be formed of at least one elastic member selected from a group consisting of synthetic resin, synthetic rubber, silicon, foamed resin, and urethane.
The elastic member may be waterproof coated.
A groove portion into which the pedal arm is inserted may be formed in an upper surface of the main body.
The main body may include a surface member that is a pipe member having a hole therein and a predetermined sectional shape extending along a center axis, and an internal member arranged in the hole of the surface member and maintaining the sectional shape of the surface member.
The surface member and the internal member may be integrally formed.
The internal member may have a net-type section extending along the center axis C of the surface member, in which a plurality of through-holes having one of a variety of shapes including a diamond shape, a polygonal shape, a circular shape, and an oval shape are continuously arrayed.
The internal member may include a reinforcement plate that is a plate member extending to a rear side from a front surface portion of the surface member that comes in contact with a foot of a driver.
The reinforcement plate may be formed only in a portion of a front end portion on an imaginary line that horizontally connects the front surface portion of the surface member to a rear surface portion of the surface member.
The main body may include a side plate that closes the hole of the surface member.
The surface member may include a pedal arm corresponding unit formed to correspond to a shape of a lower surface of the pedal arm, and a pedal corresponding unit formed to correspond to a shape of a lower surface of the pedal.
The main body may include an abrasion prevention unit that is arranged in a portion that comes in contact with a foot of a driver.
The main body may be a wall structure surrounding a space formed between a lower surface of the foot pedal unit and the indoor floor surface of the vehicle.
The main body may include a pair of side wall members arranged to be separated from each other, and a front wall member closing a front end portion of the pair of side wall members.
The front wall member may be a folded wall member having a plurality of folds that are extendable and compressible in a vertical direction.
Advantageous Effects
According to the present invention, the device for preventing an external object from entering a space under a foot pedal unit of a vehicle includes a main body formed of an elastic member that is elastically deformable and arranged between a lower surface of the foot pedal unit and an indoor floor surface of the vehicle. Accordingly, the external object does not enter a clearance space under a pedal arm and a pedal during running of a vehicle, and thus, traffic accidents may be prevented.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example of a conventional vehicle foot pedal unit;
FIG. 2 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to an embodiment of the present invention;
FIG. 3 is a side view of the device for preventing an external object from entering a space under a foot pedal unit of a vehicle of FIG. 2 ;
FIG. 4 illustrates a state in which the device for preventing an external object from entering a space under a foot pedal unit of a vehicle of FIG. 2 is installed at a foot pedal unit of a vehicle;
FIG. 5 illustrates a state in which a pedal is pressed and a pedal arm is rotated when the device for preventing an external object from entering a space under a foot pedal unit of a vehicle of FIG. 2 is installed at the foot pedal unit of a vehicle;
FIG. 6 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention;
FIG. 7 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention;
FIG. 8 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention;
FIG. 9 is a cross-sectional view taken along line VIII-VIII of FIG. 8 , illustrating a state in which a pedal is pressed and thus a pedal arm is rotated when the device is installed on the foot pedal unit;
FIG. 10 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention;
FIG. 11 is a cross-sectional view taken along line XI-XI of FIG. 10 , illustrating a state in which the device is installed on the foot pedal unit;
FIG. 12 illustrates a state in which, a pedal is pressed and thus a pedal arm is rotated when the device is installed on the foot pedal unit;
FIG. 13 illustrates an applied example of the device of FIG. 10 that is installed for both of a clutch and a brake; and
FIG. 14 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention.
BEST MODE
Hereinafter, the present invention will be described in detail by explaining preferred embodiments of the invention with reference to the attached drawings.
FIG. 2 is a perspective view of a device for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to an embodiment of the present invention. FIG. 3 is a side view of the device for preventing an external object from entering a space under a foot pedal unit of a vehicle of FIG. 2 . FIG. 4 illustrates a state in which the device for preventing an external object from entering a space under a foot pedal unit of a vehicle of FIG. 2 is installed at a foot pedal unit of a vehicle.
Referring to FIGS. 2 to 4 , a device 100 for preventing an external object from entering a space under a foot pedal unit of a vehicle according to the present embodiment prevents an external object E from entering a space under the foot pedal unit 1 of a vehicle, as illustrated in FIG. 1 , and includes a main body 10 , a coupling member 20 , and an abrasion prevention member 30 . The foot pedal unit 1 includes the pedal arm 2 that is rotatably provided and the pedal 3 that is coupled to an end portion of the pedal arm 2 .
The main body 10 is formed of an elastic member that is elastically deformable, is arranged between the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 5 of the vehicle, and includes a surface member 11 and an internal member 12 .
The main body 10 may be formed of at least one elastic member selected from a group consisting of synthetic resin, synthetic rubber, silicon, foamed resin, and urethane. In the present embodiment, the main body 10 is manufactured of polyurethane foamed resin that is waterproof-coated after foaming processing.
Accordingly, the main body 10 exhibits a superior compression rate such that, when an uncompressed size is 100%, the main body 10 may be easily compressed by a compression force to a size of about 10-20% of the original size, and a superior self-restoration feature when a compression force is removed.
The surface member 11 has a predetermined sectional shape extending along a center axis C, is a pipe member having a hole H therein, and includes a pedal corresponding unit 13 and a pedal arm corresponding unit 14 . The pedal arm corresponding unit 14 has a concave shape in a rear upper surface of the main body 10 to correspond to the shape of the lower surface 4 of the pedal arm 2 . The pedal corresponding unit 13 has a convex shape in a front upper surface of the main body 10 to correspond to the shape of a lower surface of the pedal 3 .
The internal member 12 is arranged in the hole H of the surface member 11 to maintain a sectional shape of the surface member 11 . The internal member 12 has a net-type section extending along the center axis C of the surface member 11 in which a plurality of through-holes H 1 having a variety of shapes including a diamond shape, a polygonal shape, a circular shape, an oval shape, etc. are continuously arrayed. In the present embodiment, the internal member 12 has a net-type section in which the through-holes H 1 , each having a diamond shape, are continuously arrayed. In the present embodiment, the surface member 11 and the internal member 12 are formed to have the same thickness T 1 .
A reinforcement plate 18 , which is a plate member horizontally extending to a rear side from a front surface portion 15 of the surface member 11 that comes in contact with a foot of a driver, is inserted in a front lower portion of the internal member 12 . Since the reinforcement plate 18 is formed only in a portion (L 1 -L 2 ) of a front end portion on an imaginary line C 1 horizontally connecting the front surface portion 15 of the surface member 11 and a rear surface portion 16 of the surface member 11 , the reinforcement plate 18 is not inserted in a portion (L 2 ) of a rear end portion of the internal member 12 .
In the present embodiment, as illustrated in FIG. 3 , since a thickness T 2 of the reinforcement plate 18 is larger than a thickness T 1 of the surface member 11 and the internal member 12 , a counterforce of the reinforcement plate 18 in response to an axial force and a bending force is greater than that of the surface member 11 and the internal member 12 .
In the present embodiment, the internal member 12 is integrally formed with the surface member 11 , which may be mass-produced by manufacturing a cutting mold corresponding to the sectional shape of the main body 10 and performing a punching process using the cutting mold.
The coupling member 20 is used to couple a lower surface portion 17 of the surface member 11 and the indoor floor surface 5 of the vehicle. In the present embodiment, a double-sided tape having an adhesive force on opposite surfaces thereof is used as the coupling member 20 .
The abrasion prevention member 30 is arranged at a portion that may come in contact with the foot of a driver. In the present embodiment, a pad formed of a nonwoven fabric that exhibits superior durability and may be easily folded is used as the abrasion prevention member 30 . The abrasion prevention member 30 is attached on the front surface portion 15 of the surface member 11 .
The device 100 configured as above is formed of an elastic member that is elastically deformable and is arranged between the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 5 of the vehicle. Since the device 100 includes at least one of the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 5 of the vehicle, the external object E does not enter the clearance space 6 under the pedal arm 2 and the pedal 3 while the vehicle is running so that traffic accidents may be prevented.
Also, since the device 100 prevents the external object E from entering the clearance space 6 under the pedal arm 2 and the pedal 3 while the vehicle is running, a traffic accident that may occur when the vehicle is not able to stop when stopping of the vehicle is required and a traffic accident that may occur when the vehicle is hit by another vehicle running behind because the vehicle is not able to accelerate when accelerating of the vehicle is required may be prevented. Also, installation of the device 100 may provide a driver with a sense of safety.
In addition, since the device 100 is installed in the clearance space 6 between the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 5 of the vehicle, dust coming from the outside does not accumulate in the clearance space 6 , thereby not contaminating the inside of the vehicle. Accordingly, cleaning the vehicle including the inside thereof becomes easy, and thus, a comfortable driving environment may be provided to a driver.
Since the lower surface portion 17 of the main body 10 of the device 100 is coupled to the indoor floor surface 5 of the vehicle, the main body 10 does not escape from the clearance space 6 under the pedal arm 2 and the pedal 3 while the vehicle is running.
Since the main body 10 of the device 100 is formed of at least one elastic member selected from a group consisting of synthetic resin, synthetic rubber, silicon, foamed resin, and urethane, the main body 10 exhibits a superior compression rate when the pedal 3 is pressed by the driver as illustrated in FIG. 5 , and a superior self-restoration feature to restore the original shape of the main body 10 when the pedal 3 is not pressed as illustrated in FIG. 4 .
Since the elastic member of the main body 10 of the device 100 is waterproof-coated, deterioration of the self-restoration feature and durability due to intrusion of moisture from the outside may be prevented.
In addition, since the main body 10 of the device 100 includes the surface member 11 having a predetermined sectional shape extending along the center axis C and being a pipe member having the hole H therein and the internal member 12 arranged in the hole H of the surface member 11 and maintaining the sectional shape of the surface member 11 , the device 100 may easily maintain the original shape even when inserted into the clearance space 6 and exhibits a superior self-restoration feature.
Since the surface member 11 and the internal member 12 of the main body 10 of the device 100 are integrally formed together, a coupling process or an adhesion process between the surface member 11 and the internal member 12 is unnecessary, and thus, a manufacturing process may be simplified and the total manufacturing cost may be reduced.
Also, since the internal member 12 of the device 100 is formed as a net-type section, in which the through-holes H 1 having a variety of shapes including a diamond shape, a polygonal shape, a circular shape, an oval shape, etc. are continuously arrayed and extend along the center axis C of the surface member 11 , the compression rate and self-restoration feature of the internal member 12 may be improved, the material costs of the internal member 12 may be reduced, and a sense of decoration may be improved, compared to a case when no through-holes H 1 are formed.
In addition, since the internal member 12 of the device 100 includes the reinforcement plate 18 , which is a plate member extending to the rear side from the front surface portion 15 of the surface member 11 that comes in contact with the foot of a driver, even when a horizontal compression force is applied to the main body 10 by the foot of a driver, the main body 10 may easily maintain the original shape.
Since the reinforcement plate 18 is formed only in the portion (L 1 -L 2 ) in the front end portion of the imaginary line C 1 horizontally connecting the front surface portion 15 of the surface member 11 and the rear surface portion 16 of the surface member 11 , the device 100 may be easily installed in the foot pedal unit 1 having a different length or shape according to the type of a vehicle. In other words, a space, as long as the length L 2 along which the reinforcement plate 18 is not inserted, exists for the length of the foot pedal unit 1 in an area where the device 10 may be installed.
Also, since the surface member 11 includes the pedal arm corresponding unit 13 formed to corresponding to the shape of the lower surface 4 of the pedal arm 2 and the pedal corresponding unit 14 formed to correspond to the shape of the lower surface of the pedal 3 , the device 10 may be installed by being easily inserted into a space under the lower surface 4 of the foot pedal unit 1 .
Since the main body 10 includes the abrasion prevention member 30 that is arranged in a portion that may come in contact with the foot of a driver, the outer circumferential surface of the surface member 11 of the device 100 may be prevented from being damaged or abraded due to repeated contacts with the foot of a driver.
FIG. 6 is a perspective view of a device 200 for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention. Since the structure and effect of the device 200 according to the present embodiment are almost the same as those of the device 100 according to the above-described embodiment, the detailed descriptions of the device 200 will be omitted herein and only differences between the device 200 and the device 100 will be discussed below.
The device 200 includes a main body 210 having a pair of side plates 19 closing the hole H of the surface member 11 , instead of the main body 10 . The side plates 19 is a member formed of the same material as that of the surface member 11 . Accordingly, the device 200 may prevent intrusion of a relatively small object E or moisture through the through-holes H 1 of the internal member 12 .
FIG. 7 is a perspective view of a device 300 for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention. Since the structure and effect of the device 300 according to the present embodiment are almost the same as those of the device 100 according to the above-described embodiment, the detailed descriptions of the device 300 will be omitted herein and only differences between the device 300 and the device 100 will be discussed below.
The device 300 includes a main body 310 that is manufactured as a single mass without additional spaces therein, instead of the surface member 11 and the internal member 12 . The main body 310 is manufactured of a polyurethane (PU) foamed resin that is waterproof-coated after foaming processing, like the main body 10 . However, considering a compression rate, a foaming rate is increased to be higher than that of the main body 10 so that a foamed resin having a relatively large amount of air bubbles may be used.
Since the device 300 includes the main body 310 that is manufactured as a single mass, a cutting mold having a complicated structure to form the through-holes H 1 does not need to be manufactured, and thus the overall manufacturing costs may be reduced.
In the present embodiment, although the inside of the main body 310 is completely filled without any additional space, the main body 310 may have a structure in which a concave space portion (not shown) is inwardly recessed from a rear surface or a lower surface of the main body 310 .
FIG. 8 is a perspective view of a device 400 for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention. Since the structure and effect of the device 400 according to the present embodiment are almost the same as those of the device 300 according to the above-described embodiment, the detailed descriptions of the device 400 will be omitted herein and only differences between the device 400 and the device 300 will be discussed below.
The device 400 includes a main body 410 having a groove portion 141 formed in an upper surface thereof and in which the pedal arm 2 may be inserted.
Accordingly, with regard to the device 400 , when a driver presses the pedal 3 as illustrated in FIG. 9 , a front end portion of the main body 410 disposed under the pedal 3 is compressed relatively much and a rear end portion of the main body 410 disposed under the pedal arm 2 is not compressed or is compressed relatively less. Compared to a case when no groove portion 141 is formed, a resistance force felt by the driver when pressing the pedal 3 is reduced.
FIG. 10 is a perspective view of a device 500 for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention. Since the structure and effect of the device 500 according to the present embodiment are almost the same as those of the device 100 according to the above-described embodiment, the detailed descriptions of the device 500 will be omitted herein and only differences between the device 500 and the device 100 will be discussed below.
The device 500 includes a main body 510 that is a wall structure surrounding the clearance space 6 formed between the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 5 of a vehicle, instead of the main body 10 .
In the present embodiment, the main body 510 includes a pair of side wall members 511 arranged at the left and right sides of the pedal arm 2 and a front wall member 512 closing a front end portion of the side wall members 511 . The side wall members 511 and the front wall member 512 have the same structure and material as the main body 10 of the device 100 , whereas a width of the surface member 11 of each of the side wall members 511 in the left and right directions is relatively shorter than a width of the main body of the device 100 in the left and right directions.
Since the main body 510 has a wall structure surrounding the clearance space 6 formed between the lower surface 4 of the foot pedal unit 1 and the indoor floor surface 56 of the vehicle, the device 500 is advantageous in that overall material costs are lower than those of the devices 100 , 200 , 300 , and 400 .
Since the main body 510 includes the side wall members 511 arranged to be separated from each other and the front wall member 512 closing the front end portion of the side wall members 511 , the device 500 is advantageous in that the main body 510 may be mass-produced by punching a sheet of a PU foamed resin material and having a relatively small thickness.
Also, regarding the device 500 , when a driver presses the pedal 3 as illustrated in FIG. 12 , the front wall member 512 disposed under the pedal 3 is compressed relatively much and the side wall members 511 disposed under the pedal arm 2 are not compressed or is compressed relatively less. Thus, a resistance force felt by the driver when pressing the pedal 3 is reduced. Also, a fatigue destruction phenomenon of the side wall members 511 is reduced so that a usage life of the device 500 is increased.
FIG. 13 illustrates an application example of the device 500 of FIG. 10 that may simultaneously protect both of a foot pedal unit 1 a of a brake and a foot pedal unit 1 b of a clutch. The application example of the device 500 includes three side wall members 511 and one front wall member 512 .
In the application example of the device 500 , since the number of the side wall members 511 in use is reduced by one compared to a case of using two devices 500 , the overall manufacturing costs may be reduced and the device 500 may be structurally stable.
In the present embodiment, although the main body 510 has a plane shape of a “π” shape, the plane shape of the main body 510 may be modified to have a plane shape corresponding to the plane shape of the foot pedal unit 1 .
FIG. 14 is a perspective view of a device 600 for preventing an external object from entering a space under a foot pedal unit of a vehicle, according to another embodiment of the present invention. Since the structure and effect of the device 600 according to the present embodiment are almost the same as those of the device 500 according to the above-described embodiment, detailed descriptions of the device 600 will be omitted and only the differences between the device 600 and the device 500 will be discussed below.
The device 600 according to the present embodiment includes a front wall member 612 , which is a folded wall member having a plurality of folds capable of being vertically extended or compressed, instead of the front wall member 512 where the through-holes H 1 , each having a diamond type, are continuously arrayed.
The front wall member 612 is a so-called zebra structure that is manufactured of a synthetic resin sheet having a small thickness. Since the front wall member 612 is a folded wall member having a plurality of folds that may be vertically extended or compressed, fatigue destruction is not generated even when repeated pressing operations of the pedal 3 occur, and thus, the device 600 has a superior compression rate when the pedal 3 is pressed.
Also, as the front wall member 612 may perform a function of the abrasion prevention member 30 of the device 100 , the device 600 has the advantage of not requiring separate attaching of the abrasion prevention member 30 .
Although in the above-described embodiments the main body 10 is mass-produced through a punching process using a cutting mold after manufacturing the cutting mold corresponding to the sectional shape of the main body 10 of FIG. 3 , the main body 10 may be mass-produced by an extrusion molding method instead of the punching process.
Although in the above-described embodiment the main bodies 10 , 210 , 310 , 410 , and 510 are each coupled to the indoor floor surface 5 of the vehicle, the main bodies 10 , 210 , 310 , 410 , and 510 may be each coupled to the foot pedal unit 1 only or both of the indoor floor surface 5 of the vehicle and the foot pedal unit 1 .
Although in the above-described embodiments a double-sided adhesive tape is used as the coupling member 20 to couple the lower surface portion 17 of the main body 10 and the indoor floor surface 5 of the vehicle with each other, other coupling methods such as screw coupling or Velcro coupling may also be used.
Although in the above-described embodiments the abrasion prevention member 30 , which is a pad of an unwoven fabric material, is used as the abrasion prevention unit arranged in a portion that may come in contact with the foot of a driver, other abrasion prevention members formed of a variety of materials may also be used. Also, a foaming rate is partially reduced in a portion that may come in contact with the foot of a driver so that a hard portion may be formed.
As described above, according to one or more of the above embodiments of the present invention, the main body is formed of an elastic member that is elastically deformable and arranged between the lower surface of the foot pedal unit and the indoor floor surface of the vehicle. Thus, an external object may not be inserted in the clearance space under the pedal arm and the pedal while a vehicle is running, and thus, traffic accidents may be prevented.
While the present invention has been particularly shown and described with reference to preferred embodiments using specific terminologies, the embodiments and terminologies should be considered in descriptive sense only and not for purposes of limitation. Therefore, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
|
The present invention relates to a device for preventing an external substances from being inserted into the lower part of a foot pedal unit of a vehicle, and the device prevents external foreign substances from being inserted into the lower part of a vehicular foot pedal unit which includes a pedal arm and a pedal combined with an edge of said pedal arm, wherein the invention comprises a body which: is formed as a clastic member that is clastically transformed; is disposed between a lower side of said foot pedal unit and an indoor bottom surface of the vehicle; and is combined with said foot pedal unit and/or said indoor bottom surface of the vehicle, wherein said body is formed to prevent external foreign substance from being introduced to the lower side of said pedal arm and said pedal. According to the present invention, no external substances are introduced to a lower gap between the pedal arm and the pedal when the vehicle is running, thereby is preventing fatal traffic accidents.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to warp knitting machines having a weft thread magazine comprising a pair of separated weft thread forwarding means. These forwarding means have, in the drive direction, a plurality of equidistantly spaced holding means for transversely placed weft threads. Machines of this type may include weft threads presentation means activated by a control arrangement for separating the first weft thread from the others following and presenting the first thread in the vicinity of the needles.
2. Discussion of the Relevant Art
In a known warp knitting machine of this type (Mayer warp knitting automatic or Raschel machine with weft thread magazine KS2MSU or RS4MSU) the forwarding means are driven with a normal speed, that is, at a rate such that one weft thread is presented to the needles at each needle cycle. The weft thread presenting means are activated at each needle cycle to engage and present a weft thread to the needles. When the holders of the forwarding means carry weft threads, each is knotted into each stitch row. The weft threads are layed into the forwarding means by thread guides on a reciprocating carrier which moves back and forth between the forwarding means. Within this group of thread guides different weft threads may be employed or, equally, certain positions may be left unused. The pattern repeat is however limited to the number of thread guides.
It is already known (German patent application OLS No. 2401050) that the pattern repeat can be increased by altering the weft threads fed to the thread guides. In this mode, new weft threads are knotted onto old weft threads. In accordance with an older suggestion (German application No. P3040393) at least two thread guide groups may be provided to the carrier which can be activated or de-activated by choice.
Accordingly, there is a need for an improved warp knitting machine with a weft thread magazine of the above described type. Wherein the pattern repeat in all known forms can be readily increased.
SUMMARY OF THE INVENTION
A warp knitting machine according to the principles of the present invention has a cyclically operable needle bed for producing ware inlayed with weft threads. The machine also has a weft thread insertion means including a pair of spaced forwarding means for carrying the weft threads toward the needle bed. The machine also has a drive means and a plurality of holders. The holders are separately mounted equidistantly on each of the pair of forwarding means for holding transversely positioned, spaced sequences of the weft threads. The drive means is coupled to the pair of forwarding means and is operable to drive them at an arrival rate equal to or less than one weft thread per cycle of the knitting machine.
By employing apparatus of the foregoing type, an improved knitting machine is provided in that the drive arrangement for the weft thread forwarding means may operate at a speed less than the usual speed at which the weft threads would be presented to the needles, that is, slower than every needle cycle. Furthermore, the control arrangement controlling weft thread presentment is only activated during a portion of an appropriate needle cycle.
The achievement of the lower running speed of the weft thread forwarding means may be provided from a form of warp knitting machine in which the drive arrangement has a drive shaft which is driven from the main shaft of the warp knitting machine with a number of revolutions corresponding to normal speed. It is thereby sufficient to connect the forwarding means with this drive shaft via a revolution reduction arrangement.
In a preferred arrangement a weft thread presenter separates a leading thread from a weft thread forwarder and presents this thread to the needle bed. In this arrangement a weft thread deflector can remove the weft thread to a remote position and thus delay its presentment to the needle bed. The presenter and/or the deflector can therefore time the arrival of weft threads. It is preferable to time the operation of the deflector and/or presenter by a timing chain whose projections are preset to establish the desired pattern of weft thread delivery. The chains can run at the usual or a reduced speed.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully understood, it will now be described, by way of example, with references of the accompanying drawings in which:
FIG. 1 is a schematic side view of a weft thread magazine and other parts of a warp knitting machine, according to the present invention;
FIG. 2 is a more detailed schematic side view of the knitting arrangement, control means of the weft thread presenter and the weft thread deflectors of FIG. 1;
FIG. 3 is a lapping diagram of the prior art;
FIG. 4 is a lapping diagram obtainable in one variation of the present invention; and
FIG. 5 is another lapping diagram obtainable in another variation of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The warp knitting machine of FIG. 1 comprises machine frame 1 and its working area 2 comprising needles 3, slider 4, knockover sinkers 5 and needle holders 6. Elements 3-6 are supported to allow reciprocation in the usual manner so that warp threads (not shown) may be knitted together, one course for each cycle of needles 3. On opposite sides of the needle bed there are provided forwarding means 7 equipped with a plurality of equally spaced holders 8. The forwarding means 7 are generally speaking, formed from a pair of endless, parallel chains. Holders 8 are preferably upright members terminating in a knob, hook or other thread holding device. Forwarding chains 7 travel over a plurality of rollers 9, 10, 11, 12 and 13 in that order and direction. Roller 12 is power driven by output drive shaft 18. The revolutions of drive shaft 14 depend upon the main shaft of the warp knitting machine 1 to which it is connected. A drive means is shown herein as shaft 14 driving revolution reduction means 15 which further comprises a setting arrangement 16. Arrangement 16 thus serves as an adjusting means and has two internal wheels 17 which form a switching drive. Alternatively, arrangement 16 may comprise a changable gear drive or a continuously adjustable drive. The output of arrangement 15 is output shaft 18 which connects with and drives roller 12.
Mounted in a direction transverse to chains 7 are two parallel, spaced rails 19 and 20 supporting carriage 21 by its running wheels 22 and 23. So mounted, carriage 21 can reciprocate transversely to forwarding means 7, in a backwards and forwards motion. Running wheels 19 and 20 are journalled onto frame 24 which supports beam 25 having a plurality of spaced thread guides. Frame 24 has a lower bushing 26 slidably supporting rod 27. Rod 27 is in the form of a reciprocating carrier which moves in the direction of arrow "X" and from which several thread guides 28 depend. Two horizontal, longitudinally aligned rollers 29 and 30 are connected to carrier 33 on its end opposite guides 28 (on the same side of bushing 26 as working area 2). Rollers 29 and 30 straddle and engage transverse steel band 31 which at each end thereof is tensioned in holding arrangements 32, cowl-like devices, at least one connected to lever 35 via rod 33. Lever 35 is rotatable about axis 34 and pivotally connected to rod 33 which moves arrangement 32 backwards and forwards. Rotatably mounted on a lower branch of lever 35 is roller 36. Roller 36 runs on the perimeter of cam disc 37 which rotates at a speed proportional to the cycling rate of machine 1. Simultaneously, carriage 21 moves in the transverse direction. A plurality of weft threads 38 unwound from group 39 of spools 40 are led to thread guides 28 via guide means in beam 25. The tension to the threads is provided by spring-biased tension rollers 41 between beam 25 and spools 40. In this manner "n" weft threads are led by a transverse motion from "n" holders 8 in one forwarding means 7 to "n" holders in the other forwarding means 7. The subsequent relative motion between guides 28 and forwarding means 7 causes relative displacement of "n" holder spaces and subsequently leads to looping threads 38 around another "n" holder upstream in the first mentioned forwarding means.
FIG. 2 illustrates the position of the weft threads 42 on the forwarding means 7 as placed on the holders 8, in the vicinity of work area 2. The illustrated forwardmost weft thread 42a is separated from the subsequently following weft threads 42 by means of weft thread presenter 43. Presenter 43, as explained further hereinafter, can move on a closed path to engage thread 42a and present it to needles 3. A control means 44 provides that at least occasionally, weft thread presenter 43 is activated during just part of an appropriate needle cycle.
A first part of this control arrangement 44 comprises a pattern means in the form of drum 45 whose rate of rotation is controlled by the main shaft of machine 1. Encircling drum 45 is an appropriate chain 46 having preselected outer ridges and encircling another wheel (not shown). The protrusions of chain 46 displace swingable lever 49 about fixed axis 48 by means of contact roller 47 journalled on the proximal end of lever 49. The other distal end of lever 49 is connected with a second lever 51 via articulating rod 50. Lever 51 rotates toothed wheel 52. Said toothed wheel 52 rotates rotatable eccentric cam 55 about fixed axis 54 by means of chain 53.
Angle lever 56 has an inverted "L" shape with its upper end carrying weft thread presenter 43. The other end of lever 56 cooperates with drive rod 59. Lever 56 is rotatable about eccentric cam 55. Lever 56 is operated via its lower end which pivotally connects to lever 58, the latter being rotatable about axis 57. The drive rod 59 pivotally connects to the end of lever 58 opposite the lower end of lever 56. Drive rod 59 is connected with the main shaft of warp knitting machine 1 via an eccentric cam (not shown) so that an upward and downward movement is provided for each cycle and thus the thread provider 43 periodically protrudes between the weft threads 42. The pattern chain 46 is so provided that the presentation movement of the weft thread presenter 43 does not occur at each needle cycle. Thus, the weft thread providers are only activated during a portion of the needle cycle.
Also instead of the mechanism just described employing eccentric cam 55, a multiple lever arrangement can be used. An example of a multiple lever arrangement is given in U.S. Ser. No. 312,744; (patent application).
A second portion of control arrangement 44 comprises weft thread deflector 60 which is rotatable mounted about fixed axis 61 and may be rotated out of the totally inactive setting shown into the setting noted in phantom wherein at least the forwardmost of the weft threads 42b is lifted so far that it finds itself outside the presentation path of the weft thread presenter 43. For this purpose there is provided a second pattern drum 62 coaxially mounted with drum 45 and preferably driven at the same speed. Drum 62 has an appropriate pattern chain 63 which is contacted by contact roller 64 rotatably mounted on lever 65. Lever 65 is also rotatably mounted on axle 48 and has on the end opposite roller 64, a pivotal connection to rod 66. Motion is transferred to weft thread deflector 60 by means of rod 66, pivotally connected to the end of deflector 60 distal from needles 3.
Pattern chains 46 and 63, pattern chain drums 45 and 62 as well as the drive taken off from the main shaft comprise the normal arrangements for weft thread machines.
In operation, the speed of forwarder 7 can be set to a slower speed than usual, that is, slower than one weft thread 42 being provided to needles 3 for each cycle. This speed is set by setting means 16 of adjustable reduction arrangement 15. It is particularly desirable to provide a speed of 1/p of the normal speed where p is an integer. At the same time there is provided a coupling of the control arrangement 44 to this reduced speed. The pattern chains 46 and 63 thus serve as a coordination arrangement.
For example, certain arrangements as illustrated by FIGS. 3-5 are possible.
In the lapping diagrams the groups G are illustrated as comprising 6 weft threads which show the pattern repeat. As a matter of practicality, group G could comprise up to 24 weft threads. The single arrows show by their direction the movement path of carrier 21 while laying the weft threads. Their conjunction with stitch rows "M" show which stitch rows are provided with weft threads and which are weft-thread free.
The working mode of FIG. 3 shows the usual situation. The reduction drive 15 is so set that the output shaft 18 has the same number of revolutions as the input shaft 14. The forwarders 7 move at the usual speed in which the needles 3 are provided with a weft thread 42 at each cycle. The pattern chain 46 comprises a high spot for each needle cycle, in order to bring the weft thread provider 43 into the presentation path. The pattern chain 63 has no raised portions. Therefore prior to each stitch cycle of needles 3, presenter 43, in response to motion by rod 59 protrudes between the weft threads, entering behind forwardmost thread 42a. Due to the concurrent action of pattern chain 46, cam 55 is activated so that presenter 43 moves into the vicinity of needles 3 which subsequently perform a stitch. As a result weft thread 42 is laid into the knitted ware in the usual fashion. The presenter 43 then retreats to a position at which the next weft thread 42 can be engaged. Weft thread deflectors 60 always remain in their position shown by continuous lines. This gives rise to the weft thread arrangement in accordance with FIG. 3 in which each stitch row is provided with a weft thread and the pattern repeats itself after six stitch rows.
It is particularly advantageous to provide that the drive arrangement 15 may provide several different speeds by means of a setting arrangement 16 and that the arrangement 44 may be adjusted to each speed by means of an adjusting arrangement. The drive arrangement 15 should be preferably settable to not only the usual drive speed but a lesser drive speed. Thus, by changing the setting the pattern repeat may be appropriately changed as described presently.
In the embodiment of FIG. 4 the reduction drive 15 is so set that the number of revolutions of the drive shaft 18 comprises only one third of the number of revolutions of shaft 14. The forwarding means 7 thus move at approximately 1/3 of the normal speed and present a weft thread only every third cycle of needles 3. The pattern chain 46 comprises raised portions in such a distance from each other that the weft thread presenter 43 only moves into the presentation path at every third needle cycle. Pattern chain 63 comprises such a number of raised portions that weft thread deflector 60 generally finds itself in the position indicated in phantom position and only descend at every third needle cycle to the position shown by solid lines. Only when deflector 60 and forwardmost thread 42b resting thereon descend, can weft thread provider 43 interact with thread 42b and carry it forward. Otherwise threads near but not ready to be inlayed are held out of the needles. There is thus provided a lapping diagram wherein only every third stitch row is provided with weft threads.
In this construction the pattern repeat is increased so that there are provided weft thread free stitch rows even though each holder on the forwarding means 7 is provided with a weft thread. When, for example, a weft thread 42 is knotted in only at each third needle cycle the pattern repeat is increased threefold. This aim is achieved through the lower drive speed of forwarding means 7 and the special control of the thread presenter 43 which only grasps and present a thread when the knotting-in of a weft thread 42 is actually desired. This arrangement is also possible when weft threads are changed thru knotting or shifting of the thread guides (see German OLS No. 2401050 and U.S. Ser. No. 312,744 respectively).
Since a weft thread is not presented at each cycle there is no accumulation of thread 42 if the weft thread presenter 43 does not operate during each cycle. Also, the presenter 43 does not always have to grasp the threads 42 at the same place. It is sufficient if it is grabbed anywhere in the presentation path.
In the foregoing preferred embodiment the drive arrangement 7 is adjustable to an intergral proportion of the usual drive speed, so that the weft threads are knotted into every second, third or the like stitch row. By means of appropriate adjustment of the control arrangement it is also possible to work with intermediate values of the speed and then for example, provide for different separations between subsequent weft threads.
In the embodiment of FIG. 5 the speed of forwarders 7 is unchanged (1/3 of the usual speed). The pattern chain 46 controls the weft thread providers so that at the third, sixth, tenth, twelfth, fifteenth and eighteenth needle cycle a weft thread presentation movement occurs. In a similar manner pattern chain 63 controls weft thread deflector 60 so that only at the named needle cycles is the deflector 60 lowered to the inoperative position shown by solid lines. There is thus provided a pattern repeat in which the number of the weft thread free stitch rows follows the pattern 2,2,3,1,2,2. This basically requires delaying presentment of a weft thread at the ninth cycle. To this end deflector 60 remains raised and presenter 43 is not activated so that no weft thread is laid in during this ninth cycle. In the tenth cycle, however, chain 63 causes deflector 60 to descend and chain 46 activates presenter 43 to carry a weft thread into the vicinity of needles 3. Again, deflector 60 and presenter 43 are operated to present weft threads 42 only at the rows specified above.
There is another possibility wherein the control arrangement 44 relies primarily on the weft thread deflector 60 which can be similarly activated by its pattern drive 63. At least any first thread 42a is held outside the presentation path of the thread presentation means 43 by assistance of such a thread deflector. The action of the thread presenter 43 within a particular time span, may be delayed. It is even possible to execute a presentation movement of the weft thread presenter 43 during each needle cycle and at the same time maintain weft thread free stitch rows.
The foregoing apparatus found it particularly advantageous if the reducing means 15 is utilized as the setting means. For example, the setting means may be a switch gear. It may also comprise a change gear drive. In some cases a continually adjustable drive may be advantageous. However, other arrangements are possible wherein speeds are changed by hydraulic, electromechanical or other means. Also while a pattern chain drive is preferred as the control arrangement, other devices which, by predetermined choice, activates or suppresses the presentation movement of the weft thread presenter 43 are possible. A very simple way of activating the weft thread presenter 43 has been illustrated although more complex systems can be devised.
It will be understood that various changes in the details, materials, arrangement of parts and operating conditions which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principles and scope of instant invention.
|
A weft thread insertion magazine in a warp knitting machine has a pair of separated forwarding chains driven by a drive arrangement. These forwarding chains each have equidistant holders for holding transversely placed weft threads. The drive arrangement can provide the forwarding chains with a lower speed than the normal speed at which weft threads are provided to the needles, that is, at a rate less than one thread per needle cycle. In particular the drive shaft of the warp knitting machine may be connected to the forwarding chains by means of a revolution reducing arrangement. A control arrangement regulates the separation of at least the first weft thread from the others following and the presentation of this first one into the vicinity of the knitting needles. This control arrangement comprises either a weft thread presenter, a weft thread deflector or a combination of both. The control mechanism only activates the weft thread presentation or deflection during a portion of the appropriate needle cycle. In this manner the pattern repeat can be substantially increased.
| 3
|
RIGHTS TO INVENTIONS UNDER FEDERAL RESEARCH
There was no federally sponsored research and development concerning this invention.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to storage of medical supplies and more particularly to a rack for holding packaged catheters.
(2) Description of the Related Art
Catheters come in many different configurations and construction as well as different length. Typically, each catheter is separately packaged. Each package will be about 48" long and about 3" wide. Many of the packages will be longer or shorter and may vary in width. Normally the package is only a fraction of an inch in thickness, the thickness depending upon the diameter of the catheter contained therein. Also, typically, the catheter package will have a hanging hole at the top thereof.
A medical laboratory supply room will often have more than 1,000 catheters therein.
Most of the catheters which will be used are described as heart catheters inasmuch as they have a terminal end with the tip within or near the heart.
Typically, before this invention, packages of catheters were hung on rods or pegs extending from a pegboard attached to a wall of a laboratory or supply room. It will be understood that the wall space of laboratories or supply rooms is often quite limited since it is necessary to have filing cases or equipment or supply shelves or other supply containers in the available space which is often is adjacent to the walls. Therefore, it was not uncommon to have several packages of catheters hanging from a single peg.
It will be understood that this method of storage was not satisfactory As stated before, valuable wall space was used for storing the catheters, it was difficult to inventory the catheters, and also it was difficult to locate a catheter when needed. It will be understood that often catheters are used in medical emergencies, and the difficulty or time consumed in trying to find the proper catheter is sometimes critical. In any event, the person in charge of the medical supplies is normally a highly skilled person, and even in the least busy times it is well not to waste time of the supply room personnel.
Before this application was filed, the applicant caused a search to be made in the U.S. Patent and Trademark Office. The following patents were found on that search:
______________________________________BRADY 274,457MIADOWICZ 1,729,004HANSEN 1,697,866TURNBULL 2,334,518RASTOCNY 3,734,301______________________________________
TURNBULL discloses a rotary clothesline.
BRADY discloses a nursery towel rack.
RASTOCNY, MIADOWICZ, and HANSEN each disclose display devices.
These patents are considered pertinent because the applicant believes the Examiner would consider anything revealed by an experienced patent searcher to be relevant and pertinent to the examination of this application.
SUMMARY OF THE INVENTION
(1) Progressive Contribution to the Art
I have invented a rack for storing packages of medical catheters.
I have discovered a more efficient way to store catheter packages so that the catheter packages may be readily located and also require less storage space. This is done by storing the catheters upon rods which extend from struts which radiate from a rotable hub. The hub is supported by a column extending upward from a pedestal.
(2) Objects of this Invention
An object of this invention is to store packages of medical catheters.
Further objects are to achieve the above with devices that provide compact, economical, space saving, dust free environment for the catheter storage, and where the catheters are easily identifiable, and the devices are sturdy, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, connect, adjust, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hanger according to this invention showing a few catheter packages hanging thereon.
FIG. 2 is a side elevational view of a hanger without packages with some of the struts removed for clarity of illustration.
FIG. 3 is a top plan view without the pedestal for clarity of illustration.
FIG. 4 is a detailed view of one rod on one strut taken substantially on line 4--4 of FIG. 3.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements is provided:
______________________________________ 10 pedestal 12 column 14 lower section 16 upper section 18 clamp means 20 bottom portion 22 turntable 24 upper portion 26 hub 28 struts 30 first rod 32 second rod 34 third rod 36 fourth rod 38 tips 40 handle 42 label______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there may be seen a rack or hanger wherein column 12 rises from the pedestal being attached thereto. The column h`s two sections, lower section 14 with upper section 16 telescoped therein. Clamp means 18 on the top of the lower, outer section 14 is in the form of a set screw. It forms means for securely attaching the two sections of the column 12 into an adjusted position.
The bottom portion 20 of turntable 22 is attached to the top of column 12, which would be the top of the upper section 16. The upper portion 24 of the turntable 22 is securely attached to the bottom of hub 26. The turntable has ball bearings.
It will be understood that the turntable 22 forms a means for allowing the hub 26 to be rotated relative to the column 12 Also, it will be apparent that if the hub 26 may be rotated relative to the column 12 it is also rotated relative to the pedestal 10.
A plurality of arms or struts 28, specifically six, radiate from the hub 26. The struts 28 are horizontal and evenly spaced about the hub. The struts 28 are all of the same length. Four hanger rods are attached to each strut 28. The rods are designated as first rod 30, second rod 32, third rod 34, and fourth rod 36. Referring to the drawing, the first rod 30 is proximal of the hub 26; and therefore, will be referred to as the proximal rod. The fourth rod 36 is near the distal end of the strut 28; and therefore, will be referred to as the distal rod. The hanger rods 30-36 are all horizontally oriented and at right angles normal to the strut 28. Each of the rods extends for an equal distance on each side of the strut. Tip 38 on each distal end of each rod angles upward so that catheter packages hung on the rod are retained thereon in normal usage. When it is desired to remove a catheter from the rod, they may be readily removed from the rod and likewise, they are readily placed upon the rod when replenishing the supply of catheters on the rack or hanger.
The first rod 30 is the shortest of all the rods. The length of the first rod is such that so that the tips 38 of the first rod 30 is separated from the tip of the first rod 30 on the adjacent strut 28, a sufficient distance so that the catheters can be easily placed upon and removed from the rods 30. The second rod 32 is longer than the first rod 30, which is to say that the first rod 30 is shorter than the second rod 32. The distance between the tips of the second rods 32 on adjacent struts 28 is sufficient so that there is access to the first rods 30. There is more distance between the tips of the second rod 32 than there is between the tips of the first rods 30. The term "distance between the tips" in this specification refers to the distance between the tip of a rod on one strut and the tip of a rod on the adjacent strut.
Likewise, the distance between the tips of the third rods 34 is greater than the distance between the tips of the first rods 30 or the second rods 32. By having the distance between the tips of the third rods 34 greater than the distance between the inner arms, access can always be had to the inner arms. The distance between the tips of the distal rods 36 is greater than the distance between any of the other tips. Therefore, as stated before, there is always adequate access to the catheters upon the inner rods.
Handle 40 provides a convenient hand hold on the distal end of each of the struts 28. The personnel in the laboratory may readily hold the array of struts and rods in a steady position by placing one hand on the handle 40 while removing or replacing catheter packages upon any of the hanger rods.
Label 42 in the form of a plastic plate provides a surface upon which indices may be placed indicating the catheters upon the rods of that arm. This label is located on the struts 28 between the handle 40 and the distal rod 36. Therefore, the label is distal of the fourth rod 36 and near the handle 40.
I prefer the hub to be about 60" above the floor and the distance from handle 40 on one strut 28 to handle 40 on the opposite strut to be about 52". In such a situation, the pedestal 10 would have a diameter of less than 52". It is desirable that the pedestal have sufficient diameter to provide a stable base for the holder or rack. It may be readily seen that with this arrangement there are a total of 48 pegs or half rods extending upon which to place catheters. These 48 are arranged with eight half rods on either side of a bay, the bay being the open space between adjacent struts. Although ordinarily only similar type catheters or catheters length will be placed on any given half bay, this is not essential. I.e., catheters of different types may be placed upon the same strut. The label at the end of each strut is useful in helping the personnel find the right catheter as needed. Also, by having numerous places to put the catheters, they may be easily inventoried for reordering.
The embodiment shown and described above is only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention. For example, I prefer that the column be made of aluminum alloy and the arms of tubing and hub of aluminum. Also, I prefer that the entire rack be chrome plated so that it is more acceptable in medical surroundings such as a hospital.
The restrictive description and drawing of the specific examples above do not point out what an infringement of this patent would be, but are to enable one skilled in the art to make and use the invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims.
|
In a medical supply room, packaged catheters are hung upon a rack for ready access. The rack has six arms radiating from a rotatable hub. The catheters are hung upon rods which extend across each of the arms.
| 0
|
REFERENCE TO RELATED APPLICATIONS
The present application claims priority from U.S. Provisional Patent Application Ser. No. 61/471,302, which was filed Apr. 4, 2011, under the title “EQ/IQ Equinus Brace”; U.S. Provisional Patent Application Ser. No. 61/489,398, which was filed May 24, 2011, under the title “Hinged Equinus Brace with Toe Wedge”; and U.S. Provisional Patent Application Ser. No. 61/583,474, which was filed Jan. 5, 2012, under the title “Adjustable-Sole, Hinged Equinus Brace with Toe Wedge,” the disclosures of which are expressly incorporated by reference.
FIELD
The present disclosure relates to devices and processes used to treat ankle equinus. More specifically, the present disclosure relates to braces or device and their methods of use to treat equinus by stretching the Gastrocnemius muscle and/or the Soleus muscle.
BACKGROUND
Equinus is typically described as a condition in which the upward bending motion of the ankle is limited. Equinus is defined as the inability or lack of ankle joint dorsiflexion less than a right angle relative to the leg.
Equinus may result in a lack of flexibility past the right angle relative to the leg. Someone suffering with equinus may lack the flexibility to bring the top of foot 18 past a right angle (90°) relative to the leg and toward the front of the leg. A typical maximum ankle range of motion for dorsiflexion is indicated as twenty-five degrees (25°) less than a right angle relative to the leg. Equinus may also be characterized as a limited ankle range of motion for dorsiflexion which is no more than five (5°), ten (10°) or even fifteen degrees) (15°) less than a right angle relative to the leg.
There are several possible causes for limited range of ankle motion. Limited range of ankle motion is often due to tightness in the calf muscles (the soleus muscle and/or the gastrocnemius muscle). Shortening of the gastrocnemius muscle (also known as gastroc equinus) is a very common condition which may affect most people because the gastrocnemius muscle crosses two joints. The gastrocnemius muscle originates above knee 12 joint, while the soleus originates below knee 12 joint. Both muscles join to form the Achilles tendon, which attaches to the heel. Therefore, the gastrocnemius muscle crosses two joints: knee 12 and the ankle, while the soleus muscle only crosses the ankle joint.
Regardless of the cause of limited ankle motion, someone suffering with equinus can develop a wide range of foot problems. There are several ways to treat limited ankle range of motion, such as gastroc equinus, including stretching exercises, orthotics with heel lifts, padding, molded shoes, serial casting, as well as night splints and braces.
Many current night splints allow user 22 to sleep with their knees bent. Current night splints and braces do not lock knee 12 into extension as they do not extend above the knee. Failure to lock knee 12 into extension means that a person experiencing gastroc equinus does not stretch gastrocnemius muscle, and therefore is only stretching the soleus muscle.
Many current night splints and braces are awkward and uncomfortable for sleeping. Since night splints and many current braces are supposed to be worn throughout the night, an awkward or cumbersome night splint or brace may cause a user to either not get a good night's sleep or cause a user to remove the device. If user 22 does not get a good night's sleep, user 22 may not choose to use the device in the future. This lack of compliance leads to the current devices not performing their intended function.
Even if a knee is kept completely straight by a user, the night splint or brace is not the reason for a complete stretch of gastrocnemius muscle, because there is no above the knee extension locking the knee joint.
If the night splint or brace does not lock the knee in full extension while dorsiflexing the ankle joint, the device is not providing the preferred method of treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a back view of calf muscles with a knee at extension and an ankle at neutral position.
FIG. 2 is a side view of the calf muscles of FIG. 1 .
FIG. 3 is a perspective view of calf muscles with a knee in flexion and the ankle in dorsiflexion.
FIG. 4 is a perspective view of a brace/device according to an embodiment of the present disclosure.
FIG. 5 is a side view of the brace of FIG. 4 and calf muscles with a knee at extension and an ankle in dorsiflexion.
DESCRIPTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments illustrated in the disclosure, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
As shown in FIGS. 1 and 2 , thigh 10 , knee 12 , calf 14 , ankle 16 , foot 18 , and calf muscles 20 of user 22 are illustrated. Calf muscles 20 are shown as gastrocnemius muscle 24 and soleus muscle 26 . Each of these muscles 24 , 26 shares a common insertion (attachment) via Achilles tendon 28 into the posterior calcaneus. Soleus muscle 26 originates at the proximal to medial portions of tibia 30 and fibula 32 . Soleus muscle 26 and gastrocnemius muscle 24 unite via their respective apponeurosis to form Achilles tendon 28 . Unlike soleus muscle 26 , gastrocnemius muscle 24 originates at posterior femur 34 just above knee 12 and also inserts into heel 36 . Gastrocnemius muscle 24 crosses two joints: knee 12 and ankle 16 .
As illustrated with knee 12 in extension and ankle 16 in normal position, soleus muscle 26 and gastrocnemius muscle 24 are not stretched to capacity in a person with normal ankle range of motion including maximum ankle dorsiflexion of twenty-five degrees (25°). In a person with limited ankle range of motion, such as equinus, soleus muscle 26 or gastrocnemius muscle 24 may be stretched to capacity with knee 12 in extension for gastroc equinus or gastrosoleal equinus and ankle 16 in normal position or in a dorsiflexed position.
As illustrated in FIG. 3 , a person with limited ankle range of motion due to gastroc equinus, moving knee 12 from extension to flexion releases gastrocnemius muscle 24 from full stretch capacity. A person suffering from gastroc equinus may be able to place ankle 16 in dorsiflexion with knee 12 in flexion even though gastrocnemius muscle 24 is shortened.
Device 40 according to an embodiment of the present disclosure is illustrated in FIG. 4 . Device 40 is constructed from plastic molded shell 42 including footplate 44 , medial rod 46 and lateral rod 48 . Medial rod 46 and lateral rod 48 are each terms used to describe a plurality of elongated rods 46 , 48 and additional components. Medial rod 46 and lateral rod 48 each extend from above knee 12 of user 22 to foot 18 of user 22 .
Medial rod 46 is described to correspond to the medial side of the leg of user 22 . Lateral rod 48 is described to correspond to the lateral side of the leg of user 22 . It is understood that in this embodiment each elongated rod can function as either medial rod 46 or lateral rod 48 depending upon the needs of user 22 . It is envisioned that device 40 can be used on either leg of user 22 . It is also envisioned that by switching device 40 from one leg of user 22 to the other leg of user 22 , medial rod 46 becomes lateral rod 48 and vice versa.
Medial rod 46 and lateral rod 48 each include femur adjustment 50 , knee hinge 52 , and tibia adjustment 54 . Femur adjustment 50 includes a slidably attached extension to femur rod 56 of either medial rod 46 or lateral rod 48 . Femur adjustment 50 allows for proper sizing and fit of device 40 about the thigh of user 22 . In one embodiment, femur adjustment 50 independently extends femur rod 56 to about the middle of thigh 10 of user 22 . Femur adjustment 50 also facilitates use of device 40 with users of varying leg length.
Knee hinge 52 connects at least two of the plurality of elongated rods 46 , 48 . Knee hinge 52 is configured to be located somewhat at, below or above knee 12 of user 22 .
Knee hinge 52 allows for anterior or posterior rotation of at least one of the plurality of elongated rods 46 , 48 . Rotation of femur rod 56 may aid in insertion of user's leg into device 40 or removal of user's leg from device 40 . Knee hinge 52 also includes a locking feature which allows knee 12 of user 22 to be locked in extension. As discussed in greater detail below, locking knee in extension aids in stretching the gastrocnemius muscle of user 22 . In the alternative, knee hinge 52 also allows for unlocking of knee 12 of user 22 in flexion. Unlocking knee 12 of user 22 in flexion may aid in isolated stretching of the soleus muscle of user 22 .
Tibia adjustment 54 provides a slidably attached extension between tibial rod 55 of either medial rod 46 or lateral rod 48 and components of footplate 44 . Tibia adjustment 54 allows for proper sizing and fit of device 40 about the lower leg or calf 14 of user 22 . Tibia adjustment 54 also facilitates use of device 40 with users of varying leg length.
Furthermore, independent tibia adjustment 54 allows for medial rod 46 and lateral rod 48 to have different heights. As illustrated in FIG. 4 , knee hinges 52 for medial rod 46 and lateral rod 48 share the same axis of rotation. However, knee hinges 52 are not required to be coaxial or may be coaxial. Device 40 with non-coaxial knee hinges 52 may be useful for a user having Genu Varum, Genu Valgum, Tibial Varum, or Tibial Valgum deformity. Device 40 with multiaxial ankle hinges 58 may be useful to provide ankle dorsiflexion of user 22 and correction of forefoot varus, forefoot valgus, rearfoot varus, or rearfoot valgus.
Footplate 44 is described as the base of device 40 and support for foot 18 of user 22 . Footplate 44 is well padded, including heel 36 . Footplate 44 is also adjustable in width from narrow to wide for wider legs or feet 18 of user 22 .
Footplate 44 is also adjustable to allow for shoe size-based adjustment from back to front. This shoe size adjustment ranges in various embodiments from children's size 1 pediatric shoes to adult size 24. Adjustment would vary by device 40 depending on the target user group. For example, one common size range adjusts from size 6 female to size 14 male.
Footplate 44 includes ankle hinge 58 , sole 60 , and optional toe wedge 62 . Ankle hinge 58 connects medial rod 46 and lateral rod 48 to footplate 44 . Ankle hinge 58 is configured to be located adjacent to the ankle of user 22 .
Ankle hinge 58 allows for plantarflexion and dorsiflexion of the ankle of user 22 . Ankle hinge 58 allows for precise control of ankle position of user 22 . Ankle hinge 58 also includes a locking feature which allows user's ankle to be locked in any position, such as normal, plantarflexion or dorsiflexion. In combination with other components of device 40 , ankle hinge 58 aids in stretching user's gastrocnemius and soleus muscles, among other things. Specifically, ankle hinge 58 allows for locking user's ankle in dorsiflexion while knee hinge 52 allows for locking user's knee in extension. The combination of knee in extension and ankle in dorsiflexion aids in full stretching of the gastrocnemius and soleus muscles of user 22 .
Footplate 44 also includes goniometer 64 located near ankle hinge 58 . Goniometer 64 allows for precise measurement of user's ankle position. It is also envisioned that external locking systems, such as a lockout pin (not shown), may be utilized to hold footplate 44 at a prescribed ankle position. This requested ankle position can be precisely measured, monitored, or adjusted with reference to goniometer 64 .
Sole 60 is removably coupled to the bottom side of footplate 44 and includes tread pattern 61 to prevent slippage. As shown in FIG. 4 , sole 60 is illustrated as a negative heel rocker sole. Negative heel rocker sole 60 is useful for walking or standing with fixed dorsiflexion ankle joint position. Multiple negative heel rocker soles 60 are available at varying angles to match different angles of dorsiflexion. For example, negative heel rocker sole 60 may have five-degree (5°), ten-degree (10°), and fifteen-degree (15°) angles. Additional negative heel rocker sole degree angles are envisioned.
Toe wedge 62 is optionally included with footplate 44 . Toe wedge 62 is configured to be located beneath the hallux of user 22 . Toe wedge 62 is configured to engage user's Windlass Mechanism, which dorsiflexes the hallux to tighten the plantar fascia thereby supinating the hindfoot and further stretching the Gastrocsoleus complex and additionally the plantar fascia. Multiple toe wedges 62 are available at varying angles. For example, toe wedges 62 may have any degree from thirty degree (30°) to ninety degree) (90°) angles. Additional toe wedge angles are envisioned. Alternative mechanisms for engaging the Windlass Mechanism are envisioned. For example, a loop of soft rubber may go over the hallux to dorsiflex the ankle of user 22 in order to engage the Windlass Mechanism with a Velcro strap.
Device 40 may also include adjustable straps 66 with optional padding 68 over the thigh, over the lower leg or calf 14 , the dorsal midfoot and at ankle 16 . Adjustable straps 66 and padding 68 extend about 4-6 cm anterior and posterior above knee 12 of user 22 . Additional adjustable straps 66 with pads 68 anterior and posterior to the tibia and calf extending from the tibial tubercle to the inferior border of the calf of user 22 are also envisioned.
FIG. 5 illustrates device 40 in use by user 22 . Device 40 is effective in treating equinus. Device 40 is also effective in treating equinus associated with any of the following other conditions: Heel Spur Syndrome/Plantar fasciitis; neuromuscular disorders such as Cerebral Palsy and Friedreich's Ataxia; congenital disorders such as Congenital Equinus, Clubfoot, Vertical Talus, and, Calcaneal Valgus; Pediatric Flexible Flatfoot deformity; Adult Flexible Flatfoot deformity; Tibialis Posterior Tendon Dysfunction; Achilles tendonitis; Achilles tendon injuries; Haglund's Deformity; Retrocalcaneal heel spurs and tendonosis; Tarsal Coalitions; Bunion deformities; Metatarsalgia; Forefoot pain; Charcot deformity; Diabetic forefoot ulcers and toe ulcers; Equinovarus deformities from post-injury or post-stroke patients; Post Transmetatarsal or Chopart's amputation patients; Midfoot degenerative joint disease at Lis Franc's joint or Chopart's joint; Hypermobile first ray disorders and Cross-over toe deformities.
FIG. 5 is also useful in illustrating methods of treating equinus by stretching user's gastrocnemius muscle. The following illustrated steps of treating equinus using device 40 are: (a) locking knee 12 of user 22 in extension using knee hinge 52 of device 40 , (b) locking ankle 16 of user 22 in dorsiflexion using ankle hinge 58 of device 40 , thereby stretching user's gastrocnemius muscle 24 and soleus muscle 26 . In another embodiment, the additional step of measuring the angle of user's ankle 16 is evident by use of goniometer 64 ( FIG. 4 ) of device 40 .
Because device 40 is a targeted stretch of gastrocnemius muscle 24 and soleus muscle 26 , device 40 may be used for a shorter period of time than a traditional night splint. Device 40 may yield quicker and more effective results in correction of equinus. Device 40 may provide the same benefit of a traditional night splint without user 22 having to wear device 40 overnight. For example, device 40 worn for two 30 minute sessions per day may provide the same benefit of a traditional night splint worn overnight. This example is based on a meta-analysis by Radford et al. in the British Journal of Sports Medicine 2006. In comparison to a traditional night splint, device 40 may not need to be worn overnight, improving user compliance and providing user with a more comfortable and restful sleep.
Device 40 may be used for a shorter treatment period than other devices. For example, device 40 may be used for one (1) to three (3) months. Some users, especially athletic participants and children, may benefit from a maintenance program after treatment. The maintenance program may involve use of device 40 on a less regular schedule for a period of time to maintain the desired correction.
Device 40 may come with written or digital instructions for users, physicians and therapists. Device 40 may be packaged with Frequently Asked Questions or links to websites for additional information, such as instructions on use.
While the inventions have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that the preferred embodiment has been shown and described and that changes and modifications that come within the spirit of the invention are desired to be protected.
|
Devices and processes used to treat ankle equinus. More specifically, the present disclosure relates to a brace and the corresponding method of use to treat equinus by stretching the Gastrocnemius muscle.
| 0
|
This is a continuation of Ser. No. 395,157 filed Sept. 7, 1973, now abandoned.
BACKGROUND OF THE INVENTION
In recent years, increasingly more reinforced concrete buildings are being demolished to be replaced with new buildings solely by reason of outmoded functionality despite the fact that they are still in perfect condition from the standpoint of durability. In demolishing such buildings, there have heretofore been employed such methods as a steel ball hung from the top of the boom of a crawler crane which is swung against concrete structures, the use of explosives for breaking up concrete structures and the use of a preumatic drill, for example. The method using the steel ball entails a relatively high vibration level in spite of rather low noise level and produces a fairly large amount of dust, and therefore necessitates measures for protecting the neighborhood against possible nuisance. The use of explosives involves high vibration and noise, levels, although momentarily, the use of a pneumatic drill suffers from a fairly high noise level in spite of an extremely low vibration level. Thus, all the conventional methods have their disadvantages.
This invention, therefore, aims to provide a method for breaking existing reinforced concrete structures safely and relatively inexpensively while reducing the generation of noise, vibration and dust as much as possible and also to provide devices for practicing said method.
SUMMARY OF THE INVENTION
The method for breaking concrete structures according to the present invention is characterized by a basic procedure of placing a loading member of a static loading means in contact with a concrete structure, for example horizontal structures such as slabs, sub-beams and main beams and vertical structures such as internal walls, external walls and columns, disposing on the reaction side thereof a reaction force supporting means, generating bending stress in said concrete structure by virtue of the static load exerted by the static loading means via said loading member and breaking the concrete structure near the load point or at the points at which the concrete structure is supported.
The method of this invention can be applied equally effectively to horizontal structures and vertical structures. In breaking horizontal structures, the method can utilize slabs, sub-beams and main beams on the lower floor for securing the reaction force supporting means, making the selection of reaction force relatively simple and easy. Where vertical structures are to be broken, walls and rigid frames erected on the opposite side can be utilized for securing the reaction force supporting means. Where no convenient objects are available for securing said means, the reaction force supporting member can be applied directly against the concrete structures to be broken. In this case, the concrete structures themselves serve as the supports for the reaction force.
In any case, the load point may properly be fixed either near the edge or close to the centre of such peripherally fixed board-like structures as slabs and walls to suit the conditions of the work site. In the case of a load exerted close to the centre of a slab or wall, for example, bending cracks first propagate radially on the side opposite the side of load application from a position corresponding to that of load application and then the wall is broken in a conical shape centering round the point of load application, followed by tensile breakage of the entire wall. The load can be applied to the extent of crack formation in the structure, to a further extent to achieve tensile breakage or to the furthest extent by causing breakage of steel reinforcement, the selection of the extent of breaking being readily accomplished by controlling the degree of load application after due consideration of the site conditions.
Normally, floor slabs and beams are reinforced with steel bars so as to provide high resistance to forces exerted vertically in the downward direction. They are relatively weak against thrusting forces exerted upwardly in the vertical direction. Therefore, floor slabs on the second floor can be broken by applying a load upwardly from the first floor side. In the case of walls, a load is applied on one side alone or on both sides to form breakage at the edge portion or close to the central portion. Thus, a given concrete building can be pulled down without generating noise and vibration.
Depending on the dimensions of a particular concrete structure, the method of the present invention may, of course, require the basic procedure to be repeatedly performed sequentially at a plurality of points, spaced effectively from one another, so as to bring the concrete structure to complete breakage.
The term "static loading means" as used in connection with this invention refers to a means for exerting static load to a given concrete structure via a loading member so as to generate bending stress in said concrete structure. As a specific example it may be a hydraulic jack which is provided at the head portion thereof with a loading member adapted to be placed in contact with the concrete structure so as to exert static load thereon and which is connected through an oil conduit to an oil pressure generating and controlling unit. The term "reaction force supporting means" as used herein refers to a means for holding back the reaction force which is generated when bending stress occurs in the concrete structure in consequence of the application of static load thereto via the loading member of the static loading means. As a specific example it may be a member which is fastened to a suitable concrete structure, if one is available in the neighborhood of the structure being broken, as the structure of the reaction. In the absence of such a convenient neighboring structure, the term refers to a reaction force supporting member which is disposed at points other than the load point on the concrete structure to be broken.
Various embodiments of devices which may be used for the present invention are as follows. Where neighboring concrete structures are available to provide a reaction force, there may be used.
1. a device wherein a hydraulic loading means adapted to be actuated by an oil pressure generating and controlling unit is disposed between a loading member and a reaction force suporting means so as to cause bending stress to be generated in the concrete structure,
2. a device wherein the reaction force supporting means corresponding to that of the device (1) has a greater contact area,
3. a device which is a modification of the device (1) having a loading member and a loading means disposed on a freely movable truck and a reaction force supporting means disposed on the lower portion of said truck,
4. a device wherein a hydraulic jack is disposed on the upper part of a freely movable truck provided at the under section thereof with a suporting means of a large contact area intended as a reaction force supporting means, the hydraulic jack being connected to an oil pressure and controlling unit,
5. a device wherein a hydraulic jack is disposed on the upper part of a truck provided at the under part thereof with a supporting member of large contact area intended as a reaction force supporting means and at the upper part thereof with a freely remotely controllable oil pressure generating and controlling unit, and said jack is connected to said oil pressure generating and controlling unit,
6. a device wherein a hydraulic jack is disposed on a truck provided at the lower section thereof with a supporting means of a large contact area capable of being moved forward and backward by means of a lifting jack so as to function as a reaction force supporting means,
7. devices which are modifications of the devices (4) to (6) having a hydraulic jack fitted with a spacer,
8. devices which are modifications of the devices of (4) to (6) having a loading head and a hydraulic jack disposed so as to be drawn out to an operation position and retraced to a resting position,
9. devices which are modifications of the devices (7) having a spacer disposed so as to be drawn out to an operating position and retracted to a resting position,
10. a device wherein a freely expandable arm has one of the ends thereof attached to a freely movable truck in such a way as to be able to rotate freely in a plane perpendicular to said truck, and a unit having a loading means operable by an oil pressure generating and controlling unit disposed between a loading member and a reaction force supporting means so as to generate bending stress in the concrete structure is attached to the other end of said arm in such way as to be able to rotate freely relative to said arm,
11. a device in which a freely extensible arm has one of the ends thereof attached to a freely movable truck in such way as to be able to freely rotate in all directions in planes horizontal and perpendicular to said truck, and a unit having a loading means operable by an oil pressure generating and controlling unit disposed between a loading member and a reaction force supporting means so as to generate bending stress in the concrete structure is attached to the other end of said arm in such way as to be able to rotate freely relative to said arm, and
12. a device wherein a hydraulic jack supporting frame freely and liftably suspended by a suspending wire along a beam or column of a concrete structure and a connecting frame freely and liftably suspended by a suspending wire along another frame or column are connected by connecting rods positioned on opposite sides of said two beams or columns, and a loading head adapted to confer concentrated load upon the face of the beam or column is fastened to the end of a freely retractable piston rod of a hydraulic jack connected to an oil pressure generating and controlling unit.
Where no adjacent concrete structures are available, there may be used a device wherein a hydraulic jack connected to an oil pressure generating and controlling unit is disposed on the axis of symmetry of an arched reaction force supporting frame, a loading head adapted to confer concentrated load upon one surface of the concrete structure to be broken is fastened to the end of a piston rod of the hydraulic jack, and a reaction force supporting member adapted to be held in contact with the concrete structure is attached to each of the two free ends of said reaction force supporting frame.
A conventional jack will suffice as the hydraulic jack to be used as a static loading means. The hydrauric jack is preferably an oil jack, which is connected to the oil pressure generating and controlling unit via oil tubes. The approximate capacity expected of the jack is of the order of 10 to 25 tons for slabs, 25 to 100 tons for sub-beams and 50 to 200 tons for main beams. As regards the shape of the loading head, a hemispherical or conical head permitting concentrated application of load and a flat head with rather larger area of load application can both be used effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation illustrating a first embodiment of a device for breaking concrete structures according to the present invention,
FIG. 2 is a side elevation illustrating the device of FIG. 1 in its operative condition.
FIG. 3 is a plan view of FIG. 2,
FIGS. 4 and 5 are each a side elevation illustrating a second embodiment of the device of the present invention in its operative condition.
FIG. 6 is a plan view of FIG. 5,
FIG. 7 is a side elevation illustrating a third embodiment of the device according to the present invention.
FIG. 8 is a front view of the device of FIG. 7,
FIGS. 9 and 10 are each a side elevation illustrating the device of FIG. 7 in its operative condition,
FIG. 11 is a side elevation illustrating the use of the device of FIG. 7.
FIG. 12 is a side elevation illustrating a fourth embodiment of the device according to the present invention.
FIG. 13 is a plan view illustrating, in an operative condition, a fifth embodiment of the device according to the present invention,
FIG. 14 is a side elevation of the device of FIG. 13,
FIG. 15 is a side sectional view illustrating, in an operative condition, a sixth embodiment of the device according to the present invention,
FIG. 16 is a plan view of the device of FIG. 15,
FIG. 17 is a partially cutaway side elevation illustrating, in an operative condition, a seventh embodiment of the device according to the present invention, and
FIG. 18 is a plan view of the device of FIG. 17.
DETAILED DESCRIPTION
FIGS. 1 to 6 illustrate one form of the device for breaking concrete structures according to the present invention. On a freely movable truck 1 are disposed an oil pressure generating and controlling unit 2 capable of being freely controlled by a remote means and a spacer 5 provided at the head portion thereof with a hydraulic jack 4 with a loading head 3. A truck lifting jack 6 adapted to give a forward and backward motion to a reaction force supporting member 7 having a large contact area is attached to the lower section of the truck 1 or to the end of the spacer 5. The oil jack 4 and truck lifting jack 6 are connected to each other via the oil pressure generating and controlling unit 2 and oil conduits 8 and 9.
FIGS. 1 to 3 illustrate a device designed for breaking horizontal structures and FIGS. 4 to 6 a device designed for breaking vertical structures. Referring to FIGS. 1 to 3, a spacer 5 provided at the head portion thereof with a hydraulic jack 4 with a loading head 3 is mounted on a truck 1 freely movable by means of wheels 10, together with an oil pressure generating and controlling unit 2 which is provided with a cap tire cord 12 extended to permit remote control by a hand switch 11 and an electric cable 13 connected to a power source (not illustrated). Under truck 1, a truck lifting jack 6 is disposed vertically to serve the purpose of moving forward and backward a reaction force supporting member 7 having a sufficient contact area. The truck lifting jack 6 adds to convenience of handling. The hydraulic jack 4 and the truck lifting jack 6 are connected via oil conduits 8 and 9 to the oil pressure generating and controlling unit 2. In the present case, the spacer 5 is fixed to the truck in such a way as to be capable of being drawn out to an operating position or retracted to a resting position. To facilitate the handling of the spacer 5, it is attached by a fastener 15 to a supporting rail 14.
In the embodiment shown in FIGS. 4 to 6 wherein like parts are denoted by like numerals as compared to FIGS. 1 to 3, there is a difference in that the truck lifting jack 6 is fastened to the extremity of the spacer 5. There are additionally provided a supporting jack 16 serving to give a vertical motion to the horizontal spacer 5 and an oil conduit 17 connecting the jack 16 to the oil pressure generating and controlling unit 2.
Each of the two devices described above is manoeuvered on a work site by work men pushing manually. Then, the oil pressure generating and controlling unit 2 is actuated and the truck lifting jack 6 is operated to cause the reaction force supporting member 7 to push against the floor surface 18 until the truck 1 is lifted to a suspended position as illustrated in FIG. 2, or to cause said member 7 to be held in contact with a wall 19 as illustrated in FIG. 5. Thereafter, the hydraulic jack 4 pushes the loading head 3 against the wall 20 to be broken until breakage occurs at the point of load application. Thus the device of this invention has mounted on the freely movable truck 1 the means for imparting static load to the concrete structure 20, with the various parts of said means operated by remote control. Therefore, it excels in mobility and safety and permits the work of demolishing buildings to be accomplished without generating noise and vibration. Since the reaction force supporting member 7 has a larger contact area, the force per unit area to be applied by the loading head 3 of the hydraulic jack 4 is without exception greater than that exerted by the reaction force supporting member 7. Even when the concrete structure 20 to be broken and the concrete structure 19 taken as the source of reaction force are of same construction, breakage invariably occurs on the former side. With this device, therefore, it never happens that the floor slab or wall by which the present device is supported will resist against the load. In the devices of FIGS. 1 to 6, the reaction force supporting member 7 may be attached directly to the truck 1 or the spacer 5 without incorporating the hydraulic jack 6.
FIGS. 7 to 11 illustrate another embodiment of the device for breaking concrete structures according to the present invention. A freely extensible boom 22 is attached at one end thereof to a freely movable truck 21 in such a way as to be able to rotate freely in a plane perpendicular to said truck 21. To the other end of the boom 22 is attached a spacer 28 provided with a loading head 26 and a reaction force supporting member 27 so as to impart bending stress to the concrete structure 23 to be broken through a hydraulic jack 25 operated by an oil pressure generating and controlling unit 29. The spacer 28 is attached to the boom 22 via a universal coupling 30 for example an oil motor, in such a way as to be able to rotate freely relative to the boom 22.
FIGS. 7 and 8 illustrate this embodiment in the state in which it travels to the structure 23 to be broken i.e. in a state in which the device is held at rest. The boom 22 is a hydraulic jack which is connected via oil conduits 33 and 34 to the oil pressure generating and controlling unit 29 and is freely extensible by the operation of the oil pressure generating and controlling unit 29. The boom 22 is attached at the lower end thereof to the truck in such way that it can be freely rotated in a plane perpendicular to the truck 21 by the operation of a hydraulic jack 35 which is connected via oil conduits 37 and 36 to the oil pressure generating and controlling unit 29. The truck 21 in this embodiment is a bulldozer which is provided with a clearing board 38, endless tracks 39, an engine 40 and an operator's seat 41.
FIG. 9 illustrates this embodiment in a state in which the device is in the process of breaking a concrete structure such as slab or beam. After this device has been transported to the work site in the state illustrated in FIGS. 7 and 8 the oil pressure generating and controlling unit 29 is put in to operation so that the boom 22 and the universal coupling 30 will be moved to a position permitting the loading head 26 at the head of the hydraulic jack 25 to face the concrete structure 23. The reaction force supporting member 27 attached to the spacer 28 is brought into firm contact with the floor. Then, the oil pressure generating and controlling unit 29 is operated so as to bring the loading head 26 into contact with the concrete structure 23. Finally, static load is delivered through the loading head 26 to the concrete structure 23 to generate bending stress therein until the accumulated stress breaks the concrete structure 23.
FIG. 10 illustrates this device in a state in which it is in the process of breaking a concrete structure such as wall or column. In this case, desired breakage can be accomplished by repeating the procedure illustrated in FIG. 9 except that the reaction force supporting member 27 is held in contact with an adjacent concrete structure 24 such as wall or column. In this case, since the contact area of the loading head 26 is smaller than that of the reaction force supporting member 27, breakage occurs on the concrete structure 23. It never happens that breakage will occur in the concrete structure 24.
FIG. 11 illustrates a case in which beam separated by a large span from an adjacent beam is being broken by using the device illustrated in FIGS. 7 to 10 in conjunction with another device of the same design, except that the loading head 26 attached to the head of the hydraulic jack 25 is substituted with a reaction force supporting member 42. The reactor force supporting member 27 fastened to the hydraulic jack 25 as illustrated in FIG. 11 may be moved forward and backward by the operation of the hydraulic jack 25.
The embodiment illustrated in FIGS. 7 to 11 operates very efficiently because the powered vehicle can transport the truck 21 to the work site and accurately locate the spacer 28 at a prescribed position in the work site.
The position of the spacer 28 can be finely adjusted by the operation of the truck 21 and further, broken pieces resulting from the breakage of the concrete structure 23 can be cleared by the clearing board 38.
FIG. 12 illustrates another embodiment of the device for breaking concrete structures according to the present invention. In this embodiment, a freely extensible arm 44 is attached at one end thereof to a freely movable truck 43 in such way as to be able to rotate freely in all directions in planes horizontal and perpendicular to the truck 43. A spacer 47 provided with a loading head 45 and a reaction force supporting member 48 and also provided with a hydraulic jack 46 operated through the oil conduits 60 and 61 by an oil pressure generating and controlling unit 50 is attached via a universal coupling 49 to the other end of the arm 44 in such way as to be able to rotate freely relative to the arm 44.
The arm 44 can freely be pulled upward and downward by the operation of hydraulic jacks 54 and 55 which are actuated by the oil pressure generating and controlling unit 50. By the operation of a rotation member 56 mounted on the truck 43, the arm 44 can be rotated to all directions in a plane horizontal to the truck 43. The arm 44 is attached at one end thereof to the truck 43 and at the other end to the spacer 47 via a universal coupling 49 such as oil motor. This spacer 47 may be identical with the spacer 28 illustrated in FIG. 7.
In this device, an operator in the operator's seat 57 operates an engine 51 to actuate the oil pressure generating and controlling unit 50 so as to fold the arm 44 by means of hydraulic jacks 54 and 55 and hold the spacer 47 in an stowed position under the arm 44. The truck is driven to the work site, with the arm 44 and the spacer 47 dept in the stowed position. After the truck has arrived at a prescribed position in the work site, the arm 44 is stretched so that the loading head 45 fixed to the spacer 47 faces the concrete structure 58 to be broken and the reaction force supporting member 48 is brought into contact with the floor 59. Thereafter, the oil pressure generating and controlling unit 50 is operated so as to bring the loading head 45 into contact with the concrete structure 58 and apply bending stress on the concrete structure 58 until breakage occurs.
In this device, the spacer 47 can freely be rotated to all directions around a universal coupling 49 attached to the spacer 47. Further, the arm 44 to which the universal coupling 49 is attached can freely be extended or contracted and turned right or left and up or down by means of the hydraulic jacks 54 and 55 disposed on the arm 44. Therefore, the spacer 47 can freely be rotated in all directions in planes horizontal and perpendicular to the truck 43. As a consequence, the spacer 47 can be placed at the work site and operated to break the concrete structure without reference to the arrangement in which the concrete structure is positioned.
The truck 43 can travel on endless tracks 52 and the clearing board 53 can clear broken pieces resulting from the breakage of concrete structure by the loading head 45. The operator who drives the truck 43 can set the spacer 47 at any prescribed position on the work site. The position of the spacer 47 can then be adjusted finely by the operation of the truck 43. Thus, this device performs with high efficiency.
The reaction force supporting member 48 fastened to the oil jack 46 as illustrated in FIGS. 7 to 11 may be adapted so as to freely be moved forward and backward by the operation of the hydraulic jack 46.
FIGS. 13 and 14 illustrate yet another embodiment of the device for breaking concrete structures according to the present invention. In this embodiment a hydraulic jack supporting frame 64 freely and liftably suspended by a suspending wire 72 along a beam or column 70 of a concrete structure and a connecting frame 65 freely and liftably suspended by a suspending wire 73 along another beam or column 71 are connected by connecting rods 66 positioned at opposite sides of the two beams or columns 70, 71. A loading head 62 adapted to apply concentrated load upon the opposite face of the beam or column 70 is fastened to the end of a freely retractable piston rod 61 of a hydraulic jack 60 connected via oil conduits 67 and 68 to an oil pressure generating and controlling unit 76. The rear end of the hydraulic jack 60 is interlocked with the connecting frame 65 through the supporting member 63 having a greter load receiving area.
In the diagrams, 69 is a metal piece for fastening the suspending wires 72 and 73, and 74 and 75 respectively a thread formed on the connecting rod 66 and a nut screwed on the thread.
Once the supporting frame 64, the connecting frame 65 and the two connecting rods 66 are set around the two columns 70 and 71 spaced by a certain distance from each other as shown in the diagrams, this device can quite easily be set to any desired height of the columns 70 and 71, by simply adjusting the suspending wires 72 and 73. When the device is set at a suitable position, the loading head 62 is pushed out by operating the piston rod 61 of the hydraulic jack 60 by the oil pressure from the oil pressure generating and controlling unit 76. Since the supporting frame 64 of the oil jack 60 is fastened with the two connecting rods 66 and the connecting frame 65 on to the other column 71, and further since the load receiving area of the loading head 62 is far smaller than that of the connecting frame 65, the static load exerted by the loading head 62 to the surface of the column 70 eventually breaks that portion of the column. By sequentially shifting the device to other positions selected for breakage on the same column and repeating the procedure, the entire column 70, however long it may be, can be broken with extreme simplicity.
The supporting member 63 fixed to the rear of the hydraulic jack 60 as illustrated in FIGS. 13 and 14 may be adapted so as to be moved forward and backward by means of the hydraulic jack 60.
FIGS. 15 to 18 illustrate another embodiment of the device for breaking concrete structures according to the present invention. In this embodiment, a hydraulic jack 81 connected via oil conduits 79 and 80 to an oil pressure generating and controlling unit 78 is fixed on the axis of symmetry of a reaction force supporting frame 77 having the shape of an arch. A loading head 83 adapted to confer concentrated load upon the face 91 of the concrete structure to be broken is attached to the end of the piston rod 82 of the hydraulic jack 81. Reaction force supporting members 84 adapted to be held in contact with the plane 92 opposite the plane 91 of the concrete structure 90 are formed at the ends of the arched reaction force supporting frame 77.
FIGS. 15 and 16 illustrate a case in which this device is used for breaking concreat structures such as walls and floors. FIGS. 17 and 18 illustrate another case in which breakage of concrete structures such as columns and beams is effected by a modification of the present device.
In either case, a loading head 83 adapted to confer concentrated load upon one face 91 of the concrete structure 90 to be broken is attached to the end of the load applying piston rod 82 of the hydraulic jack 81 on the axis of symmetry of the arched reaction force supporting frame 77 and reaction force supporting members 84 adapted to be held in contact with the face opposite the face 91 are formed at ends of the reaction force supporting frame 77. A supporting member 85 having a large contact area is fastened to the rear portion of the hydraulic jack 81 and this supporting member is so disposed as to be brought into contact with the reaction force supporting frame 77. In the case of FIGS. 15 and 16, anchor bolts are used as the reaction force supporting members 84. These anchor bolts are passed through holes 86 bored in advance through the concrete structure 90 to be broken and fixed in position by means of washers 87 and nuts 88 to suspend the device.
In the case of FIGS. 17 and 18, pin joints are used as the reaction force supporting members and they are suspended by means of suspending wires 89, for example. The oil pressure generating and controlling unit 78 and the hydraulic jack 81 are co-nected with oil conduits 79, 80 to each other to permit free forward and backward motion of the loading head 83. This connection by means of oil conduits is common to both the cases under discussion.
The reaction force generated against the concentrated static load exerted by the loading head 83 can be equally supported by the reaction force supporting members 84 which are separated by substantially equal distances from the point of load application. Further, since the reaction force supporting members 84 are held in contact with the face 92 opposite the surface 91 of the concrete structure 90 on which the static load is applied by said loading head 83. The concrete structure itself can serve as the source of reaction force in the case of a horizontal concrete structure 90 as illustrated in FIG. 15 and in the case of a vertical concrete structure 90 as shown in FIG. 17 as well. Moreover the reaction force supporting members 84 which are formed at free ends of the arched reaction force supporting frame 77 can easily be located outside the range within which the breakage caused by the load of the loading head 83 has its effect. The object of the present invention, therefore, can be accomplished by accurately applying concentrated load for the breakage and performing the work of breaking safely and efficiently.
The supporting member 85 fixed to the rear portion of the hydraulic jack 81 as illustrated in FIGS. 15 to 18 may be adapted so as to be moved forward and backward by the operation of the hydraulic jack 81.
Working examples which specifically illustrate the method of this invention will be described below with reference to the devices illustrated in the attached drawings.
EXAMPLE 1
The device illustrated in FIG. 1 was used to apply static load to the centre of a floor slab on a second floor (slab area 3.6 m × 4.8 m. slab thickness 105 mm, reinforcement with main steel bars 13 mm and sub-steel bars 9 mm in diameter) upwardly from the first floor. First cracks occurred when the load rose to 5 tons and breakage accompanied by a booming sound occurred when the load reached 8 tons.
A hole similar in shape to the hemispherical loading head occurred on the side of load application (ceiling side) and an opening of a square of about 70 cm was formed on the opposite side (floor side). Then, the device was moved to the four corners of the floor slab one after another operated to apply the same static load. Substantially the same effects of breakage were obtained. Finally, the steel exposed through the broken holes were cut off by a gas burner.
EXAMPLE 2
The device illustrated in FIG. 4 was used to break a wall on the first floor (wall area 4.8 m (width) × 4.98 m (height), reinforcement with horizontal and vertical steel bars invariably 9 mm in diameter, wall concrete thickness 140 mm and mortar coat thickness 25 mm), with an iron plate 180 mm square used as the loading head. The static load was applied at a point 1 m above the floor surface and 1.4 m from the side wall. Initial cracks occurred when the load rose to 4 tons, the cracks increased in size accompanied by a small sound when the load rose to 12 tons, and breakage with a booming sound occurred when the load reached 14 tons.
A hole similar in shape to the loading head was formed on the side of load application (inside the room) and a cracked portion of an area of about 90 cm × 70 cm was formed on the opposite side (outside the room), with the cracked portion protruding by about 4 cm. After the breakage, the loading head was pushed ahead to the full stroke of the jack 4 without increasing the magnitude of the static load. As a consequence, a concrete portion similar in area to the loading head was pushed put of the wall surface and the cracked portion fell out of position.
Thereafter, the loading head was shifted to varying heights of the wall by operating the jack 16 and operated to repeat the procedure. Substantially the same effects of breakage were obtained. Finally, the steel bars exposed through the broken holes were cut off by a gas burner.
EXAMPLE 3
To one of the square columns (500 mm × 500 mm square, reinforcement with 10 steel bars of 22 mm in diameter) facing to each other at a space interval of 6 m, static load was applied at a point of 2 m height above the floor in such a manner as shown in FIGS. 13 and 14. The main beams were kept attached between the columns.
Initial cracks occured and ran obliquely towards the loading head from the inside surface of the column when the load reached 120 tons. Then another cracks appeared at the outside surface arround the connecting parts of the columns with the main beams. When the load got to 170 tons, the cracks around the loading head got larger with a booming sound. Successively, the load was applied to the column. Though the load lowered down gradually, the cracks around the loading head and the connection parts were increased and finally the steel bars were exposed.
On the other hand, cracks also occurred around the connecting parts of the column with main beams on the reaction side and they were increased. Initial cracks were also found around the place where connection frame was locked.
EXAMPLE 4
The device as shown in FIGS. 17 and 18 having an arch-shaped reaction force supporting frame each end of which was provided with a reaction force supporting member at 4 m interval, was used to break 7 m span main beam (700 mm by 350 mm, reinforcement with two steel bars of 22 mm diameter at the upper section and three steel bars of the same diameter at the lower section). The device was powered with oil jack and when the load reached 40 tons, initial cracks ran obliquely towards the loading head from the surface opposite the loading side.
When the load reached 60 tons, the cracks were enlarged much with a booming sound and, at the same time, the connecting parts of the main beam with the columns and other parts of the main beam cracked. The jack was successively loaded. Though the load lowered down gradually, the cracks around the loading head and the connecting parts were developed, so that the steel bars were exposed at last.
|
Concrete structures including horizontal structures such as slabs, sub-beams and main beams and vertical structures such as internal walls, external walls and columns are broken by a static load applied to the concrete structure by a loading member of a static loading means, which causes bending stress to build up in the concrete structure and finally brings about breakage of the structure. The static load may be applied by hydraulic means, preferably mounted on a movable vehicle.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a packaging method for a flip-chip type semiconductor device, and more particularly to a method of connecting the electrodes of a semiconductor chip to a printed circuit board by soldering.
2. Description of the Related Art
A flip-chip type semiconductor device in which a plurality of solder bump electrodes formed on the surface of semiconductor chips are connected directly to a wiring pattern of a circuit board is broadly in use in the LSI field for the reasons that it permits high density packaging and enables one to obtain high bonding reliability. The technology for this device is described in, for example, an article by Sato et al. entitled "Micro-solder Bonding Technology for IC-LSI", Processings of the Japan institute of Metals, Vol. 23, No. 12 (1984), pp. 1004-1013.
In accordance with the prior art, solder bonding is carried out by applying soldering flux to a circuit board with a wiring pattern formed thereon, positioning the solder bump electrodes of semiconductor chips to the pads of the wiring pattern and binding them with soldering flux, then melting the solder (referred to reflowing hereinafter) by heating. In this process, the soldering flux has an important action of temporarily binding the positioned semiconductor chips by virtue of its bonding power, in addition to the action of smoothly carrying out reflowing.
On the other hand, accompanying the increase in the level of integration of LSIs, heat dissipation from the semiconductor chips of the flip-chip type semiconductor device has become an important technical issue, which necessitates the provision of a heat dissipating means on the rear surface of the semiconductor chips. As one of such heat dissipation methods Rao R. Tummala published an article entitled "Advance Packaging Technologies in U.S.--An Overview", IMC 1988 Proceedings, Tokyo, May 25-27, 1988, pp. 12-17 in which he proposed a structure wherein a cooling piston is pressed mechanically against the rear surface of one semiconductor chip by means of a spring. In addition, R. Darveaux, et al. propose a method in which a heat sink is commonly fitted to the rear surfaces of a plurality of semiconductor chips via a piece of indium with certain thickness in an article entitled "Thermal/Stress Analysis of a Multichip Package Design", Proceedings of the 39th Electronic Components Conference, May 1989, pp. 668-671.
However, the conventional method of temporarily binding semiconductor chips using soldering flux generates problems related to the bonding reliability and the yield due to the fact that many harmful impurities contained in the soldering flux are brought into contact with the front surface of the semiconductor chips. In particular, in view also of the circumstance that the reduction of intrusion of harmful impurities into various materials becomes severe in proportion to the advance of the level of integration and fine geometry of semiconductor chips, it is necessary to exclude soldering flux from the fabrication process.
Moreover, according to the above-mentioned conventional method the rear surfaces of various semiconductor chips, after reflow, do not find themselves located on the same plane, and the height deviation among the rear surfaces of the plurality of semiconductor chips becomes large. This is the reason why the cooling means with long heat dissipation path and complicated structure has to be arranged for each of the semiconductor chips as mentioned above. On the other hand, the aforementioned method of commonly fitting a heat sink by canceling the difference in the height among the plurality of semiconductor chips by forming the indium piece to have a large thickness (500-800 μm, for example) is not desirable because it results in the increase in the thermal resistance up to the location of the heat sink.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a packaging method for a flip-chip type semiconductor device which connects solder bump electrodes of semiconductor chips to pads of the wiring pattern of a printed circuit board without generating problems related to the bonding reliability and the yield.
It is another object of this invention to provide a packaging method for a flip-chip type semiconductor device which connects in a simple way a heat sink commonly to the rear surfaces of a plurality of semiconductor chips by reducing the thermal resistance.
A feature of this invention resides in that the method of packaging a flip-chip type semiconductor device includes a process of temporarily binding the rear surface side of a plurality of semiconductor chips that have solder bump electrodes formed on the front surface side to the respective predetermined locations on the flat surface of a block by means of wax of, for example, film thickness 5-10 μm as an adhesive, and a process of preparing a circuit board having a wiring pattern with a plurality of pads formed on the surface thereof, whereby the plurality of the semiconductor chips are bonded in a lump to the circuit board by positioning the block and the circuit board by placing the flat surface of the block so as to face the surface of the circuit board, bringing the solder bump electrodes and the pads into contact without the intermediary of soldering flux by letting them approach with each other, and bonding the solder bump electrodes to the pads by causing the solder of the solder bump electrodes reflow. In the last process of the reflow of the solder is desirable to be carried out in an atmosphere of a halogen gas.
Further, it can be arranged such that the solder bump electrode consists of a high melting point solder part and a low melting point solder part, the heating process has a first heat treatment process at a first temperature and a second heat treatment process at a second temperature higher than the first temperature, whereby local bonding is performed by melting only the low melting point solder part by the first heat treatment process, removing the block from the rear surfaces of the semiconductor chips, then carrying out the final bonding by melting the high melting point solder part and the low melting point solder part in the second heat treatment in the state where the rear surfaces of the semiconductor chips are placed on a flat surface of a jig. In this case, it is desirable to carry out electrical tests of the circuit board having the semiconductor chips locally bonded, between the first heat treatment process and the second heat treatment process.
As in the above, according to this invention, the temporary binding of the semiconductor chips is carried out on the rear surface side of the semiconductor chips and hence there does not exist soldering flux on the front surface side of the semiconductor chips. Therefore, there will occur absolutely no generation of problems related to the bonding reliability and the yield caused by the many harmful impurities contained in the soldering flux.
Moreover, according to this invention, reflow is carried out by bonding the rear surface side of a plurality of semiconductor chips to the flat surface of the block or the flat surfaces of the block and the jig, so the difference in the height among the rear surfaces of the plurality of semiconductor chips after the reflow is almost negligibly small, and all of the rear surfaces are located on the substantially same plane. Accordingly, it is possible to connect the heat sink commonly to the rear surfaces of the plurality of semiconductor chips with reduced thermal resistance by the use of a thin film of such material as thermal grease as the adhesive.
Furthermore, the positioning of the block and the circuit board may be done by forming positioning through holes in the block and a positioning pattern on the circuit board, and observing the pattern via the through holes. In this case, the block may be constructed of a silicon wafer of (100) surface, and form the positioning through holes by selective anisotropic etching of the silicon wafer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other objects, features and advantages of this invention will become apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1A and FIG. 1B are sectional views as arranged in the order of the processes for showing the conventional packaging method of a flip-chip type semiconductor device;
FIG. 2 is an impurity analysis table for describing the issues of the prior art;
FIG. 3A to FIG. 3E are sectional views as arranged in the order of the processes for showing a first embodiment of the packaging method according to the invention;
FIG. 4A is a plan view showing the case when block 1 in FIG. 3 is constructed of a silicon wafer, and FIG. 4B is a sectional view when the block in FIG. 4A is cut along the line A--A' and seen in the direction of the arrows;
FIG. 5 is a plan view showing an example of the block;
FIG. 6 is a perspective view showing the state of mounting semiconductor chips on the block;
FIGS. 7A, 7B are schematic views showing open and closed positions for illustrating an alignment method of the semiconductor chip to the block; and
FIG. 8A to FIG. 8F are sectional views as arranged in the order of the processes for showing a second embodiment of the packaging method according to the invention, wherein FIG. 8E is a plan view and all of the rest are sectional views.
DESCRIPTION OF THE PRIOR ART
First, referring FIG. 1, the packaging method according to the prior art will be described. Liquid rosin soldering flux 11 is applied to a circuit board 7 having a wiring pattern formed thereon, and a semiconductor chip 4 with elements such as transistors and a wiring pattern formed on its surface 15 side is pressed face-down in the direction of the arrow to align the solder bump electrodes on the surface 15 to the pads 8 of the wiring pattern and to bind them temporarily by means of the soldering flux 11 (FIG. 1A). Then, the bonding of the electrodes and the pads is carried out through formation of solder balls 10 by reflow of the solder (FIG. 1B).
The result of analysis for the contents of Cl - and Na + which are impurities harmful to the semiconductor chip are summarized in FIG. 2. As is clear from the figure, soldering flux contains far more amount of harmful impurities compared with polyimide that constitutes the semiconductor chip or molded resin which is the packaging material. Therefore, the bonding reliability and the yield are deteriorated in the above-mentioned method in which the surface 15 side where elements are formed is brought into contact with the soldering flux 11.
Moreover, in the above-mentioned method the deviation (ΔH) of the height of the rear surface 14 of each semiconductor chip 4 becomes large. For example, when the total of nine semiconductor chips 4, namely, three in a row by three in a column, are mounted on the same circuit board and bonded with solder, the difference ΔH between the maximum and the minimum heights among the rear surfaces 14 of the semiconductor chips amounts to as large of value as 100-150 μm. Consequently, it is difficult to mount a heat sink commonly with reduced thermal resistance on the rear surface of a plurality of semiconductor chips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 3, the first embodiment of the packaging method of the invention will be described.
First, as shown in FIG. 3A, wax 2 soluble to such a solvent as alcohol is applied to a thickness of 5-10 μm to a flat finished surface 21 of a piece of stainless steel of square shape, with side length of 40-100 mm and thickness of 5 mm. At each of four places in the periphery of the block 1 there is formed a through hole 3 which is to be used later for positioning with respect to the circuit board.
Next, as shown in FIG. 3B, a plurality of semiconductor chips 4, having solder bump electrodes 5 formed on the front surface 15 side where semiconductor elements, wirings and the like are mounted, are fixed by bonding with wax 2 at predetermined locations of the flat surface 21 of the block 1 by moving the chips with the rear surface 14 side facing downward. The solder bump electrode 5 of this embodiment is formed by solder plating a lead-tin alloy into a shape with square cross-section of side length 100-200 μm and height 50-150 μm.
Next, as shown in FIG. 3C, the circuit board 7 is placed on stage 6 of the bonder. The circuit board 7 consists of a piece of silicon with square cross-section of side 30-100 mm and thickness 0.5-2.0 mm. A multilayer interconnection pattern consisting of a polyimide film and a metallic film of copper, gold, aluminum or the like is formed on the surface 22 of the board 7 and bonding pads 8 are formed connected to the pattern. The plane area of the bonding pad 8 has a size morginally larger than the plane area of the solder bump electrode, and it is formed on the surface 22 to a film thickness of 5-6 μm by copper plating at the same time as the alignment marks 9 are formed. Then, the smooth surface 21 of the block 1 and the surface 22 of the circuit board 7 are placed opposing to each other, and the block 1 and the circuit board 7 are positioned by viewing the alignment marks 9 via the through holes 3 by a microscope.
Following that, a plurality of solder bump electrodes 5 and the plurality of pads 8 are brought into contact by lowering the block 1 vertically downward. Since there is not involved soldering flux in this invention, solder reflow is carried out at a temperature in the range of 200°-300° C. in a heat treatment furnace of an inert gas containing a halogen gas in order to realize smooth reflow. The solder bumps 5 are converted to solder balls 10 due to surface tension when they are melted, whereby the bump electrodes are bonded to the pads. After cooling, the block 1 is detached from the rear surfaces 14 of the plurality of semiconductor chips 4 by washing and removing the adhesive 2 with an alcoholic solvent (FIG. 3D).
Regarding the topic of solder reflow itself in a halogen gas atmosphere it is disclosed by P. A. Moskowitz, et al. in an article entitled "Thermal Dry Process Soldering", J. Vac. Sci. Technol., A4(3), May/June 1986, pp. 838-840.
Next, as shown in FIG. 3E, a heat sink 19 is fitted to the exposed rear surfaces of the semiconductor chips via thermal grease 18, such as a highly heat conductive silicone (elastomer type). According to this embodiment, the deviation (ΔH) of the height of the rear surfaces 14 of the semiconductor chips 4 becomes small by the presence of the flat surface 21 of the block 1. For example, when a total of nine, namely, three in a row by three in a column, semiconductor chips are mounted and bonded by soldering on the identical circuit board 7, it is possible to confine the difference ΔH between the maximum and the minimum heights of the rear surfaces of the semiconductor chips to a range of 5 to 10 μm. Accordingly, the thickness of thermal grease 18 can be made as thin as 10-70 μm and the thermal resistance between the rear surfaces of the semiconductor chips and the heat sink can be made low, so it is possible to fully exhibit the high speed and high output performance of the semiconductor chips. Thermal grease in this case acts as a heat conducting material as well as an adhesive. In order to increase the adhesive strength it is desirable to provide also a mechanical fixing means such as screws and pins at some appropriate places that are not explicity indicated in the figure.
Moreover, in sealing the circuit board and the semiconductor chips into a package, it is possible to form a heat dissipation system of low thermal resistance by thermally connecting the package to a package cap made of high heat conducting material via thermal grease since the rear surfaces of a plurality of semiconductor chips are in flat state.
FIG. 4A and FIG. 4B are a plan view and a sectional view, respectively, when the block 1 in FIG. 3 is made of a silicon wafer. On the rear surface 24 of a silicon wafer 16 of (100) crystal face with 4 inch diameter and 400 μm thickness, a silicon dioxide film (not shown) is formed as a mask material by photolithography, and four pieces of through holes 3 are formed by anisotropic etching. As shown in FIG. 4B, the structure of the through hole 3 has sloped surfaces stopped by the (111) face characteristic of anisotropic etching. The hole has a larger size on the rear surface 24 side, and is tapered toward the front surface 25 side where it has the shape of a square of 3 μm side.
According to the present method, it is possible to form through holes for alignment with respect to the circuit board 7 since the photolithography technique and the etching technique used in the manufacture of semiconductor wafers can be employed as they are.
FIG. 5 is a plan view showing the block 1 in FIG. 3 made of stainless steel in which the semiconductor chips are to be mounted and bonded at locations indicated by the lines with alternate long and two short dashes. At each of these locations a pair of cross-shaped alignment marks 35 are notched on the front surface 21. On the other hand, alignment marks are formed on the front surfaces of the semiconductor chips at the time of forming wiring patterns on the front surface side. Since these alignment marks on the front surfaces of the semiconductor chips need be detected from the rear surface side, infrared rays are employed for the alignment.
FIG. 6 is a perspective view showing the state of mounting the semiconductor chips 4 on the block 1. The block 1 is mounted on a predetermined position of a base table 31 by the help of guide pins 33, fixed there by evacuation through vacuum holes 32, and the semiconductor chips 4 are mounted and bonded one by one on the block 1.
Referring to FIG. 7, the method of aligning the semiconductor chips to the block will be described. As shown in FIG. 7A, a half mirror 41 is placed between the block 1 vacuum sucked to the base table 31 and the semiconductor chip 4 the front surface 15 side thereof is vacuum sucked to a collet 43 movable in X direction, Y direction and θ direction. An alignment mark 45 on the semiconductor chip 4 and the alignment mark 35 on the block 1 are viewed overlapped through a half mirror 41 of a CCD camera 42 that uses infrared rays 46, and are brought to precise overlapping by adjusting the motion of the collet 43 in the X direction, Y direction and θ direction. Then, the half mirror is withdrawn sideways and the collet 43 is lowered in vertical direction to bring the semiconductor chip into contact with the block (FIG. 7B), and the vacuum suction of the semiconductor chip to the collet is released. Next, another semiconductor chip is vacuum sucked to the collet and a similar operation is repeated.
Next, referring to FIG. 8, the second embodiment of the packaging method according to the invention will be described. Since identical symbols are assigned in FIG. 8 to components identical or similar to those in FIG. 3, further description on these components will be omitted.
First, as shown in FIG. 8A, the smooth surface 21 of the block 1 is coated with wax 52 with melting point 100° C. to a thickness of 5-10 μm.
Next, as shown in FIG. 8B, the rear surface 14 side of the semiconductor chip 4 is bonded to a predetermined location on the smooth front surface of the block 1 with wax 52. A solder bump electrode 55 of this embodiment on the front surface 15 of the semiconductor chip 4 has a structure obtained by stacking low melting point solder 57 formed by solder plating on high melting point solder 56 formed by solder plating.
Next, as shown in FIG. 8C, a circuit board 7 is placed on a stage 6 of the bonder, the smooth front surface 21 of the block 1 and the front surface 22 of the circuit board 7 are arranged facing with each other, and the positioning of the block 1 to the circuit board 7 is carried out by viewing the alignment marks 9 via the through holes 3.
Next, as shown in FIG. 8D, a plurality of the bump electrodes 55 are respectively brought into contact with the plurality of pads 8 by vertically lowering the block 1. In this invention there is involved no soldering flux. A preliminary reflow is carried out in a heat treat furnace of an atmosphere of inert gas containing a halogen at a temperature of 110°-130° C. for 30 sec to 3 min to perform local bonding by melting only the low melting point solder 57 of the bump electrodes 55. At this time, wax 52 looses its adhesive power by foaming, permitting the removal of the block 1 from the rear surfaces 14 of the semiconductor chips 14.
Next, as shown in FIG. 8E, electrical inspections of the circuit board with locally connected semiconductor chip is carried out by bringing an inspection probe 59 to a pad 64 for connecting an external terminal formed in the periphery of the circuit board 7, and is located at the tip of a wiring pattern 58 having a pad 8 connected to a solder bump electrode of the circuit board. Units which passed the electrical tests are sent to the next process, whereas among those which failed the tests but are reparable or correctable are subjected again to the electrical tests after necessary remedy and those passing the tests are sent to the next process.
As shown in FIG. 8F, in the next process, the rear surfaces 14 of the semiconductor chips are placed, and are brought into contact with, flat bottom surface 62 of a jig 61 made of carbon, the rear surface 23 of the circuit board 7 is covered with a carbon lid 63, and the main reflow of solder is carried out in a heat treat furnace of inert gas atmosphere containing a halogen at a temperature range of 200° to 350° C. for 30 sec to 5 min. As a result of this, bonding of the semiconductor chips and the circuit board is achieved by the formation of solder balls 10 due to surface tension, by the melting of the high melting point solder 56 of the solder bump electrode 55 and the remelting of the low melting point solder 57 which was melted in the preliminary reflow and solidified on cooling.
Then, a heat sink means may be provided on the rear surface of the semiconductor chips as needed similar to the case of the first embodiment.
According to the second embodiment, the rear surfaces of the semiconductor chips are placed on the flat surface 21 of the block 1 at the time of the preliminary reflow, and are placed on the flat bottom surface 62 of the jig at the time of the main reflow. Therefore, the deviation (ΔH) of the rear surface height among a plurality of the semiconductor chips can be made small as in the case of the first embodiment.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as other embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover any modifications or embodiments within the scope of the invention.
|
In a packaging method for a flip-chip type semiconductor device, the method in which the rear surface sides of a plurality of semiconductor chips having solder bump electrodes on their front surfaces are fixed temporarily with an adhesive to the respective predetermined locations on the flat surface of a block, the block and a circuit board are positioned by placing the flat surface of the block opposed to the front surface of the circuit board where pads are formed, the solder bump electrodes and the pads are brought into contact by bringing them close to each other without the intermediary of soldering flux, and the plurality of semiconductor chips are bonded in a lump to the circuit board by welding the solder bump electrodes to the pads through reflowing of the solder of the solder bump electrodes by subjecting them to heat treatment.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention refers to a lamp for vehicles, which is integrated in the surface of a vehicle part, which is removable and which is designed with at least one solar module, one energy storage, an illumination device as well as a plug connection in order to supply a consumer with stored energy and/or to feed the energy storage of the vehicle.
[0003] 2. Description of the Relevant Prior Art
[0004] DE 198 55 258 C1 and DE 100 42 100 A1 refer to lamps (flashlights) which are designed with at least one collector, solar module, energy storage, illuminating body and one plug connection arranged in a frame as one unit, which can be removed from a sun visor of a vehicle in order to be utilized outside the vehicle.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to further develop such a lamp, which in addition to being supplied with energy from solar modules, should be useable with a wireless remote control, for switching it on and off, or used as remote control itself.
[0006] To solve this object, a sensor device is installed within the lamp and/or external thereto which is remote-controlled in order to trigger a switching process. Further advantageous developments are described in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawing:
[0008] [0008]FIG. 1 shows a sectional view of a lamp body with a thin-film solar module layer attached peripherally;
[0009] [0009]FIG. 2 shows a sectional view of a lamp body with lamellar solar cells attached peripherally;
[0010] [0010]FIG. 3 is a schematic diagram of a lamp with energy supplement via a fuel cell.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] The lamp installed in a sun shield, or installed at the vehicle ceiling or at the back of the vehicle seats can be of an oval type. However, a box type form or a symmetric or non-symmetric form is possible also as well as a concave or convex embodiment. The lamp body 1 consists of a fluorescent material which can be blow-molded. In this way, a production of the system “lamp” in a flat form is possible. However, other types of production especially considering the location of utilization or considering the requirement of being able to easily exchange the lamp parts within the lamp body 1 are possible. The separation of a lamp body 1 in two parts 1 a , 1 a can be provided. They are connectable with another to form a unit by means of a ring-shaped spring lock 1 c , e.g. via a localized spring lock with a respectively arranged film hinge. This makes it possible—aside from a reflecting aluminum layer 1 d -to further arrange replaceable solar cells 4 to be illuminated and at least one illumination device (of a light saving design) 5 .
[0012] The lamp body 1 can be equipped with a light-transmitting coating 3 a on its visible exterior or periphery 1 ′, which protects the lamp body from damages and contamination, on the one hand, while the coating can be colored to match the color of the surroundings, on the other hand. The light transmittance will be ensured by selecting a respective material or by providing openings such a holes or slots 3 a′.
[0013] Since the entire lamp body 1 preferably consist of luminesce material as a light collector, solar cells 4 , 4 ′ can be provided on the periphery of the lamp body as well as in its interior. The arrangement of the solar cells as a layer 4 or lamellas 4 ′ depends on the provision of a reflecting aluminum layer 1 d in the interior of the lamp body 1 and the type of light transfer, known in the art, from the lamp body 1 onto each individual solar cell 4 , 4 ′. The utilization of translucent solar cells 4 , 4 ′ appears favorable since, in this way, the light is able to reach adjacent solar cells thereby increasing their energy generation.
[0014] To arrange the solar cells 4 —especially the thin-film solar cells—as a layer on the periphery of the lamp body 1 , a polyimide (capton) foil (not shown) can be used onto which flexible solar cells 4 are welded, soldered or glued. LEDs can be applied on the polyimide foil, especially thin, flexible and lamellar type organic LEDs (OLEDs) and/or polymeric LEDs (PLEDs) as an illumination device 5 as a circuit diagram as well in the interior of the lamp body 1 , for instance, around its notch 3 in order to increase the illumination power of the (flashlight) light. A sensor device in the form of a capton-sensor 6 embodied as a thin-film can also be applied. Other suitable sensors are, for instance, capacitive, optoelectronic, piezoelectronic, inductive and infrared sensors. The sensors are designed by known semiconductor technology, e.g. on the basis of silicon or gallium-arsenic.
[0015] The installation of solar cells 4 ′ of lamellar type perpendicular on the periphery 1 ′ of the lamp body 1 as well as in its interior as a glass cover in a construction known in the art, result in a best possible transmission of the luminescence light onto these solar cells with respective energy generation. However, it also results in an increased constructional expenditure so that the cost/benefit factor compared with, for instance, a usage of several simple lamps with solar cells fixed onto the surface of the lamp body according to the invention could play a decisive roll.
[0016] The lamp body 1 shows—for instance on a side opposite the side on which the light impinges from the exterior—a notch 3 . The notch enables the light—which is enhanced by the aluminum foil 1 d —to emerge from the interior of the lamp body 1 . This notch 3 can be closed, if necessary, with a translucent and/or slidable or hinged solar cell 4 a.
[0017] The lamp according to the invention is provided with a sensor device having at least one sensor 6 (indicated in FIG. 3) for reception and one sensor 6 ′ for transmission of signals. The sensors are placed within the lamp body 1 or externally on the lamp body 1 —in general so as to be visible. For encoding and/or decoding of radio waves or rays (e.g., infrared rays) which impinge upon the sensor 6 , at least one chip 7 is installed in the lamp body 1 . In this way, the sensor 6 of the lamp can be used, for instance, not only for wireless on and off switching of the lamp but can also be used as a sender 6 ′ for turning on the brake light via an installed transmitter sensor 6 when actuating the brake pedal. The low energy consuming sensors 6 and 6 ′ as well as chips 7 can be operated by the energy of the energy storage 8 of the lamp supplied by the energy generated by the solar cells 4 , 4 ′. The energy storage 8 is preferably in the form of a thin-film power condenser (see U.S. Pat. No. 6,104,597), and takes up little space.
[0018] When the inventive lamps are installed, for instance, in vehicle door handles, they can be activated via a RF-radio signal or optically by an infrared signal via the ignition key by means of a reception sensor 6 and can thus illuminate the area in front the door. With such an arrangement, no wiring is necessary anymore for switching on the lamp in the vehicle when opening the vehicle door. This wireless door contact could also correspond with an electronic car key or even with the heat radiation of a person; however, this would be a questionable solution in regard to safety consideration and enablement of theft.
[0019] By installing a printed circuit board with an auxiliary circuit in the lamp body 1 and an auxiliary illumination body 5 ′, especially an organic light-emitting diode (OLED) and/or a polymeric light-emitting diode (PLED), at least one auxiliary illumination body 5 ′ can be switched on automatically in case of failure of the diode(s) of the illumination device 5 which is installed in or on the lamp body.
[0020] Depending on the vehicle type—passenger car, truck and the like, train, boat, airplane etc. —lamps are required in various sizes and emitted light intensity (lux). For this reason the luminous intensity of a “flashlight” is often insufficient. In general, it is possible to bundle the energy generated in the solar cells 4 , 4 ′ and the batteries, e.g. power condensers 8 , for supplying one or more larger lamps with the assistance of plug connections 9 installed at the lamp bodies 1 and, if necessary, supplement it with energy from the vehicle battery. Additional energy may come from at least one lamellar membrane fuel cell 12 with the assistance of hydrogen cartridges 10 as shown in the circuit diagram according to FIG. 3.
[0021] In the circuit diagram of FIG. 3 a “piezo-sensor” 6 a is shown which controls the operation of light-emitting diodes 5 , 5 ′ and, in the case of one diode 5 failing, switches on a near-by auxiliary diode 5 ′ automatically. This is important especially when the installation of a display (not shown) comprised of OLED foil and/or PLED foil is provided at the lamp.
[0022] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
|
The invention relates to a lamp for vehicles which is integrated in the surface of a vehicle part and which is removable. The lamp is switched on and off via a radio signal and/or a light beam of an infrared diode received by a sensor. The fluorescent plastic material of the lamp body, the solar cell, the sensor, the storage elements and the LED (OLED and/or PLED) form a unit of the lamp and this unit can be mounted and removed a such.
| 1
|
FIELD OF THE INVENTION
[0001] This invention relates to audio transducers.
BACKGROUND OF THE INVENTION
[0002] Many different information, entertainment and communication devices having displays have been designed. It is desirable to use such devices to present multimedia, generally in the form of images and sound. Accordingly, such devices require interfaces capable of presenting information both in audio and visual forms.
[0003] Personal computers can be used to present real-time multimedia, for example to function as video telephones so that a user is provided with both voice and image of a person with whom he or she talks. A typical personal computer comprises a microprocessor based central unit and a keyboard. The monitor usually comprises a casing containing a CRT (Cathode Ray Tube) typically having a diagonal dimension of at least 35 cm (14 inches). If the personal computer is configured to produce sound, it is convenient to locate a speaker on each side of the CRT either integrated into the monitor casing or provided as discrete units. The personal computer may also comprise a microphone. Integration of the speakers into the monitor casing facilitates initial connecting of peripherals to the computer.
[0004] The speakers typically used in these devices are dynamic speakers. Other types of speakers have been suggested. EP 847 670 discloses a CRT monitor which has electrostatic speakers in the form of panels integrated into either side of the monitor casing. The electrostatic speakers integrate a vibrating diaphragm and an actuator to vibrate the diaphragm. Thus, an actuating diaphragm actuates itself to vibrate. This provides a speaker with reduced thickness, but also reduces the length of the maximum movement of the diaphragm resulting in a lower acoustic power per unit area of the diaphragm. Locating such speakers on the sides of the monitor casing allows them to extend from the front of the monitor casing to the back, thus allowing the areas of the sides of the monitor casing to be used while causing only a small increase to its width. However, since the speakers are arranged facing outwardly rather than towards a user, this arrangement directs sound sideways rather than towards the front of the monitor.
[0005] In the future it is intended that multimedia should also be presented by mobile stations such as those used in cellular telecommunications systems. Multimedia presentation has been suggested particularly for mobile stations of the so-called third generation. The Nokia® 9110 communicator is an example of a mobile station presently used to present audio and video signals. This is a multifunction mobile station having two hinged parts. The parts open to reveal a QWERTY keyboard in one part for entry of alphanumeric text and a large LCD-display (Liquid Crystal Display) in the other part for displaying information to a user. This mobile station can wirelessly communicate using fax, e-mail and telephony services. It also allows hands-free (HF) telephone calls to be made using a built-in speaker and a microphone. The speaker is mounted inside the mobile station and sound is conveyed via a specific conduit to the open space surrounding the mobile station. The speaker and the conduit occupy space within the mobile station. Accordingly, in using a speaker arrangement of a particular size a compromise is made between audio quality and space consumption. In addition to the HF-speaker, there is another speaker associated with the earpiece. This further increases the space occupied within the mobile station, and furthermore requires holes to be provided in the mobile station's casing, which provides entry points for dust and moisture.
[0006] As the size of handheld mobile stations such as mobile phones and smart telephones is a limiting factor, it is necessary to select speakers for such devices to be as small as possible. The need to maintain good audio quality and provide a small speaker volume will increase in the future. Additional functionality required to implement the third generation of mobile stations will inherently lead to bigger mobile stations and/or shorter periods of idle time and talk times due to increased power consumption. There is a conflict between very limited size and relatively high power consumption. If the size is limited to a comfortable maximum, it may be too small to hold a sufficiently high-capacity battery, or vice versa, a high-capacity battery that can operate the device for a long period would require too much space. Therefore there is a desire to miniaturise components of mobile stations. However, as speakers are miniaturised, the small size impairs the audio response making reproduced speech and other audio signals difficult to understand and/or less pleasant to listen to.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention, there is provided an audio transducer for changing a signal between an acoustic form and an electrical form, the audio transducer comprising an actuating diaphragm, a stator, and a support for supporting the actuating diaphragm adjacent to the stator, characterised in that both the actuating diaphragm and the stator comprise transparent material.
[0008] Advantageously, the audio transducer can be placed between a user and an object such as a screen without preventing the user from seeing the object, since the actuating diaphragm and the stator are transparent. This allows the transducer to be placed in front of objects that need to be seen.
[0009] According to a second aspect of the present invention, there is provided an audio-visual device comprising
[0010] an optical device, and
[0011] an audio transducer for changing a signal between an acoustic form and an electrical form, the audio transducer comprising an actuating diaphragm, a stator, and a support for supporting the actuating diaphragm adjacent to the stator,
[0012] characterised in that
[0013] both the actuating diaphragm and the stator comprise transparent material and
[0014] the audio transducer is arranged adjacent to the optical device.
[0015] It is advantageous to combine a transparent audio transducer and an optical device. Thus, the very same area can be used to output or input image and to output or input sound or voice.
[0016] Preferably, the actuating diaphragm is arranged to vibrate in response to an electrical signal interacting with the actuating diaphragm to generate an acoustic response. Alternatively, the actuating diaphragm is arranged to vibrate in response to an acoustic signal interacting with the actuating diaphragm to generate an electrical response.
[0017] Preferably, the audio transducer is a speaker, a microphone, or a combination of both. In an embodiment of the invention in which the audio transducer is a transparent element disposed between a user and a display, this may provide a relatively large display surface area to be used as an acoustic element.
[0018] The optical device may be a mobile station, a mirror, a window, an electrical display, a solar cell, a touch screen or an illuminator. An electrical display is a display device comprising a screen, an input for receiving an electrical input signal and means for displaying on the screen texts or images corresponding to the electrical input signal.
[0019] Since the invention allows the surface area needed for a display to show information to be used for the audio transducer, a compact size of user interface device can be made with an audio transducer not smaller than the screen. This allows manufacture of smaller user interface devices and manufacture of user interface devices of ordinary size, but with an improved audio quality. Alternatively, if the optical device is a solar cell, then the surface of the solar cell can be used also to output sound, and efficiency of surface usage improves. If the audio response originates from the region of the optical device, the audio response appears, to a user, to come from the optical device. A display according to the invention used for video conferencing gives a realistic impression when the sound appears to come from the display. A rear-view mirror may be arranged to tell a user how far an object is behind a vehicle. A window of a shelf in an exhibition may tell about a particular exhibit.
[0020] Preferably, the audio-visual device is a mobile station further comprising a radio block for radio communication.
[0021] Preferably, the display is arranged to be visible through the actuating diaphragm.
[0022] An advantage of the invention is that the diaphragm of the transducer itself carries out the conversion between acoustic and electrical forms of signals. Dedicated movement conversion elements such as coils or magnets are not necessary. Thus, the transducer requires only a small depth in which the diaphragm may be located to vibrate. Additionally, providing the transducer on the outer surface of an optical device (adjacent to, for example, a display or a solar cell) makes it unnecessary to provide a sound-conveying conduit. This frees some space within the casing of the device for other components or allows manufacture of smaller devices without reducing functionality. A transducer provided by the invention has a relatively large surface, which also increases the maximum sound pressure when the transducer is used as a speaker and increases the sensitivity of the transducer when the transducer is used as a microphone. Furthermore, when the transducer is used as a speaker, sound appears to come from the image rather than from one side. Correspondingly, when the transducer is used as a microphone, a user is able to speak directly at the display and the transducer is able to receive the speech efficiently.
[0023] Preferably, the display is used as a stator for the actuating diaphragm. This reduces number of parts required.
[0024] Preferably, the actuating diaphragm is located between an outer protective diaphragm and the display so as to protect the actuating diaphragm from mechanical damage. In this case, the outer protective diaphragm allows a user to see through it. It may be transparent. Preferably the outer diaphragm is electrically conductive and arranged additionally to function as a stator for the actuating diaphragm. Preferably, the outer diaphragm is made of a material that allows sound waves to travel through itself in order that sound produced by the transducer is audible to a user of the audio-visual device. The outer protective diaphragm may be made of a porous material or provided with openings. Alternatively a grid could be used to protect the actuating diaphragm whilst also allowing the sound waves to be conveyed from the actuating diaphragm to space surrounding the audio-visual device.
[0025] Preferably, the actuating diaphragm is used to produce sound for an earpiece of an audio-visual device in addition to providing sound from the display.
[0026] According to a third aspect of the present invention, there is provided a method of producing an audio-visual response, wherein a transparent and electrostatic actuating diaphragm is arranged in a nominal position adjacent to an electrical display. The method comprises the steps of:
[0027] displaying an image on the electrical display, and
[0028] feeding an electrical audio signal to the actuating diaphragm to cause it to vibrate in order to generate a sound.
[0029] Advantageously, the method gives a user an impression of sound originating from the electrical display.
[0030] According to a fourth aspect of the present invention, there is provided a method of manufacture of a device comprising a display, a speaker, and a transformer to drive the speaker, comprising the steps of:
[0031] attaching a transparent actuating speaker diaphragm adjacent to the display, and
[0032] coupling the transparent actuating diaphragm to the transformer to drive the transparent actuating diaphragm as a sound producing vibrating element.
[0033] The present invention enables production of a compact and lightweight device by integration of a display and speaker so that they both occupy the same area. Therefore, there is no need to leave openings for a speaker in the casing of the device and penetration of dust and moisture into the device can be largely avoided. In addition, the production process becomes simplified, because separate openings need not to be made for arranging audiophonic access between the speaker and the space surrounding the device.
[0034] The present invention is applicable to devices such as mobile phones, electrical games, and wireless telephones, as well as to bigger devices such as laptop computers or displays for desktop computers. It is particularly suited to thin displays such as LCD- or electroluminescence displays. In general, the present invention may be used in applications where there is lack of space and a relatively large display is required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0036] [0036]FIG. 1 shows a speaker arrangement according to the present invention;
[0037] [0037]FIG. 2 shows another speaker arrangement according to the present invention;
[0038] [0038]FIG. 3 shows a mobile station incorporating a display according to the present invention; and
[0039] [0039]FIG. 4 shows a block diagram of the mobile station of FIG. 3.
DETAILED DESCRIPTION
[0040] [0040]FIG. 1 shows a speaker arrangement SYS 1 according to the present invention. The speaker arrangement SYS 1 is used with a display device having an electrical display. A display device in the form of a mobile station is described in relation to the later Figures. The arrangement comprises an electrostatic speaker having a transparent actuating diaphragm ACT (an actuator), a transparent stator S 1 and an insulating support SUP holding the actuating diaphragm ACT and the stator S 1 adjacent to each other. The stator S 1 comprises an electrically conductive material, which is for example a coating on a display screen. The display screen is not shown in this embodiment. The stator S 1 is in the form of an electrically conductive film integrated onto another surface of a display device using the speaker arrangement, for example, onto an electro-optical device such as a CRT, an LCD screen or a solar cell. The electrically conducting film may comprise indium or titanium oxide. Alternatively, the stator may carry on its surface a metallic grid of very thin wires to act as an electrically conductive element. This construction is known from electromagnetic compatibility covers.
[0041] The actuating diaphragm ACT is protected against mechanical damage by a guard S 2 in the form of a thin metal grid. Alternatively it may be a transparent plastic diaphragm. All that is required of the guard is that it allows a user to look through it and see the display and allows the passage of sound waves.
[0042] In this embodiment of the invention in which a transparent speaker or microphone is arranged on the display, some of the light emanating from or reflected by the display should be able to pass through the speaker or microphone so that a user is able to see the display. In an embodiment of the invention in which a transparent speaker or microphone is placed in front of a solar cell, an audio transducer according to the present invention should allow the passage of some light through itself to allow the solar cell to transform solar energy into electricity. A suitable material for the actuating diaphragm is transparent Mylar™ polyester film that is manufactured by Du Pont. A suitable thickness is in the range of approximately 10 μm. Such a film is coated with a metal or similarly electrically conductive material. Such a film is known from the manufacture of polyester capacitors. MartinLogan has used chemically coated Mylar film in electrostatic speakers. The film is mounted whilst being stretched so as to leave a residual tension in the film. Electrically conductive plastics are known to a person skilled in the art.
[0043] The speaker arrangement SYS 1 comprises a driving circuit for supplying a rapidly varying voltage across the actuating diaphragm and the stator. The driving circuit comprises an amplifier A 1 , a first resistor R 1 , an audio transformer TF 1 having first and second output nodes N 1 and N 2 , a DC voltage supply HVbias, and a second resistor R 2 .
[0044] Operation of a single ended speaker arrangement will now be described. The amplifier A 1 is a differential amplifier having two inputs IN 1 and IN 2 for receiving low-voltage audio signals. The amplifier A 1 also has a connection to ground GND and a connection to operating voltage VBAT (supplied by a battery) for receiving a supply voltage, and outputs OUT 1 and OUT 2 for providing an amplified audio signal. The first resistor R 1 is used to limit the current in the amplifier A 1 to protect it against excessive currents. After the first resistor R 1 the audio signal is supplied to the audio transformer TF 1 for boosting of the voltage of audio signal by a factor of approximately 50 in order to provide an output voltage of approximately 200 Volts peak to peak voltage. The first output node N 1 of the audio transformer TF 1 is coupled to a negative node of HV bias. A positive node of HV bias is connected to the actuating diaphragm ACT via the second resistor R 2 . The second output node N 2 of the audio transformer TF 2 is coupled to the stator S 1 . A high voltage power source HVbias coupled between the first node N 1 and the second resistor R 2 is used to maintain a constant charge in the speaker. The second resistor R 2 has a high resistance and is connected in series with HVbias and ACT in order to guarantee a constant charge operation. The resistance of the second resistor R 2 is in the range of 10 MΩ to 100 MΩ.
[0045] Initially there is equilibrium, wherein the actuating diaphragm ACT has a constant voltage and constant charge, and there is a voltage U 1 between it and the stator S 1 . To generate sound the equilibrium is disturbed. An amplified audio signal changes the voltage of the stator S 1 in relation to the voltage of the actuating diaphragm ACT. The balance of attractive and repulsive forces acting on the actuating diaphragm ACT due to S 1 changes, the actuating diaphragm ACT moves and sound is thus generated. Tension within the actuating diaphragm ACT applies a return force back to its nominal position, that is an idle position where it was before the movement. The tension also acts to prevent the actuating diaphragm ACT from touching the stator S 1 .
[0046] The voltage required to drive the speaker depends on number of parameters, including the areas of the actuating diaphragm ACT and the stator S 1 , the gap between the actuating diaphragm ACT and the stator S 1 , the tension of the actuating diaphragm ACT, the intended sound pressure level (SPL), the desired frequency response and the level of HVBias voltage (SPL increases with increasing HVBias voltage). It should be understood that the areas and shapes of the actuator ACT and the stator S 1 do not have to be identical nor do their electrical conductivities. In an embodiment in which the guard S 2 is used, its sound dampening properties based on its shape, size, thickness, porosity, and the size and number of openings will have an effect, which will need to be taken into account. The sheet resistance (Ω/square) for the actuator may be for example 100 kΩ/square.
[0047] [0047]FIG. 2 shows a speaker arrangement SYS 2 according to a second embodiment of the present invention. The arrangement is similar to the first embodiment and corresponding reference signs have been applied to corresponding parts. In this embodiment, the guard S 2 is used as a second stator to enhance driving of the actuating diaphragm ACT. This reduces distortion of sound and increases the sound pressure level SPL. In this two stator arrangement the first node N 1 is an intermediate node which is present on the secondary coil of the transformer. The number of turns in the coil between N 1 and N 2 usually equals to the number of turns between N 2 and N 3 . The nodes in the ends of the coil are denoted as N 2 and N 3 . N 3 is coupled to S 1 and N 2 is coupled to S 2 . Between N 1 and ACT there is coupled in series the HVbias voltage and the resistor R 2 . In an alternative embodiment, an intermediate voltage is arranged with two equal capacitors or resistors connected in series between the nodes N 2 and N 3 of the transformer TF 1 . Then the voltage output corresponding to the node N 1 will be available in the joint of the two capacitors or resistors. The HVBias voltage is connected to node N 1 as described above.
[0048] The operation of the speaker arrangement SYS 2 is similar to the operation of the speaker arrangement SYS 1 . The actuating diaphragm ACT has a constant voltage relative to the stators in an idle mode, that is when the speaker arrangement SYS 2 is in operation but no sound is produced. Amplified audio voltages are applied across the two stators S 1 and S 2 so that the actuating diaphragm ACT experiences an attractive force towards one stator and a repulsive force towards another stator. Thus, the speaker arrangement SYS 2 operates in a push-pull manner. A step change in the audio signal causes a simultaneous change in the attraction between S 1 and ACT and in the repulsion between S 2 and ACT.
[0049] [0049]FIG. 3 shows a side view of a mobile station MS according to the present invention. The mobile station MS comprises the speaker arrangement of FIG. 2. Accordingly, corresponding reference signs have been applied to corresponding parts. A display DSPL is integrated inside the mobile station MS and its top surface functions as a stator. An actuating diaphragm ACT is sandwiched between the guard S 2 and the display DSPL so that there is a gap on both sides of the actuating diaphragm ACT leaving space for it to vibrate. A conduit SC 1 leads from the gap between the actuating diaphragm ACT and the display DSPL. One end of the conduit SC 1 opens into the space behind ACT and the other end opens into an opening on a side of the mobile station MS opposite the display DSPL. The arrangement provides a user with two different speakers, both of which use the same electronics and the same actuating diaphragm. The arrangement is even more suitable in a foldable two-part device, in which the display DSPL is located on an inner surface and thus contained within the device when it is closed. This reduces the projection of sound in a direction opposite to the direction of sound coming from the earpiece speaker SPK 2 . To hinder penetration of dust into the device, the conduit can be closed with a tense diaphragm extending across the conduit. The speaker makes air surrounding it to vibrate, and the air further makes the tense diaphragm to vibrate in the conduit. This diaphragm then transmits the vibration to the air on its other side thus passing the sound through itself.
[0050] [0050]FIG. 4 shows a block diagram of the mobile station of FIG. 3. The mobile station has a Master Control Unit MCU that may be a microprocessor, a Digital Signal Processor DSP or any other functionally similar unit. The MCU controls the other blocks of the mobile station. These blocks include an RF block for Radio Frequency processing of data and a memory block MEM comprising Random Access Memory (RAM) to store instructions to be executed by the MCU, a Read Only Memory ROM for conserving execution instructions in non-volatile memory, and non-volatile memory such as Flash-ROM or digital memory disk(s) which allows non-volatile and re-writeable conserving of data that may change, for example to store user information. The mobile station has an input means for receiving input from a user response, such as a keyboard KB. It also has both an electrical display DSPL and a solar cell SCELL for generating operating voltage for the mobile station and/or recharging a battery BATT of the mobile station. The electrical display DSPL is a low power-consuming device such as an LCD (Liquid Crystal Display).
[0051] Using the RF block, the mobile station can receive video images to be shown on the display DSPL. This allows the mobile station to present real-time multimedia, for example video conferencing.
[0052] This paper presents the implementation and embodiments of the invention with the help of examples. It is obvious to a person skilled in the art, that the invention is not restricted to details of the embodiments presented above, and that the invention can be implemented in another embodiment without deviating from the characteristics of the invention. Thus, the presented embodiments should be considered illustrative, but not restricting. For example when using the invention for monitors of computers or TV-screens it is natural that the display does not need to be of a low power consuming type such as an LCD screen. Hence, the possibilities of implementing and using the invention are only restricted by the enclosed patent claims. Consequently, the various options of implementing the invention as determined by the claims, including the equivalent implementations, also belong to the scope of the present invention.
|
A device (MS) having an electrical display (DSPL) is equipped with a transparent electrostatic diaphragm (ACT) vibrateably attached in front of the display. The display has been made electrically conductive and used as a stator of thus formed electrostatic speaker (TD 1 ). A fluctuating DC-voltage is conducted to the diaphragm and display in order to resonate the diaphragm and produce sound respective to the fluctuation. The transparency of the diaphragm allows a user to see the display through the diaphragm. Alternatively, the similar arrangement can be used to implement a transparent electrostatic microphone on the display.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data communication system and a data communication method for controlling data communications between computers interconnected through a network.
2. Description of Related Art
FIG. 12 is a block diagram showing a conventional data communication system, in which the reference numeral 1 designates a network structured using Ethernet or FastEthernet; 2 and 3 each designate an operator station (OPS) that exchange message communications or the like with a host computer 4 and controllers 5 and 6 ; 4 designates the host computer that exchanges message communications or the like with the operator stations 2 and 3 or controllers 5 and 6 ; and 5 and 6 each designate the controller that exchange message communications or the like with the operator stations 2 and 3 or the host computer 4 .
Next, the operation of the conventional data communication system will be described.
Although the host computer 4 , operator stations 2 and 3 and the like interconnected through the network 1 exchange message communications with each other, if a message collision occurs on the network 1 , problems arise in that the messages are delayed or suffer a loss.
To avoid the collision on the network 1 , the conventional system employs a token passing method which allows the host computer 4 and the like to transmit only when they acquire the token.
Besides the foregoing conventional system, Japanese patent application laid-open No. 8-180006/1996 discloses a technique that allots, to computers interconnected through a network, transmission time slots that enable message transmission, thereby preventing a plurality of computers from sending messages to the network in the same time slot. However, if the computer that manages the transmission time slots halts owing to a failure, it becomes impossible for other computers to send messages.
With the foregoing configurations, the conventional data communication systems have a problem in that although they can avoid the message collision on the network 1 , if the host computer 4 that acquires the token suffers a breakdown or loses the token, it becomes impossible for the operator system 2 or the like connected to the network 1 to continue subsequent message transmission.
Incidentally, it will be possible to restart the transmission of messages by adding a complicated mechanism for detecting the loss of the token to retransmit the messages, in which case a problem still remains in that the operator system 2 or the like cannot transmit the messages until the new token is issued.
SUMMARY OF THE INVENTION
The present invention is implemented to solve the foregoing problems. It is therefore an object of the present invention to provide a data communication system and a data communication method capable of reducing the delay or loss rate of messages involved in message collisions, and enabling the other computers to transmit even if some computer suffers a failure.
According to a first aspect of the present invention, there is provided a data communication system including an internal computer connected with one or more external computers through a network, the data communication system comprising: memory means for storing a first information amount that each of the external computers can receive in a communication cycle; storing means for storing a second information amount that is transmitted to each of the external computers in the communication cycle; addition means for adding, when transmitted data to one of the external computers is placed in a transmission queue, an information amount of the transmitted data to the second information amount which is stored in the storing means and is associated with the one of the external computers; and transmission means for transmitting the transmitted data to the one of the external computers only if the addition result of the addition means does not exceed the first information amount that the one of the external computers can receive. This offers an advantage of being able to reduce the delay or loss rate of a message, and to enable other computers to transmit messages even if some computer suffers a failure.
Here, the memory means may store a third information amount that the internal computer can transmit in the communication cycle; the storing means may store a fourth information amount that the internal computer transmits in the communication cycle; and the addition means may add, when transmitted data is placed in a transmission queue, an information amount of the transmitted data to the fourth information amount stored in the storing means, and wherein the data communication system may further comprise:
inhibiting means for inhibiting transmission of the transmitted data to the external computers if the addition result of the addition means exceeds the third information amount. This offers an advantage of being able to prevent transmitted data that exceeds the transmission capability of the operating system of the transmitting end from being requested, thereby enabling the computer of the transmitting end to smoothly carry out processings other than the transmission processing.
The memory means may store a maximum receivable information amount that each of the external computers assigns to the internal computer. This offers an advantage of being able to prevent the internal computer from transmitting data that exceeds the receiving capability of the external computer even when the external computer receives data from other external computers.
The first information amount and the second information amount may be each represented in terms of a number of data.
The first information amount, the second information amount, the third information amount and the fourth information amount may be each represented in terms of a number of data.
The first information amount and the second information amount may be each represented in terms of a number of packets.
The first information amount, the second information amount, the third information amount and the fourth information amount may be each represented in terms of a number of packets.
The transmission means may retransmit, if an acknowledge signal is not sent back over a predetermined time period from one of the external computers to which the transmission means transmits transmitted data, the transmitted data to the one of the external computers.
The transmission means may halt its retransmission of the transmitted data if a number of times of the retransmissions reaches a predetermined upper limit.
The data communication system may further comprise saving means for saving, when the transmitted data is divided into packets and a header of each of the packets is overwritten on a part of the transmitted data, the part of the transmitted data into a save area, and for restoring the part of the transmitted data to its original area after transmitting a current packet including the header which is overwritten on the original area.
According to a second aspect of the present invention, there is provided a data communication method of a system including an internal computer connected with one or more external computers through a network, the data communication method comprising the steps of: storing a first information amount that each of the external computers can receive in a communication cycle; storing a second information amount that is transmitted to each of the external computers in the communication cycle; adding, when transmitted data to one of the external computers is placed in a transmission queue, an information amount of the transmitted data to the second information amount which is associated with the one of the external computers; and transmitting the transmitted data to the one of the external computers only if the addition result does not exceed the first information amount that the one of the external computers can receive.
Here, the data communication method may further comprise the steps of: storing a third information amount that the internal computer can transmit in the communication cycle; storing a fourth information amount that the internal computer transmits in the communication cycle; and adding, when transmitted data is placed in a transmission queue, an information amount of the transmitted data to the fourth information amount; and inhibiting transmission of the transmitted data to the external computers if the addition result exceeds the third information amount.
The first information amount and the second information amount may be each represented in terms of a number of data.
The first information amount, the second information amount, the third information amount and the fourth information amount may be each represented in terms of a number of data.
The first information amount and the second information amount may be each represented in terms of a number of packets.
The first information amount, the second information amount, the third information amount and the fourth information amount may be each represented in terms of a number of packets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment 1 of a data communication system in accordance with the present invention;
FIG. 2 is a sequence table illustrating an algorithm of a transmission task;
FIG. 3 is a sequence table illustrating an algorithm of a reception task;
FIG. 4 is a diagram showing a transmission reception capability table;
FIG. 5 is a diagram showing a host management table;
FIG. 6 is a diagram showing a channel management table;
FIG. 7 is a list showing library functions;
FIG. 8 is a block diagram showing an embodiment 2 of the data communication system in accordance with the present invention;
FIG. 9 is a sequence table illustrating an algorithm of the transmission task;
FIG. 10 is a sequence table illustrating an algorithm of the reception task;
FIG. 11 is a diagram illustrating a packetizing mechanism at a transmitting end; and
FIG. 12 is a block diagram showing a conventional data communication system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described with reference to the accompanying drawings.
Embodiment 1
FIG. 1 is a block diagram showing an embodiment 1 of a data communication system in accordance with the present invention. In FIG. 1, the reference numeral 11 designates a host (computer) that is configured using Ethernet or FastEthernet and is connected to a network; and 12 designates application software that places, when transmitting a message to an external host through the network, the transmitted message (transmission data) in a transmission queue 15 in middleware 13 using library functions 14 , and retrieves, when receiving a message from an external host, the received message (received data) from a reception queue 16 in the middleware 13 using the library functions 14 .
The reference numeral 13 designates the middleware that transmits transmitted messages through a channel (a one-way channel interconnecting hosts in one to one correspondence), and receives received messages through a channel at the same time; 15 designates the transmission queue in which the transmitted messages are placed; 16 designates the reception queue in which the received messages are placed; 17 designates a table (memory means) for storing the number of bytes (number of data) or the number of packets the present host can transmit in a communication cycle, and for storing the number of bytes (number of data) or the number of packets each external host can receive in the communication cycle; 18 designates a memory (storing means) for storing the number of bytes (number of data) or the number of packets of the data the present host actually transmits in the communication cycle, and for storing the number of bytes (number of data) or the number of packets of the data actually transmitted to each external host h in the communication cycle; 19 designates a transmission task (addition means, transmission means and inhibiting means) for transmitting the transmitted messages considering the transmission capability of the present host or the reception capability of external hosts; and 20 designates a reception task for receiving the received messages.
Next, the operation of the present embodiment 1 will be described with reference to sequence tables shown in FIGS. 2 and 3, which illustrate the algorithm of the transmission task and reception task, respectively.
When the host 11 transmits a message to an external host, the transmission task 19 in the middleware 13 transmits UDP (user datagram protocol) packet (transmitted message) considering the transmission capability of the present host 11 or the reception capability of the external (destination) host. In this case, the host 11 acquires necessary information from a transmission reception capability table 17 a , a host management table 17 b and a channel management table 17 c in the table 17 , which will now be described briefly before entering the description of the operation.
Transmission reception capability table 17 a (see, FIG. 4 ).
The transmission reception capability table 17 a stores parameters about the communication cycle of the transmission task and parameters about the transmission reception capability of the hosts. The description of the parameters is as follows.
1. T_tick
It indicates the communication cycle of the transmission task. For example, a value such as 10 milliseconds is stored.
2. L_recv
A maximum number of bytes that the present host can receive in the communication cycle.
3. P_recv
A maximum number of packets that the present host can receive in the communication cycle.
4. L_send
A maximum number of bytes that the present host can transmit in the communication cycle.
5. P_send
A maximum number of packets that the present host can transmit in the communication cycle.
6. L_[h]recv
A maximum number of bytes that each host [h] other than the present host can receive in the communication cycle, which is allocated to the present host by the host [h].
7. P_[h]recv
A maximum number of packets that each host [h] other than the present host can receive in the communication cycle, which is allocated to the present host by the host [h].
Host Management Table 17 b (see, FIG. 5 ).
The host management table 17 b stores identifiers h that are used by the present host for identifying the external hosts, and IP (Internet Protocol) addresses corresponding to the identifiers h.
Channel Management Table 17 c (see, FIG. 6 ).
Channel Chi, where i (=0, 1, 2, . . . , N) is an identifier for identifying the channel, is a one-way communication path for establishing one to one connection between the hosts, and the channel management table 17 c stores parameters or the like about the channels. The description of the parameters is as follows.
1. Cycle T [i]
It indicates a communication cycle or minimum transmission interval of a message.
2. Message Length M[i]
It indicates a maximum transmittable message length.
3. Direction (transmit/receive)
It indicates the communication direction of a channel seen from the present host.
4. Destination Host Identifier
It is an identifier of the destination host.
5. Flag (idle/transmit/acknowledge-retransmit)
It is a parameter for checking the communication state of the channel.
6. Transmitted Seq#
The sequence number of the last message in the messages that have already been transmitted.
7. Acknowledged Seq#
The sequence number of the last message in the messages that have been acknowledged of their arrival.
Next, the operation will be described in more detail after a brief description of the function_send( ) of the library functions 14 , which the application software 12 uses when transmitting the transmitted message to an external host.
The contents of the function_send( ) are shown in FIG. 7 . It is a function for placing the transmitted message in the transmission queue 15 (FIFO queue) prepared for each channel.
Here, the channel identifier Chi of the channel to be 1 Q used is substituted into the argument ch_id, and one of literal constants BLOCK and NONBLOCK is substituted into the argument flags (In the case where the literal constant BLOCK is substituted, if the transmission cannot be achieved because of the overflow of the queue or the like when the function is called, the function call is blocked (is not returned) until the transmission is enabled, and is returned after completing the transmission. On the other hand, in the case where the literal constant NONBLOCK is substituted, if the transmission is disabled when the function is called, an error is returned).
Furthermore, a pointer to a sbuf_t structure is substituted into the argument sbuf, the number of bytes of a transmitted message is substituted into the member “size”, and a pointer to an area that stores the transmitted message is substituted into the member “data”.
When the transmitted message is placed in the transmission queue 15 in this way, the transmission task 19 transmits the message placed in the transmission queue 15 to the destination host. Being activated at every T_tick interval, the transmission task 19 substitutes zeros into the temporary variables l_send, p_send, l_[h] recv and p_[h]recv to initial them (step ST 1 ).
Referring to the channel management table 17 c after initializing the temporary variables, the transmission task 19 surveys channels with their communication direction is “transmit” seen from the present host, and checks whether the transmission channels reach a transmission time. If any one of them reaches the transmission time, the transmission task 19 changes the flag of that channel from “idle” to “transmit” (steps ST 2 -ST 4 ).
The transmission time of the channels can be obtained from the time the host is activated, T_tick and the number of times of activations until now.
Changing the flag from “idle” to “transmit”, the transmission task 19 decides whether there is any untransmitted packet (a packet that is not yet transmitted among the packets constituting the transmitted message) in the transmission queue 15 of the channel Chi associated with the flag (steps ST 10 -ST 13 ).
If no untransmitted packet is present, the transmission task 19 searches the transmission queue 15 for the next channel because it is not necessary to carry out the transmission processing of the current channel. If any untransmitted packet is present, on the other hand, the transmission task 19 acquires from the stored value of the temporary variable l_send the sum total of the bytes that are transmitted by the present host in the current communication cycle.
Furthermore, the transmission task 19 acquires from the stored value of the temporary variable l_[h] recv the sum total of the bytes that are transmitted to each external host h in the communication cycle, and acquires from the stored value of the temporary variable p_[h] recv the sum total of the packets that are transmitted to each external host h in the communication cycle.
Acquiring the stored values of the temporary variables l_send and the like, and obtaining the total byte number the present host has transmitted in the communication cycle, the transmission task 19 adds to the total byte number the number of bytes of the untransmitted packet, and decides whether the present host is capable of transmitting the untransmitted packet by comparing the addition result with the L_send (the maximum number of bytes transmittable by the present host in the communication cycle) at step ST 14 .
If the addition result exceeds the L_send, the transmission task 19 decides that the present host cannot transmit the untransmitted packet because the addition result exceeds the transmittable byte number in the communication cycle.
Likewise, the transmission task 19 adds the number of bytes of the untransmitted packet to the total number of the bytes that have already been transmitted to the destination host h in the communication cycle, and decides whether the destination host is capable of receiving the untransmitted packet by comparing the addition result with the L_[h]recv (the maximum number of bytes receivable by the destination host h in the communication cycle, which is allotted to the present host by the destination host) at step ST 15 .
If the addition result exceeds the L_[h]recv, the transmission task 19 decides that the destination host h cannot receive the untransmitted packet because the addition result exceeds the receivable byte number of the destination host h in the communication cycle.
Then, the transmission task 19 adds one to the total number of packets transmitted to the destination host h in the communication cycle (when a plurality of packets are transmitted simultaneously, the number of the packets are added instead of one), and decides whether the destination host is capable of receiving the untransmitted packet by comparing the addition result with P_[h]recv (the maximum number of packets the destination host h can receive in the communication cycle, which is allotted to the present host by the destination host h) at step ST 16 .
If the addition result exceeds the P [h]recv, the transmission task 19 decides that the destination host h cannot receive the untransmitted packet because the addition result exceeds the receivable byte number of the destination host h in the communication cycle.
Afterward, the transmission task 19 transmits the untransmitted packet to the destination host h at step ST 17 only if the addition results are below the L_send, L_[h]recv and P_[h]recv, respectively.
After transmitting the untransmitted packet to the destination host h, the transmission task 19 updates the temporary variables by adding to the l_send and l_[h]recv the byte number of the transmitted packet, and by adding one to the p_send and p_[h]recv (step ST 18 ).
If the transmitted packet is the final packet of the transmitted message, the transmission of the transmitted message is completed. Thus, the transmission task 19 changes the flag of the channel Chi from “transmit” to “idle”, and removes the transmitted message from the transmission queue 15 at step ST 19 .
If there are any application programs that are blocked from the call of the function_send( ) associated with the channel Chi, one of the application programs is released so that its transmitted message is placed in the transmission queue 15 .
After completing the transmission of all the channels, the transmission task 19 terminates the transmission processing. On the other hand, if the present host is incapable of transmitting a packet of a minimum packet length L_packet, min, the transmission task 19 compares the temporary variable p_send with the P_send (the maximum packet number the present host can transmit in the communication cycle).
If the temporary variable p_send reaches the P_send, the transmission task 19 decides that the present host is incapable of transmitting, and completes its processing at step ST 20 .
Alternatively, the transmission task 19 can completes its processing if the value obtained by subtracting the temporary variable l_send from the L_send is less than L_packet,min.
Next, the operation will be described of receiving UDP packets (received message) transmitted from an external host.
A message transmitted from an external host is received by the reception task 20 . The reception task 20 , which is activated at step ST 31 when a packet arrives from the network, checks the matching of the sequence number of the message and the packet number (order of packets within the message).
Here, the sequence number of the message and the packet number are added to each packet, and the packet number is increased one by one beginning from “0” assigned to the initial packet of the message.
More specifically, the reception task 20 makes a decision that the received packet is the initial packet of the message if a temporary buffer (not shown) does not store any packet. Thus, if the packet received in this situation has a packet number other than “0”, the reception task 20 decides that a packet in the message is lost, discards the received packet and awaits the next packet (steps ST 32 and ST 33 ).
On the other hand, if the packet number of the received packet is “0”, the reception task 20 stores the received packet in the temporary buffer at step ST 34 .
Here, it is necessary that the sequence number in the received packet equals the sequence number in the packets stored in the temporary buffer, and the packet number of the received packet equals one plus the packet number of the latest packet stored in the temporary packet. Accordingly, unless these conditions are satisfied, the reception task 20 , considering that a packet loss takes place in the message, discards the packets in the temporary buffer, and awaits the arrival of the next packet (steps ST 35 and ST 36 ).
In contrast, if these conditions are met, the reception task 20 stores the received packet in the temporary buffer at step ST 37 .
Thus, the reception task 20 repeats the foregoing processing until the final packet of the message is received (step ST 38 ). When the final packet is stored in the temporary buffer, the reception task 20 assembles the original message from all the packets stored in the temporary buffer at step ST 39 , and discards the packets in the temporary buffer at step ST 40 after placing the message in the reception queue 16 (FIFO queue).
If the reception queue 16 is full, the oldest or latest message is removed from the queue in a prescribed procedure.
If there are any application programs that are blocked from the call of the function_recv( ) associated with the current channel, one of the application programs is released so that it acquires a received message from the reception queue 16 .
After completing the foregoing processing, the reception task 20 awaits the arrival of the next packet at step ST 41 .
Once the received message has been placed in the reception queue 16 , the application software uses the function_recv( ) in the library functions 14 . Thus, the function_recv( ) will be described briefly.
The contents of the function_recv( ) is shown in FIG. 7 . It is a function for reading the received message from the reception queue 16 prepared for each channel.
Here, the channel identifier Chi of the channel to be used is substituted into the argument ch_id, a pointer to an area for storing the read received message is substituted into the argument buf, and a maximum length of a read message is substituted into the argument limit_size. If the length of the received message in the reception queue 16 is longer than the limit_size, initial limit_size bytes of the message are stored.
The size of the read received message is substituted into the argument “size”. If the length of the received message is longer than the limit_size, the value of the length is stored. One of the literal constants BLOCK and NONBLOCK is substituted into the argument flags (in the case where the literal constant BLOCK is substituted, if no received message is present in the reception queue 16 , the function call is blocked until a message arrives at the channel. On the other hand, in the case where the literal constant NONBLOCK is substituted, if no received message is present in the reception queue 16 , an error is returned).
Although the division of the transmitted message is not described in the present embodiment 1, the transmission task 19 can divide the transmitted message as needed, and outputs the divisions to the network as the UDP packets.
Each packet includes the sbuf_t structure as shown in FIG. 7 as its header, and retains, following the header, a part of the contents (data portion) of the original message.
In the sbuf_t structure, the member ch_id_at_sender denotes the channel identifier at the transmitting end; the member ch_id_at_receiver denotes the channel identifier at the receiving end; the member addr_sender denotes the IP address at the transmitting end; the member msg_seq_num denotes the sequence number of the message; the member packet_id denotes the packet number in the message; and the member “size” denotes the length (number of bytes) of the data portion in the packet.
No byte is assigned to the member “data”, and the header does not include the member “data”.
As described above, the present embodiment 1 is configured such that when transmitting a message to a destination host, the transmission task 19 in the middleware 13 considers the transmission capability of the present host and the receiving capability of the destination host before transmitting the message. This offers advantages of being able to reduce not only the delay of the message due to collision of the messages, but also the loss ratio of the message, thereby enabling the host to transmit a message even if some other host suffers a failure.
In the present embodiment 1, messages are transmitted asynchronously between the hosts without establishing synchronization between them. Thus, a failure of a particular host has no effect on the external hosts, thereby enabling them to transmit the messages free from the failure. It is known that assurance of the maximum byte number and maximum packet number transmitted in a fixed time (10 msec, for example) from the hosts assures the network load of less than a predetermined amount, which in turn reduces the delay or loss rate of the messages due to the message collision on the Ethernet (see, reference 1)
Reference 1: Steven L. Beyerman and Edward J. Coyle, “The Delay Characteristics of CSMA/CD Networks”, IEEE Transaction on Communications, Vol. 36, No. 5, pp. 553-563, May 1998.
Embodiment 2
FIG. 2 is a block diagram showing an embodiment 2 of the data communication system in accordance with the present invention, in which the corresponding portions to those of FIG. 1 are designated by the same reference numerals and the description thereof is omitted here.
In FIG. 8, the reference numeral 21 designates a reception task that not only performs the same functions as the reception task 20 , but also places into an acknowledge reception queue 22 an acknowledge packet (acknowledge signal), when receiving it from an external host; 22 designates the acknowledge reception queue for storing the acknowledge packet; 23 designates an acknowledge task that acquires the acknowledge packet from the acknowledge reception queue 22 , reads-from the acknowledge packet a channel identifier i and a sequence number, and updates an acknowledged sequence number of that channel; 24 designates a transmission task 24 (addition means, transmission means and inhibiting means) that not only has the same functions as the transmission task 19 , but also compares, after transmitting a message, a transmitted sequence number in the channel management table 17 c with the acknowledged sequence number, and retransmits the message if they do not agree over a predetermined time.
The operation of the present embodiment 2 will now be described with reference to the sequence table of FIGS. 9 and 10 . FIG. 9 is a sequence table illustrating algorithm of a transmission task, and FIG. 10 is a sequence table illustrating algorithm of a reception task.
In a plant supervisory control system, for example, even if some messages of supervisory data are lost which are periodically sent from a controller to an operator station, it will little effect on the whole system.
However, if a command message for updating setting values is lost which is sent from the operation station to the controller under instructions of an operator of the plant, it will have a decisive effect on the whole system.
Thus, retransmission of a lost message, and transmission of an acknowledge of a message back to the transmitting side are very important for such a system.
In the foregoing embodiment 1, however, although the transmission task 19 transmits a message, the application software 12 of the transmitting side cannot confirm whether the destination host receives the message or not, and hence cannot retransmit the message.
In view of this, the present embodiment 2 adds the acknowledge reception queue 22 and acknowledge task 23 . Specifically, receiving a transmitted message, the destination host transmits to the originating host an acknowledge packet indicating that it receives the transmitted message.
The acknowledge packet includes the channel identifier i and the sequence number of the current message.
When the acknowledge packet is sent back to the transmitting host in this way, the reception task 21 receives it, and places it in the acknowledge reception queue 22 at step ST 71 .
Placing the acknowledge packet into the acknowledge reception queue 22 will activate the acknowledge task 23 which acquires the acknowledge packet from the acknowledge reception queue 22 , and reads from the acknowledge packet the channel identifier i and the sequence number of the transmitted message.
Identifying the channel associated with the transmitted message from the channel identifier i, the acknowledge task 23 updates the acknowledged sequence number of that channel to the sequence number of the transmitted message.
On the other hand, the transmission task 24 compares, after transmitting the message, the transmitted sequence number in the channel management table 17 c with the acknowledged sequence number, and if the two sequence numbers agree (when the acknowledge task 23 updates the acknowledged sequence number to the sequence number of the transmitted message), the transmission task 24 makes a decision that the transmitted message arrives at the receiving host without fail. Unless the two sequence numbers agree over the predetermined time period, the transmission task 24 retransmits the transmitted message.
If the number of times of the retransmissions reaches a predetermined number (upper limit), the transmission task 24 stops the retransmission of the transmitted message, and notifies the application software 12 of that fact.
More specifically, if the transmission task 24 makes a decision at step ST 4 that a transmission time has not yet come, it makes a decision at step ST 51 whether an acknowledge-retransmission time has come or not, and if the time comes, it changes the flag of the channel to “acknowledge-retransmit”.
The acknowledge-retransmission time for a transmitted message of the channel is determined as follows with respect to the transmission time t_start.
t _start+ T _ack, t _start+2 T _ack, . . . , t _start+ N _ack· T _ack
where N_ack is the predetermined number of times of the acknowledge-retransmissions for the channel, T_ack is a maximum multiple of the T_tick that does not exceed (T/N_ack), and T is the cycle of the channel. If the positive T_ack that meets these conditions is not present, a decision is made that the acknowledge-retransmission of the channel is impossible.
Subsequently, the transmission task 24 performs the following processings on the channel whose direction is “transmit” and whose flag is indicative of “acknowledge-retransmit”.
If the transmission task 24 has begun the retransmission of a message, and has already transmitted a few packets, it carries out the subsequent packet transmission processing (steps ST 54 and ST 58 ).
On the other hand, if the transmission task 24 has not yet started the retransmission of a message, it checks whether an unacknowledged message is present or not by comparing the transmitted sequence number with the acknowledged sequence number of the current channel at step ST 55 .
If the two sequence numbers agree, the transmission task 24 completes the processing of the channel. In contrast, if they disagree, the transmission task 24 checks whether the number of times of the acknowledge-retransmissions of the transmitted message reaches the predetermined number N_ack of the acknowledge-retransmissions of the channel, and if it reaches the N_ack, it makes a decision that the time out of the transmission takes place, and sends to the application software 12 an exceptional notification at step ST 56 . Unless it reaches the N_ack, the transmission task 24 prepares for the retransmission the message that was sent most recently (step ST 57 ).
From step ST 58 onward, the transmission task 24 picks up a packet from the retransmitted message, and transmits it. Through steps ST 59 -ST 65 , the transmission task 24 makes a decision as to whether the transmission of the packet causes an overload on the transmission capability of the present host or on the reception capability of the receiving end, and only if it decides that the transmission does not cause the overload, it transmits a packet, and updates the temporary variables. When transmitting the packet, the transmission task 24 decides whether another packet with the minimum length is transmittable within the current cycle, and if impossible, it completes its processing.
Embodiment 3
In the foregoing embodiments 1 and 2, the transmitting end divides a message into several data portions, and forms packets by adding to the beginning of each data portion a header with the sbuf_t structure as shown in FIG. 7 . Since the original data is stored in a continuous area on the main memory, one of the following steps must be taken to generate the second and following packets.
(1) Overwrite the header on the data portion of the preceding packet.
(2) Copy the data portion on another area, and adds the header to the copied data portion.
The original data is required in a case of the retransmission of the message, which becomes necessary if an unacknowledged state occurs after the transmission of the message as in the foregoing embodiment 2. The method (1), however, cannot be used without change because the original data is lost by overwriting the header. On the other hand, the method (2) will increase the CPU load of the host because it takes a not negligible time to copy the entire data portions of the message on the main memory.
In view of this, the present embodiment 3 takes steps as illustrated in FIG. 11 . It copies, before overwriting the header of each of the second and following packets on the data portion of the previous packet, the data portion on which the overwriting is made to a save buffer, and copies the content of the save buffer back to the original area after transmitting the packet, thereby leaving the original message, and preventing the entire message from being copied on the main memory.
Since the length of the header is much shorter than the length of the data portion, the CPU time required for copying the corresponding portion to the save buffer and copying back to the original area will be much shorter than the CPU time taken to copy the entire data portions.
FIG. 11 is a diagram illustrating the packetizing mechanism at the transmitting end. At step a), the application software 12 , which calls the library function_send( ), provides a transmitted message.
Since the data portions of the message are provided in the form of the member “data” with the sbuf_t structure, the area with the sbuf_t structure for storing the header of the first packet is provided in advance by the application software 12 .
At step b), the first packet # 1 is generated and transmitted. Subsequently, the area on which the header of the next packet is overwritten is copied to the save buffer.
At step c), the second packet # 2 is generated and transmitted, followed by the copy to the save buffer in the same manner.
At step d), the final packet # 3 is transmitted, and at step e), the contents of the save buffer are copied back to the original area.
|
A data communication system includes in middleware a transmission task that transmits a message to a receiving host computer through a network, considering the transmission capability of the transmitting host computer and the receiving capability of the receiving host computer. This solves the problem in a conventional data communication system in which, if a host computer loses a token after acquiring it, operator stations and the like connected to a network are unable to send a message.
| 7
|
RELATED APPLICATION
This application is a continuation of application Ser. No. 08/482,843, filed Jun. 7, 1995 now abandoned, which is a continuation-in-part application of Ser. No. 08/118,186, filed Sep. 9, 1993, now abandoned.
FIELD OF THE INVENTION
The present invention relates to recycling wastepaper, and more particularly to recycling processes for recovering papermaking fibers and for making absorbent granular materials from wastepaper.
BACKGROUND OF THE INVENTION
It has been common practice for many years to make paper, especially tissue, from recycled paper. Paper recycling has in recent years become an important and attractive alternative to disposal of wastepaper by deposition in landfills or by incineration. When the wastepaper source includes a significant amount of coated paper, as much as 30-45% of the original wastepaper will be reject material which is unusable for papermaking. This reject material has typically been discarded in landfills. Increasing costs and decreasing availability of landfill space makes it desirable to find beneficial uses for this reject material.
In the process of recycling waste paper, such as newspapers, magazines, office paper waste, the paper fibers are separated from the other solid components by using large quantities of water. The printing materials, such as laser print, photocopier print and ink, are removed before the paper fibers are conducted to the papermaking machine. Usually, these rejected solid materials are discharged with the water into large settling basins. The solid materials that settle out in the basins are then dumped in a landfill, or otherwise discarded. The material that settles out in the basins is known as paper mill sludge.
The increasing cost of wastepaper makes it desirable to capture as much of the papermaking fibers as practicable. In view of the large quantities of water required for papermaking, it is important to use a process that conserves water. There have been various proposals for systems for utilizing rejected solid materials such as paper mill sludge to produce absorbent granules and other products. Kaolin clay is one of the rejected solid materials that has been recognized as having good absorbent capabilities.
Conventional absorbent granules are produced from naturally occurring clay and are commonly used as agricultural chemical carriers. However, some of the agricultural chemicals (e.g., Diazinon) react with clay carriers. Accordingly, it would be advantageous to develop an agricultural chemical carrier that contains clay, but does not react with agricultural chemicals. Also, naturally occurring clays tend to create dust during handling. This is potentially hazardous to workers.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an efficient and economical wastepaper recycling process for recovering fibers for use in papermaking and producing useful granular products from the reject stream. It is another object of this invention to produce a granular product that has high absorbency, is free flowing, substantially dust free and has high resistance to attrition. A further object is to produce a material of broad utility as a water and oil absorbent.
The process of this invention utilizes wastepaper, preferably office waste that is printed with laser print, photocopier print, or other inks, as well as stationery and magazines that have a coated surface. The wastepaper is pulped with water, caustic and surfactants to produce a slurry containing cellulose fibers, cellulose fines and fillers. The slurry passes through wire washers which separate papermaking fibers from the fines and fillers. Papermaking fibers are a mixture of long and short fibers, although it is recognized that some of the short fibers will pass through the screens. For the purposes of this description, long fibers are greater than about 1 mm in length and short fibers are between about 1 mm and about 0.1 mm in length. The papermaking fiber stream, also referred to as the "accepts stream", is directed through a cleaning and deinking step and then to a conventional papermaking machine for processing into paper. Separately, various streams from the papermaking machine and other sources are passed through a fiber recovery system where a series of wire washers separate papermaking fibers from these streams, sending the papermaking fibers back to the cleaning and deinking stages. The rejects from this fiber recovery system contain essentially the same solid materials as the first reject stream mentioned above. These reject streams are combined and sent to a flotation clarifier where a flocculating polymer is added and air is injected to cause the suspended solids (fines and fillers) to be concentrated as a flotate. Clarified water is removed from the clarifier for reuse in the process.
In order to sterilize the absorbent material, the flotate stream is pasteurized at a minimum temperature of 160 degrees F., and then a second flocculating polymer is added to the flotate stream. This flotate stream then passes through a belt press or similar dewatering device where the water content is further reduced. The filter cake from the belt press is in the form of a gray, wet cake. The wet cake then passes to a size reducer where the material is broken up. The wet granules are then sent through a conveyor dryer to produce dry granules of irregular shape and having good absorbent characteristics.
The granules produced by this process have a high liquid holding capacity. The term granules is intended to include small particles and chunks that may be as large as 0.5 inches across. Their composition, by weight, is approximately 35-50% inorganic fillers (kaolin clay, calcium carbonate, titanium dioxide) and 50-65% organic (cellulose fines, starches, tannins, lignin, etc.). Less than 10% of the cellulosic material in the granules is in the form of fibers greater than 1 mm in length. The granules are free flowing and resistant to attrition. The bulk density of the granules is between about 28-38 lbs./cu.ft. These granules are useful as oil and water absorbents as well as carriers for agricultural chemicals.
DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is illustrated in the accompanying drawings, in which:
FIG. 1 is a schematic view of the process and apparatus for recovering the papermaking fibers and manufacturing the granules according to the present invention; and
FIG. 2 is a graph of the particle size distribution of the material before and after the pin mixer.
DETAILED DESCRIPTION
The process of this invention utilizes wastepaper that is collected from offices or other sources that contain primarily recyclable paper grades, including magazines (with clay and calcium carbonate based coatings) and printed paper such as paper used for laser printing, photocopying and other paper.
Referring to FIG. 1, wastepaper is supplied to a hydropulper 2 along with water, caustic agents, such as sodium hydroxide, and dispersants to separate the fiber from the other components of the wastepaper. Plastics, debris and other foreign objects are removed by conventional means. The pulp slurry from the hydropulper, which contains more than 95% water, passes through a pipe 4 to a washer 6 where several conventional washing steps are performed. In the washer 6, the slurry flows over wire screens where fibers useful for papermaking pass across the screens and the reject stream passes through the screens and is conducted out of the washer through a pipe 16. The screens have slotted openings of about 100 to 300 microns in width. Preferably, the screens are semi-cylindrical and the slurry is sprayed tangentially onto the screens. Fibers suitable for papermaking pass across the surface of the screens, while small particles, such as kaolin clay, cellulose fines and other suspended solids pass through the screens. Some of the fibers may also pass endwise through the screens. The papermaking fibers from the surface of the screen are included in the accepts stream that is pumped through the pipe 8 and are subject to further cleaning, deinking and processing, indicated at 10, before being supplied through a pipe 12 to a papermaking machine 14.
The reject stream from the washer 6 is in the form of a slurry containing less than 1.5% solids. Typically, 50% by weight of the solids are fillers such as kaolin clay, calcium carbonate and titanium dioxide. The remaining 50% is mostly sugars, tannins, lignins, and cellulose fiber or fines, which is referred to generally herein as cellulosic material. To the extent there are cellulose fibers in the reject stream, most of these fibers are less than 1 mm in length. This slurry, which contains at least 98.5% water, is conducted through the pipe 16 to a dissolved air flotation clarifier 18. Suitable clarifiers are commercially available (e.g., Supracell from Krofta, or Deltafloat from Meri). A flocculating polymer, such as Drewfloc 441 from Drew Chemical Co., or Calgon TRP 945, is added to the reject stream in the pipe 16 before the slurry enters the clarifier. Air is injected into the feed stream of the clarifier 18. The slurry fills the clarifier 18, and the flocculated suspended solids float on the air bubbles to the surface of the clarifier. At this point, the mat of solids, which has a consistency of 3-9%, is skimmed or raked off the surface and removed from the clarifier through the pipe 20. The clarified water from the clarifier 18 is conducted back into the hydropulper 2 through the pipe 22 to be reused and a portion of the clarified water is recycled via pipe 33 to other places in the mill.
In accordance with this invention, nearly all unscreened mill process effluents that contain papermaking fibers are treated in a fiber recovery unit 26. Here the stream passes through screens that separate the papermaking fibers from fillers such as kaolin clay, cellulose material, sugars, lignins, tannins, etc., in a manner similar to the washer 6. This effluent includes some reject water streams, dumping or spills from pulp and paper chests, plant wash-ups, etc., indicated as stream 24 in FIG. 1. Previously, this effluent would have been discharged to a sewer. Papermaking fibers are returned through pipe 28 from the fiber recovery unit 26 to the washer 6. Pipe 30 conducts the reject stream from the fiber recovery unit 26 to the clarifier 18.
The white water stream 25 from the papermaking machine is supplied to another flotation clarifier 27 where the flocculated suspended solids are removed in the same manner as in the clarifier 18. Process white water stream 23 is returned to the washer 6.
The flotate from the clarifiers 18 and 27 is supplied to a heater 36 through pipes 20 and 34 respectively. The heater 36 may be of any suitable type, such as a steam injection unit, or a heat exchanger. The flow rate of the stream and the heat applied should be sufficient to raise the temperature of the stream for sufficient time to achieve pasteurization of the stream. Preferably, the stream should be heated to a temperature of at least 160° F.
The stream passes out of the heat exchanger 36 through a pipe 38, and a second polymer (such as Drewfloc 453 from Drew Chemical Co.) is added to the slurry to cause the solids to dewater as the slurry enters a belt press 40. The belt press can be any one of the commercially available units (e.g., Kompress Belt Filter Press, Model GRS-S-2.0 from Komline Sanderson). At the outlet of the belt press, the filter cake contains 35-40% solids. Process white water from the belt press is returned to the hydropulper 2 through the pipe 42.
If a filter cake having a higher solids content is desired, a screw press may be used after the belt press, or instead of the belt press. Alternatively, a belt press with compressive rolls can be employed. The filter cake would pass through the nip between the rolls for additional dewatering. These arrangements can be used to produce a filter cake having a solids content of up to 45%.
If small particles are desired as the final product, the filter cake from the belt press 40 is conveyed by a screw conveyor 44 to a pin mixer 46 (such as the Turbulator from Ferro-Tech). The pin mixer has a cylindrical shell and a rotatable shaft mounted on the central axis of the shell. The shell is stationary and is supported on a frame so that the central axis of the shell is horizontal. The shaft has radial pins that are spaced about 1/8" from the interior wall of the shell. Pieces of the filter cake from the conveyor 44 are deposited in the shell at one end of the shell. The rate of filling of the shell should be adjusted so that the cake material occupies only about 2% of the volume of the shell. By maintaining a low density in the pin mixer 46, the filter cake is broken up by the rotating pins so that individual granules are separated as the material progresses from the inlet of the pin mixer to the outlet. It has been found that the pin mixer 46 produced optimum size particles for use as an agricultural carrier by running in the middle of its speed range, which is at 1500-4500 feet per minute tip speed of pins. Higher speeds give larger particles. Lower speeds yield a larger variability in sizes, with no net increase in smaller sized granules. It has been discovered that, when operating the mixer with a partially filled chamber in the middle of its speed range, the pin mixer 46 reduces the size of the particles as compared to the size of the particles that are discharged from the screw conveyor 44.
The effect of the pin mixer 46 on the particle size is shown in FIG. 2, which compares the percent of particles retained on screens of progressively smaller openings (higher mesh numbers). As shown in FIG. 2, a substantially greater percentage of the particles that are discharged from the pin mixer 46 have a smaller size than the particles entering the pin mixer 46. Another way of stating this is that FIG. 2 shows that only 8% of the particles discharged from the pin mixer 46 have a size large enough to be retained on a #8 mesh screen or larger (e.g., #4), while 25% of the particles supplied to the pin mixer have a size large enough to be retained on a #8 mesh screen or larger. Additives may be added at this point (e.g., to increase density or absorbency) but it is important not to increase the water content of the press cake since this would cause the particles to agglomerate, yielding a larger than desirable particle size and a less absorbent product. Operating the pin mixer in this fashion allows for uniform densification of the granules. It has been found that backmixing dried granules with the wet feed prior to the pin mixer also leads to a smaller, denser granule.
Preferably, up to 50% by weight of the dried granules can be added. No additional binders are necessary since the matrix produced by the kaolin clay, along with the lignin, tannin, starch and short fibrils starch and short fibrils in the feedstock, serve as the binder for the granules. The resulting open pore structure yields an absorbent irregular particle.
From the pin mixer 46, the granulated but still moist material moves, preferably under the force of gravity, onto a swing conveyor 48, to the belt of a conveyor dryer 50, such as a Proctor & Schwartz two-zone conveyor dryer. The belt is porous and a fan blows hot air through the belt to dry the granules. The velocity of the air flow is sufficiently low to avoid movement of the granules on the belt. At the outlet, the granules have a minimum solids content of 90% by weight, and preferably greater than 95%.
Vibrating screens 52, such as manufactured by Sweco, are used to classify the material by size according to product specifications.
Alternatively, instead of supplying filter cake to the pin mixer 46, the filter cake from the belt press 40 may be conveyed by a conveyor 54 to a dryer 56, such as a Komline Sanderson paddle-type dryer, as shown schematically in FIG. 1. In the dryer 56, the filter cake particles are further dried and may be ground into fine dry particles. The dried particles may have any desired solids content depending on the time and extent of drying. Preferably, the particles have a solids content of 90 to 100% by weight. Even more preferably, the particles have a solids content of 96 to 99% by weight. Also, the particles desirably have a bulk density of from 45 lbs/ft 3 to 50 lbs/ft 3 and a size ranging from 4 to 300 mesh.
The particles from dryer 56 may be used directly as a product, or optionally mixed with wet filter cake particles at the dry/wet particle mixing stage 60. The dry particles from dryer 56 are conveyed through 62. The wet particles are conveyed through 58. Alternatively, the dried particles from dryer 56 may be returned to the main conveyor 44 and mixed with the filter cake particles to produce a final product. Preferably, the dry/wet particle mixing whether in a separate mixing stage 60 or in the main conveyor 44 provides a product having a solids content of from 40 to 60% by weight, preferably 45 to 50% by weight. Alternatively, the wet particles from the belt press 40 may be used directly with little or no mixing of dry particles. The particles used as a final product either with or without addition of dry particles from the dryer 56 have a bulk density of from 50 lbs/ft 3 to 60 lbs/ft 3 and a size ranging from 4 to 100 mesh. The mixing ratio of dry particles from dryer 56 to wet particles from belt press 40 ranges from 0 to 50% by weight, preferably 5 to 30% by weight.
The purpose of the heater 36 is to prevent the growth of bacteria in the material produced by this process. If the filter cake or the granules from the pin mixer 46 are conducted through a dryer, as described above, the heater 36 may be omitted since any bacteria will be killed in the dryer. However, if coarse wet particles are produced, it is necessary to kill the bacteria. An alternative to the heater 36 would be the use of a stationary horizontal cylinder with a rotating auger that would advance the particles through the cylinder. Steam injected into the cylinder would heat the material sufficiently to cause the bacteria to be killed.
The granules produced by this process contain approximately 50% by weight of organic materials, such as cellulosic fines, starches, tannins and lignins. The granules contain less than 10% fiber by weight over 1 mm in length. The inorganic fillers comprise about 50% by weight of the granules and are made up primarily of kaolin clay, calcium carbonate and titanium dioxide. The granules have a substantially uniform density throughout. The granules have an irregular, generally spherical shape and have a porous outer surface. The granules from the conveyor dryer 50 vary in size. Typically, about 50% will be retained on an 8×16 mesh screen, i.e., 50% would pass through an U.S. Sieve No. 8 mesh screen but would be retained on a 16 mesh screen. Typically, the remaining portion would be about 40% in the 16×30 mesh size range, and about 10% in the 20×60 mesh size range. The granules have a bulk density of about 30-40 lb./cu. ft. Bulk density can be increased by adding prior to the pin mixer a densifier such as Barium Sulfate.
The granular material according to the present invention is able to withstand agitation such as might occur during shipment, handling, and storage. Resistance to attrition of the granules is between 90 and 95%. This percentage is based on the following test procedure. A weight of 75 grams of sample is shaken on a limiting screen for ten minutes and 50 grams of the material retained is then shaken in a pan for ten minutes with ten steel balls (5/8" in diameter). The entire sample is then shaken on the limiting screen for ten minutes. The percentage of the original 50 grams retained on the limiting screen is the resistance to attrition cited above. Granular material according to the present invention has been found to generally have a pH between 8.5-9.4.
Granular material according to the present invention is adapted to absorb various liquids to desired degrees as a function of percentage of weight of the granules. When the granular material according to the present invention is intended for use as an agricultural carrier, it has a liquid holding capacity (LHC) toward odorless kerosene of between 25-29%. The material for use as a floor absorbent, when tested with material retained on an 8×35 mesh, is able to absorb about 70-80% of its weight of water, and about 50-60% of its weight of oil.
Since particles or granules used as an agricultural carrier are preferably small, the use of the pin mixer is an effective way to obtain smaller particles in an efficient manner. It has also been found that the particles produced using the pin mixer have less tendency to produce dust during the treatment and storage of the dry particles than naturally occurring clay. This is particularly important when the particles are used as an agricultural carrier because of the presence of herbicides or pesticides that may adversely affect workers if substantial amounts of dust are present. These granules are also useful as oil and grease absorbents and as pet litter.
While this invention has been illustrated and described in accordance with preferred embodiments, it is recognized that variations and changes may be made therein without departing from the invention as set forth in the claims.
|
A process is disclosed which utilizes the "non-papermaking" portion of waste paper to produce a highly absorbent, essentially fiber-free granule which can be used, for example, as an agricultural chemical carrier. The process maximizes the amount of long (papermaking) fiber sent to the paper machine. The waste paper is broken up in a hydropulper, and the pulp stock is screened so that papermaking fibers are retained and sent forward to the papermaking process, and the solid material in the reject stream, such as kaolin clay and inorganic materials pass through a flotation clarifier to separate the solids. The slurry is then dewatered by means of a belt press to form a filter cake. The filter cake then enters a pin mixer where it is broken up into individual granules. The granules are then dried to a solids content of greater than 95%.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to refrigerating systems or chilling systems, and more particularly, to an apparatus and method for controlling a hot gas bypass valve to eliminate or minimize surge in centrifugal liquid chilling systems.
2. Description of the Related Art
As is generally known, surge or surging is an unstable condition that may occur when compressors, such as centrifugal compressors, are operated at light loads and high pressure ratios. It is a transient phenomenon characterized by high frequency oscillations in pressures and flow, and, in some cases, a complete flow reversal through the compressor. Such surging, if uncontrolled, causes excessive vibrations and may result in permanent compressor damage. Further, surging causes excessive electrical power consumption if the drive device is an electric motor.
It is generally known that a hot gas bypass flow helps avoid surging of the compressor during low-load or partial load conditions. As the cooling load decreases, the requirement for hot gas bypass flow increases. The amount of hot gas bypass flow at a certain load condition is dependent on a number of parameters, including the desired head pressure of the centrifugal compressor. Thus, it is desirable to provide a control system for the hot gas bypass flow that provides optimum control and is responsive to the characteristic of a given centrifugal chiller system.
An hot gas bypass valve control in the prior art is an analog electronic circuit described in U.S. Pat. No. 4,248,055. This prior art control provides as its output a DC voltage signal that is proportional to the required amount of opening of the valve. This prior art method requires calibration at two different chiller operating points at which the compressor just begins to surge. As a consequence of this, a good deal of time is consumed performing the calibration and it requires the assistance of a service technician at the chiller site. Further, variation of flow is necessary for many applications, and therefore, repeated calibration of the control is required. Another disadvantage of the prior art method is that it makes the false assumption that the surge boundary is a straight line. Instead, it is often characterized by a curve that may deviate significantly from a straight line at various operating conditions. As a consequence of this straight line assumption, the hot gas bypass valve may open too much or too little. Opening the valve too much may result in inefficient operation, and opening it too little may result in a surge condition.
SUMMARY OF THE INVENTION
The advantages and purpose of the invention are set forth in part in the description that follows, and in part is obvious from the description, or may be learned by practice of the invention. The advantages and purpose of the invention is realized and attained by means of the elements and combinations particularly pointed out in the claims.
To attain the advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, systems and methods consistent with this invention automatically calibrate a surge control of a refrigeration system including a centriftigal compressor, a condenser, pre-rotational vanes, a load, and an evaporator through which a chilled liquid refrigerant is circulated. The system or method comprises a number of elements. First, systems or methods consistent with this invention sense a presence of a surge condition, sense a head parameter representative of the head of the compressor, and sense a load parameter representative of the load. Second, systems or methods consistent with this invention store the head parameter and the load parameter when the surge condition is sensed as calibration data to be used by the control of the refrigeration system.
To attain the advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, systems and methods consistent with this invention control a hot gas bypass valve in a refrigeration system including a centrifugal compressor, a condenser, pre-rotational vanes, and an evaporator through which a chilled liquid refrigerant is circulated. The system or method comprises a number of elements. First, systems or methods consistent with this invention sense a current pressure representative of the current pressure of the liquid refrigerant in the condenser, sense a current pressure representative of the current pressure of the liquid refrigerant in the evaporator, and sense a current position representative of the current position of the pre-rotational vanes. Second, systems or methods consistent with this invention control the operation of a hot gas bypass valve so as to avoid surging in the compressor in response to a comparison of the current condenser pressure, the current evaporator pressure, and the current vane position, or functions thereof, to stored calibration data.
The summary and the following detailed description should not restrict the scope of the claimed invention. Both provide examples and explanations to enable others to practice the invention. The accompanying drawings, which form part of the detailed description, show one embodiment of the invention and, together with the description, explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and together with the description, serve to explain the principles of the invention. In the drawings,
FIG. 1 is a diagram of a refrigeration system and control panel consistent with this invention;
FIG. 2 is a diagram of a table that stores control pressure ratios and corresponding prerotational rotational vane position index and a plot of the values in the table, each consistent with this invention;
FIGS. 3A, 3 B, 3 C are a flow diagram of the Adaptive Hot Gas Bypass control process consistent with this invention;
FIGS. 4A, 4 B, 4 C are a flow diagram for the sub-process of recording or storing control pressure ratios in a table as shown in FIG. 2;
FIGS. 5A, 5 B, 5 C are a flow diagram for a hot gas bypass valve control sub-process consistent with this invention; and
FIG. 6 is a flow diagram for a sub-process for determining the PRV index shown in of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of embodiments of this invention refers to the accompanying drawings. Where appropriate, the same reference numbers in different drawings refer to the same or similar elements.
FIG. 1 is a diagram of a refrigeration system 100 and control panel consistent with this invention. Refrigeration system 100 includes a centrifugal compressor 110 that compresses the refrigerant vapor and delivers it to a condenser 112 via line 114 . The condenser 112 includes a heat-exchanger coil 116 having an inlet 118 and an outlet 120 connected to a cooling tower 122 . The condensed liquid refrigerant from condenser 112 flows via line 124 to an evaporator 126 . The evaporator 126 includes a heat-exchanger coil 128 having a supply line 128 S and a return line 128 R connected to a cooling load 130 . The vapor refrigerant in the evaporator 126 returns to compressor 110 via a suction line 132 containing pre-rotational vanes (PRV) 133 . A hot gas bypass (HGBP) valve 134 is interconnected between lines 136 and 138 which are extended from the outlet of the compressor 110 to the inlet of PRV 133 .
A control panel 140 includes an interface module 146 for opening and closing the HGBP valve 134 . Control panel 140 includes an analog to digital (A/D) converter 148 , a microprocessor 150 , a non-volatile memory 144 , and an interface module 146 .
A pressure sensor 154 generates a DC voltage signal 152 proportional to condenser pressure. A pressure sensor 160 generates a DC voltage signal 162 proportional to evaporator pressure. Typically these signals 152 , 162 are between 0.5 and 4.5V (DC). A PRV position sensor 156 is a potentiometer that provides a DC voltage signal 158 that is proportional to the position of the PRV. A temperature sensor 170 on supply line 128 S generates a DC voltage signal 168 proportional to leaving chilled liquid temperature. The four DC voltage signals 158 , 152 , 162 , and 168 are inputs to control panel 140 and are each converted to a digital signal by A/D converter 148 . These digital signals representing the two pressures, the leaving chilled liquid temperature, and the PRV position are inputs to microprocessor 150 .
Microprocessor 150 performs with software all necessary calculations and decides what the HGBP valve position should be, as described below, as well as other functions. One of these functions is to electronically detect compressor 110 surge. Microprocessor 150 controls hot gas bypass valve 134 through interface module 146 . Micro-processor 150 also keeps a record of PRV 133 position and pressure ratio in non-volatile memory 144 for each surge event, as described below. The conventional liquid chiller system includes many other features which are not shown in FIG. 1 . These features have been purposely omitted to simplify the drawing for ease of illustration.
Methods and systems consistent with this invention self calibrate adaptively by finding the surge points as the chiller operates. This Adaptive hot gas bypass (Adaptive HGBP or AHGBP) process creates a surge boundary which represents the actual surge curve, not a linear approximation. This is accomplished by electronically detecting compressor surge when it takes place and storing in non-volatile memory 144 numerical values which represent the compressor head and chiller load when the surge takes place. In the preferred embodiment, the numerical values represent the control pressure ratio, as defined below, and PRV position for each detected surge condition. In this way, the control panel 140 remembers where surge took place and can take the appropriate action to prevent surge from occurring in the future by referencing the values stored in memory.
Different parameters can be used to represent the compressor head. For example, the method in U.S. Pat. No. 4,248,055 uses compressor liquid temperature (CLT) to represent compressor head. According to U.S. Pat. No. 4,282,719, which is incorporated by reference, the pressure ratio is a better representation of compressor head than the CLT. The pressure ratio is defined as the pressure of the condenser minus the pressure of the evaporator, that quantity divided by the pressure of the evaporator. While both CLT and pressure ratio can be used in the application of the present invention, the present preferred method is to detect and use the pressure ratio.
According to U.S. Pat. No. 4,248,055, the difference between the evaporator returning chilled water temperature (RCHWT) and leaving chilled water temperature (LCHWT) can be used to represent the chiller cooling load. While those parameters can be used with the broadest aspect of this invention, in the preferred embodiment this invention uses the pre-rotation vane (PRV) position to represent chiller cooling load. Use of the PRV position minimizes variations due to flow. Further, because the control is self-calibrating, applications in which full load corresponds to partial open vanes should not present a problem.
In the preferred embodiment, the method and system disclosed in U.S. Pat. No. 5,764,062, which is incorporated by reference, is used to detect a surge condition. When a valid surge event occurs, the process of the invention detects and/or determines the parameters of load and compressor head. Preferably, the process of the invention detects and determines the current PRV position and calculates the current pressure ratio, and then subtracts a small margin. According to the invention, data is organized relative to a PRV index value. For instance, a given PRV position is converted into a percentage from zero to 100%. A current PRV index value of 1 could represent a PRV percentage of zero to 5%. A current PRV index value of 2 could represent a PRV percentage of 5% to 10%, etc. This method of determining the PRV index is exemplary only. Another, preferred method is described below and in FIG. 6 .
The process then accesses a table of all possible PRV index values. Each PRV index has one control pressure ratio associated to it. FIG. 2 shows an example of such a table and a plot of the PRV index versus the control pressure ratio. The PRV index ranges from 1 to 20, and the stored control pressure ratios are represented by the small letters ‘a’ through ‘t’. The slope of the curve in FIG. 2 is generally positive. The stored control pressure ratios correspond to the sensed pressure ratios for a given PRV index value, minus a small preselected margin. This table is stored in non-volatile memory 144 . Alternatively, the table can store other information such as the evaporator pressure, the condenser pressure, the PRV position, among other data that may be useful for determining the conditions under which surge takes place.
If a surge is detected at a given PRV position and no control pressure ratio is stored at the PRV index value corresponding to that PRV position, the process stores the current pressure ratio, minus a small margin, as the stored control pressure ratio at that PRV index. The small margin is defined by the user and is programmable through control panel keypad.
The hot gas bypass valve is opened or closed based on a comparison of periodically sensed values of the current pressure ratios with a stored control pressure ratio in the table, at a given PRV index. If the current pressure ratio is greater than the stored control pressure ratio, the HGBP valve 134 is opened by an amount proportional (by using a proportion coefficient) to the difference between the current pressure ratio and the stored control pressure ratio. This corresponds to operating point A in FIG. 2 . The proportion coefficient may be programed through control panel 140 . As time progresses, if the current pressure ratio increases above the stored control pressure ratio stored in the table, the HGBP valve 134 is opened further to eliminate surge. The valve 134 starts to close as the current pressure ratio decreases toward the stored control pressure ratio in the table.
If the current pressure ratio is less than or equal to the stored value in the table, the valve 134 remains closed because this corresponds to normal operation. This corresponds to operating point B in FIG. 2 .
If the characteristics of the system changes so that compressor 110 surges while operating at a point on or below the curve in FIG. 2, the stored control pressure ratio in the table is decreased incrementally. This automatically causes the HGBP valve 134 to open more in order to stop surge. Once the surge condition has ceased the final value stored in the table represents the new surge boundary associated with that PRV index. Instead of decreasing the stored control pressure ratio, it is possible to increase the proportion coefficient, which would also automatically cause the HGBP valve 134 to open more in order to stop a surge. Under other circumstances, it is possible that the system characteristics can change so that it would be beneficial to increase the stored control pressure ratios instead of decreasing them. In this situation, it is possible to adaptively increase the stored control pressure ratios by control methods well known in the art.
The above process continues as chiller load conditions change and therefore is self calibrating. In this way, the table of stored control pressure ratios is created, revised and maintained and reflects where the surge boundary is at a given time so that HGBP valve 134 is opened and closed at the appropriate chiller operating points. The table may not necessarily store a control pressure ratio point for each PRV index because the vanes may not operate above partially open conditions for some applications. For instance, the PRV percentage may never reach 95 to 100% and thus PRV index value of 20 may not have a stored control pressure ratio associated to it. On the other hand, if a surge is detected at a PRV index with no stored control pressure ratio, the sensed pressure ratio is used to create a stored control pressure ratio (by slightly decreasing the sensed ratio).
FIGS. 3A, 3 B, and 3 C show a flow chart of the AHGBP control process consistent with this invention. This flow chart, and ones that follow, contain variables and constants, which are included in parentheses in the description below.
Microprocessor 150 executes the AHGBP control process once per second, although it is not limited to this particular period of time. When the AHGBP control process starts, the absolute value of the leaving chilled water 128 S temperature (LCHWT) rate of change (lchwt 13 rate) is compared to the programmable stability limit (stability_limit) (step 1 ). Temperature sensor 170 measures the LCHWT. The stability limit, if exceeded, represents a dynamic condition that invalidates storing control pressure ratios. If the LCHWT rate is greater than the stability limit (step 1 ), then the stability timer (stability_timer) is checked (step 2 ). In the preferred embodiment, the stability limit is 0.3° F. per second. If the timer has expired (step 2 ), then a surge hold-off timer (surge_hold_off_timer) is started (step 3 ) in order to create a window of time for storing control pressure ratios in the case where a surge creates the unstable LCHWT condition. Control pressure ratios are stored in a sub-process discussed below and shown in FIGS. 4A, 4 B, 4 C. The surge hold-off and stability timers are checked in that sub-process. The stability timer is reset to its starting time (step 4 ) in order to assure that a time delay has occurred after the unstable condition has subsided.
Next, the current pressure ratio (dp_p) is assigned the value of ((Condenser Pressure/Evaporator Pressure)−1), which is equal to ((condenser pressure -evaporator pressure)/evaporator pressure) (step 5 ). The pressure ratio should only have positive numbers. Therefore, if the pressure ratio is negative (step 6 ), it is assigned the value of zero (step 7 ). Next, the average pressure ratio (dp_pa), is assigned the average value of the past N pressure ratios, including the current pressure ratio (step 8 ). In the preferred embodiment, N is equal to ten. Averaging the pressure ratio prevents erroneous values from fluctuations due to surges. Then, the timers used in this process are updated (step 9 ). Updating the timers involves decreasing their values until they reach zero.
While this AHGBP process is executed, a separate surge detection process continuously detects whether surge conditions are present in compressor 110 . As stated above, the preferred method of detecting surge conditions is discussed in U.S. Pat. No. 5,764,062. When the surge detection process detects a surge condition, it then “validates” the surge condition. A “valid” or “validated” surge is not only when surge conditions are present, but when there is a high confidence that a surge is actually occurring. When the surge detection process detects a valid surge, it flags it by setting a variable (surge) to TRUE.
If surge conditions are not detected in the compressor (validated or not) (step 10 ), the PRV position (prv) is stored in a memory buffer location (prv_prior_to_surge) (step 11 ) to provide an accurate indicator of the PRV position prior to surge. If surge conditions are detected in the compressor (validated or not) (step 10 ), the PRV position stored in this memory buffer location remains what it was at the beginning of the surge condition.
Next, if the surge delay timer has elapsed (step 12 ), the validity of the surge condition is checked (step 14 ). The surge delay timer prevents overwriting the previously stored control pressure ratios if another surge occurs immediately after the present surge. Therefore, the timer provides a time period that allows the system to adjust to action taken by the by the process to the original surge. This timer is discussed and initialized in a sub-processes described below and in FIGS. 4A, 4 B, and 4 C. If a valid surge is detected (surge=TRUE), the values of the PRV position prior to surge (prv_prior_to_surge) and average pressure ratio (dp_pa) are stored in temporary variable locations (plot_prv and plot_dp_p, respectively) (step 15 ). If conditions permit, they are recorded, i.e. stored in the table (step 16 ), which is explained in detail below and in FIGS. 4A, 4 B, and 4 C. The surge condition (surge_condition) is acknowledged (step 17 ) by indicating this on the control panel user display. Then, the surge flag is cleared (FALSE) (step 18 ). Finally, the Hot Gas Bypass Valve sub-process is performed (step 19 ), which is described below and in FIGS. 5A, 5 B, and 5 C. The HGBP Valve sub-process determines the amount of valve opening or closing.
If the surge delay timer has not elapsed (step 12 ), the surge flag is cleared (FALSE) (step 13 ) and the Hot Gas Bypass Valve sub-process is performed (step 19 ). The surge flag is cleared step 13 and 18 ) because the AHGBP process took action or is currently taking action to take the system out of any validated surge. The surge detection process, discussed above, will set the surge flag (surge) if necessary.
The point recording sub-process (step 16 ) is described in FIGS. 4A, 4 B, and 4 C. This process executes whenever a valid surge is detected (step 14 ). This process takes the PRV position before surge (plot_prv) and the average pressure ratio (plot_dp_p) and stores them as control parameters into a table, such as one shown in FIG. 2, if the appropriate qualifications are met.
First, the process checks if the system conditions are stable and the LCHWT is operating at set-point. It does this by checking whether the current LCHWT is within plus or minus 0.5° F. of its set-point (setpoint) and the temperature control has been stable for 60 seconds (stability timer) or it is within 8 seconds of the start of new unstable LCHWT condition (surge hold-off timer) (step 20 ). If these conditions are met, then the current PRV index (prv_index) is assigned a value based on the PRV position just before the surge event (step 22 ). The stability timer (stability_timer) and the surge hold-off timer (surge_hold_off_timer) are described above and in FIGS. 2A, 2 B and 2 C. The set-point is a temperature programmed by the user through the control panel 140 . In the preferred embodiment, the set-point temperature is 44° F. Calculation of the PRV index is described in more detail in FIG. 6 below.
Next, if no control pressure ratio is stored in the table at the current PRV index (surge_pts[prv_index]) (step 23 ) (a zero means that no control pressure ratio has been stored), the process searches for a stored control pressure ratio with a higher PRV index. (steps 25 , 26 , and 27 ). The process does not search beyond the maximum PRV index value (MAX_PRV_INDEX). In the preferred embodiment, the PRV index ranges from zero to a maximum of 15.
If there is a higher PRV index with a previously stored control pressure ratio and it is less than the average pressure ratio temporarily stored (plot_dp_p) (step 28 ), the process assigns the table position at the current PRV index (prv_index) the value at the higher PRV index minus a programmable margin (surge_margin) (step 30 ). This serves as a precaution against storing a value which is greater than any value at a higher PRV index because in the preferred embodiment the curve should have a positive slope, as shown in FIG. 2 .
If there is no higher PRV index that has a previously stored control pressure ratio (step 28 ), or it is greater than or equal to the average pressure ratio temporarily stored (plot_dp_p) (step 28 ), the process assigns the control pressure ratio at the current PRV index (prv_index) with the average pressure ratio value temporarily stored (plot_dp_p) minus the programmable margin (surge_margin) (step 29 ). This stored control pressure ratio is now the stored control pressure ratio corresponding to that PRV index. In the preferred embodiment, the value of the programmable margin is between 0.1 and 0.5.
If a control pressure ratio is stored in the table (step 23 ), then the process subtracts from this value the programmable margin (surge_margin) (step 24 ). In this case, the process is adapting and re-calibrating to changed system conditions, as explained above. In all cases, the minimum value a control pressure ratio may have is 0.1. If the actual value is below 0. 1, the control pressure ratio is assigned the value of 0.1 (steps 31 , 32 ). An average pressure ratio of 0.1 or less is well below what would ordinarily be calculated and is used merely as a precaution to prevent a zero from possibly being placed in the table (because a zero indicates that a control pressure ratio is not entered into the table at that PRV index). At this time, a surge response is required (step 33 ), and is flagged (surge_response_required), i.e. the HGBP valve needs to be opened to stop surge.
If the LCHWT condition is not met and the temperature conditions are not met (step 20 ), then the unit conditions are not stable or the LCHWT is not operating at set-point. In this case, a control value should not be stored in memory, but a surge response is still needed (independent of the surge response required flag, discussed above). Therefore, the process adds a programmable response increment (response_increment) to the surge response (surge_response) (step 21 ). The surge response is the amount the HGBP valve is opened in order to stop surge, and its value is determined in the HGBP valve control sub-process explained below and in FIGS. 5A, 5 B, and 5 C. In all cases, the process sets a surge delay timer (step 34 ) so that no control pressure ratios are stored in memory before the system has a chance to respond to the HGBP valve response.
The HGBP valve control sub-process (step 19 ) is described in more detail in FIGS. 5A, 5 B, and 5 C. This sub-process determines the valve response comprising how much the valve should be opened or closed. Three terms contribute to the total valve response. The first term, the set-point response, is proportional to the current pressure ratio minus the control pressure ratio at the current PRV index. The second term, the surge response, is the amount the HGBP valve is opened in response to surge. This term is exclusive of the set-point response and always returns to zero during normal non-surge conditions.
The third term is the minimum digital to analog converter (DAC) response. The interface module 146 comprises the DAC, which is necessary to control signals to the HGBP valve 134 . The DAC has a minimum value (DA_MIN) it can receive, which corresponds to the closed HGBP valve position. Thus, the total valve response is equal to the set-point response plus the surge response plus the minimum DAC response.
First, the PRV index is assigned a value indicative of the current PRV position (prv) (step 35 ). Assigning the PRV index is explained in more detail below and in FIG. 6 . If the PRV index contains a previously stored control pressure ratio, and the current average pressure ratio is greater than that value (step 36 ), then the set-point response is assigned the value of a proportion coefficient (factor) multiplied by the difference of the two values (step 38 ). In other words, a response is taken that opens the HGBP valve by an amount proportional to the difference between average pressure ratio and the stored control pressure ratio at the current PRV index. The proportion coefficient is programmable through control panel 140 and preferably ranges from 10 to 100.
If either a control pressure ratio is not assigned for the current PRV index or the average current pressure ratio is less than the stored value at that PRV index (step 36 ), the process checks if a surge response requirement is flagged (surge_response_required) (step 37 ) because no set-point response will take place. If a surge response is required (step 37 ), then the surge response (surge_response) is incremented (surge_response increment) (step 39 ). Preferably, the surge response increment is 5% of the full scale, but it is not limited to this.
In all cases, the surge response required flag is cleared (step 40 ) because no further surge response is necessary until another valid surge takes place. If the surge delay timer and the cycle response timers (cycle_response_timer) are expired (step 41 ), the surge response component of the HGBP valve control is slowly lowered (step 42 ) by a preset amount (response_decrement) toward zero to determine whether surge occurs again. The cycle response timer prevents the HGBP valve from opening or closing too quickly by only allowing valve movement in periodic intervals. This preset amount (response_decrement) is preferably 1% of the full scale. In this way, the HGBP valve position is optimized by only allowing the set-point response component of the HGBP control to ultimately contribute to the valve opening in the steady state.
The surge response should not be negative. Therefore, if the surge response is below zero (step 43 ), it is set to zero (step 44 ). If the current average pressure ratio is less than or equal to the stored control pressure ratio at the PRV index value (step 45 ), the process subtracts the response increment from the set-point response (step 46 ) so that the HGBP valve is slowly moved to its closed position.
The set-point response should also not be negative. Therefore, if the set-point response is below zero (step 47 ), the process sets the set-point response to zero (step 48 ). The cycle response timer (cycle_response_timer) is reset (step 49 ) so that this portion of the HGBP valve process is executed once every 10 seconds.
The total valve response (total_value_response) is equal to the set-point response plus the surge response plus the minimum DAC value (DA_MIN) (step 50 ). The DAC has a minimum value it can receive (DA_MIN), which corresponds to a closed valve position. The maximum the total valve response allowed is the full scale DAC range value (FULL_SCALE) plus the minimum DAC value (step 51 , 52 ). The process then opens or closes the HGBP valve (step 60 ) in response to the total valve response necessary by means of interface module 146 .
FIG. 6 is a flow chart of a sub-process for determining the PRV index (prv_index) for the stored control pressure ratios. If the PRV value (prv_value) is less than 40% (step 53 ), then the index value returned (step 58 ) is the PRV value divided by four (step 54 ). If the PRV value is not less than 40% (step 53 ), but is less than 100%, then the index returned (step 58 ) is the PRV value divided by ten, plus six. If the PRV value is not less than 100% (step 55 ) then the index returned (step 58 ) is the maximum value allowed (MAX_PRV_INDEX). In the preferred embodiment, the maximum value allowed is 15, the PRV value ranges between zero and 100%.
The specification does not limit the invention. Instead it provides examples and explanations to allow persons of ordinary skill to appreciate different ways to practice this invention. The following claims define the true scope and spirit of the invention.
|
An adaptive control apparatus and a method for automatically controlling a refrigeration system as a function of cooling load and head. A control panel controls the operation of a hot gas bypass valve so as to avoid surging of the compressor in response to cooling load and head. The control apparatus and method also allow for automatic self calibration.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2006-223085 filed Aug. 18, 2006.
BACKGROUND
1. Technical Field
The present invention relates to an optical scanning device and an image formation apparatus, and more particularly relates to an optical scanning device which deflects light beams emitted from plural light sources with a deflection element to carry out scanning exposure and an image formation apparatus including the optical scanning device.
2. Related Art
In recent years, multi-color production of a document has progressed and attempts have been made to improve the productivity of color imaging at an image formation apparatus. A color laser printer which uses plural photoreceptors to improve the productivity of color imaging has come onto the market.
In an exposure device which is used in the image formation apparatus that utilizes plural photoreceptors, a system is used in which plural scanning devices corresponding to the respective photoreceptors are arranged in a row. However, in order to reduce size, reduce number of components and further reduce cost, a system in which plural beams are deflected by a single deflector to scan the plural photoreceptors has been proposed.
As a scanning optical system for forming electrostatic latent images on photosensitive surfaces of respective photosensitive drums, there is a system in which polygon mirrors and image focusing optical systems are provided one-to-one for the respective photosensitive drums. However, providing four sets of polygon mirrors and image focusing optical systems is problematic in terms of cost. Therefore, in recent years there has been a scanning optical system in which a single polygon mirror is utilized in common and plural laser beam fluxes are simultaneously scanned therewith, and thereafter the laser beam fluxes are respectively incident at individually corresponding focusing optical systems and are guided to the respective photosensitive drums.
To respectively separately illuminate the plural light beams onto plural scanned surfaces, it is necessary to separate the plural light beams after deflective reflection by the polygon mirror, and for light sources with the same wavelength, spatial separation is necessary. A required spatial separation can be achieved by, for example, causing the light beam to be incident on a deflection surface (a reflection surface) of the polygon mirror from an oblique angle in a slow scanning plane. However, in a scanning optical device of which the optical structure is compact, because light path length for spatial separation is short, the oblique incidence angle on the reflection surface is large. Consequently, problems arise in that a scanning line on the scanned surface curves and image focusing performance deteriorates.
SUMMARY
In an aspect of the present invention, an optical scanning device includes: a light source; a first optical element that converts light emitted from the light source to parallel light; a deflection element that deflects the light in a fast scanning direction to scan a surface of an object to be scanned with the light at a constant speed; a second optical element that guides the light to the deflection element; and a third optical element that focuses the light deflected by the deflection element onto the surface of the object to be scanned, at least one surface among surfaces of the third optical element that intersect the light including a surface form which affects only one of fast scanning direction characteristics or slow scanning direction characteristics at an image plane.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention will be described in detail with reference to the following figures, wherein:
FIG. 1 is a view showing an image formation apparatus which is equipped with an optical scanning device relating to the present invention.
FIG. 2 is a perspective view showing the interior of the optical scanning device relating to the present invention.
FIGS. 3A and 3B are views showing arrangements of components and light paths of the optical scanning device relating to the present invention.
FIGS. 4A and 4B are expanded views showing the light paths of the optical scanning device relating to the present invention.
FIG. 5 is a view showing a common f-θ lens of the optical scanning device relating to the present invention.
FIG. 6 is a view showing an individual f-θ lens of the optical scanning device relating to the present invention.
FIG. 7 is a graph showing forms of scanning lines of different colors at the optical scanning device relating to the present invention.
FIG. 8 is a graph showing magnification shifts of the different colors at the optical scanning device relating to the present invention.
FIG. 9 is a graph showing image plane curvatures separately for sagittal and tangential directions at the optical scanning device relating to the present invention.
FIGS. 10A , 10 B and 10 C are graphs showing variations in characteristics in the fast and slow scanning directions when a variable C 0 of an S 2 surface of the individual f-θ lens is varied in the optical scanning device relating to the present invention.
FIGS. 11A , 11 B and 11 C are graphs showing variations in characteristics in the fast and slow scanning directions when a variable A 2 of the S 2 surface of the individual f-θ lens is varied in the optical scanning device relating to the present invention.
DETAILED DESCRIPTION
—Basic Structure—
FIG. 1 shows an image formation apparatus which is equipped with an optical scanning device relating to an exemplary embodiment of the present invention.
For example, FIG. 1 shows a full-color laser printer provided with the optical scanning device relating to the exemplary embodiment of the present invention.
This image formation apparatus 10 , as shown in FIG. 1 , is structured with main portions thereof being developing devices 30 Y to 30 K for yellow (Y), magenta (M), cyan (C) and black (K), which include respective photoreceptor drums 32 Y to 32 K, charging rollers for primary charging which contact against the photoreceptor drums 32 Y to 32 K, and an ROS (raster output scanner) 20 which emits laser beams 31 Y to 31 K for the colors yellow (Y), magenta (M), cyan (C) and black (K).
The photoreceptor drums 32 Y, 32 M, 32 C and 32 K are disposed with a fixed spacing therebetween so as to have a common tangential plane, to form, what is called, a tandem-type color printer. Signals corresponding to image information for the respective colors are rasterized at an unillustrated image processing unit and inputted to the ROS 20 . In a laser optical unit, the laser beams for the respective colors yellow (Y), magenta (M), cyan (C) and black (K) are modulated, and are irradiated at the photoreceptor drums 32 Y to 32 K of the corresponding colors.
At the above-mentioned photoreceptor drums 32 Y to 32 K, image formation processes for the respective colors are carried out with a well-known electrophotography system. Firstly, photoreceptor drums which use, for example, OPC photoreceptors are used as the photoreceptor drums 32 Y to 32 K, and these photoreceptor drums 32 Y to 32 K are driven to rotate. DC voltages are applied to surfaces of the photoreceptor drums 32 Y to 32 K by the charging rollers, and thus the surfaces are charged to around, for example, −300 V.
The laser beams 31 Y to 31 K corresponding to the colors yellow (Y), magenta (M), cyan (C) and black (K) are irradiated by the ROS 20 , which serves as an exposure device, onto the surfaces of the photoreceptor drums 32 Y to 32 K to which the surface potentials have been applied, and electrostatic latent images corresponding to the inputted image information for the respective colors are formed. The laser beams 31 Y to 31 K are emitted by the ROS 20 and write the images. Thus, the surface potentials of image exposure portions of the photoreceptor drums 32 Y to 32 K are discharged at image line portions, that is, exposed areas, and the electrostatic latent images are formed.
Then, the electrostatic latent images corresponding to the colors yellow (Y), magenta (M), cyan (C) and black (K) which have been formed at the surfaces of the photoreceptor drums 32 Y to 32 K are developed by the developing devices 30 Y to 30 K of the corresponding colors. Thus, toner images of the colors yellow (Y), magenta (M), cyan (C) and black (K) are developed on the photoreceptor drums 32 Y to 32 K, rendering the images visible.
Developing agents formed of carriers and toners of the respective different colors yellow (Y), magenta (M), cyan (C) and black (K) are filled in the respective developing devices 30 Y to 30 K. These developing devices 30 Y to 30 K are supplied with toner from unillustrated toner supply devices, and the supplied toners are thoroughly agitated with the carrier by augers inside the developing devices 30 Y to 30 K and charged up by friction.
The toners, which are agitated with the carrier, and electrostatically charged by friction and supplied onto developing rollers 33 , form magnetic brushes structured of the carriers and the toners, due to magnetism of magnetic rollers, and these magnetic brushes touch against the photoreceptor drums 32 Y to 32 K. A developing bias voltage is applied to the developing rollers 33 and the toners on the developing rollers 33 are transferred to the electrostatic latent images formed on the photoreceptor drums 32 Y to 32 K. Thus, the toner images of the colors yellow (Y), magenta (M), cyan (C) and black (K) are formed.
Then, positioning over paper P of the toner images of the colors yellow (Y), magenta (M), cyan (C) and black (K) that have been formed on the developing devices 30 Y to 30 K is implemented, and the toner images are respectively superposingly transferred. Thus, a final full-color toner image in which the colors cyan (C), magenta (M) and black (K) are respectively superposed on a monochrome Y image is formed as a four-color superposed image.
Finally, the full-color toner image of yellow (Y), magenta (M), cyan (C) and black (K) that has been formed on the paper P is heated and fused by a fixing device 34 and is fixed onto the paper P, and the image formation processing sequence ends.
—Optical Scanning Device—
FIG. 2 shows an optical scanning device relating to the present embodiment, and FIGS. 3A and 3B show light paths of the optical scanning device.
As shown in FIG. 2 , at the ROS 20 , which is the optical scanning device, the laser beams 31 are emitted from respective light sources 21 for the four colors Y to K. The laser beams 31 are made to be parallel fluxes by collimator lenses 22 , are focused in a fast scanning direction in line by a cylindrical lens, and are deflected in a fast scanning direction by a polygon mirror 23 .
As a method for incidence of the beams onto the polygon mirror 23 , tangential offset incidence, in which plural beams are provided with different angles in the fast scanning direction, sagittal offset incidence, in which plural beams are incident at respectively different angles in the slow scanning direction, and the like can be considered. In the case of the present embodiment, the laser beams 31 of the respective colors that are incident at a reflection surface 23 A have respectively predetermined angles in the slow scanning direction (a vertical direction in the drawing), and are incident with offsets from one another in a sagittal direction. Thus, a size of the reflection surface 23 A in the slow scanning direction can be made smaller.
However, as mentioned earlier, for light sources with the same wavelength, spatial separation is required in order to guide the light beams from the corresponding light sources for the respective colors to the photoreceptor drums 32 Y to 32 K. The required spatial separation can be achieved if, for example, the laser beams 31 are caused to be incident on the reflection surface 23 A from directions oblique in a slow scanning sectional plane. However, if the ROS 20 is reduced in size, light path lengths for spatial separation are shorter, and therefore the oblique incidence angles at the reflection surface 23 A are larger. Consequently, problems arise in that scanning lines on scanned surfaces are curved and imaging performance is adversely affected. In order to counter this, with the present embodiment, surface forms of common and individual f-θ lenses are specified as will be described later.
The laser beams 31 , that have been deflected by the polygon mirror 23 are incident at a common f-θ lens 24 , are divided in the slow scanning direction into two-color sets, and are incident at first mirrors 25 A and 25 B. That is, the laser beams 31 Y and 31 M for yellow (Y) and magenta (M) are incident at a first mirror 25 A, and the laser beams 31 C and 31 K for cyan (C) and black (K) are incident at a first mirror 25 B.
The laser beams 31 are further divided into one-color sets in the slow scanning direction after the first mirrors 25 A and 25 B, and are incident at second mirrors 26 Y, 26 M, 26 C, 26 K. That is, as shown in FIG. 3A , the laser beams 31 Y and 31 M are incident at second mirrors 26 Y and 26 M, respectively, and the laser beams 31 C and 31 K are incident at second mirrors 26 C and 26 K, respectively. The laser beams 31 Y and 31 K, which are closer to two ends in the slow scanning direction, are simply reflected at the second mirrors 26 Y and 26 K. Then, the laser beams 31 Y and 31 K are incident at individual f-θ lenses 28 Y and 28 K and are focused as scanning lines 29 Y and 29 K.
Meanwhile, the laser beams 31 M and 31 C are incident on and reflected at third mirrors 27 M and 27 C, respectively, are incident at individual f-θ lenses 28 M and 28 C, and are focused as scanning lines 29 M and 29 C.
Here, for the individual f-θ lenses 28 Y to 28 K mentioned above, rather than four lenses with individual shapes being used, a feature of the present exemplary embodiment being a structure in which light paths are symmetrical in the slow scanning direction is utilized, and sets of two individual f-θ lenses which have the same forms are used.
That is, the individual f-θ lenses 28 Y and 28 K are lenses which have the same forms but which differ in arrangement position and orientation, and the individual f-θ lenses 28 M and 28 C are lenses which have the same forms but which differ in arrangement position and orientation. Thus, for the individual f-θ lenses 28 , it is sufficient to provide two kinds of lenses in sets of two for the whole apparatus, and therefore component numbers can be reduced and cost can be lowered.
Furthermore, molded products from plastic mold are used for the common f-θ lens 24 , the individual f-θ lenses 28 and suchlike. Thus, there are advantages in a reduction of a number of parts (f-θ lenses and cylinder mirrors) in the scanning optical system, a reduction in thickness of the polygon mirror 23 , a reduction in component costs, an improvement in a degree of freedom of layout of the optical elements, and so forth.
—Light Path and Surface Form—
FIGS. 4A and 4B show expanded views of light paths of the optical scanning device relating to the present embodiment.
As shown in FIG. 4A , in the present embodiment, the light paths of the four colors coincide in the slow scanning direction at the polygon mirror, and the individual f-θ lenses are provided for the respective colors as a final f-θ lens.
As a consequence, the occurrence of curvature of the scanning lines (bowing) is unavoidable. In a “tandem-type” color printer as for the present embodiment, it is necessary to reduce the number of lenses in order to reduce size and lower cost of the optical scanning device. Therefore, functionality that is required from each lens is greater.
However, as mentioned earlier, if a complex surface form in order to produce desirable characteristics in the fast scanning direction and a complex surface form in order to produce desirable characteristics in the slow scanning direction are applied to the same surface, independently modifying of the fast scanning direction characteristics and the slow scanning direction characteristics at a time of f-θ lens mold modification or the like in order to push initial performance, is difficult.
If a surface with a form such that fast-scanning characteristics (beam diameter, magnification and the like) and slow scanning characteristics (beam diameter, bow correction and the like) are corrected at the same surface is used at an f-θ lens, the characteristics cannot be modified independently for fast scanning and slow scanning by modifications during making of the lens (molding conditions, mold modification and the like), and establishing lens performance is difficult. For example, in a case of unsatisfactory slow scanning characteristics and satisfactory fast scanning characteristics, if the slow scanning characteristics are modified, fast scanning characteristics will deteriorate.
That is, if fast scanning direction characteristics are adjusted, slow scanning direction characteristics will also be affected thereby, and if slow scanning direction characteristics are adjusted, fast scanning direction characteristics will also be affected thereby. Therefore, it is difficult to satisfactorily adjust capabilities for both.
Accordingly, with the present embodiment, a surface form which does not feature characteristics that will affect fast scanning direction performance is applied to a surface for satisfying slow scanning direction characteristics (for example, as mentioned earlier, slow scanning direction image plane curvature correction and scanning line curvature correction in a case of sagittal offsetting), and a surface form which does not feature characteristics that will affect slow scanning direction performance is applied to a surface for satisfying fast scanning direction characteristics (linearity correction and fast scanning direction image plane curvature correction), which will be mentioned later. Thus, it is possible to implement pushing of performance of the lenses independently for the fast scanning direction and the slow scanning direction.
—Common f-θ Lens—
FIG. 5 shows a common f-θ lens of an optical scanning device relating to the present embodiment.
As shown in FIG. 5 , in the present embodiment, in the common f-θ lens 24 , if a surface of at which the laser beam 31 is incident is S 1 and a surface of from which the laser beam 31 is emitted is S 2 , the incidence surface S 1 is an anamorphic aspherical surface, and the emission surface S 2 is a y toric surface.
Now, in the emission surface S 2 which is a y toric surface, curvature in an x direction, that is, the slow scanning direction, is always constant, and the emission surface S 2 has a surface form which is made by rotating a form represented by z(y) mentioned below about a y axis.
That is, if
CUY is a fast scanning direction curvature at an optical axis origin,
K is a conic constant, and
A, B, C and D are higher-order coefficients in the y-axis direction,
then the emission surface S 2 of the common f-θ lens 24 is represented by the equation:
z
(
y
)
=
CUY
·
y
2
1
+
1
-
(
1
+
k
)
c
2
y
2
+
Ay
4
+
By
6
+
Cy
8
+
Dy
10
Furthermore, if
CUX is a slow scanning direction curvature at the optical axis origin,
CUY is the fast scanning direction curvature at the optical axis origin,
Kx is a conic constant in the slow scanning direction
Ky is a conic constant in the fast scanning direction
AR, BR, CR and DR are even-order coefficients of rotational symmetry,
AP, BP, CP and DP are odd-order coefficients of rotational symmetry, and
C 0 is a slow scanning direction radius of curvature at the optical axis origin,
then the incidence surface S 1 of the common f-θ lens 24 is represented by the equation:
z
=
CUX
·
x
2
+
CUY
·
y
2
1
+
1
-
(
1
+
kx
)
·
CUX
2
·
x
2
-
(
1
+
ky
)
·
CUY
2
·
y
2
+
AR
{
(
1
-
AP
)
x
2
+
(
1
+
AP
)
y
2
}
2
+
BR
{
(
1
-
BP
)
x
2
+
(
1
+
BP
)
y
2
}
3
+
CR
{
(
1
-
CP
)
x
2
+
(
1
+
CP
)
y
2
}
4
+
DR
{
(
1
-
DP
)
x
2
+
(
1
+
DP
)
y
2
}
5
—Individual f-θ Lens—
FIG. 6 shows an individual f-θ lens of an optical scanning device relating to the present embodiment.
As shown in FIG. 6 , in the present embodiment, in the individual f-θ lens 28 , if a surface at which the laser beam 31 is incident is S 1 and a surface from which the laser beam 31 is emitted is S 2 , the incidence surface S 1 is a y toric surface, and the emission surface S 2 is a surface which is made by linking circular arcs which have curvature radii R(y) determined for positions y in the fast scanning direction with a generatrix produced by x1(y) in the x-y plane serving as peak points. This emission surface S 2 is a surface at which the generatrix curves and the curvature in the slow scanning direction varies along the fast scanning direction.
The incidence surface S 1 of the individual f-θ lens 28 is defined by an equation the same as for the above-described emission surface S 2 of the common f-θ lens 24 .
On the other hand, the emission surface S 2 of the individual f-θ lens 28 is described by the equations:
(
x
-
x
1
(
y
)
)
2
+
(
z
-
R
(
y
)
)
2
=
R
(
y
)
2
x
1
(
y
)
=
x
0
+
∑
n
=
1
2
n
A
2
n
y
2
n
R
(
y
)
=
C
0
+
∑
n
=
1
2
n
B
2
n
y
2
n
C 0 is a slow scanning direction radius of curvature at the optical axis origin, B 2n , is a higher-order coefficient, with respect to a fast scanning direction, of a slow scanning direction radius of curvature, X 0 , A 2n each is a form of generatrix in a slow scanning direction.
C 0 , B 2n , X 0 , A 2n are handled as variables in designing. After the desired characteristics are obtained, these become constants which express surface form.
If the variables C 0 , B 2n , X 0 , A 2n , etc. used in these equations are altered, they will have no effect at all on fast scanning direction characteristics, as described below.
Because the surface form of the emission surface S 2 is prescribed as described above, situations in which slow scanning direction performance is affected when fast scanning direction characteristics are adjusted, or fast scanning direction performance is affected when slow scanning direction characteristics are adjusted can be prevented.
That is, a surface form which does not provide characteristics that will affect fast scanning direction performance is applied to a surface for satisfying slow scanning direction characteristics (for example, as mentioned earlier, slow scanning direction image plane curvature correction and scanning line curvature correction at a time of sagittal offsetting), which is to say the emission surface S 2 of the individual f-θ lens. Conversely, a surface form which does not provide characteristics that will affect slow scanning direction performance is applied to a surface for satisfying fast scanning direction characteristics (linearity correction and fast scanning direction image plane curvature correction). Thus, it is possible to implement pushing of capabilities of the lenses independently for the fast scanning direction and the slow scanning direction.
—Lens Characteristics—
FIGS. 7 to 11C show design performances of color registration characteristics and imaging characteristics of the optical scanning device relating to the present embodiment.
As shown in FIG. 3A , in the optical scanning device relating to the present embodiment, pairs of the individual f-θ lenses 28 with respectively different forms are used for the outer side two colors (the colors Y and K) and the inner side two colors (the colors M and C), and various characteristics principally differ between these two systems.
With a center in the fast scanning direction being 0, shapes of scanning lines of the laser beams 31 are shown in FIG. 7 and linearities (magnification shifts) are shown in FIG. 8 .
As shown in FIG. 7 , the shapes of the laser beams 31 are substantially flat for both the outer side two colors (the colors Y and K) and the inner side two colors (the colors M and C), and offset between scanning lines of those colors over the whole of a scanning region is kept to below a few μm. With regard to inclinations of the scanning lines, the scanning lines of the respective colors can be made to respectively coincide by rotation adjustment of the individual lenses in a plane which is perpendicular to the optical axes.
As shown in FIG. 8 , there are substantially no differences in magnification variation characteristics between the outer side two colors (the colors Y and K) and the inner side two colors (the colors M and C), and these can similarly be kept to below a few microns over the whole of the scanning region.
FIG. 9 shows an image plane curvature characteristic with the center in the fast scanning direction being 0.
As shown in FIG. 9 , defocus values for all the colors are kept to within 1.0 mm peak-to-peak, and the image plane curvature characteristic is excellently corrected.
Accordingly, in order to adjust characteristics in a sagittal direction while maintaining characteristics in a meridional direction, a structure of the present embodiment is used, that is, a surface form which does not feature characteristics that will affect fast scanning direction performance is applied to a surface for satisfying slow scanning direction characteristics (for example, correction of beam diameter in the sagittal direction). Thus, it is possible to correct an image plane curvature characteristic without unpreferably affecting characteristics in the meridional direction.
For example, as shown in FIGS. 10A to 10C , the variable C 0 of the S 2 surface of the individual f-θ lens 28 relating to the present embodiment, that is, the slow scanning direction radius of curvature at the optical axis origin, is altered by −5% to +5%, and fast scanning direction characteristics (linearities and fast scanning image planes) and slow scanning direction image plane positions are compared for these cases. Here, even though slow scanning direction image plane position is shifted as shown in FIG. 10C , the fast scanning direction characteristics hardly change at all, as shown in FIGS. 10A and 10B . Thus, it is possible to move slow scanning direction image plane position without affecting fast scanning characteristics.
Alternatively, as shown in FIGS. 11A to 11C , the variable A 2 of the S 2 surface of the individual f-θ lens 28 relating to the present embodiment, that is, a coefficient which determines the form of the generatrix, is altered by −5% to +5%, and fast scanning direction characteristics (linearities and fast scanning image planes) and scanning line forms are compared for these cases. Here, even though the scanning line form is changed as shown in FIG. 11C , the fast scanning direction characteristics hardly change at all, as shown in FIGS. 11A and 11B . Thus, it is possible to adjust the scanning line form without affecting fast scanning characteristics.
—Concluding Remarks—
In the present embodiment as described above, a surface form which does not feature characteristics that will affect fast scanning direction performance is applied to a surface for satisfying slow scanning direction characteristics (for example, slow scanning direction image plane curvature correction and scanning line curvature correction in a case of sagittal offsetting), and a surface form which does not feature characteristics that will affect slow scanning direction performance is applied to a surface for satisfying fast scanning direction characteristics (linearity correction and fast scanning direction image plane curvature correction). Therefore, it is possible to adjust characteristics of the lenses independently for the fast scanning direction and the slow scanning direction, and to pursue optical performance.
—Other Remarks—
An exemplary embodiment of the present invention has been described hereabove, but the present invention is not in any way limited to the example described above, and obviously various embodiments are possible within a scope not departing from the spirit of the present invention.
That is, although the present exemplary embodiment is applied to a tandem-type full-color image formation apparatus, this is not a limitation. Obviously, for example, single-color monochrome image formation apparatus, image formation apparatus of three colors or less, and the like may also be used.
|
An optical scanning device includes: a light source; a first optical element that converts light emitted from the light source to parallel light; a deflection element that deflects the light in a fast scanning direction to scan a surface of an object to be scanned with the light at a constant speed; a second optical element that guides the light to the deflection element; and a third optical element that focuses the light deflected by the deflection element onto the surface of the object to be scanned, at least one surface among surfaces of the third optical element that intersect the light including a surface form which affects only one of fast scanning direction characteristics or slow scanning direction characteristics at an image plane.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The invention relates, in general, to the drilling of wells. More specifically, the invention relates to the spinning together and apart segments of drill pipe such as are used in the drilling of oil and water wells.
2. Related Art.
The drilling of deep holes requires the attachment of many segments of pipe in series. These connections may conventionally be made by threading the male end at the bottom of one pipe into the female end of another. These holes are lengthened as additional pipe lengths are successively added to the drill string in this manner. To remove the drill string, this process is reversed. The present invention offers a device that makes the formation and removal of such strings easier, safer, and quicker.
A number of inventions have attended to the desire for a simple and useful machine for spinning drill pipe. These devices employ a number of different mechanisms for retaining and spinning lengths of pipe.
Rauch, U.S. Pat. No. 6,065,372, offers a power wrench for spinning drill pipe in which the subject pipe length is pressed firmly against two serrated rollers by an idler roller that is actuated by an air ram. The serrated rollers, driven by means of drive chains and a single hydraulic motor, impart spin to the pipe.
Rae, U.S. Pat. No. 5,660,087, discloses a pipe spinner in which a multiplicity of symmetrically located rollers engage and rotate drill pipe sections which are held in place under the force of a piston rod that extends via a bell crank to clamp the pipe.
Brooks, U.S. Pat. No. 4,381,685, provides a power wrench in which a single motor drives a single serrated drum designed to engage and spin the subject pipe segment. The pipe is pressed into firm contact with the serrated surface of the drum using a C-shaped clamp.
Hudson, U.S. Pat. No. 4,221,269, describes a power wrench in which a drill pipe length is received between three urethane-coated rollers that are driven by three rotary hydraulic motors to spin the pipe.
Bartos, U.S. Pat. No. 3,392,609, presents a drill pipe spinning apparatus in which a drill pipe is engaged and rotated by two sets of rollers situated one above the other. Other power wrenches for drill pipe are presented in other patents. However, none of these employ the specific configuration or realize the intrinsic advantages of the present invention.
SUMMARY OF THE INVENTION
The present invention is a device for spinning together and breaking apart the joints of drill strings used in well construction. The invention makes these processes safer, quicker, and more convenient for well drillers.
The invention comprises a wrench system that meets requirements for handling operations involving larger drilling pipes or rods, including casings, preferably 6 to 16 inches in diameter. The preferred components of the wrench include: two (2) pairs of serrated power rollers for gripping the pipe, two (2) hydraulic motors used in conjunction with two (2) pairs of drive chains and double sprockets for spinning the serrated rollers, an adjustment mechanism for the wrench to fit various size pipes, and an attachment means for moveably securing the apparatus to a drill rig. The preferred embodiment also includes a system for minimizing the operational risks associated with using the tool.
The apparatus is designed to hang, by wire cable or other suitable means, from the mast of any established drill rig and is easily positioned manually by the operator. The preferred supporting elements, which are typically available on drill rigs, include hydraulic power to run the motors and compressed air to drive the air rams. The invention preferably includes a safety feature comprising a simple switch or other suitable control means. When in the “off” position, the switch prevents the moving parts from engaging, thereby minimizing the risk of injury to machine operators.
Operation of the wrench requires first manually positioning the device's pair of arms about the subject pipe segment and securing the segment between the pairs of serrated rollers. The arms are first manually adjusted to accommodate the approximate outer diameter of the subject pipe length, and secondly the actuation of two air rams closes the arms tightly upon the pipe segment. With the pipe length gripped tightly, the two hydraulic motors spin the rollers to impart spin to the pipe. The motors continue to drive the rollers until the threaded male end of one pipe is securely seated within, or removed from, the female end of another.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the invented power wrench with the chain guard removed for clarity.
FIG. 2 is a top view of the power wrench depicted in FIG. 1 , but with the chain guards installed, and with a large pipe engaged for spinning.
FIG. 3 is a top view of the power wrench depicted in FIG. 2 , but with a smaller pipe engaged.
FIG. 4 is a partial, side crossectional view along lines 4 — 4 of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures, several views of the invented power wrench 10 are presented. The majority of the preferred components are shown and numbered in all figures and, for illustrative purposes, a pipe length in position for spinning is included in FIGS. 2 and 3 . To simplify the description, the components will be separated into two functional systems: the drive assembly and the engagement assembly.
The structural base for both systems is comprised of a T-shaped frame 12 and two engaging arms 14 and 14 ′. The frame 12 and engaging arms are shown in top view in FIGS. 1-3 . The engaging arms 14 and 14 ′ are constructed of a top and bottom cheek plate, 16 and 16 ′, respectively with attendant bolts and spacers as shown in FIG. 4 . The cheek plates 16 and 16 ′ are moveably mounted to the frame 12 such that the wings 18 of the frame are positioned between the top and bottom cheek plate, as shown in FIG. 4 . These components are preferably constructed of ⅜″ T-1 steel plate, although those skilled in the art may substitute possible alternatives. The configuration of the arms and frame, such as the placement of axle holes and spacers, may vary to the extent that adjustment of the performance of the essential functions of each is still possible.
The drive assembly preferably includes two hydraulic motors 20 and 20 ′, one on each engaging arm. The motors are situated beneath the operating parts and are protected by motor guards 22 and 22 ′, respectively, as shown in FIGS. 2 and 3 . Each motor will drive a pair of drive chains 24 connected to a double sprocket assembly 25 . The double sprocket assembly 25 preferably comprises an upper and lower toothed sprocket portion arranged co-axially on the motor-driven axle. The double sprocket drives two endless chain drives. At the end of each drive chain, opposite the double sprocket, are upper and lower roller sprockets 26 and 26 ′, respectively. These roller sprockets are preferably situated at or near the top of the upper and lower roller axles such that the upper roller sprocket lies in the same plane as the upper double sprocket and the lower roller sprocket lies in the same plane as the lower double sprocket. The upper and lower roller double sprockets rotate the upper and lower drive chains, respectively. Other arrangements are possible where the desired interaction between the roller sprockets and the double sprocket is accomplished. The preferred configuration incorporates 14 toothed sprockets with taper lock and number 50 chain drives with ⅝″ pitch. The roller axles extend through the top and bottom cheek plates and the ends are secured to the appropriate plate by means of a sealed ball bearing or other suitable connection. Rotation of the roller sprockets drives the distal and proximal rollers, 28 and 28 ′, respectively, which engage and spin the subject pipe length.
The serrated distal and proximal rollers are configured co-axially with the upper and lower roller sprockets. When engaged, the serrated surface grips the outer surface of the received pipe length to impart spin to the pipe. The toothed surface significantly enhances the frictional contact between the rollers and the drill pipe. The rollers in the preferred embodiment are approximately 5″ in diameter and 3″ wide. To initiate spinning, the hydraulic motors are started slowly once the subject pipe length is clamped tightly between the two pairs of serrated rollers situated at the forward end of the engaging arms and surrounding the pipe-receiving space, as shown in FIGS. 2 and 3 .
Sufficient engagement of the drill pipe to the power rollers is accomplished by closing the engaging arms 14 and 14 ′ tightly upon the pipe segment. The engaging arms of the preferred embodiment may be adjusted in two ways. Adjustment of the swivel pins 30 and 30 ′ permits abduction and adduction of the engaging arms along the frame to make large adjustments. The swivel pins 30 and 30 ′ may be secured in various positions along the wings of the frame to increase or decrease the pipe-receiving space as desired. Small adjustments, such as those required to fully clamp the pipe within the pairs of rollers, are accomplished via two compressed air rams 32 and 32 ′ that can be driven in or out. As shown in FIGS. 1-3 , the air rams 32 and 32 ′ are attached at their distal ends to the back end of the engaging arms, opposite the rollers, and one attached at their proximal ends to frame 12 . This way, upon actuation, the air ram 32 and 32 ′ generate a pivoting motion about the swivel pins. Extension of the air rams tightens the arms upon the pipe, and retraction of the rams releases the drill pipe segment. The engaging arms 14 and 14 ′ are driven uniformly by the air rams to ensure that the drill rod segment contacts both sets of rollers equally and aligns with the center of the receiving space.
The invented system allows the drill pipe segment to be clamped between the engaging arms in firm contact with the serrated rollers. The pipe length may then be spun into, or out of, proper engagement with another pipe length to install or remove long drill strings. The mechanisms involved with engagement and driving of the invented power wrench are both simple and reliable.
For use, the power wrench is typically suspended by a wire cable, or other suitable connection, from a point at or near the top of a drill rig mast. In one embodiment, a cable 34 is connected to the two eyelets 36 and 36 ′ on the power wrench at a height appropriate for manual operation of the tool. The eyelets 36 ans 36 ′ are positioned such that the cable 34 connected from one eyelet to the other intersects the center of gravity of the wrench. With the tool connected, secured, and suspended from the cable in this manner, the machine operator may easily grasp the balanced wrench by a pair of handles and position it near the subject drill pipe or move it to an out of the way place.
The wrench requires the use of a bracing mechanism when operational to counteract the reactionary spinning forces imparted to the device by the drill string. A stop bar (not shown) is employed to brace the power wrench against an available, stable structure such as a mast post. The wrench must be started slowly to allow the stop bar to position itself securely against the mast or other structure.
To initiate operation of the tool, the safety mechanism must first be inactivated. This mechanism prevents unintentional activation of the machine due to accidental contact with the control levers. The safety comprises a means of locking the compressed air control lever in an inactivated state that prohibits movement of the lever without first intentionally releasing the lever. When locked in place, the safety prohibits the arms from engaging. This allows operators and laborers to work safely around the device with minimal risk of accidental injury. When the mechanism is released the arms are free to close upon the subject drill rod. The safety is positioned so that it is easily within the reach of the operator.
To engage, the operator moves the wrench such that the arms surround, and possibly contact, the subject drill rod and the air rams are then actuated to clamp the rod firmly between the pairs of rollers. With the arms engaged, the rollers are turned by the hydraulic motors until the spinning procedure is satisfactorily completed, i.e., until the male end of one rod is tightly seated within, or removed from, the female end of another.
Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the scope of the above description, included drawings and the following claims.
|
An adjustable power wrench is provided for spinning together, and apart, sections of pipe used in long drill strings such as are typically seen in water well and oil drilling. The wrench is preferably designed for use with large diameter drill pipes or rods, including casings. Two sturdy engaging arms, each containing a pair of serrated power rollers driven by a hydraulic motor, are manually positioned about the subject pipe length. The arms are closed about the pipe by two air rams, one for each engaging arm, to engage the serrated rollers and impart spin to the pipe. The apparatus is preferably supported by wire cable in a balanced fashion from the mast of an available drill rig.
| 4
|
This is a division of application Ser. No. 178,546, filed 4/7/88 and now U.S. Pat. No. 4,861,874.
BACKGROUND OF THE INVENTION
The invention relates to the lowering of the number of carbamate groups in products made of cellulose carbamate. As is well known, cellulose carbamate is a compound formed when cellulose is heated at elevated temperature in the presence of urea. Cellulose carbamate is an alkali-soluble compound, and this permits it to be converted into the shape of various products by preparing an alkaline solution thereof and then precipitating the products from the solution in desired form, for example, as fibers, films, spongy products, etc.
One of the factors which influences the properties of cellulose carbamate products, and consequently the use thereof, is the carbamate content, that is the number of carbamate groups in the cellulose chains. It is known that carbamate groups to a certain extent increases the sensitivity of the products to water and as a consequence has an effect on the wet strength of the products.
It is possible by reducing the number of carbamate groups to influence the wet strength properties of the products to a desired degree. U.S. Pat. No. 4,583,984 discloses a process for lowering the quantity of carbamate groups by treating the products with alkali solutions. This procedure in principle makes it possible to completely eliminate the carbamate groups, whereby products consisting of regenerated cellulose are obtained.
It has been found, however, that the lowering of the quantity of carbamate groups with the aid of alkali has an adverse effect on certain strength characteristics, particularly in the case of industrial scale wherein maximum fast and efficient removal of carbamate groups is aimed at, for example, using concentrated alkali solutions or high treatment temperatures.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide a process for the lowering of the carbamate content of products made from cellulose carbamate without incurring the above mentioned drawbacks.
It is another object of the present invention to provide products made of cellulose carbamate with the carbamate content thereof reduced in accordance with the process of the invention.
Other objects and advantages of the present invention will be apparent from a reading of the specification and of the appended claims.
With the above and other objects in view, the present invention mainly comprises the lowering of the carbamate content of products made of cellulose carbomate by treating such products with solutions of a base which contain one or several alkali metal salts, particularly alkali metal carbonates, sulfates, phosphates, borates and acetates.
The base used in the process of the invention should be a strong inorganic or organic base. From the standpoint of price and efficiency of treatment, the inorganic bases are preferred, namely alkali metal hydroxides, particularly sodium hydroxide. The preferred solvent is water. The preferred organic base is tetramethylammonium hydroxide. The concentration of the base is preferably in the range of 0.5 to 5% by weight.
The alkali metal salts used according to the present invention are those which are highly soluble in basic solutions. Among the salts are the carbonates, sulfates, phophates, borates and acetates of the alkali metals. The preferred alkali metal is sodium.
Consequently, the preferred salts according to the present invention are one or more of the salts: sodium carbonate, sodium sulfate, sodium borate and sodium acetate. The preferred quantity of the salt is 5-35% by weight. This quantity refers to the quantity of dry salt. The quantities may be correspondingly increased when the salts contain water of crystallization.
The treatment according to the present invention is preferably performed at elevated temperatures, of from room temperature to 120° C. When low temperatures are employed, there is a risk that the treatment time will become too long, although lower temperatures can be used. However, in the case of an industrial process, the treatment time should not be long and the high reaction speed is therefore aimed at by elevating the reaction temperature and/or using a concentrated base solution. The most suitable treatment temperature is between about 80°-100° C. and the treatment time at this temperature may be five seconds to ten minutes.
The treatment is conveniently carried out by immersing the product to be treated, for the desired time, at the desired temperature, in the treatment solution. The products to be treated may be in any conceiveable form. From the standpoint of industrial efficiency, it is preferred that the product be in the form of a continuous product which is passed through the treatment solution at such speed that the product will be in contact with the solution for the desired time.
Subsequent to the treatment, the product is washed, for example, with water. The washing water may contain a small amount of acid in order to eliminate any base that may have remained in the product. A suitable acid for this purpose is acetic acid. The products are then dried in normal manner.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples are given to illustrate the present invention. The scope of the invention is not, however, meant to be limited to the specific details of the examples.
In these examples, the amount of carbamate groups was characterized by means of the nitrogen content as measured by means of the so called Kjeldahl method. The method has been described, e.g., in: Snell-Hilton, Encyclopedia of Industrial Chemical Analysis, Interscience Publishers, New York, 1968, Vol. 2, p. 530.
EXAMPLE 1
Cellulose carbamate fibers were prepared by impregnating bleached sulfite cellulose with urea. Impregnation was accomplished by immersing the cellulose in liquid ammonia containing 16% urea and 20% water. Upon impregnation the cellulose was dried at room temperature to remove the ammonia, and thereafter at 100° C. to remove the water. The dry, impregnated cellulose was heated at 140° C. during 3 hrs., whereby it was converted to cellulose carbamate, which had, after washing with water, a nitrogen content of 3.4%, calculated on the dry matter.
This cellulose carbamate was activated by soaking it in water for one hour, followed by NaOH addition and dissolving of the cellulose carbamate products, with agitation at -5° C., during one hour. The solution thus obtained was yellowish, and clear. It was filtered and deaerated by vacuum treatment. The solution thus obtained was spun with a miniature spinning machine through a nozzle piece with 300 holes of 50 μm diameter, into a precipitation bath containing 8% sulphuric acid and 20% Na 2 SO 4 .
The cellulose carbamate sheets thus obtained were treated with an aqueous solution containing 2% by weight sodium hydroxide and 10% by weight sodium carbonate. The treatment was carried out by immersing the fibers at 90° C. in the treatment solution, in which they were kept for treatment periods of different lengths. After treatment, the fibers were washed with water containing some acetic acid.
The characteristics of the fibers used for starting material and of those which were obtained are set forth in Table 1.
TABLE I______________________________________ Treatment time, sCharacteristic 0 30 60 120______________________________________Nitrogen content, % 2.3 1.20 0.81 0.41dtex 1.1 2.12 2.08 2.02Tensile strength when dry, cN/dtex 2.43 2.33 2.46 2.35Breaking elongation, % 8.6 14.9 14.7 14.2Loop strength, cN/dtex 0.31 0.45 0.42 0.44______________________________________
EXAMPLE 2
As in Example 1, cellulose carbamate fibers were produced, and treated with an aqueous solution containing 2% by weight sodium hydroxide and 20% by weight sodium carbonate. The treatment was carried out at 90° C., using various treatment times. After treatment, the fibers were washed with water containing acetic acid, and dried.
The characteristics of the fibers thus obtained are set forth in Table 2.
TABLE 2______________________________________ Treatment time, sCharacteristic 0 30 60 120______________________________________Nitrogen content, % 2.08 0.91 0.47 0.32dtex 1.53 1.59 1.58 1.54Tensile strength when dry, cN/dtex 2.30 2.52 2.39 2.44Breaking elongation, % 9.2 11.4 11.9 11.4Loop strength, cN/dtex 0.36 0.39 0.39 0.40______________________________________
EXAMPLE 3
As in Example 1, cellulose carbamate fibers were produced, and treated with an aqueous solution containing 4% by weight sodium hydroxide and 20% by weight sodium carbonate. The treatment was carried out at 100° C., using various treatment times. After treatment, the fibers were washed with water containing acetic acid.
The characteristics of the fibers thus obtained are set forth in Table 4.
TABLE 4______________________________________ Treatment time, sCharacteristic 0 30 60 120______________________________________Nitrogen content, % 3.03 0.56 0.41 0.26dtex 1.60 1.79 1.81 1.76Tensile strength when dry, cN/dtex 2.59 2.40 2.49 2.43Breaking elongation, % 8.6 16.5 15.8 16.4Loop strength, cN/dtex 0.29 0.57 0.655 0.64______________________________________
EXAMPLE 5
As in Example 1, cellulose carbamate fibers were produced, and treated with an aqueous solution containing 4% by weight sodium hydroxide and 26% by weight sodium sulfate. The treatment was carried out at 100° C., using various treatment times. After treatment, the fibers were washed with water containing acetic acid, and dried.
The characteristics of the fibers thus obtained are set forth in Table 5.
TABLE 5______________________________________ Treatment time, sCharacteristic 0 30 60______________________________________Nitrogen content, % 3.03 0.58 0.40dtex 1.60 1.77 1.70Tensile strength when dry, cN/dtex 2.59 2.33 2.47Breaking elongation, % 8.3 16.1 14.6Loop strength, cN/dtex 0.29 0.63 0.49______________________________________
COMPARISON EXAMPLE 1
As in Example 1, cellulose carbamate fibers were produced, and treated with a 2% by weight aqueous solution of sodium hydroxide. The treatment was carried out at 100° C., using various treatement time. After treatment, the fibers were washed as in Example 1.
The characteristics of the fibers thus obtained are set forth in Table 6.
TABLE 6______________________________________ Treatment time, sCharacteristic 0 30 60 120______________________________________Nitrogen content, % 2.31 0.89 0.59 0.34dtex 2.15 2.33 2.41 2.26Tensile strength when dry, cN/dtex 2.28 1.74 1.72 1.95Breaking elongation, % 10.4 23.9 25.3 20.6______________________________________
CAMPARISON EXAMPLE 2
Comparison Example 1 was repeated, using the treatment temperature 90° C. The results are presented in Table 7.
TABLE 7______________________________________ Treatment, sCharacteristic 0 30 60 120______________________________________Nitrogen content, % 2.22 1.18 0.79 0.45dtex 2.07 2.39 2.39 2.35Tensile strength when dry, cN/dtex 2.36 1.74 1.75 1.88Breaking elongation, % 8.6 24.2 24.8 27.4______________________________________
Comparison Examples 1 and 2 reveal that when cellulose carbamate fibers are treated with a basic solution which does not contain soluble alkali metal salts as in Examples 1-5, the strength of the product is impaired and the elongation considerably increased.
While the invention has been set forth with respect to specific treatment solutions, it is apparent that variations and modifications can be made without departing from the spirit or scope of the invention.
|
The carbamate content of cellulose carbamate products is reduced by treating such products with solutions of a base, which solution also contains one or several alkali metal salts, particularly carbonates, sulfates, phosphates, borates and acetates.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device and a process for signal analysis. The signals can be of general form and can be present especially as one-dimensional, particularly time signals. Signals of this type in the area of engineering are derived for example from noise signals, as are caused by running machinery. Another example from the area of engineering is signals which represent a regular machine state, or which are characteristics of a brief or continuing defect. These defects can relate to the machinery itself, or a product produced by this machinery.
2. Description of Related Art
The numerous and varied signal analysis processes of type to which this invention is directed are known. If the ratio between a signal portion of interest and a noise portion is large enough, analysis is usually less difficult. But, it is of special interest and considerable difficulty to extract those signal portions which are strongly adulterated by noise. Likewise, it is of special interest to identify individual signals or those which occur only briefly or sporadically and possibly stochastically when a host of other signals is present at the same time.
For example, it is known that it is extremely difficult to identify bearing noise in a machine when the signal/noise ratio becomes less than a value of roughly 0.25 (compare British Journ. of NDT, Vol. 35 No. 10, p. 574 ft). The use of conventional Fourier analyses has almost no effect in this case.
Furthermore, a device for detecting or analyzing machinery damage of a type to which this invention is also directed, especially for detection of errors on roller bearings, is known from U.S. Pat. No. 3,842,663. This patent explains a standard problem which occurs when machinery or bearing damage is detected. This is based on the fact that the noise periodically emitted by bearing defects or other defective hardware parts is much smaller than regular noise which is produced by this machinery and may be present as solid-borne noise.
The approach presented in U.S. Pat. No. 3,842,663 is based on acquiring machinery noise, such as for example transmission or bearing noise, by means of a suitable detector and converting it into an electrical signal. In this case, the damaged bearing or machine parts produce pulse-like noise portions which preferably excite the natural resonances of this detector. Its electrical output signal is processed by a pre-filter and a demodulator. The resulting signal then corresponds essentially to a pulse series. In this pulse series, an individual pulse represents an individual noise caused by sudden motion components.
In periodically repeated pulses of this type, it is possible to determine an especially pronounced or emerging signal frequency with an output-connected spectral analyzer. This frequency, at a known base frequency of the machinery or certain rpm and characteristics of a bearing, allows a conclusion regarding a defect within the machine or bearing.
U.S. Pat. No. 5,679,900 describes how the aforementioned device can be used by using a switchable filter in a paper-making machine. This document also considers that the machinery defects can be characterized by pulse-like vibration portions compared to regular machinery noise, and that they can be emphasized by suitable vibration sensors and by suitable signal processing against the base noise of the machinery and mechanical assemblies.
But, the described devices and processes are subject to the disadvantage that efficient, and thus expensive, spectral analyzers must be provided for reliable representation of the results obtained or additional complex filter units must be connected on the input side.
In addition, the pulse like vibration portions tend to be characterized by significant amplitude, but of rather little energy content. This is because of their short duration. In terms of energy, such pulse-like vibration portions are likely to be “buried” in background noise and thus difficult to impossible to find.
SUMMARY OF THE INVENTION
The primary object of the invention is to improve the quality of analysis results and to significantly reduce the required effort for detecting machine damage, especially bearing damage, by cost-favorable electronic circuitry or data processing.
Another object of the invention is to make available a device and process for improved signal analysis which is especially suitable for detection of an early stage of incipient bearing or machinery damage.
It is also the object of the invention to devise a device and process by which improved, more effective analysis or detection is possible for recognition of those signal portions which are characterized by only a brief presence in time, i.e., transient signal effects. The process in accordance with the invention can, moreover, be used, for example, for detection of very noisy signals.
The invention is based on the finding that a sampled time signal usually present in digitized form can be interpreted as an ordered set of individual events with an inner correlation which is initially unknown. The invention is furthermore based on the finding that the results of conventional, known correlation analyses can be supplemented and improved by abandoning the practice of combining with one another of sections of these signals which are shifted relative to one another in time. Rather, in accordance with the invention, each individual event (according to the definition above) of a signal to be examined is combined at least once with one or more other individual events, which are separated from each other by a time difference. Then, the results of the individual combinations are sent for classification. In particular, it is of interest according to the invention to provide for classification purposes one such combination in the manner of a distribution which has been formed by summation. The x-axis of this distribution is preferably arranged by time classes. The individual time classes correspond to the time differences so that the results of the individual combinations can be fitted into the distribution using the underlying time differences. It is advantageous for combination of the events to perform multiplications each time. However, for this purpose, other binary logic operations can be used, for example, summation or determining a maximum.
According to one preferred approach of the invention, it is provided that each event be combined with all its predecessors or with those predecessors which are located in its immediate vicinity. According to another approach of the invention, it is provided that each event be combined with any other and the results of the combination likewise be sent for classification.
According to still another implementation of the invention, it is provided that events of predefined “quality” (i.e. having predefined characteristics) be preselected for constituting a “filtered” signal, consisting of such specific events which then are to be combined with any other, and the results of the combination be sent for classification in a comparable way.
In accordance with the invention, the classification results obtained by a distribution analysis can be evaluated either directly or can be sent for additional analysis. Here, it is especially useful to normalize those extreme values of a resulting frequency distribution by a mapping rule which can be interpreted to relate to an integral multiple of a time difference between two predetermined extreme values. One such extreme value, therefore, belongs to a time class of the distribution which is characterized by a smaller (difference) time value than the time classes of the integral multiple of the first extreme value.
In the direct evaluation of the resulting classification result (i.e. classification function), it can be enough to check the function values of individual time classes with reference to a predefined threshold value. Another direct evaluation involves, for example, checking the observed extreme values, especially maximum values, of a resulting distribution. According to the present invention, the result of these comparisons then yields the desired conclusion, whether repetitively occurring signal portions of a “noisy” signal can be considered detected or not.
In an additional type of evaluation according to the invention, a resulting distribution can be transformed, for example, by means of a Fourier transform, from the time domain into the frequency domain. In this way, it is possible to acquire an idea of whether and which values of a resulting frequency distribution are present as time-multiples, roughly in the manner of a so-called “cepstrum” analysis.
In special embodiments, the inventive device is characterized by the following partially optional features:
There is a sensor for acquiring machinery noise and for conversion into an electrical signal, and preferably, an analog or digital rectifier for forming the absolute value of the electrical signal.
The device determines, from a signal caused by the machinery noise, special results which are defined in terms of time and intensity.
The device has one, preferably two or more, peak value detectors with different recovery times or decay time constants.
The device has one or more time analyzers for analysis of the output signals of the peak value detectors. In this case, the time analyzers can determine the respective instants of intermediate maximum or minimum values of the electrical signal as time events. The respective time points together with the pertinent signal amplitudes can be stored in a buffer.
The device can form product values from stipulated signal amplitudes of selected time points and can perform frequency analysis.
The device can execute the indicated frequency analysis by time classes which can be essentially freely selected according to predetermined assessment criteria.
The device can undertake frequency analysis using a weighted distribution.
In the execution of frequency analysis for evaluation of a machine or bearing state, the device uses only those events which have a sufficient or significant difference from a noise level.
The device is equipped with a unit for acquisition and proportional subtraction of those functional values which correspond to a multiple of a base time value.
The device is equipped with an evaluation unit by which a frequency measure which belongs to a base time value is evaluated in that whether, what type, and to what extent there is machinery or bearing damage.
The device is equipped with a registration unit with which predefined time values and base time values can be stored over a longer time interval so that at a later time measured in weeks or months, analysis can be performed and a display of the degree of damage for a bearing or for a machine component is possible over greater time intervals.
The device has means with which it is possible to use two or more events of a signal which follow one another directly in time to prepare and store a product or a product sum for the intensities of these events. The products or product sums can be supplied for frequency analysis and subsequent evaluation.
The device has means with which it is possible that relatively large time differences for events can be assumed and processed. The time differences are at least as great as corresponds to a maximum expected repetition time for an event which can be assigned to a special type of damage.
The device can have threshold detectors with decay time constants which agree in terms of order of magnitude with the repetition times or period durations of the effects of the machinery damage or defects to be examined.
The device has means with which a resulting event value is produced by a logic operation from two event intensities at a time (specially defined intensities of the electrical signal) and the logic operation is effected by product formation, by summing, by determining a maximum value or by another relation.
The device can have a means for digital or analog preprocessing of the signal, for rectification or for absolute-value generation of a signal.
The device can have a means for identifying the intermediate extreme values (maximum or minimum values) of the signal. Using such means, an event can be classified according to the instant of its occurrence and its intensity.
For these reasons, the device advantageously has one or more peak value detectors, each of which is characterized by a defined recovery time or decay time constant.
The device has a means for forming and evaluating several frequency distributions in a multiplicity of damage duration categories.
The device can have a selection stage which provides for an event defined in time, triggering or influencing only that peak value detector which is characterized by the time constant which is the largest at the time.
The above described or additional features of the invention can be formulated alternatively or optionally as follows:
The device for detecting or analyzing machinery damage is especially suited for detecting repeated, pulse-like portions of a time-variant signal and especially for recognizing machinery noise which is caused by roller bearing damage, and the device has the following components:
a sensor, especially in the form of an acceleration sensor, for acquiring and converting the time-variant signal into an electrical AC signal,
especially at least one filter stage and one signal conversion stage for producing positive definite signal portions, i.e., no negative values result.
at least one peak value detector stage with preset discharge time constant for detecting the time occurrence of individual relative extreme values (maximum values or minimum values) of the AC signal,
a storage unit which stores the times and the intensity (amplitude) of the recognized individual relative extreme values over a predetermined time window (observation interval),
a computer which can multiplicatively combine the recognized individual relative extreme values, i.e. their assigned intensities, so that corresponding product values are produced,
a classification unit for processing of product values which can compute and store at least one distribution (histogram),
furthermore, a pattern recognition unit for analysis of at least one distribution according to preset criteria, especially according to predefined absolute frequency values.
The device can have one or more additional reference signal generators for generating sawtooth reference signals with a steep rise and comparatively slow fall; furthermore, one or more trigger stages for repetitive triggering of the reference signal generators.
The device can have a signal analysis stage in which sampled, time-discrete signals are used to trigger one or more of the trigger stages. These signals can then be compared to the sawtooth reference signals.
The device is able to store different special samples according to their respective instants of occurrence and pertinent signal intensities (amplitude). Furthermore, it has a computer for forming arithmetic products, a classification unit for forming one or more histograms and a pattern recognition unit for classification of histograms according to predetermined criteria.
The device has an analysis unit by which a large number of events can be determined and a large number of logic operations can be sent for histogram analysis until an output by the analysis unit or an evaluation unit according to stipulated statistical criteria can be regarded as being steady-state or statistically relevant.
The device is equipped with one or more comparison stages for checking that stipulated boundary values have—alternatively—been exceeded, have not been reached, or are identical; and the device can have, in particular, a signaling stage. The signaling stage is used for signaling if preset boundary values, filed in the form of histogram values, have been exceeded.
The device can have a digital computer with which time events are determined and with which the data of these events are further processed.
The invention is also based on the finding that the time length of the signals which occur in pulses on the machinery or bearings and which are caused, for example, due to defects or deformation of bearing parts is generally rather short. For this reason, their determination by means of a Fourier transform is difficult due to the other noise components present on a bearing or a machine.
Therefore, according to the invention, it is more advantageous to identify the fraction of pulse-like signal portions per individual event. With these individually determined events, it is then easier to identify the parameters of their occurrence in time. With the data obtained in this way, underlying causes can also be determined in an early stage of damage of machinery or bearings, especially in roller bearings.
However, it is generally not enough to check an individual frequency of the noise spectrum. Rather, e.g. for roller bearings one has to check at least four (4) basic separate frequencies which could indicate damage. These frequencies are referenced, for example, to the dimensions of the inner ring, the outer ring, the rollers and the cage of a roller bearing. Since these frequencies can occur in any combinations, the teaching of U.S. Pat. No. 3,824,663 is only of limited benefit.
With the object of identifying the individual pulse-like noise portions of a faulty machine or bearing, in accordance with the invention, it is provided that these noise portions be analyzed by means of detection for intermediate maximum and minimum values of the acquired and filtered noise signal without the need for a more complex frequency analysis unit, such as a FFT analyzer. One approach according to the invention is to provide one or more peak value detectors which study a prefiltered signal, after its rectification or absolute value generation, for conspicuous time points and the pertinent signal intensities.
Here, it is very advantageous for the individual peak value detectors to have different decay times. In this way, pulse-like noise events, hereinafter simply called events, can be better studied and identified both in different time-scale domains and also in different intensity ranges. According to the invention, it is especially advantageous to study, not individual events and their assigned formation times, but the combination of at least two events which are adjacent in time or apart in time. The combination of at least two events is preferably undertaken such that a multiplicative combination of the two intensity values of the respective events is performed. The statistics to be determined for the product values formed in this way and the pertinent time differences allow conclusions to be drawn about the composition of the repetition times involved, and thus, the nature of underlying machine damage or roller bearing damage. Under certain circumstances, it is enough to study a correspondingly formed frequency distribution or the statistics of the event products over assigned difference times to ascertain whether predefined time domains which can be assigned to one of the aforementioned roller bearing damage frequencies exceed a stipulated threshold or not.
In the invention, it is assumed that it is generally enough to analyze a time interval which comprises only a few to a few hundred seconds. The signals belonging to this time interval can be digitized and stored in a digital memory. Furthermore, in accordance with the invention, it is assumed that a plurality of the described means, functions and processes can be executed not only with analog electronic means, but alternatively or additionally with digital ones, i.e. computer-based. The latter approach then uses the corresponding software for analogous implementation of the means, functions and relationships provided in accordance with the invention.
These and further objects, features and advantages of the present invention will become apparent from the following description when taken in connection with the accompanying drawings which, for purposes of illustration only, show several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a time signal with discrete, positively definite sample values;
FIG. 2 is a graph of a distribution of the results of logic operations, based on a plurality of sample values;
FIG. 3 is a block diagram of a preferred embodiment of the invention; and
FIG. 4 is a pulse diagram for explanation of the process in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The time signal 10 shown in FIG. 1 is present inherently in a positive signal form. If this prerequisite is not present, either only positive or only negative signal components can be examined. It is of special importance according to the invention to make a time signal positive, optionally by absolute value generation or squaring. The time signal 10 is represented for further processing by individual sample values (for example, 11 , 12 ). To do this, conventionally, there is an analog-digital converter (ADC) which samples and digitizes the time signal with a preferably constant sampling time T s . Events 21 , 22 , 23 , 24 , 25 which occur more or less regularly are of special interest, particularly in the assessment of machinery noise or in quality analysis of continuously produced products. These events differ by their time difference and also by different intensity values (ordinate A). In the example shown, the time difference values labeled 1 T x and 2 T x are especially conspicuous. It is important that the respective, relatively large intensity values, according to the logic operation of the invention, will yield especially large “tallies” with subsequent classification. This applies especially in a logic operation of the multiplicative type.
The signal analysis proposed in accordance with the invention, therefore, works differently than conventional processes. This is, based on the following consideration: When pulse-like signal portions of short duration, but relatively high amplitude compared to the noise level, occur, these signal portions are of special importance, i.e. high information content. They are supplied to the further analysis process by means of increased evaluation factors, and thus, in a nonlinear manner. Consequently, it is necessary to first suitably identify the indicated pulse-like signal portions; this can take place, for example, by recognizing peak values which are examined above a predefined threshold value. If the pulse heights of two such peak values are multiplied by one another, the information content of these two peak values is evaluated to a nonlinear extent. The corresponding value of a product determined in this way, according to the invention, enters with an increased proportion into the frequency distribution which classifies by time differences. Therefore, in a direct approach, these product values are assigned to that time difference class which corresponds to the time difference of the two pulse-like peak values just examined for the usually noisy signal which is to be analyzed.
This circumstance is shown in FIG. 2 . The abscissa of the representation corresponds to a time measure. More accurately, time differences “Δt” are specified by the abscissa. A tally W is given versus these time differences. A tally entered at a time difference Δt is based, as described above, for example, on the sum of all product terms found which underlie a correspondingly large time difference. Instead of adding, a respective tally value for a value of Δt can also be determined by an incremental advance, in the manner of a frequency count. A distribution determined by a multiplicative logic operation with the values found and added subsequently is given by reference number 30 . For time differences with a value 1 * T s , of course, the frequency values 41 are especially large. Other especially conspicuous values 42 , 43 for difference times 1 * T x and 2 *T x are based on the high intensities in the vicinity of time events 21 , 22 , 23 , 24 , 25 by paired product formation leading to correspondingly large portions of the values of the tally function W.
The block diagram shown in FIG. 3 has a vibration sensor 2 which is attached permanently, or according to the prior art, detachably, to a machine 1 . It can be made, for example, as an acceleration sensor which converts mechanical vibrations and noise caused by the machine 1 , also especially by its bearings, into an electrical signal. The latter is sent to an amplifier 3 and then to a suitable filter combination, for example, filter 4 , 5 having high-pass filters or bandpass filters to filter out high frequency signal portions. This approach and the subsequent rectification or absolute value generation, optionally squaring of the signal, in a rectifier stage 6 are known, likewise the use of an output-connected lowpass stage 7 .
From the output of the lowpass stage, which has a comparatively low-resistance output, the signal is sent to a peak value detector unit which contains at least two separate peak value detectors. The three peak value detectors shown in FIG. 3 comprise, for example, the respective R-D-C combinations with a resistor 111 , a diode 121 , a capacitor 131 and the corresponding components 112 , 122 , 132 and 113 , 123 , 133 . The diodes 121 , 122 , 123 shown may have roughly ideal properties. The resistor 113 has a resistance which is, for example, 10 times greater than the resistance value of resistor 112 , and for example, 100 times greater than the resistance value of the resistor 111 . In this way, different discharge time constants are assigned to the indicated R-D-C combinations. They have a ratio of 1:10:100 in the example shown. Therefore, signal voltages which correspond to the peak values of the signal values which have reached a maximum in the interim can be tapped on the capacitor terminals which are not connected against the reference potential. Based on the different charging time constants, however, larger peak voltages are recorded on the larger RC combinations, as is explained in the description of FIG. 4, below.
The peak values tapped on the indicated terminals are, therefore, with greater probability, an indicator of a noise event which has a pulse-like nature and with the corresponding probability originates from repetitive machinery damage. As FIG. 3 shows, according to the invention, a plurality of suitable peak value detectors determines not only events with especially great intensity, but also those with a smaller intensity.
In order to determine the respective instant of occurrence of individual peak voltage values on the capacitors, according to the embodiment shown in FIG. 3, between the capacitor and reference potential line, a zero current detector 141 , 142 , 143 or differentiator is connected. Its output signals are essentially pulse-shaped or have at least one steep edge. These pulse-like signals are optionally combined by a signal conditioning stage 50 or are relayed directly to a time-pulse height storage unit 70 .
With the time-pulse height storage unit 70 , on the one hand, instants are recorded which can be assigned to the occurrence of the described peak voltage values. On the other hand, at the same time, the pertinent actual pulse heights of the signal delivered by the filter 3 (reference number 7 in FIG. 3) are determined by a suitable means, for example, an analog-digital converter 60 . In this way, over a predetermined time interval, for example, 1 to 10 seconds, a plurality of data are acquired which are possibly the result of machinery or bearing damage, and which provide information both on the instants of occurrence and also the intensities of these signals.
It is advantageous to provide preferably digital means for the time-pulse height storage 70 . The time-pulse height storage 70 can also be designed as a ring storage so that the characteristics of the signal which are oldest at the time are overwritten with those of the current, most recent signal.
In any case, the data of a filled time-pulse height storage 70 are used to produce special product values. To do this, the intensity value for each recorded event (except for the first) is multiplied by that of the one recorded previously. To do this a multiplier 80 is used. The corresponding product value and the underlying time difference are sent to distribution analysis. This takes place as follows: A classification unit 100 has individual registers which are assigned to defined time classes, for example, 400 time classes with the same (or different) width.
Individual register contents can be changed, therefore, depending on an observed or current time value, for example, by incrementing (increasing its value by a value of 1) or by summing (increasing its value by a summand, especially a summand made available by product formation).
Since, for the aforementioned formed products, the value of the respectively pertinent time difference is also known, depending on this time difference, a respective corresponding register of the classification unit 100 is increased by summing, preferably by summing by the value of the product.
In the different registers of the classification unit 100 , therefore, by storing a plurality of individual products, a distribution (histogram) is mapped quantitatively. If all values are stored, special classes or registers of the distribution will have significantly higher values compared, for example, to the average of all classes.
In one modification of the process, the formation of intensity products is performed similarly, but with the difference that the preceding event values or pulse height values are not used as the multiplier, but their predecessors, etc.
However, to assign a formed product to the distribution by means of the classification unit, in turn, that underlying time difference is used which was filed in the time-pulse height storage 70 for the corresponding multipliers and multiplicands.
When the arithmetic/logic unit 90 has created all of the products to be formed by means of a multiplier 80 and sent them to the classification unit 100 , it is ascertained with the comparison unit 110 which time classes of the classification unit 100 are most heavily occupied, therefore, are characterized by the largest function or frequency values. Furthermore, it is ascertained whether they differ significantly from the average of the values.
It is pointed out that the above described computation process works exclusively with arguments of the time domain. Nor is product formation with trigonometric functions performed. By this measure and the limitation to multiplication terms with special information content, otherwise necessary computing power or time is saved.
For a machine 1 , if its rotational frequency (rpm) and its rolling bearing parameters are known, according to the known formulas, it can be predicted which repetition times or frequencies can be expected for which bearing damage. According to the invention, it is therefore possible to check by means of the comparison unit 110 those time classes which are filed in the classification unit 100 and which correspond to the repetition times which are caused by specific bearing damage. Furthermore, it is of interest to check those time classes which correspond to a multiple of these predetermined repetition times.
If, in one or more of these classes, a frequency value is ascertained which is greater than one defined previously, or which differs from the average of the frequencies with a stipulated significance, this can be interpreted as an indicator for incipient or existing bearing damage. In this case, the arithmetic/logic unit 90 can activate a external signaler, for example, a signal lamp 120 .
It may be stated that the combination of peak detectors as depicted by reference numerals 1 xy (x counting from 1 to 4 , y counting from 1 to 3 ), signal conditioning unit 50 and comparator(s) 160 form a selection unit 150 .
FIG. 4 shows the output signals of the individual peak value detectors and the time variation of the respective signal functions.
The signal tapped at the output of the filter 3 is positive and in FIG. 4 is labeled with reference number 200 .
The signal generated by the peak value detector 111 , 121 , 131 has a comparatively small time constant and is identified by reference number 201 .
As is apparent from FIG. 4, the signal 201 is carried or raised by the signal function 200 up to the intermediate maximum values for time values 211 , 212 , etc., to then drop towards a value of zero with a predetermined time constant, until repeated carrying up to a subsequent peak value takes place. As is apparent, in this way, intermediate maximum values with relatively low intensity are also specified and identified. Accordingly, the average value of the signal 201 is also comparatively small.
Similarly, the signal from peak value detector 112 , 122 , 132 identified by the reference number 202 is raised only at times 221 (=213), 222 (=216) by the triggering signal function up to corresponding intermediate maximum values 321 , 322 in order to subsequently drop with its preset time constants. This time drop in the example shown is essentially exponential, but can also have a linear behavior or according to another stipulated, especially monotonically decreasing time function.
Similarly the signal from peak value detector 113 , 123 , 133 identified by the reference number 203 is raised only at time 231 (=222, =216) by the triggering signal function up to its intermediate maximum value with the peak value.
Since the time constant underlying the signal 203 is greater than that of signal 201 and the signal 202 , this signal 203 represents only a few marked values which, however, are characterized by a comparatively high intensity.
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto, and is susceptible to numerous changes and modifications as known to those skilled in the art. Therefore, this invention is not limited to the details shown and described herein, and includes all such changes and modifications as are encompassed by the scope of the appended claims.
|
A device for detecting or analyzing machinery damage is used preferably in the determination of defects in roller bearings. Pulse-like machinery or bearing noise acquired by a sensor is converted into special time signals. These time signals correspond to events which are basically periodic in occurrence. The time signals are sent to one, preferably several, classification units depending on the time differences. Before classification, combination of adjacent time signals or events is performed using their pulse heights. The combining is multiplicative or obeys some other bivalent relation. Classification forms a frequency distribution with an abscissa which is divided into time units. Specific characteristics of the frequency distribution provide information on incipient or manifest machinery damage.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to an agitating type washing machine in which an agitating wheel is driven to operate reciprocally in opposite directions by a drive motor.
In an agitating type washing machine, an agitating wheel disposed in the center on a bottom of the machine is reciprocally rotated within a predetermined angle to effect intended washing operations, as widely known in the art. Conventionally, in order to effect such a reciprocal motion, such an agitating type washing machine includes a gearing, a link mechanism, and so on, by way of which rotation of a motor is transmitted to an agitating wheel. Thus, an agitating type washing machine is applicable particularly to a large volume washing machine. However, since a mechanism for producing a reciprocal motion therein is complicated and is thus expensive in cost, it is difficult to employ such a mechanism for a small washing machine.
In recent years, in order to introduce an agitating type into a small washing machine, an agitating type washing machine has been proposed in which a motor is directly controlled to run in opposite directions using a timer and so on to reciprocally rotate an agitating wheel. This system only necessitates control of duration of energization of a motor and thus can be produced advantageously at a low cost. However, it is disadvantageous in that reciprocal angular rotations of an agitating wheel will not be held constant depending upon variations in an amount of the washing, a voltage of a power supply, and so on, thus preventing sufficient performance of functions inherent to the agitating type.
In particular, since this system is a timing controlling system which utilizes a timer, an interval of time from interruption of energization of a motor to actual stopping thereof is long when the machine is run either without a load, that is, without any washing, or with a little washing. On the contrary, when the machine has a large amount of washing to wash, such washing acts to brake the motor and hence the motor is stopped in a reduced interval of time. Accordingly, if an interval of time required to stop a motor of the machine is determined for no load running of the machine which provides a maximum interval of time for stopping, then when there is a large amount of washing, some wasteful time will appear before the machine is run in the opposite direction after deenergization of the motor, resulting in deterioration in efficiency of washing. Further, since durations of energization of a motor are held constant, angular rotation of an agitating wheel will be large when there is a little washing, but on the contrary, when the machine has a large amount of washing, angular rotation of the agitating wheel will be small. Thus, the system is disadvantageous in that it presents characteristics which are reverse to those required for such a washing machine. Accordingly, if it is intended, in such conditions, to wash a given amount of washing, then when there is no water in a washing tank, that is, upon no load running of the machine, the agitating wheel may rotate in several rotations and thus there may possibly be a danger of a hand of a man or the like being caught by the agitating wheel. A system has also been proposed in which a plurality of water flows are determined in prior in accordance of amounts of washing and one of such water flows may be selected by means of a push button switch or the like each time the machine is used, in order to prevent damage. But, in this system, the amount of washing must be measured accurately each time the machine is used. Furthermore, such measurement is troublesome and results in insufficient attainment of performance of the washing machine. Besides, it is also disadvantageous in that, if an operator inadvertently forgot to selectively set a water flow, the clothing might be damaged.
A further system has also been proposed in which a number of controlled time intervals are provided in accordance with amounts of washing and are changed over to wash a given amount of washing. But, this system is also disadvantageous in that it is accompanied by a complicated control.
SUMMARY OF THE INVENTION
The present invention has thus been made in consideration of the circumstances as described above.
It is an object of the invention to provide an agitating type washing machine which can be controlled to attain a constant or uniform angle of reciprocal rotation of an agitating wheel to improve reliability of washing performances of the machine.
It is a further object of the invention to provide an agitating type washing machine wherein two different angles of rotation of an agitating wheel for no load running and running under a load, which are both equal to or less than 360 degrees, are set in prior to washing means of a controller composed of an operating processing device, a memory, and so on, which are automatically changed over for no load running and for running under a load in response to an angle signal for detecting an angle of rotation of the agitating wheel. The motor is reversed after the agitating wheel has been stopped so that an angle of rotation of the agitating wheel which moves by inertia is made relatively large when there is a small amount of articles to be washed whereas such an angle is made relatively small when there is a large amount of articles to be washed. The period of time for a reciprocal motion of the agitating wheel is varied depending upon the amount of articles to be washed so that the optimum number of reciprocal motions may be automatically set.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing an embodiment of an agitating type washing machine of the present invention;
FIG. 2 is a sectional view taken along the line A--A of the FIG. 1;
FIG. 3 is a schematic diagram showing a control system for the arrangement of FIG. 1;
FIG. 4 is a circuit diagram showing the details of the control system of FIG. 3;
FIG. 5 is a flow chart showing the operation of the arrangement of FIG. 1 and particularly of the control system of FIG. 3;
FIG. 6 is a flow chart showing another operation of the control system of FIG. 3;
FIG. 7 is a sectional view showing another embodiment of the washing machine;
FIG. 8 is a sectional view taken along the line A--A of FIG. 7;
FIG. 9 is an enlarged partially cutaway perspective view showing a rotation angle detector;
FIG. 10 is a sectional view showing a further embodiment of the washing machine;
FIG. 11 is a sectional view taken along the line A--A of FIG. 10;
FIG. 12 is a perspective view showing another embodiment of a rotation angle detector;
FIG. 13 is a sectional view similar to FIG. 11;
FIG. 14 is a sectional view taken along the line A--A of FIG. 13; and
FIG. 15 is an enlarged partially cutaway view showing a rotation angle detector secured to the motor shaft.
DETAILED DESCRIPTION OF THE EMBODIMENTS
An embodiment of the present invention will now be described with reference to the accompanying drawings. Referring to FIGS. 1 and 2 a washing tank 2 is secured within the outer housing 1 of a washing machine and articles are washed in the washing tank 2. A main shaft 3 is mounted water-tight at the center of a bottom of the washing tank 2 and is supported for rotation by means of a main shaft bearing 4. An agitating wheel 5 is mounted on the main shaft 3 within the washing tank 2, and a pulley 6 is mounted at a bottom end of the main shaft 3 and has a plurality of detection holes 7 for detection of a rotational angle of the agitating wheel 5 perforated in a predetermined spaced relationship along a circular line therein (FIG. 2). A rotational angle detector 8 includes a light emitter 9 and a light receiver 10. Light receiver 10 receives, at a position of a detection hole 7 of the pulley 6, a beam of light projected from the emitter 9 and produces the number of pulse signals corresponding to an angle of rotation of the pulley 6 and hence an angle of rotation of the agitating wheel 5. A washing machine drive motor 11 is mounted on the bottom in the outer housing 1. Another pulley 12 is mounted on the motor 11. A belt 13 interconnects the pulleys 6 and 12. Rotation of the motor 11 is thus transmitted to the agitating wheel 5 by way of the pulleys 6 and 12 and the belt 13.
FIG. 3 shows a control system for the arrangement of FIGS. 1 and 2 control circuit 14 includes a memory 15, an operating processing device 16, an input control 17 and an output control 18. A power source is connected to the control circuit 14 by way of a switch 19. Detection signals representative of an angle of rotation of the agitating wheel 15 detected by the rotational angle detector 8 are inputted to the control circuit 14 through the input control 17 and are operated and processed by the memory 15 and the operating processing device 16. A signal produced as a result of such processing is applied as a control signal to the motor 11 through the output control 18 so as to rotate the motor 11 in a clockwise or counterclockwise direction in accordance with the output signal.
FIG. 4 shows the details of the circuit of FIG. 3. The reference numeral 19 designates a power switch; 20 a d.c. power for a gate power of thyristors 51 and 52 which turn on or off the clockwise and counterclockwise rotation of the motor 11 respectively and a drive power for a microcomputer 22 having a memory 15 and an operation processor 16 within the control circuit 14; 21 a clock generator which produces reference clock time for the microcomputer 22; 17 an input controller. The input controller converts the sinusoidal electric output which is generated from the rotation detector 10 in synchrorism with the rotation into pulse like electric output and then applies it to an input port K 1 of the microcomputer. Reference numeral 18 designates an output controller including photocouplers 53 and 54 and the thyristors 51 and 52 which control the turn-on or turn-off of the clockwise and counterclockwise rotation of the motor 11 in response to signals from output ports R 1 and R 2 of the microcomputer.
FIG. 5 is a flow chart which indicates operations of the arrangement and particularly of the control system thereof as described above. Step 100 is a rotational direction flag setting step at which a flag is set which represents a running direction of the motor 11, and next step 101 is a rotational angle setting step for setting an angle of rotation of the agitating wheel 5 (an angle over which the motor is energized). Thus, at step 101, the number of pulses N corresponding to an angle of rotation is set, and this value is stored in a register X at next step 102. Subsequent step 103 is a rotat direction discriminating step for discriminating between rotational direction of the motor 11. Step 106 is a counter step for counting the angle of rotation of the agitating wheel 5 (the number of pulses from the rotational angle detector 8). The count is inputted to a register T. Step 107 is a comparing step at which the angle of rotation of the agitating wheel 5 is compared with the preset value N in order to determine if the former reaches the latter, step 109 is a stopping discriminating step at which it is determined that pulse signals from the rotational angle detector 8 are terminated and hence the agitating wheel 5 is stopped, and step 110 is a rotational direction setting step at which a direction of rotation of the motor is set. Reference numerals 122 and 123 designate angle comparing steps at which an angle of rotation before the agitating wheel 5 is stopped is compared with a reference angle of rotation. Further, reference numerals 124, 125 and 126 designate each an operating step at which the reference angle is added to or subtracted from the angle of rotation of the agitating wheel 5, and a result of any such operation is placed into the X register so as to control energization of the motor 11 to coincide the angle of rotation with the reference angle or rotation.
Upon starting a washing operation, articles to be washed, water and a cleanser are charged into the washing tank 2, and the power switch 19 is switched on. Then, at step 100, the flag F is set to 1 for clockwise rotation of the motor 11, and at step 101, the number N of pulses corresponding to a reference angle of rotation of the agitating wheel 5. The value X is stored in the X register at step 102. At step 103, it is determined if the motor 11 is to rotate in the clockwise or counterclockwise direction of F=1 here, it is determined that the motor 11 is to rotate in the clockwise direction. As a result, at subsequent step 104, the motor 11 thus begins to rotate in the clockwise direction. The pulley 6 is thus rotated by the motor 11 to rotate the agitating wheel 5 whereupon a pulse signal is produced from the rotational angle detector 8. At next step 106, the pulse is counted by the counter, and the count is put into the T register. At step 107, the contents of the T register and the X register are compared with each other, and if T<X, then control goes back to step 103 to continue the clockwise rotation of the motor 11. On the contrary, if T>X, that is, when the angle of clockwise rotation of the agitating wheel 5 comes equal to or exceeds beyond the reference angle of rotation, control advances to step 108 at which the motor 11 is deenergized. The motor 11 thereafter continues its clockwise rotation due to its inertia, and meanwhile at step 120, pulse signals are further counted and the count is put into the T register. At step 109, it is determined from the presence or absence of pulse signals if the agitating wheel 5 is actually stopped or not, and when the agitating wheel 5 is not yet in a stopped condition, then control goes back to step 120 to continue a counting operation of such pulse signals. When it is determined that the agitating wheel 5 is in a stopped condition, then zero is put into the X register at step 121. At next step 122, the pulse number N representative of the reference angle of rotation which is preset at step 101 and the pulse number T representative of the angle of actual rotation are compared with each other, and when T>N, control goes to step 124 which is an operation processing step at which the number of pulses (T-N) corresponding to an angle by which the actual angle of rotation exceeds the reference angle is calculated, and a value of the reference rotational angle pulse number N less (T-N) is put into the A register. On the other hand, when T=N, then control goes from step 123 to step 126 at which the pulse number N is placed into the X register. Further, if T<N from some reason, then control goes from step 123 to step 125 at which a shortage pulse number (N-T) is calculated, and the value (N-T) added by the pulse number N is placed into the X register. Then, at next step 110, it is determined that F=1, and accordingly control goes to step 111 at which the rotational direction flag F for the motor 11 is reset to zero. Then at next step 113, the T register is also reset, and control goes back to step 113. Since F=0 now, control advances from step 103 to step 105 at which the opposite counterclockwise rotation of the motor 11 is started to rotate the agitating wheel 5 in the counterclockwise direction. The program will thereafter proceed in a similar manner as for the clockwise rotation of the motor 11. As a result, the agitating wheel 5 repeats reciprocal rotations until the power switch 19 is switched off to complete washing of the articles to be washed.
Thus, in the present embodiment, a surplus or deficit of an angle of actual rotation relative to a reference angle of rotation of the agitating wheel 5 in a rotation in one of clockwise and counterclockwise directions is compensated in a rotation of the same in the other direction, as described above. As a result, angles of reciprocal rotation of the agitating wheel 5 in opposite directions are held substantially uniform, thereby eliminating irregular washing performances to improve reliability of washing performances of a washing machine.
FIG. 6 is a flow chart showing a further embodiment of the present invention in which an angle of rotation of the agitating wheel during no load running of the machine is smaller than that during running under a load, and changing over between no load running and running under a load is effected automatically in response to a detection signal as described above. In the embodiment, the motor is reversed after the agitating wheel has stopped, an angle or rotation of the agitating wheel is held in any case less than 360 degrees including rotation by inertia, and a period of time required for a reciprocal motion of the agitating wheel is changed in accordance with the amount of articles to be washed, utilizing a difference in rotation by inertia.
Referring to FIG. 6, step 200 is a step at which a no load running flag is set in order that a washing running may be effected by all means under no load to enable detection of a load to be effected upon starting of running of the machine. Step 201 is a step at which a rotational direction flag for the motor 11 is set. Step 202 is a step for setting an angle of rotation of the agitating wheel for no load running (running in a condition in which there is no water nor any article in the washing tank 2), and thus at step 202, the number of pulses N 1 is set corresponding to an angle of rotation of the agitating wheel. Then at next step 203, the value N 1 is placed into the register X 1 . Step 204 is a step for setting an angle of rotation of the agitating wheel during running under a load, and at step 204, the number of pulses N 2 is set, which value is inputted, at step 205, into a register X 2 in a similar manner as in the case of no load running. Step 206 is a step at which a direction of rotation of the motor 11 is changed over. Step 209 is a counter step at which an angle of rotation of the agitating wheel 5 (the number of pulses) upon energization of the motor 11 is counted, and at step 214, an angle of rotation of the agitating wheel 5 is counted while the agitating wheel 5 rotates by its own inertia after the motor 11 has been deenergized, such counts being placed into the T register; a sum total of both counts represents an angle or actual rotation of the agitating wheel 5. Step 210 is a load changing over step at which at an angle of rotation of the agitating wheel 5 (duration of energization of the motor 11) is changed over between for no load running and for running under a load, and at steps 211 and 212, angles of rotation are compared. Step 215 is a stopping discriminating step at which it is discriminated that the agitating wheel 5 has been stopped upon the basis of the fact that there is no pulse signal received from the rotational angle detector 8, and step 218 is a step at which a direction of rotation of the motor 11 is set. The no load running rotational angle set value N 1 and the load running rotational angle set value N 2 have a relation N 1 <N 2 , and the set value N 1 is determined such that the angle of rotation of the agitating wheel 5 including rotation by inertia upon no load running is smaller than 360 degrees and is greater than an angle of rotation corresponding to the rotation angle set value N 2 including the rotation angle of the agitating wheel 5 by inertia and on the other hand, the set value N 1 is determined such that it is smaller than the angle of rotation corresponding to the set value N 2 including the angle of rotation of the agitating wheel 5 including rotation by inertia upon running under a load. Further, the set value N 2 is determined such that the angle of rotation of the agitating wheel 5 including rotation by inertia upon running under a load does not exceed 360 degrees.
Now, operations of the apparatus as described just above will be described. At first, articles to be washed, water and a cleanser are put into the washing tank 2 and the power switch 19 is switched on. Then, at step 200, the no load running flag F 1 is set to 1, and at step 201, the running direction flag F 2 is set to 1 (for clockwise rotation). At step 202, the no load running rotational angle N 1 of the agitating wheel 5 (duration of energization of the motor 11) is set, and at step 203, the value N 1 is put into the register X 1 . At next step 204, the load running rotational angle N 2 (duration of motor energization) is set, and at step 205, the value N 2 is put into the register X 2 , thus completing initialization of the system.
Then, control goes to step 206, at which F 2 =1 is determined so that control further goes to step 207 at which the motor 11 is rotated in the clockwise direction to rotate the agitating wheel 5 clockwise, thus starting a washing operation. At the same time at step 209, an angle of rotation of the agitating wheel 5 is detected by means of the rotational angle detector 8 and a pulse signal is added to the register T from the detector 8. At the load changing over step 210, F=1 is determined, and hence, control goes to the no load running rotational angle discriminating step 211 at which the count of the register T is compared with the count of the register X 1 . Here, when T<X 1 , that is, when the agitating wheel 5 does not yet reach the preset angle, control goes back to step 206 to continue the clockwise rotation of the motor 11. On the contrary, when T≧X 1 , that is, when the agitating wheel 5 reaches the preset angle, control goes to step 213 at which the motor 11 is deenergized. As a result, the agitating wheel 5 enters rotation by inertia while an angle over which the agitating wheel 5 further rotates is added to the register T at step 214. Such counting is continued until the agitating wheel 5 is stopped. The angle of rotation of the agitating wheel 5 by inertia is large when there are a small amount of articles to be washed, and on the contrary when there are a large amount of articles to be washed, it is small. Thus, the angle of rotation of the agitating wheel 5 varies substantially in proportional relationship to the amount of articles to be washed, and as a result, the number of reciprocal motions of the agitating wheel 5 per minute varies automatically.
Then at next stopping discriminating step 215, it is confirmed that the agitating wheel 5 has been stopped upon the basis of the fact that there is no more pulse signal received from the rotational angle detector 8, and at step 216, a load condition is determined. Since now a washing operation is proceeding and the machine is actually under a load, an angle of rotation by inertia is relatively small and thus T<X 2 . As a result, it is determined that the machine is running under a load (that is, during washing) at step 216, and at next step 217, the flag F 1 is reset to zero. Since F 2 =1 at subsequent motor rotational direction setting step 218, control goes to step 219 at which the flag F 2 is reset to zero, and at step 221, the register T is cleared T=0 whereafter control goes back to step 206. Since now F 2 =0 at step 206, control goes to step 208 at which the motor 11 begins its counterclockwise rotation to rotate the agitating wheel 5 in the counterclockwise direction. At step 209, the number of pulses corresponding to an angle of rotation of the agitating wheel 5 is put into the register T, and then, since F 1 =0 at next step 210, control goes to step 212 at which, since the washing machine is now under a load, the machine is rotated over a greater angle then during no load running. The program will thereafter proceed in a similar manner as for the clockwise rotation of the machine. Thus, the agitating wheel 5 will repeat its reciprocal motions to continue its washing operations until the power switch 15 is switched off.
Thus, the washing machine positively utilizes rotation by inertia of an agitating wheel such that the agitating wheel is rotated in a reverse direction after rotation thereof in one direction has been stopped and, in consideration of a difference in rotation by inertia depending upon an amount of articles to be washed, a period of time for a reciprocal motion of the agitating wheel is changed in accordance with an amount of articles to be washed so as to cause water flows appropriate for the amount of such articles to be automatically produced, thereby preventing damage to cloths of such articles. Further, an angle of rotation of the agitating wheel or duration of energization of a motor during no load running in which relatively large rotation by inertia is involved is made smaller than that during running under a load while changing over between no load running and running under a load is automatically effected in response to a detection signal from a rotational angle detector, whereby an angle of actual rotation of the agitating wheel can be controlled less than 360 degrees. Accordingly, a hand of a man or the like can be prevented from being caught by the agitating wheel and articles being washed are prevented from being entangled with each other. In this way, a washing machine of a high safety and of a high quality can be provided.
Now, description will be given of another example of detecting means which can be applied to the present invention.
While an example is shown in FIGS. 1 and 2 in which the pulley 6 has a plurality of holes 7 perforated therein for detection of an angle of rotation and is interposed between the light emitting means 9 above and the light receiving means 10 below, alternatively an independent detection disk 25 may be provided at an end portion of the main shaft 3, as shown in FIGS. 7 to 9.
Referring to FIGS. 7 to 9, the detection disk 25 is made of a magnetic material such as iron which has alternate teeth 26 and recesses 27 formed in a predetermined spaced relationship around an outer periphery thereof for detecting an angle of rotation of the agitating wheel 5. The detection disk 25 is secured to the main shaft 3. Reference numeral 8 designates an angle detector which includes a magnetic resistor element 9 and a permanent magnet 10 fixedly disposed in a spaced relationship by a predetermined distance from each other and also from a radial end of the detection disk 25. A predetermined voltage is applied to the magnetic resistor element 9. As commonly known in the art, the magnetic resistor element 9 has an electric resistance which varies in response to the intensity of a magnetic field, and the direction of a magnetic field varies in response to presence and absence of a recess 27 of the disk 25. As a result, as the detection disk 25 which is a magnetic member is rotated, an electric current flowing through the magnetic resistor element 9 varies each time as recess 27 passes thereby. In the present arrangement, the electic current is processed electrically such that, as the detection disk 25 is rotated, pulse-like electric signals corresponding to an angle of actual rotation of the agitating wheel 5 are detected.
Reference is now made to FIGS. 10 to 12 which shows a further example of detecting means. The detecting means includes a similar detection disk 25 to that of FIGS. 7 to 9, but this detection disk 25 has a side wall section 26 integrally formed to extend substantially perpendicularly in a downward direction from an outer circumferential end thereof. The side wall section 26 of the detection disk 25 has a plurality of detection recesses 27 formed in a circumferentially equally spaced relationship therein to provide a comb-like configuration to the side wall section 26. Reference numeral 8 denotes a rotational angle detector mounted on the bottom of the washing tank 2 and including a light emitting element 9 and a light receiving element 10 disposed in opposing relationship adjacent opposite sides of the side wall section 26. Thus, when a detection recess 27 is positioned between the light emitting element 9 and the light receiving element 10, light from the light emitting element 9 is received by the light receiving element 10. On the contrary, when a portion of the side wall section 26 other than the detection recesses 27 is positioned between the light emitting element 9 and the light receiving element 10, light from the light emitting element 9 is interrupted thereby. Accordingly, pulse signals which correspond to an angle of rotation of the agitating wheel 5 are outputted from the light receiving element 10.
It is to be noted that the rotational angle detector 8 of the example described just above may alternatively be constituted such that the detection disk 25 is made of a magnetic material such as, for example, iron and the light emitting element 9 and the light receiving element 10 are replaced by a Hall element and a permanent magnet, respectively. In particular, a predetermined voltage is applied to the Hall element 9, and as commonly known in the art, an electric current flowing through the Hall element 9 varies in response to the intensity of a magnetic field due to a Hall effect, and the direction of a magnetic field varies in response to presence and absence of a recess 27 of the disk 25. As a result, as the detection disk 25 which is a magnetic member is rotated, an electric current flowing through the Hall element 9 varies each time a recess 27 passes thereby. The electric current is processed electrically such that, as the detection disk 25 is rotated to rotate the side wall 26, pulse-like electric signals corresponding to an angle of actual rotation of the agitating wheel 5 are detected.
It is to be mentioned that an angle of rotation can be detected similarly if the Hall element is otherwise replaced by a magnetic resistor element which has an electric resistance which varies in response to the intensity of a magnetic field.
It is also to be mentioned that, while only the examples of detecting means which involve detection of an angle of rotation of the agitating wheel 5, an angle of rotation of the agitating wheel can otherwise be detected indirectly from detection of the number of rotations of the agitating wheel. Such an example is illustrated in FIGS. 13 to 15. In this arrangment, a reduction ratio which is determined by a pulley 6 and a motor pulley 12 is almost 10:1 so that one complete rotation of a motor will rotate an agitating wheel 5 by an angle of about 36 degrees.
In the arrangment of FIGS. 13 to 15, a motor 11 having high rigidity has a rotation detector 30 disposed therefor for detecting the number of rotations of the motor. The rotation detector 30 includes a cylindrical permanent magnet 31 fixedly mounted on a lower end 29' of a motor shaft 29, a generating coil 32 wound in a cylindrical form around an outer periphery of the permanent magnet 31 with a predetermined air gap left therebetween, and a magnetic shield member 33 disposed in the air gap between the permanent magnet 31 and the generating coil 32 to partially interrupt a magnetic field of the permanent magnet 31. Since, in the rotation detector 30 having such a construction as described above, rotation of the motor shaft 29 will rotate the permanent magnet 31 fixedly mounted thereon, a sinusoidal electric current is induced in the generating coil 32 in synchronized relationship to rotation of the permanent magnet 31, as commonly known in the art. The sinusoidal electric current is processed electrically so that, as the motor 11 rotates, pulse-like electric signals are outputted in synchronism therewith. In this way, the rotation detector 30 is disposed in the motor 11 in which most parts are made of metal materials so that rotational conditions of the motor can be detected directly. This construction thus assures high accuracy in assembly and high workability and enables accurate and stabilized detection of rotational conditions of a motor.
|
In an agitating type washing machine a washing drive motor is run reciprocally in opposite directions to rotate an agitating wheel within a washing tank alternately in one and the other directions to perform intended washing. The washing machine comprises a rotational angle detector for detecting an angle of rotation of the agitating wheel, and a control for controlling the motor in response to a detection signal from the rotational angle detector. The control controls such that an angle of rotation of said agitating wheel by energization of the motor during running under a load is made smaller than that during no load running and that changing over between running under a load and no load running is automatically effected in response to a detection signal from the rotational angle detector, and controls rotation of said agitating wheel to an angle equal to or less than 360 degrees including rotation by energization of the motor and rotation by inertia whether during running under a load or no load.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a hydraulic control system for pressurizing clutches in an automatic transmission. The invention pertains more particularly to a hydraulic control system for an automatic transmission which, upon sensing an unacceptable combination of pressurized clutches, reverts to the combination that produces a predetermined speed ratio.
2. Description of the Prior Art
An automatic transmission for automotive use includes planetary gearsets whose elements are hydraulically connected or held in order to produce selected ratios of the engine crankshaft speed to the speed of the output of the transmission. Automatic gear change transmissions may be controlled by electronic means which produce analog current signals that operate solenoid valves. These valves connect hydraulic line pressure to selected clutches and brakes, or vent the hydraulic cylinder of these elements to atmosphere. The control system should operate such that, in the event of a control system malfunction, the transmission may operate in at least one forward speed ratio and in reverse drive in order to allow the vehicle to be driven to a service station for repair.
Line pressure in an automatic transmission is usually established by connecting the output of a hydraulic pump to a pressure regulator valve through which the regulated fluid is directed to selectively operated shift valves, which control the engagement of clutches and brake servos whose selective engagement produces the various speed ratios of which the transmission is capable. If the pressure applied to the various clutches differs beyond a certain limit or if the clutches that are concurrently pressurized is inconsistent with the schedule or pressurized clutches required to produce the several drive ratios of the transmission, then incorrect operation will result. It is preferred, in the event of such unscheduled clutch engagement or malfunction of the electronic control that operates solenoid valves, that the hydraulic control system automatically operate to engage those clutches required to produce a predetermined forward speed ratio. Furthermore, reverse drive operation should result without reference to the electronic control.
SUMMARY OF THE INVENTION
In the hydraulic control system, according to this invention line pressure is applied through selective operation of a manual valve to a feedback valve on which are developed pressure forces produced by clutch pressure applied to the clutches whose engagement is necessary for the higher forward drive ratios. A feedback valve applies a force to the feedline valve in oppostion to the pressure forces produced by the forward drive ratio clutches. These valves sense the application of an unscheduled pressurized clutch combination and sense if a scheduled combination has clutch pressure below a critical magnitude. If either of these conditions is present, the feedline through which the clutches are pressurized by operation of the electronic control are vented and a second feedline is connected to line pressure. Those clutches whose engagement is necessary to produce a predetermined forward speed ratio are pressurized from the second feedline.
A solenoid operated clutch actuator valve selectively connects the first feedline to the various clutches so that the clutches are quickly filled and quickly vented. The pressure drop across an orifice of a given size determines the state of the actuator valve in accordance with an electrical signal applied to the solenoid winding.
In the event of a tie-up during shifting or an electronic system malfunction, the solenoid feed valve cooperates with a solenoid feedback valve to produce a snap action that prevents the feed valve from hunting between positions. Pressure forces developed on differential pressure areas of the feed valve are balanced in part by an opposing pressure force and by the force of a spring which maintains clutch pressure in the unpressurized clutch within limits. The feed valve and feedback valve sense if clutch pressure exceeds certain limits during shifting and sense if one clutch pressure exceeds a certain limit when the other two are at normal clutch regulated pressures.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 and 2 show a schematic diagram of the hydraulic control system according to this invention.
FIG. 3 shows a schedule for the forward drive ratios and reverse drive ratio of the transmission and the various clutches and servos that are pressurized to produce each of these drive ratios.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Refering to FIG. 1, the transmission is supplied with enough fluid to keep a torque converter 10 completely filled, operate the hydraulic controls, lubricate the working parts and provide a reverse of fluid in the sump 12, which is a storage space in the oil pan at the bottom of the transmission case. Atmospheric pressure in the sump forces fluid through the sump screen 14 and into the evacuated inlet of the pump 16. Fluid delivered by the pump is displaced at a volumetric rate which is in proportion to the speed at which the pump is driven. The pump is sized to deliver more fluid than the transmission needs and excess hydraulic fluid if recirculated to the sump by the pressure regulator system and other portions of the hydraulic control system.
The output of the pump connected by hydraulic line 18 supplies fluid regulated to line pressure to the manual valve 20. The pump outlet is connected through lines 22 and 28 to the control chamber 23 of a main regulator valve 24. The orifice 26 in line 21 has an appreciable pressure drop across it only when flow in line 21 reverses direction at high frequency.
The pump outlet supplies hydraulic fluid through line 28 to a central chamber of valve 24. The torque converter circuit is charged or pressurized through line 30, which leads from regulator valve 24. The converter circuit includes a relief valve 32, which is adapted to open the circuit to the pump inlet as necessary to protect the converter from excessive pressure build-up. Upon leaving the converter, hydraulic fluid passes through a check valve 34 which has a light spring that opens with low pressure to maintain a continuous fluid flow to the cooler 36. When the engine is shut down, the spring will reseat the valve, which prevents the converter oil from draining through the cooler and lubrication system back to sump. Therefore, the converter is maintained full of fluid and can begin to transmit torque through the turbine shaft as soon as the engine is started.
The pump outlet is also connected through orifice 38 in hydraulic line 40 to inlet port 42 of the boost valve 58 and through hydraulic line 44 to the inlet port of a line pressure regulator solenoid valve 46. The solenoid of valve 46 has a winding to which is applied a pulse width modulated signal produced by an electronic control system. Valve 46, which is normally closed, opens line 44 to a vent port through an orifice 48 when the solenoid winding is energized. Regulator valve 24 has a central chamber within which valve spool 50 moves due to the effect of a pressure force developed on land 52, the force of a spring 54 and pressure force developed on the land 56 of boost valve 58. The end of the valve chamber is blocked by a plug against which spring 54 bears. The pressure regulator and boost valve operates to control the pressure in line 18 between 60 p.s.i. and 260 p.s.i.
In order to fill the lines of the hydraulic system, the spool 50 of regulator valve 24 is moved by spring 54 to the lower end of the valve chamber, the pump is driven by the engine and the lines are filled at low pressure. As pressure begins to rise, spool 50 is forced upward against spring 54 to approximately the position shown in FIG. 1 permitting land 60 to open communication between lines 28 and 30 through which the torque converter circuit and hydraulic control system are fully charged.
Regulation of line pressure begins by opening and closing orifice 48 of line pressure regulator solenoid valve 46 as the windings of that solenoid are energized and de-energized in accordance with a pulse width modulated signal applied to the solenoid. Normally valve 46 is closed and its solenoid coil de-energized. Through operation of valve 46 line pressure is controlled by the pressure acting on land 56 of the boost valve 58. Maximum line pressure occurs when no pulse width modulated signal is applied to the line pressure solenoid winding. Then no hydraulic fluid flows through the orifices 38, 48 but pressure acts on the boost valve land 56, which applies a force through contact with valve spool 50 and the effect of spring 54 tending to close communication between lines 18, 22, 28 and vent port 62. Maximum line pressure results when the solenoid of valve 46 is de-energized and when the pressure force on land 56, plus the spring force are balanced against the pressure force on land 52 such that line 18 is closed to vent port 62. Minimum line pressure, which is determined with solenoid valve 46 energized, is equal to the sum of the pressure drops across orifices 38 and 48. When the duty cycle from which the signal applied to the solenoid of valve 46 is less than 100 percent and more than 0 percent, i.e., when the solenoid winding is energized for a period whose duration is proportional to the difference between the actual line pressure and the commanded line pressure, orifice 48 opens and closes cyclically. In this way line pressure is regulated between the maximum and minimum valves.
The manual valve 20 directs line pressure to the valves, clutches and servos whose actuation produces the forward and reverse drive ratios. Valve 20, whose position is controlled by the vehicle operator, receives line pressure through inlet port 64 and directs line pressure to line 66 if valve element 68 is moved to the Overdrive, 3 or 1 positions. If the valve is moved to the Park, Reverse or 1 positions, hydraulic line 67 receives line pressure. Hydraulic line 70 is pressurized with line pressure when the manual valve is moved to the Reverse position, but line 70 is open to vent port 72 when the manual valve is set other than in the Reverse position. When the manual valve is in the Overdrive, 3 or 1 positions, an electronic control system selectively energizes the windings of solenoid-operated valves 74, 76 and 78 by means of which an intermediate overdrive clutch 80, forward clutch 82 and direct clutch 84, respectively, are engaged and disengaged.
FIG. 3 shows the schedule of clutch and servo actuation required to produce the various speed ratios. While manual valve 20 is at the O/D position, any of the four forward speed ratios are produced by actuation of valves 74, 76, 78 and through operation of control valve 92. When the manual valve is at the 3 position, only the three lowest forward speed ratios can be produced. When the manual valve is at the 1 position, only the lowest forward speed ratio operation can result.
In the event of an electronic system malfunction, the transmission is shifted hydraulically to second gear through operation of a solenoid feed valve 86. When manual valve 20 is set at the Reverse position, solenoid feed valve 86 and the reverse clutch 88 are pressurized directly from the manual valve 20 with line pressure, and the low/reverse servo 90 is pressurized through operation of coast control valve 92.
Solenoid feed valve 86 has a spool element 96 on which several lands are formed. When forward clutch 82 is pressurized, hydraulic line 98 carries fluid at line pressure to a port 100 through which one face of lands 102 and 104 are pressurized. The cross sectional area of land 102 is one unit of area larger than the cross section area of land 104; therefore, the net differential area of the lands pressurized when the forward clutch is applied is one area unit. When the intermediate/overdrive clutch 80 is pressurized, hydraulic line 106 carries fluid at line pressure to port 108 through which a second differential pressure area comprising the opposite force of land 104 and one face of land 110 are pressurized. The cross sectional area of land 104 is one unit of an area larger than the cross sectional area of land 110. When either the direct clutch 84 is pressurized, or the manual valve is moved to the Reverse position, hydraulic line 112 carries fluid at line pressure to chamber 114 of the solenoid feed valve by means of which land 116 is pressurized. The cross sectional area of land 116 is substantially the same as that of lands 110 and 118, specifically one unit of area. Spool 96 has a headed end 120 which can be brought into contact with a headed end on the valve element 122 of the feedback valve 94. A spring 130 is preloaded in compression between the surfaces of land 102 and element 122. A second compression spring 132 biases element 122 leftward.
Hydraulic line 66 connects an outlet port of manual valve 20 to an inlet port of feed valve 86. Depending upon the position of spool 96, either a first solenoid valve feed line 124 or a second feed line 126 is brought into communication with inlet port 128. Solenoid feed valve 86 in cooperation with feedback valve 94 directs line pressure from port 128 to actuator valves 74, 76 and 78 if spool 96 is at the left-hand end of the valve chamber. Alternatively, if spool 96 is moved to the right-hand end of the valve chamber, valves 86 and 94 connect inlet 128 to the second feedline 126, which movement opens the first feed line 124 to vent port 134. Similarly, if line 124 is pressurized, line 126 is open to vent port 136. The first feed line 124 supplies line pressure to feedback line 138 through which the end face of element 122 is pressurized. The cross sectional area of element 122 is two unit areas.
Valves 86 and 94 operating together sense if the magnitude of solenoid feed pressure exceeds certain limits during shifting and sense if the pressure to either the direct clutch, the forward clutch or the intermediate/overdrive clutch exceeds a certain limit when the other two clutches are at line pressure. When spool 96 is at the left end of the valve chamber, direct clutch actuator valve 78, forward clutch actuator valve 76 and intermediate/overdrive clutch actuator valve 78 have solenoid feed pressure applied to inlet ports 144, 142, 140. The output from these valves carried in lines 146, 148, 150 is regulated between zero p.s.i. and line pressure, which regulation eliminates the need for accumulators to control clutch pressure during shifting. A pulse width modulated signal is selectively applied to the windings of solenoid valve 74, 76, 78, in accordance with the schedule of FIG. 3, in order to produce the second, third and fourth forward speed ratios. The solenoid of valve 76 is energized in order to engage forward clutch 82, which acts in combination with the engagement of low/reverse servo 90 to produce the first forward speed ratio.
Each of the actuating valves 74, 76, 78 includes a valve spool 152 having an orifice 154 connecting the valve chamber through an axially directed bore 156 leading to the end of valve land 158 which is formed integrally with the spool. The valve body includes a first vent port 160 and a second vent port 162 to which the valve chamber is communicated when the solenoid winding is energized. Two valve lands of equal size 164, 166 are formed integrally on the spool 152.
In operation, the intermediate/overdrive clutch 80 is filled through valve 74 when its spool 152 is in the position shown in FIG. 3 and solenoid feed line 124 is pressurized. A feedback line 170 develops a pressure force on land 164 through orifice 172, which functions to prevent cyclic movement of spool 152. The maximum pressure that can be applied to any of the clutches or servos is the line pressure. However, clutch and servo pressure can be regulated down to zero p.s.i. through operation of the actuating valve. In order to regulate clutch pressure, a pulse width modulated signal is applied to the winding of the solenoid which causes orifice 174 to open and close cyclically for variable and usually unequal periods, thereby communicating vent port 162 to the valve chamber. When orifice 174 is open, differential pressure across orifice 154 causes an unbalanced pressure force to be developed on spool 152, moving the spool downward and opening line 146 to vent port 160. During the period when the solenoid winding is de-energized, spool 152 moves upward within the chamber to the position shown in FIG. 2, and clutch pressure rises toward line pressure. It can be seen from this that the duration of the period during which the solenoid winding is energized controls the magnitude of the associated clutch pressure and in this way the clutch is vented through vent port 160 when the solenoid winding is energized for an extended period.
Referring to FIG. 3, it can be seen that the second, third and fourth speed ratios are produced when only two of the clutches in the group consisting of the forward clutch 82, direct clutch 84 and intermediate overdrive clutch 80 are pressurized. The solenoid feed valve 86 in cooperation with the feedback valve 94 operate to disconnect line pressure from solenoid feedline 124 and to connect line pressure to the second feeding 126, which directly pressurizes the forward clutch 82 and intermediate/overdrive clutch 80, thereby discounting the operation of the solenoid feed valves 74, 76, 78, when the clutch pressure in one of the lines 146, 148, 150 exceeds the predetermined limit value and the other two clutch pressure lines are within the regulated range. If the second feed line is pressurized, the transmission shifts to the second forward speed ratio where it remains until manual valve 20 is moved to the neutral position. Clutch pressure in lines 146, 148, 150 is fed back in lines 98, 106, 112 to valve 86 where each is applied to the differential areas of spool 96. The cross sectional area of element 122 of valve 94 is equal to two times each of these differential areas; therefore, the pressure in feedback line 138 opposes the force on two of the differential areas of spool 96. The third clutch pressure, therefore, acts only against the force of spring 132, which can be used to set the pressure limit on the third clutch. If this limit is exceeded, spool 96 and element 122 move to the right-hand end of their respective valve chambers and solenoid feed pressure line 124 is vented. After this occurs, spool 96 and element 122 are maintained at the right-hand end of the valve chambers, thereby snapping valve 86 to its hydraulic shift position where feed line 126 is connected to line pressure.
This position is maintained until the manual valve is moved to the Neutral position. The preloaded compression spring 130 located between spool 96 and element 122 forces spool 96 back to the left-hand end of its chamber, but when the manual valve is moved to the Reverse position, reverse pressure in chamber 114 tends to move spool 96 against this spring. The force of spring 130 assures that the spool 96 is in position to allow solenoid feedline 124 to be connected to line pressure when the manual valve is moved from the Reverse position to the Overdrive position.
The coast control valve 92 operates to regulate low/reverse servo pressure when the manual valve is in the Park and 1 positions, to connect line pressure to the low/reverse servo 90 when the manual valve is moved to the Reverse position and to prevent pressurization of the low/reverse servo when direct clutch pressure or intermediate/overdrive clutch pressure exceeds a certain limit.
When the manual valve is in the 1 position, the low/reverse servo is pressurized in order to apply the low/reverse brake band by means of which engine braking of the vehicle wheels results. However, a lower magnitude of low/reverse servo pressure is required in low gear than in reverse drive in order to prevent the brake band from slipping. For this reason the coast control valve 92 regulates low/reverse servo pressure to 25 p.s.i. when the manual valve is set at the 1 position. When the manual valve is in the Reverse position, valve 92 permits line pressure, which may vary between 60 p.s.i. and 260 p.s.i., to be applied to the low/reverse servo.
Coast control valve 92 includes a spool 176, biased by a compression spring 178 to the upper end of the valve chamber in which a vent port 180 is formed.
When manual valve 20 is moved to the 1 position, hydraulic line 67 carries fluid at line pressure to valve 92 whose spindle 176 is biased by spring 178 to the top of the valve chamber. In this position valve 92 pressurizes hydraulic line 182, through which the low/reverse servo 90 and feedback line 184 are pressurized. The pressure developed on land 186 operates against the force of spring 178 and regulates the magnitude of pressure in the low/reverse servo.
If the manual valve is moved to the Reverse position, line pressure carried in hydraulic lines 70 and 188 develops a force on the end of land 190 that adds to the force of spring 178 and acts to maintain valve spool 176 at the top end of the valve chamber. Therefore, line pressure carried to valve 92 in line 67 is applied directly to the low/reverse servo 90 through line 182.
In order to operate in the first forward speed ratio, only the forward clutch 82 and the low/reverse servo 90 can be pressurized. Therefore, when the manual valve is moved directly from the Overdrive position to the 1 position, coast control valve 92 operates to prevent the low/reverse servo from being pressurized while the transmission operates in the third or second gear ratios. Check valve 192 directs fluid at clutch pressure through line 194 to the coast control valve 92 when either the direct clutch or the intermediate/overdrive clutch is pressurized. This develops a pressure force on land 196 which adds to the force on the feedback land 186 in opposition to the spring force 178. Spool 176 is forced to the bottom of the valve chamber, which action opens the low/reverse servo line 182 to vent port 180. The magnitude of the intermediate/overdrive clutch pressure and direct clutch pressure are controlled by the electronic control system. When either of these clutch pressures decrease during a 2-1 coastdown shift, spring 178 moves spool 176 upward and the low/reverse servo pressure is again regulated to approximately 25 p.s.i.
|
The hydraulic control circuit for an automatic transmission includes solenoid-operated clutch pressure valves which selectively connect line pressure to the selected clutch as the winding of the solenoids are energized and de-energized by an electronic control system. A solenoid feed valve and feedback valve operate to connect line pressure to the input port of the several clutch actuator valves, provided the clutch pressures are within certain limits. If these limits are exceeded, line pressure is disconnected from the actuator valves and is applied, instead, automatically and without respect to electronic control, to the clutches that produce a predetermined gear ratio. A coast control valve operates to regulate pressure to a servo that is pressurized at a lower level for low gear ratio operation and at a higher level for reverse drive operation. The coast control valve vents the servo if either of the clutches that produce the predetermined speed ratio are pressurized. A line pressure regulator and boost valve act in combination with an on-off valve whose state is determined by a solenoid. Minimum line pressure is established at a minimum value, determined by the pressure drops across two orifices whose sizes are predetermined, when the solenoid opens line pressure to a vent port. Maximum line pressure is determined by pressure forces developed on a boost valve when the line pressure regulator solenoid closes the boost line to the vent port.
| 8
|
FIELD OF THE INVENTION
[0001] The present invention generally relates to wind turbines and more specifically relates to augmented wind turbines that use large convergent and divergent sections, whose vertical walls, and to a lesser extent horizontal walls, can generate significant wind shear forces and drag in strong winds.
BACKGROUND OF THE INVENTION
[0002] In general, the forces developed in augmented wind turbines will be proportional to the total wall area. Larger wall areas generally mean larger wall forces against the supporting structural elements and overall increased wind shear and drag effects. In high wind conditions or in applications involving large surface areas, these forces can lead to heavy damage to the walls, to the destruction of the convergent and divergent sections, to the danger of falling and flying objects for any local population and to a capsizing of the turbine tower. The forces of vacuum generated in the convergent and divergent sections of an augmented turbine will increase with increasing wind speed and the wall panels must be progressively retracted to prevent a collapse of the walls and structure of the convergent and the divergent. It is crucial that the panels of the side walls can be deployed and retracted progressively as the energy of the wind increases and decreases. This action should be computer controlled with alarms to the operator for abnormal operating conditions.
[0003] It is established that a convergent device located ahead of the flow turbine and a divergent device located downstream of the flow turbine will increase the speed or kinetic energy of the flow streamline in the ducted channel of the turbine located between the convergent and divergent. This increase in kinetic energy is known as the Venturi effect.
[0004] Diffuser Assisted Wind Turbines (DAWT) are a class of wind turbine that uses one-piece walled structures to accelerate wind before it enters the wind-generating element. It is well established that a DAWT will operate at higher wind speeds through the rotor blades as a result of the Venturi effect created by the diffuser. The concept of these diffuser structures and their effects has been around for decades but has not gained wide acceptance in the marketplace.
[0005] The principal reason that the DAWT has not been a commercial success comes from the fact that the large size of the diffuser structure has limited its applicability. The diffuser is most often conical in shape and is a one piece design. It has become more economical to simply increase the swept area of the rotor of a non augmented turbine. The limitation in the size of the diffuser is an economic issue but also a design issue. Large diffusers in very high winds develop tremendous forces and the structure necessary to resist these forces is both complicated and expensive.
[0006] The structural requirement in terms of resisting overturning and bending in extreme wind events which all wind turbines must be designed for by an ISO standard. The traditional DAWT turbine structure has poor drag characteristics. That combined with higher solidity of the rotor leads to substantially greater structural costs than a three bladed turbine in the support structure, the yaw bearing, and the foundation.
[0007] For these reasons, traditional DAWTs have not been a solution to improving wind energy production at the utility-scale. The power increases thus far have proved insufficient to offset the structural costs. In small wind applications where structural issues are lessened, they may be better than standard three bladed wind turbines if it can be definitively shown that they can improve output for the same cost.
[0008] To date, there exists no commercial designs for a utility-scale augmented turbine using a convergent and a divergent section connected to a ducted turbine section. The convergent section, although smaller in size than the divergent section, can still be a very large structure and resisting high wind conditions thus remains a design challenge. Convergent and divergent sections may have exterior walls that are straight and generate a rectilinear shape, or the walls may be circular and generate a conical shape or a mixture of straight and curved walls generating a more complex shape.
[0009] The normal wind speeds during turbine operations will vary from 4 to 12 m/s and the corresponding densities of the wind energy will increase 27 times from 39.3 to 1062.7 W/m 2 . A structural design could be provided for a convergent and divergent section operating strictly in low wind conditions, but this would significantly reduce the amount of energy produced by the turbine which would increase significantly the operating costs.
[0010] As the wind energy is proportional to the wind velocity cubed, tripling the wind velocity from 4 to 12 m/s implies the energy has increased by a factor of 27 (3×3×3=27). If the units were to be designed to operate as one size for all operating conditions, the required weight and size of the structural members and strength of the panels would make the turbine apparatus economically unfeasible. There is no doubt that the same size of convergent and divergent sections that is designed for a wind of 4 m/s would be destroyed or be unfeasible at a velocity of 12 m/s.
[0011] The variation in wind energy has two effects on the walls of the convergent and divergent sections. Firstly, the drag caused by the wind flowing along the walls of the structure are proportional to the wind velocity cubed and secondly, the levels of vacuum generated in the convergent and divergent sections also increase with the wind velocity cubed.
[0012] In a prior PCT patent application by the applicant (Turbine Apparatus, Application No. PCT/CA2009/000797), the configurations of the convergent and divergent to obtain optimum increase in flow velocity were established. The configurations cited were most applicable when air was the gas being used to power the rotor. One knows that by the phenomenon of dynamic similitude that the same results can be obtained for flow through a convergent divergent device if the Reynolds numbers are similar.
[0013] In order to build large augmented wind turbines, the design problem associated with high wind shear and vacuum must be addressed and the solution must be economical and not interfere with the necessity of having a very smooth inner wall surface. Thus, there is a need for an innovative solution for resolving the high wind shear and drag and vacuum problems associated with large convergent and divergent of different shapes employed to increase the wind speed through an augmented wind turbine.
SUMMARY OF THE INVENTION
[0014] An object of the present invention is to provide an apparatus that addresses at least one of the above mentioned needs.
[0015] The principal design advantages of the apparatus are the use of very large convergent and divergent sections to maximise the kinetic energy of the air as it passes through the turbine rotor and to build the walls as retractable panels such that as the wind speed increases, the size of the convergent and divergent can be progressively decreased. These two aforementioned elements adjust the size of the convergent and divergent sections to be appropriate for the prevailing wind speed, that in turn reduces the cost/kWh of the turbine installation and will produce a more competitive source of energy.
OBJECTIVES OF THE INVENTION
[0016] A first objective of the present invention is to provide an apparatus to generate electricity efficiently by a fluid turbine that is driven directly by air flow and the velocity of the fluid flow is maximised by the application of a convergent and a divergent section with an optimum size configuration.
[0017] A second objective of the present invention is to maximise the energy derived by building very large convergent and divergent sections using a modular construction rather than a one-piece construction that permits the progressive retraction of the appropriate wall areas of the convergent and divergent as the wind velocity increases.
[0018] A third objective is to provide a system for optimising the overall energy production such that at low wind speeds the areas of the convergent and divergent are in their largest overall shape and at high wind conditions the convergent and divergent assume their smallest shape. The system is designed such that, as the walls are progressively retracted, the wind velocity through the rotor blades and the vacuum created within the turbine remains relatively constant.
[0019] A fourth objective is to provide a system that produces lower cost electricity from the energy of wind and this requires the ability to use very large convergent and divergent structures that are designed to reduce the increasing drag forces generated on the overall turbine apparatus and tower structure as the wind velocity increases and to employ wall panels designed to retain their shape as the level of vacuum increases.
[0020] According to the present invention, there is provided a fluid turbine apparatus for use with at least one fluid turbine, said fluid turbine apparatus comprising:
a convergent section, said convergent section comprising an inlet and an outlet, said inlet having a area higher than said outlet, said convergent section having a first ratio being the inlet area over the outlet area and a modular grid-like structure supporting a plurality of convergent section retractable wall panels; a fluid turbine section adjacent to said outlet of said convergent section, said fluid turbine section comprising said at least one fluid turbine and having a central axis; a divergent section adjacent to said fluid turbine section, said divergent section comprising an inlet and an outlet, said inlet having an area lower than said outlet, said divergent section having a second ratio being the outlet area over the inlet area and a modular grid-like structure supporting a plurality of divergent section retractable wall panels; and a controller for selectively deploying and retracting the convergent and divergent section retractable wall panels,
wherein the fluid enters through said convergent section and exits through said divergent section.
[0025] Preferably, the aforesaid and other objectives of the present invention are realised by providing a convergent and divergent structure with modular retractable wall sections to create an augmented wind turbine that increases the velocity contacting the fluid turbine rotor, the turbine apparatus comprising:
a wind tower structure to support the weight of the turbine apparatus and the vertical and horizontal forces, in the form of weight, wind shear and drag, exerted by the wind flowing around said apparatus; a convergent section with retractable walls at each turbine apparatus, the convergent comprising an inlet and an outlet, the inlet having an area higher than said outlet, the convergent section having a first ratio being the inlet area on the outlet area, a fluid turbine section at each turbine apparatus adjacent to the outlet of the convergent section, the fluid turbine section comprising the fluid turbine, a divergent section with retractable walls at each turbine apparatus adjacent to the fluid turbine section, the divergent section comprising an inlet and an outlet, the inlet having an area lower than the outlet, the divergent section having a second ratio being the outlet area on the inlet area, a grid-like structure to support the panels that constitute the walls of the convergent and divergent sections, a set of flexible panels that can be retracted and deployed and are equipped with stiffening bars oriented in the direction of the retraction mechanism in order to hold a flat surface when operating under vacuum conditions created by the divergent section. a computerised control system that monitors the prevailing wind speed and progressively deploys or retracts specific panels of the convergent and divergent to maximise the energy produced and minimise the risk of a structural failure, an alarm system that advises the operator of any abnormality between the actual configuration of the convergent and divergent and its programmed configuration for the particular wind speed, a retractable set of deflectors that are positioned around the periphery of the outlet of the divergent and the periphery of the inlet of the convergent
wherein fluid enters through the convergent section and exits through the divergent section and wherein the fluid turbine apparatus has a third ratio being the outlet area of the divergent section on the inlet area of the convergent section.
[0035] Preferably, the combination of the convergent section, the fluid turbine section and the divergent section must be such that a Venturi effect is created. The Venturi effect derives from a combination of Bernoulli's principle and the equation of continuity. The convergent section serves to pressurize the inlet to the fluid turbine section whereas the divergent section serves to create a vacuum at the exit of the fluid turbine section.
[0036] Preferably, a plurality of structural members that connect in series and extend out from the fluid turbine section along the centerline of said fluid turbine support the retractable panels/walls of the convergent and divergent sections,
[0037] Preferably, a grouping of said retractable walls at specific distances relative to the configuration of the turbine sections is provided such that the above mentioned first second and third ratios are adjusted to hold the wind velocity relatively constant through the fluid turbine section as the wind velocity increases and decreases. This grouping of the retractable walls also adjusts and limits the drag and wind shear forces generated at different wind speeds by the turbine apparatus against the wind tower structure.
[0038] Preferably, the convergent section of the fluid turbine apparatus is defined as a section having an inlet which is larger than its outlet. The outlet of the convergent section is in contact with the inlet of the fluid turbine section. The length and configuration of the convergent section employing retractable walls are adjusted to minimise drag produced at high wind speeds and to make uniform the velocity profile at the convergent outlet so that a more even air flow is created at the inlet of the fluid section.
[0039] Preferably, the divergent section is defined as a section having an inlet which is smaller than its outlet. The inlet of the divergent section is in contact with the outlet of the fluid turbine section. The length and configuration of the divergent section employing retractable walls are adjusted to minimise drag produced at high wind speeds and to make uniform the velocity profile at the divergent inlet so that a more even vacuum is created at the inlet of the fluid section.
[0040] Preferably, it has been determined that the structural members that extend out from the turbine section will be arranged to provide a minimum of 1 and maximum of 8 vertical and horizontal modules and that each module shall support the retractable and fixed wall sections that establish its outside walls. The percentage of the surface area of the retractable wall surface to the fixed wall surface of each module may vary.
[0041] Preferably, the shape of the cross-section of the different convergent and divergent sections may vary (circular, rectangular, annular, etc.). However, the preferred shape of the cross section of the large convergent and divergent sections are rectilinear. Smaller convergent and divergent sections may be circular and preferably be similar to the shape of the cross section of the outlet of the fluid turbine section to keep a laminar flow in the divergent section.
[0042] Preferably, it is to be noted that the fluid turbine section may have a shape that differs from the divergent section and/or the convergent section. In this case a transition section is installed between the fluid turbine section and the divergent section and/or the convergent section to preserve a laminar flow.
[0043] In a further embodiment, the retractable walls may be made of fabric material and stiffeners or they may be made of hinged metallic sections. In both cases, a drive mechanism is employed to deploy and retract each of the retractable wall panels. The retractable wall panels are actuated in groupings that are determined in function of the prevailing wind speed. As the wind speed increases panels are progressively retracted to limit the vacuum within the convergent and divergent structures, to limit the drag generated by the wind against the structures and to ensure that the maximum feasible amount of energy is being produced by the fluid turbine without risk of structural damage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] These and other objects and advantages of the invention will become apparent upon reading the detailed description and upon referring to the drawings in which:
[0045] FIG. 1 is a schematic cross-section view of a possible rectilinear shaped convergent-divergent, according to a preferred embodiment of the present invention, with its walls in the retracted position.
[0046] FIG. 2 is a schematic cross-section view of the possible rectilinear shaped convergent-divergent shown in FIG. 1 , with its walls in the deployed position.
[0047] FIG. 3 is a schematic cross-section view of a modular panel section of a possible rectilinear shaped panel, according to a preferred embodiment of the present invention.
[0048] FIGS. 4 a and 4 b are schematic side and cross section views respectively of a modular flexible panel with stiffening bars and its retraction/deployment mechanism, according to a preferred embodiment of the present invention.
[0049] FIGS. 5 a and 5 b are schematic side and cross section views respectively of a circular divergent section and circular fluid turbine section with horizontally mounted aerodynamic deflectors, according to a preferred embodiment of the present invention.
[0050] FIGS. 6 a and 6 b are schematic side and cross section views respectively of a convergent section with horizontally mounted aerodynamic deflectors, according to a preferred embodiment of the present invention
[0051] Legend for above drawings:
1 : turbine tower structure 2 : convergent section 3 : fluid turbine section 4 : divergent section 5 : structural member 6 : deployable and retractable wall panel 7 : flexible panel stiffening bars 8 : panel deployment and retraction mechanism 9 : wind turbine apparatus 12 : rotating deflectors 13 : horizontally-mounted aerodynamic deflector
[0063] While the invention will be described in conjunction with an example embodiment it will be understood that it is not intended to limit the scope of the invention to such embodiment, On the contrary, it is intended to cover all alternatives modifications and equivalents as may be included as defined by the appended claims.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0064] In the following description, similar features in the drawings have been given similar reference numerals and in order to weight down the figures some elements are not referred to in some figures if they were already identified on a previous figure.
[0065] A novel fluid turbine apparatus using convergent and divergent sections and composed of retractable wall panels will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments(s) it is to be understood that the embodiment(s) described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.
[0066] A large variation in the wind energy and forces on the turbine apparatus in general, and the structure of the convergent and divergent sections in particular, means that, to operate efficiently, the design of the convergent and divergent sections must allow for a progressive decrease in the area of the convergent and divergent section walls. This requires a modular grid-like structure to support the panels of the convergent and divergent sections. Simply stated, as the wind velocity increases, selected panels are retracted and, as the wind velocity decreases, selected panels are deployed.
[0067] A controller, such as a computer control system then selectively deploys or retracts individual panels in order to control the drag and vacuum forces on the walls and to produce the maximum amount of energy at all wind speeds. This flexibility in matching wind velocity to the size of the convergent and divergent sections is absolutely necessary to assure the economic viability of a DAWT turbine operating with a convergent and divergent section.
[0068] In the event that the controller detects an abnormality in the deployment of the wall panels, an alarm would be sounded in order that the operator take immediate action before the convergent and divergent structures or the turbine apparatus incurs structural damage.
[0069] When a convergent section is used with a divergent section, the operation of the convergent section changes in that it is now always operating under vacuum; as is the divergent section. The flow conditions of the air stream as it proceeds through the convergent and divergent sections are crucial to their efficiency. The biggest problem is boundary layer separation. Once the air travelling along the face of the side walls loses too much energy with respect to the main body of air flow, the boundary layer flow stream breaks away from the wall and begins to swirl. The overall efficiency of the convergent or divergent sections begins to decrease. This requires that designs incorporate features to assure that interior wall panels remain flat and very smooth and that the members of the structure of the convergent and divergent create minimal obstruction to air flow.
[0070] Accordingly, if the panels are made of flexible material, they will include reinforcing bars that span the panel between structural members to keep them straight (flat) under the conditions of vacuum created by the divergent section. If the panel is retracted by winding itself around a horizontal axis, the bars would be positioned horizontally in the panels. If the panels are retracted by winding themselves around a vertical axis, they would be placed vertically in the panels.
[0071] If the divergent section, or part of the divergent section, were to be of a circular configuration rather than rectilinear, the challenge of the wind shear could be addressed differently. The principal challenge of wind shear and drag occurs if the wind were to strike the divergent section at right angles to the central axis of the turbine ducted tunnel. This is a completely abnormal situation as the turbine is designed to follow the wind and would be a worst case situation for wind shear and drag.
[0072] An alternative solution for wind shear and drag would be to install aerodynamic deflectors on both sides of the circular diffuser along its horizontal centre line. The deflectors would decrease the shear forces on the windward side and decrease the drag on the leeward side of the diffuser.
[0073] A convergent section designed using Borger optimisation theory (as illustrated in drawings) will have an inlet surface area much smaller than the surface area of the outlet of the divergent. Accordingly, it will be smaller in dimension than the divergent section, while the height of the side walls will be much shorter than the width of its top and bottom. Given the smaller dimensions of the side walls, it may be possible to mount the same type of aerodynamic deflectors on both side walls of the convergent as suggested above for the circular diffuser. It is understood that horizontal wind forces are always much more severe than vertical wind forces.
[0074] In order to limit the vacuum generated by the convergent and divergent sections, retractable panels would be installed in the top and bottom sections of the convergent section. By retracting and deploying these panels, the efficiency of the convergent section will increase and decrease and this in turn will modify the efficiency of the divergent section. It will be possible to limit the vacuum generated by the divergent section by simply decreasing the efficiency of the convergent section.
[0075] As discussed above, the retraction and deployment of the panels in the convergent section would preferably be under computer control and would be programmed to maximise energy production and to limit the vacuum generated. The threat of wind shear and wind drag, however, could be addressed by the use of deflectors mounted on the horizontal walls of the convergent section and of a circular divergent section and of a circular fluid turbine section.
[0076] FIGS. 1 , 2 , and 3 show the principal configurations of convergent and divergent sections that may be considered for an augmented turbine apparatus and include rectilinear, conical and annular configurations. In the preferred embodiment, the convergent section ( 2 ) and divergent section ( 4 ) are rectilinear and surround a cylindrical turbine section ( 3 ). However conical and annular convergent and divergent sections can also be used.
[0077] As shown in FIG. 3 , the modular and retractable wall panels ( 6 ) are independently controlled. As the wind velocity begins to increase and the drag on the wind turbine apparatus increases, the retractable wall panels in the modular sections of the convergent and divergent sections farthest from the fluid turbine section are retracted. If the wind shear and drag and internal vacuum continue to increase, the retractable panels ( 6 ) at the next farthest section from the fluid turbine section are retracted. This progression will continue if the wind velocity continues to increase and the result is a shortening of the length of the convergent and divergent sections with a reduction of the inlet area of the convergent section and the outlet area of the divergent section. The order of the progression is a function of the wind velocity and the capacity of the turbine electrical generator.
[0078] Similarly if the wind velocity begins to fall, the next farthest section of the convergent and the divergent sections will be deployed. This will lengthen the convergent and divergent sections and will increase the inlet area of the convergent section and the outlet area of the divergent section. The intent is to uniform the rate of power production and thereby optimise the load on the electrical system and to limit the horizontal forces on the structural members of the convergent and divergent and on the turbine tower structure.
[0079] In a further non illustrated preferred embodiment of the convergent-divergent, the farthest end sections of the convergent and divergent can advance and retract. This permits a lengthening of the convergent and divergent.
[0080] As better shown in FIGS. 4 a and 4 b , preferably, the apparatus further comprises at least one reinforcing bar ( 7 ) spanning each of the retractable wall panels ( 6 ) of the divergent section between adjacent divergent section structural members ( 5 ), or further comprises at least one reinforcing bar ( 7 ) spanning each of the retractable wall panels ( 6 ) of the convergent section between adjacent convergent section structural members ( 5 ). As mentioned above, if the panel ( 6 ) is retracted by winding itself around a horizontal axis (using a panel deployment and retraction mechanism ( 8 )), the bars would be positioned horizontally in the panels. If the panels are retracted by winding themselves around a vertical axis, they would be placed vertically in the panels.
[0081] In a further preferred embodiment shown for example in FIGS. 5 a and 5 b , rotating or pivotable deflectors ( 12 ) are placed around the outlet of the divergent section ( 4 ) and the inlet of the convergent section ( 2 ) to form a continuous barrier. These deflectors ( 12 ) serve to increase the effective surface areas of the convergent inlet and the divergent outlet and are only deployed at low wind conditions. Their role is to assist in increasing the vacuum generated in the convergent and divergent sections of the turbine at low wind conditions. In their inactive position, the deflectors ( 12 ) are parallel to the walls of the convergent and divergent sections and, in their active position, they are at right angles to the walls. The rotating or pivoting mechanism may be hydraulic, pneumatic, geared or electrical, or any other equivalent system.
[0082] Preferably, as better shown in FIGS. 5 a to 6 b and mentioned above, the convergent section, the divergent section and the fluid turbine section each further comprise horizontally-mounted aerodynamic deflectors ( 13 ) to minimise wind stress and drag.
[0083] As the person skilled in the art would understand, a plurality of types of fluid turbines may be used with the device of present invention, for example, for example a single or double walled turbine. Also for each fluid turbine, different combinations may be used, for example a different number and/or configuration of blades, the space between the wall of the water turbine section and the turbine rotor. etc.
[0084] As the person skilled in the art would understand, the parameters of the convergent section and divergent sections may differ than the example shown in this document. Similarly, the fluid turbine section may differ depending of the amount of electricity to be generated.
[0085] Although preferred embodiments of the present invention have been described herein and illustrated in the accompanying drawings, it is understood that the invention is not limited to these precise embodiments and that various changes and modifications may be effected therein without departing from the scope of the present invention.
|
A fluid turbine apparatus for use with a turbine comprising a convergent section, a fluid turbine section adjacent to an outlet of the convergent section, and a divergent section adjacent to the fluid turbine section. The fluid enters through the convergent section and exits through the divergent section. The convergent and divergent sections are constructed using a modular grid-like structure supporting retractable wall panels. The internal vacuum created by the diffuser and the wind shear stresses on the convergent and divergent sections can be limited. Configurations of the convergent and divergent sections can be adjusted to suit prevailing wind velocities. Barriers of rotating deflectors are used to increase the effective area of the convergent and divergent sections during low wind conditions. Horizontally mounted aerodynamic deflectors may be used to decrease wind shear and drag on the divergent section, the turbine section, and on side walls of the convergent section.
| 5
|
FIELD OF THE INVENTION
This invention relates to colorants comprising a chromophore having two methine moieties attached to a benzodifuranone backbone, wherein said moieties optionally have at least one poly(oxyalkylene) chain, preferably at least two such chains attached thereto. Such colorants exhibit excellent thermal stability, effective colorations, excellent low extraction rates, and effective lightfastness levels, particularly when incorporated within certain media and/or on the surface of certain substrates, particularly polyesters. The optional poly(oxyalkylene) chains also increase the solubility in different solvents or resins thereby permitting the introduction of such excellent coloring chromophores within diverse media and/or on diverse substrates as well as provides a liquid colorant which facilitates handling. Compositions and articles comprising such colorants are provided as are methods for producing such inventive colorants.
DISCUSSION OF THE PRIOR ART
All U.S. patents cited within this specification are hereby incorporated by reference.
There continues to be a need to provide versatile colorants within various applications such that the coloring agent itself exhibits excellent colorations (particularly at low color loadings and due to inherently high quantum absorption efficiency), high thermal stability, effective lightfastness, low extraction (or drastic reduction in possibility of removal therefrom via extraction by solvents or like sources), ease in handling, ability to mix thoroughly with other coloring agents and thus to provide effective different hues and tints within or on target substrates, and acceptable toxicity levels. There has been a need to provide improved colorants meeting this criteria for certain thermoplastic media, such as polyesters, such that the colorants themselves exhibit excellent compatibility therein (for instance in terms of intrinsic viscosity loss and the other characteristics desired for such plastics as noted above). In particular, such characteristics for polyesters are desired for colorants that absorb, for example, though not necessarily, within the red portion of the visible spectrum. Other hues are available as well for such a desired, high-performing polyester plastic colorant, including blue, yellow, orange, and the like, all dependent on the presence of certain coupling or modifying moieties present on the chromophore backbone itself. It is believed and, as noted above, has been determined that such desirable polyester plastic colorations with the characteristics noted above are possible through the addition of certain pendant groups to the chromophore backbone which do not act as couplers or color modifiers [such as, for example poly(oxyalkylene) groups] and thus any chromophore (and resultant hue or tint) may be utilized with the desired benzodifuranone bismethine chromophore itself.
Previous coloring agents for such end-uses have included pigments, dyes, or dyestuffs, with each having its own drawback, be it an extraction problem from the finished article, a handling problem during manufacturing due to solid dust particles, a staining problem, due to the difficulty associated with cleaning such coloring agents from manufacturing machinery after colored plastic production, and other like issues. As a result, there is a clear desire to provide easier to handle, less extractable, easy-to-clean, etc., coloring agents for introduction within thermoplastic articles to provide decorative, aesthetic, and other like effects. However, the chromophores present within such dyes, pigments, and the like, are highly desired for the hues and shades they provide within the ultimate thermoplastic articles themselves. Facilitating the introduction of such chromophores within such formulations is thus a highly desired target within the colored thermoplastic industry, whether it be in terms of handling, extraction, cleaning, or the like.
Attempts to meet this desire have included the introduction of certain standard types of polymeric colorants within plastics (be they thermoplastics or thermoset types). These colorants are primarily poly(oxyalkylenated) compounds, such as triphenylmethanes, methines, and the like (i.e., those found within U.S. Pat. No. 4,992,204, to Kluger et al.). Some of these colorants exhibit certain problems during incorporation into thermosets and thermoplastics. In thermoplastic compositions such as polyesters, many of these previously disclosed compositions are not stable at the polyester processing temperatures. As a result, the colorations provided by such polymeric colorants may be reduced in strength or changed in shade under such circumstances. Other types of colorants have been discussed within the prior art, such as azos and bisazos, but the specific colorations provided by such compounds are limited to certain hues and their utilization within polyesters is suspect from a number of perspectives (such as thermal stability, and the like). There is thus a desire to introduce new types of colorants comprising different types of chromophores for the purpose of providing new, effective, versatile colorants for such myriad end-uses as noted above and that exhibit excellent colorations, extraction, thermal stability, mixing with other coloring agents, and low toxicity, at least.
A certain class of colorants, namely benzodifuranone derivatives, exhibit excellent colorations and have been utilized within different applications, most prominently within inks, such as in U.S. Pat. No. 5,665,150 to Schwarz, and U.S. Pat. No. 5,779,778 to Gregory et al. and as disperse dyes for polyester, such as in J. Soc. Dyers Colour . 110, 1994, p, 178. The chromophores disclosed in this art are significantly structurally and thus electronically different from the inventive chromophores disclosed herein, exhibiting a substituted phenyl group attached directly to the benzodifuranone core structure, and thus cannot be classified as methines. There has also been some discussion of introducing isatin-based benzodifuranones within plastics as disclosed within published PCT Application WO00/24736 to Ciba Specialty Chemicals. Such compounds are limited to non-polymeric species and, again, require the presence of isatin as a substituent (and thus a heterocyclic pendant group attached to the double bond between such an isatin adduct and the backbone benzodifuranone compound). Apparently, such compounds provide effective colorations within plastics; however, there is no discussion of the handling issues, mixing capabilities with other colorants, migratory properties, lightfastness, or other concerns with colorants for plastics. Furthermore, the reaction with isatin is rather costly and the yield is suspect thus increasing the potential costs to the end-user and/or the consumer. A new type of benzodifuranone colorant for plastic applications (at least) is thus desirable, primarily due to the potential colorations provided by such base chromophores. Furthermore, simplified methods of producing such benzodifuranone derivatives are also desired such that the end colorant can be tailored in its constitution to any end-use application through the presence of poly(oxyalkylene) groups thereon. Such an option would thus provide much-needed versatility for such desirable coloring agents within various media (including the aforementioned plastics, liquids, foams, and the like). To date, there have been no teachings or fair suggestions of such a highly desirable, specific potentially polymeric benzodifuranone derivative colorant within the pertinent prior art or within the colorant industry itself.
DESCRIPTION OF THE INVENTION
It is thus an object of the invention to provide novel thermally stable polymeric colorants for utilization within thermoplastic and thermoset articles based on bismethine benzodifuranone backbone structures. Yet another object of this invention is to provide excellent colorations within liquid compositions (such as inks, and the like) through the utilization of the same bismethine benzodifuranone-type compounds as noted above. The features of this new chromophore are exceptionally high color strength and exceptionally high heat stability. In the liquid embodiments demonstrated herein, the colorant exhibits low extraction from thermoplastics such as polyester, little effect on the molecular weight (intrinsic viscosity) of polyester when incorporated at high color loading, low toxicity and ease of handling (homogeneous liquid). It is a further object of this invention to provide new solid dye compositions suitable for the coloration of textile materials, in particular advantageous in the dyeing of hydrophobic fibers such as polyester.
It is to be understood that the term alkyl as used throughout is intended to encompass any straight or branched alkyl moiety, having anywhere from 1 to 30 carbons therein; the same chain length applies to the term “alkoxy” as well. Also, the terms substituted phenyl and substituted polyphenyl are intended to encompass any phenyl system having any type of pendant group attached thereto, including, without limitation, alkyl groups, alkylene groups, alcohol groups, ether groups, ester groups, amine groups, nitro groups, amide groups, hydroxyls, thiols, and the like. Phenyl is basically an unsubstituted ring system (and thus includes hydrogens only as pendant groups).
The present invention preferably encompasses colorants conforming to the structure of Formula (I)
wherein Y is selected from the group consisting of hydrogen, alkyl, halogen, alkenyl, hydroxy, and alkoxy; X is selected from the group consisting of any atom that provides a heterocyclic system for the cyclic ring; B is selected from the group consisting of alkenyl, phenyl, polyphenyl, substituted phenyl, substituted polyphenyl, alkenyl-Q-A, phenyl-Q-A, polyphenyl-Q-A, substituted phenyl-Q-A, and substituted polyphenyl-Q-A, wherein Q is selected from the group consisting of N, O, S, SO 2 , SO 3 , CO 2 , SO 2 N, alkyl, and alkoxy, and A either conforms to the structure of Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof; and R′ is selected from the group consisting of hydrogen, C 1-20 alkyl, C 1-20 alkylester, halo, hydroxyl, hydrogen, thio, cyano, sulfonyl, sulfo, sulfato, aryl, nitro, carboxyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, acrylamino, C 1-20 alkylthio, C 1-20 C 1-20 alkylsufonyl, C 1-20 alkylphenyl, phosphonyl, C 1-20 alkylphosphonyl, C 1-20 alkoxycarbonyl, phenylthio; or conforms to the structure E, wherein E is an unsaturated heterocylic residue selected from the group consisting of furyl, thienyl, pyrrolyl, pyridyl, pyranyl, thiazolyl, oxazolyl, pyrazolyl, imidazolyl, thiadiazolyl, and s-triazoyl. Alternatively, E represents a saturated heterocyclic residue selected from the group consisting of tetrahydrofuryl, tetrahydrothienyl, pyrrolidyl, piperidyl, tetrahydropyranyl, piperazinyl, morphonyl, and hexahydroazepinyl. Also, E represents a hetrocyclic residue condensed with benzene rings such as benzofurnayl, benzothienyl, indolyl, benzoxazolyl, benzimidazolyl, and benzothiazolyl, as well as a phenyl substituted with any or all of R 1 , R 2 , R 3 , R 4 , and R 5 . Preferably, Y is hydrogen, X is O, R 1 , R 2 , R 3 , R 4 , R 5 , and R′ are hydrogen, with preferably, though not necessarily, at least one of R 1 , R 2 , R 3 , R 4 , and R 5 being Q-A; polyoxyalkylene constituent is ethylene oxide (EO), propylene oxide (PO), or any combinations thereof; and Q is N. Preferably, B is a moiety that exhibits conjugation when incorporated and present within the structure (I) in order to provide desired colorations, as well as a moiety including the above-defined Q-A group; more thorough descriptions of such groups are presented below.
More specifically, and preferably (though in a non-limiting capacity), the inventive benzodifuranone bismethine colorant conforms to the structure of (II)
wherein X and Y are defined as for (I), above, and wherein R 1 , R 2 , R 3 , R 4 , and R 5 are the same or different and are selected from the group consisting of hydrogen, C 1-20 alkyl, C 1-20 alkylester, halo, hydroxyl, hydrogen, thio, cyano, sulfonyl, sulfo, sulfato, aryl, nitro, carboxyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, acrylamino, C 1-20 alkylthio, C 1-20 C 1-20 alkylsufonyl, C 1-20 alkylphenyl, phosphonyl, C 1-20 alkylphosphonyl, C 1-20 alkoxycarbonyl, phenylthio, and Q-A, wherein Q is selected from the group consisting of N, O, S, SO 2 , SO 3 , CO 2 , SO 2 N, alkyl, and alkoxy, and A either conforms to the structure of Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, and R′ is selected from the group consisting of hydrogen, C 1-20 alkyl, C 1-20 alkylester, halo, hydroxyl, hydrogen, thio, cyano, sulfonyl, sulfo, sulfato, aryl, nitro, carboxyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, acrylamino, C 1-20 alkylthio, C 1-20 C 1-20 alkylsufonyl, C 1-20 alkylphenyl, phosphonyl, C 1-20 alkylphosphonyl, C 1-20 alkoxycarbonyl, and phenylthio; or conforms to the structure of E, wherein E is an unsaturated heterocylic residue selected from the group consisting of furyl, thienyl, pyrrolyl, pyridyl, pyranyl, thiazolyl, oxazolyl, pyrazolyl, imidazolyl, thiadiazolyl, and s-triazoyl. Alternatively, E represents a saturated heterocyclic residue selected from the group consisting of tetrahydrofuryl, tetrahydrothienyl, pyrrolidyl, piperidyl, tetrahydropyranyl, piperazinyl, morphonyl, and hexahydroazepinyl. Also, E represents a heterocyclic residue condensed with benzene rings such as benzofurnayl, benzothienyl, indolyl, benzoxazolyl, benzimidazolyl, and benzothiazolyl, as well as a phenyl substituted with any or all of R 1 , R 2 , R 3 , R 4 , and R 5 . Preferably, R 1 , R 2 , R 3 , R 4 , R 5 , and R′ are hydrogen, with preferably though not necessarily, at least one of R 1 , R 2 , R 3 , R 4 , and R 5 being Q-A; polyoxyalkylene constituent is ethylene oxide (EO), propylene oxide (PO), or any combinations thereof; and Q is N.
Further preferred inventive colorants conform to the following structures (III), (IV), (V), and (VI):
wherein A is represented by the Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof; and R′ is selected from the group consisting of hydrogen, C 1-20 alkoxy, C 1-20 alkyl, and C 1-20 esters.
wherein A is represented by the Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, and R′ is selected from the group consisting of hydrogen, C 1-20 alkoxy, C 1-20 alkyl, and C 1-20 esters.
wherein A is represented by the Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, and R′ is selected from the group consisting of hydrogen, C 1-20 alkoxy, C 1-20 alkyl, and C 1-20 esters.
wherein A is represented by the Formula (VII)
[polyoxyalkylene constituent] z R′ (VII)
wherein z is 1 or 2; polyoxyalkylene constituent is selected from the group consisting of at least three monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof, monomers of at least one C 2-20 alkyleneoxy group, glydicol, glycidyl, or mixtures thereof; and R′ is selected from the group consisting of hydrogen, C 1-20 alkoxy, C 1-20 alkyl, and C 1-20 esters.
Compositions comprising such compounds of (I)-(VI) are also encompassed within this invention, particularly those comprising such compounds and other coloring agents, ultraviolet absorbers, bluing agents, or mixtures thereof, as liquids or as pellets for further introduction within desired molten thermoplastic or thermoset formulations (or precursor formulations). Methods of making such compositions, particularly thermoplastics, comprising such compounds of (I)-(VI) are also contemplated within this invention.
The term “thermoplastic” is intended to encompass any synthetic polymeric material that exhibits a modification in physical state from solid to liquid upon exposure to sufficiently high temperatures. Most notable of the preferred thermoplastic types of materials are polyolefins (i.e., polypropylene, polyethylene, and the like), polyester (i.e., polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, and the like), polyamides (i.e., nylon-1,1, nylon-1,2, nylon-6 or nylon-6,6), polystyrenes, polycarbonates, polyvinyl halides (i.e., polyvinyl chloride and polyvinyl difluoride, as merely examples), and the like. Preferred thermoplastics within this invention are polyesters, and most preferred is polyethylene terephthalate.
Such thermoplastic articles include bottles, storage containers, sheets, films, fibers, plaques, hoses, tubes, syringes, and the like. Included within this list would be polyester, polystyrene and other like resinous materials in sheet form which are present within windows for strength and resiliency functions. In such an instance, the inventive colorant compounds would provide or contribute to excellent colorations to such thermoplastic articles for decorative, aesthetic, and/or protective (such as ultraviolet or infrared protection) purposes. Basically, the possible uses for such a low-migratory, thermally stable colorant for such items as thermoplastics (particularly polyesters such as transparent polyethylene terephthalate) is voluminous and cannot easily be enveloped. Other possible end-uses, however, would include within solvent systems, printing inks, within and on textiles (either on or within textiles, fibers, or fabrics), within display devices such as liquid crystal displays, and the like.
The inventive colorant compounds may be added in any amount to such thermoplastics up to their saturation limits therein. Preferably, the amount is between about 0.00001 ppm to about 25,000 ppm per total amount of resin; more preferably from about 0.001 to about 15,000 ppm; still more preferably from about 0.1 to about 5,000 ppm; and most preferably from about 100 to about 2,500 ppm. Of course, the more colorant present, the darker the shade therein. When mixed with other colorants within the target thermoplastic, the same amounts would be preferred with the saturation limit dependent upon the amount of any extra colorants therein.
The term “thermoset” or “thermosets” encompasses a polymeric solid which, upon exposure to sufficient heat or in the presence of a sufficient amount of catalyst, configures itself into a pre-determined shape. Such formulations encompassed within this term includes polyurethanes, and the like. Thus, foams, sheets, articles, coverings, and the like, are all envisioned within this definition.
The inventive colorant compounds may be added in any amount to such thermosets up to their saturation limits therein. Preferably, the amount is between about 0.00001 ppm to about 25,000 ppm per total amount of resin; more preferably from about 0.001 to about 15,000 ppm; still more preferably from about 0.1 to about 5,000 ppm; and most preferably from about 100 to about 2,500 ppm. Of course, the more colorant present, the darker the shade therein. When mixed with other colorants within the target thermoset, the same amounts would be preferred with the saturation limit dependent upon the amount of any extra colorants therein.
Other types of articles contemplated within this invention for the inventive colorant compounds include, again without limitation, thermoplastic articles, such as films, sheets, bottles, containers, vials, and the like. Other colorants may be added to or incorporated therein with such inventive colorant compounds to produce different hues and tints, again for aesthetic, decorative, and/or protective purposes. Ultraviolet absorbers may also be introduced, incorporated, and the like, in order to protect the article or, if in container for, the contents therein.
Such thermoplastic and/or thermoset colorants (and other additives) are typically added to such compositions during the injection molding (or other type of molding, such as blow molding), thereof, including, and without limitation, by mixing the liquid absorber with resin pellets and melting the entire coated pellets, or through a masterbatch melting step while the resin and absorber are pre-mixed and incorporated together in pellet form. Such plastics include, again without limitation, polyolefins, polyesters, polyamides, polyurethanes, polycarbonates, and other well known resins, such as those disclosed within U.S. Pat. No. 4,640,690, to Baumgartner et al., and U.S. Pat. No. 4,507,407, to Kluger et al. under the term “thermoplastics” and/or “thermosets”. Generally, such plastics, including the colorant, UV absorber, and other potential additives, are formed through any number of various extrusion, etc., techniques, such as those disclosed in the aforementioned U.S. patents. Preferred thermoplastics are polyesters, such as, in one non-limiting embodiment, polyethylene terephthalate. “Plastic packaging” thus encompasses containers, sheets, blister packages, and the like, utilized for storage purposes and which include the plastics in any combination as noted above.
The term “pure, undiluted state” as used in conjunction with the inventive colorant compounds indicates that the compounds themselves without any additives are liquid at room temperature. Thus, there is no need to add solvents, viscosity modifiers, and other like additives to the compounds to effectuate such a desirable physical state.
The presence of surfactants, solvents, and the like, may be utilized to alter the solubility, coloring characteristics, and the like, of the ultimate inventive benzodifuranone bismethine colorant [whether poly(oxyalkylenated) or not] which would be understood and appreciated by the ordinarily skilled artisan within this particular art. It is also understood that solid versions of such inventive colorants (e.g., dyestuffs, pigments, and the like) could be dispersed within liquid media to provide stable dispersions thereof for further utilization.
Preferably, the colorant compounds (I)-(VI) are liquid in nature at ambient temperature and pressure and at substantial purity; however, pasty, waxy, or crystalline colorants are also encompassed within this invention. In order to effectuate coloring of substrates and media, any other standard colorant additives, such as resins, preservatives, surfactants, solvents, antistatic compounds, antioxidants, antimicrobials, and the like, may also be utilized within the inventive colorant compound compositions or methods.
For liquid composition applications, the amount present should range from about 0.00001 ppm to about 30,000 ppm of the total solvent present; preferably, from about 0.001 to about 15,000 ppm; still more preferably from about 0.1 to about 5,000 ppm; and most preferably from about 100 to about 2,500 ppm. Of course, the more colorant present, the darker the shade therein. When mixed with other colorants within the target solvent, the same amounts would be preferred.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The specific formulations below, as well as the following exemplified methods of producing such and methods of coloring using such are thus indicative of the preferred embodiments of this invention (all of the initial aniline derivatives and aldehyde derivatives were produced in accordance with the method taught within U.S. Pat. No. 4,594,454 to Moore et al.):
Colorant Formation
EXAMPLE 1
To a 250 mL round bottom flask containing 33.0 g of alkoxylated (2EO 10PO 6EO) para-formyl aniline was added glycine (0.36 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone [produced in accordance with the method taught within Wood et al., Journal of the American Chemical Society , 66, 1541 (1944)] (2.98 g), and water (25 g). The ensuing reaction mixture was placed on a rotary evaporator and mixed for approximately 5 minutes. The reaction mixture was then heated to 90-95° C. for 2.5 hours while a water aspirator vacuum was applied to the rotary evaporator. The ensuing red liquid was allowed to cool to ambient temperature overnight. Water (80 g) was then added to the product. The mixture was then stirred on the rotary evaporator and heated to 75-80° C. The mixture was then poured into a separatory funnel and allowed to phase for 30 minutes during which time two layers formed. The bottom product layer was removed and mixed with an additional 80 g of water at 75-80° C. The mixture was allowed to phase in a separatory funnel as before. The bottom product layer was then removed and stripped via rotary evaporator to give approximately 28 g of a red liquid exhibiting a λ max absorbance (in methanol) of 556 nm.
EXAMPLE 2
To a 250 mL round bottom flask containing 26.2 g of alkoxylated (10EO) aldehyde of 2,5-dimethoxyaniline was added glycine (0.35 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (4.03 g), and water (20 g). The ensuing reaction mixture was placed on a rotary evaporator and mixed for approximately 5 minutes. The reaction mixture was then heated to 90-95C for 2.5 hours while a water aspirator vacuum was applied to the rotary evaporator. The ensuing blue liquid was allowed to cool to ambient temperature overnight. Water (20 g) was then added to the product. The reaction mixture was then heated to 90-95C for 2 hours while a water aspirator vacuum was applied to the rotary evaporator to give a thick blue oil exhibiting a λ max absorbance (in methanol) of 581 nm.
EXAMPLE 3
To a 3-neck, 100 mL round bottom flask containing 30 g of alkoxylated (2EO6PO 6EO) aldehyde of 2,5-dimethoxyaniline was added glycine (0.21 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (3.23 g), and water (10 g). The ensuing reaction mixture was heated to 80-85° C. for 4 hours. The ensuing blue liquid was allowed to cool to ambient temperature and stir overnight. The mixture was then transferred to a 1-neck 250 mL round bottom flask and stripped on a rotoary evaporator for 2 hours at 90-95° C. Water (90 g) was then added to the product. The solution was mixed and heated to 80° C. before being poured into a separatory funnel. The solution was allowed to phase separate. The bottom product layer was drained and was again washed as above with 90 g of water. The ensuing product layer was stripped via rotary evaporator to give 26 g of a blue oil exhibiting a λ max absorbance (in methanol) of 577 nm.
EXAMPLE 4
To a 3-neck, 100 mL round bottom flask containing 47.5 g of alkoxylated (2EO 6PO 6EO) aldehyde of aniline was added glycine (0.21 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (5.5 g), and water (10 g). The ensuing reaction mixture was heated to 75 C for 3 hours. The ensuing red liquid was allowed to cool to ambient temperature and stir overnight. Water (100 g) was then added to the product. The solution was mixed and heated to 80 C before being poured into a separatory funnel. The solution was allowed to phase separate. The bottom product layer was drained and was washed again twice as above with 100 g of water. The ensuing product layer was stripped via rotary evaporator to give 43 g of a red oil exhibiting a λ max absorbance (in methanol) of 556 nm.
EXAMPLE 5
To a 3-neck, 100 mL round bottom flask containing 70.8 g of alkoxylated (2EO 4PO 4EO) aldehyde of aniline was added glycine (0.5 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (10.5 g), and water (55 g). The ensuing reaction mixture was heated to 75C for 3 hours. The ensuing red liquid was allowed to cool to ambient temperature and stir overnight. Water (185 g) was then added to the product. The solution was mixed and heated to 75 C before being poured into a separatory funnel. The solution was allowed to phase separate. The bottom product layer was drained and washed again as above with 185 g of water. The ensuing product layer was stripped via rotary evaporator to give 56 g of a red oil exhibiting a λ max absorbance (in methanol) of 554 nm.
EXAMPLE 6
To a 1-neck, 100 mL round bottom flask containing 55.1 g of alkoxylated (16EO 10PO) aldehyde of m-toluidine was added glycine (0.4 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (2.43 g), and methanol (5 mL). The ensuing reaction mixture was placed on a rotovap and stripped at >90 C for 6 hours to give a violet oil exhibiting a λ max absorbance (in methanol) of 553 nm.
EXAMPLE 7
To a 50 mL round bottom flask containing 15.5 g of alkoxylated (8EO) aldehyde of resorcinol was added glycine (0.16 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (3.0 g), and water (20 g). The ensuing reaction mixture was placed on a rotary evaporator and mixed for approximately 5 minutes. The reaction mixture was then heated to 90-95C for 4 hours while a water aspirator vacuum was applied to the rotary evaporator to give a thick brown oil exhibiting a λ max absorbance (in methanol) of 468 nm.
EXAMPLE 8
To a 250 mL round bottom flask containing 29.2 g of alkoxylated (2EO/10PO/6EO) aldehyde of meta toluidine was added glycine (0.2 g), 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (2.6 g), and water (25 g). The ensuing reaction mixture was placed on a rotary evaporator and mixed for approximately 5 minutes. The reaction mixture was then heated to 90-95C for 5 hours while a water aspirator vacuum was applied to the rotary evaporator to give a thick violet oil. Max. Abs (MeOH) 553 nm. Water (75 g) was added to the oil and the ensuing mixture heated to 80 C. The mixture was allowed to phase and the bottom product layer separated. The product layer was washed two additional times as above. The residual water was removed via rotary evaporator to give 20 g of a violet oil λ max absorbance (in methanol) of 554 nm.
EXAMPLE 9
To a 250-ml 3-neck round bottom flask equipped with a Dean-Stark trap and a reflux condenser, were charged 2,5-dihydroxy-1,4-benzenediacetic acid-di-gamma-lactone (5 g, 30 mmol), p-dimethylamino benzaldehyde (4.5 g, 30 mmol), toluene (80 ml), piperidine (0.3 ml) and benzoic acid (0.3 g). The mixture was refluxed under nitrogen gas for 4 hours. Upon cooling to room temperature, the precipitate formed was collected by filtration and washed with toluene and acetone. After boiling with 100 ml of MeOH, the solid was collected via hot filtration and washed 3 times with 50 ml of fresh MeOH, and dried in 70C oven. A total of 7 g (84% yield) of product was obtained as a dark red solid exhibiting a λ max absorbance (in DMSO) of 561 nm.
Thermoplastic Composition Formation in Polyester
In each instance noted below, the sample liquid colorant was introduced within an injection molding operation for a polyester thermoplastic, in this instance polyethylene terephthalate (ClearTuf® 8006 PET resin from Shell). The liquid colorant, in an amount of 1,500 ppm of the total amount of resin, was blended via agitation onto the hot, dried polyethylene terephthalate resin (in pellet form). The blend of colorant and pellets was gravity fed into the feed throat of the machine. In the feed section, melting was accomplished through the utilization of a heated (heat transferred from the barrel of the machine) screw extruder which rotated. The rotation of the screw provided thorough mixing of the colorant and molten resin together producing a uniform plastic melt which was injected into a mold in order to form the thermoplastic article, for instance a 2 inch by 3 inch plaque with a uniform thickness of 50 mils and a surface area of 12.5 in 2 .
This method was followed for the production of PET plaques comprising the colorants of Examples 1 and 5, above, and provided a pleasing red shade with no visible color differences, bubbles, streaks, or other deleterious effects in both sample plaques.
The same thermoplastic production method was followed for the colorant of Examples 2 and 3, above, and provided a pleasing blue shade with no visible color differences, bubbles, streaks, or other deleterious effects in both sample plaques.
The same thermoplastic production method was followed for the colorant of Example 6, above, and provided a pleasing violet shade with no visible color differences, bubbles, streaks, or other deleterious effects.
Thermoplastic Composition Formation in Polyolefin
In each instance noted below, the liquid colorant was introduced within an injection molding operation for a polyolefin thermoplastic, for instance polypropylene. Fina 7525 MZ random copolymer polypropylene was used. The liquid colorant, in an amount of 1,000 ppm of the total amount of the resin, was blended via agitation onto the resin (in pellet form). The blend of colorant and pellets was gravity fed into the feed throat of the machine. In the feed section, melting was accomplished through the utilization of a heated (heat transferred from the barrel of the machine) screw extruder which rotated. The rotation of the screw provided thorough mixing of the colorant and molten resin together producing a uniform plastic melt which was injected into a mold in order to form the thermoplastic article, for instance a 2 inch by 3 inch plaque with a uniform thickness of 50 mils and a surface area of 12.5 in 2 .
This method was followed for the production of polypropylene plaques comprising colorant of Example 3, above, and provided a pleasing blue shade with no visible color differences, bubbles, streaks, or other deleterious effects in both samples plaques.
The same thermoplastic production method was followed for the colorant of Example 4, above, and provided a pleasing red shade with no visible color differences, bubbles, streaks, or other deleterious effects.
The same thermoplastic production method was followed for the colorant of Example 8, above, and provided a pleasing violet shade with no visible color differences, bubbles, streaks, or other deleterious effects.
Extraction Analyses for Inventive Colored Plastics
a) PET Plaques
The plaques made above were tested for extraction of color under the following procedure (having a detection limit of 10 ppb) (hereinafter referred to as the “heated alcohol extraction test”):
Eight plaques were cut in half and placed in a stainless steel extraction vessel. To the extraction vessel was added 125 g of 10% ethanol (preheated to 70° C.) was added. The vessels were sealed and then placed in a 70° C. oven for 2.5 hours. The vessels were then removed and allowed to cool to room temperature. In all cases, the plaques were separated with small glass slides and were completely immersed and exposed to the extraction solvent. This test was then duplicated for the same sample.
The extracts were then analyzed spectrophotometrically to determine the presence or absence of extracted colorant. A Beckman® DU 650 spectrophotometer with a 10.0 cm path length cell was used. The instrument was first zeroed using the extract obtained from the uncolored polyester plaques. The extract from the extraction of the plaques containing the various colorant additives was then scanned through the ultraviolet/visible range to determine the presence or absence of detectable peaks at the additives' lambda max.
TABLE 1
Extraction data for Inventive Colored PET Resins
Colorant
Result
From Example 5
undetectable for both samples
b) Polypropylene Plaques
The plaques from above were subjected to the heated alcohol extraction test in duplicate. The extracts were analyzed spectrophotometrically to determine the presence or absence of extracted colorant. A Beckman® DU 650 spectrophotometer with a 1.0 cm path length cell was used. The instrument was first zeroed using the extract obtained from the uncolored polyester plaques. The extract from the extraction of the plaques containing the various colorant additives was then scanned through the ultraviolet/visible range to determine the presence or absence of detectable peaks at the additives' lambda max.
TABLE 2
Extraction Data for Inventive Polypropylene Resins
Colorant
Result
From Example 3
undetectable for both samples
From Example 4
undetectable for both samples
From Example 8
undetectable for both samples
Thermal Stability Analyses of Inventive Colored Resins
a) Polyester
Thermoplastic plaques (2 inches by 3 inches) of polyester terephthalate (as above) were first injection molded. A total of ten plaques were then collected from the standard injection molding operation. The same injection molding machine used to produce these first ten plaques was then was paused during production of ten further plaques and allowed to remain idle for 15 minutes at the standard polyester processing temperatures (˜277° C.). At the end of the 15-minute pause, the machine was then restarted without purging the colored resin from the heated barrel of the machine. Ten consecutive plaques were then collected and numbered after resumption of the injection molding operation.
The color of the ten plaques collected from the standard operation was measured in both reflectance and transmittance on a Gretag-Macbeth Color-Eye 7000A Spectrophotometer and averaged together to represent the standard. Each of the ten consecutive plaques collected after the 15-minute hold period were measured individually and sequentially on the spectrophotometer. The color difference between the standard and the each of the ten plaques was determined by the ΔE CMC . The maximum ΔE CMC of the ten plaques collected after the 15-minute hold period represents the largest color difference and is determined to be the colorant's thermal stability. The results are tabulated below:
TABLE 3
Thermal Stability Data in PET
Colorant Composition
ΔE CMC
Example 1
1.0
Example 2
1.2
Example 3
0.8
Example 6
3.1
A ΔE CMC of less than 4 is considered to be acceptable when analyzed by this protocol.
b) Polyolefin
The liquid colorant was introduced within an injection molding operation for a polyolefin thermoplastic, for instance polypropylene. The liquid colorant was blended via agitation onto polypropylene resin (in pellet form). The blend of colorant and pellets was gravity fed into the feed throat of the machine. In the feed section, melting was accomplished through the utilization of a heated (heat transferred from the barrel of the machine) screw extruder which rotated. The rotation of the screw provided thorough mixing of the colorant and molten resin together producing a uniform plastic melt which was injected into a mold in order to form the thermoplastic article, for instance a 2 inch by 3 inch plaque with a uniform thickness of 50 mils.
Ten plaques were collected from the injection molding operation at the standard polyolefin processing temperatures (210° C.). The injection molding machine was stopped and the processing temperatures were increased 50° C. When the injection molding machine had reached the desired temperature, the material in the barrel of the machine was purged from the barrel. The machine was stopped and remained idle for 10 minutes, while the barrel was full of the material being tested. At the end of the 10-minute period, the injection molding machine was restarted without purging the colored resin from the heated barrel of the machine. Five consecutive plaques were collected and numbered after resumption of the injection molding operation.
The color of the ten plaques collected from the standard operation was measured in both reflectance and transmittance on a Gretag-Macbeth Color-Eye 7000A Spectrophotometer and averaged together to represent the standard. Each of the five consecutive plaques collected after the 10-minute hold period were measured individually and sequentially on the spectrophotometer. The color difference between the standard and each of the five plaques was determined by the ΔE CMC . The maximum ΔE CMC of the five plaques collected after the 10-minute hold period represents the largest color difference and is determined to be the colorant's thermal stability. The results are tabulated below:
TABLE 4
Thermal Stability Data in Propylene
Colorant Composition
ΔE CMC
Example 3
1.5
Example 4
2.5
Example 8
1.3
A ΔE CMC of less than 4 is considered to be excellent when examined by this protocol.
Intrinsic Viscosity Analyses of Inventive Colorants
The sample colorant was introduced within a mixing operation for a polyester thermoplastic, for instance polyethylene terephthalate (as above). The mixing step was accomplished by the use of a C.W. Brabender Electronic Plasti-Corder®, model number EPL-V5501, torque rheometer with a Type Six 2-piece mixer attachment. Cam style removable blades were used in the mixer attachment providing a medium shear-rate mixing. The temperature of the mixing chamber was set to 285° C. and controlled via electric heating and air cooling.
The liquid colorant was weighed into a small disposable syringe. The loading of the liquid colorant was determined and adjusted based on the strength of the colorant. The hot, dried polyethylene terephthalate resin, specifically M & G ClearTuf® 8006, in pellet form, was quickly weighed into a glass jar and sealed to minimize the adsorption of moisture by the resin. The torque rheometer mixing blades were turned on and set to a speed of 25 rpm as indicated by the digital display. A 25 ft 3 /h flow of dried nitrogen gas was introduced into the mixing chamber through the loading ram.
The dried polyethylene terephthalate resin was then poured into the mixing chamber and the loading ram was closed while the nitrogen gas continued to flow into the chamber. Simultaneously, a stopwatch was then started to mark the beginning of the operation. After 1 minute and 30 seconds of mixing, the loading ram was raised and the liquid colorant was dispensed into the molten polyester resin. The loading ram was lowered and the liquid colorant was allowed to mix with the molten polyester resin for an additional 1 minute and 30 seconds.
After such time, the blades were then stopped and the loading ram was raised. The blades were reversed and a metal spatula was used to remove a sample of the molten, colored polyester from the mixing chamber. This molten sample was immediately compressed between two metal plates and allowed to cool to form the final thermoplastic disk.
The intrinsic viscosity of the colored thermoplastic disk was measured according to ASTM D4603. The intrinsic viscosity of the colored thermoplastic disk was compared to the intrinsic viscosity of an uncolored thermoplastic control disk, via the formula:
IV Loss COLOR =IV UNCOLORED CONTROL −IV COLORED DISK
The uncolored thermoplastic control disk was processed in the same manner as described above but without the addition of the liquid colorant. The following table reflects these measurements:
TABLE 5
IV Performance Data for Colorant in Example 1
Loading (ppm)
IV Loss
124
0.00
474
0.00
1594
0.01
This data indicates that the inventive color compositions have little effect on the polyester molecular weight even when incorporated at amounts to produce deep shades.
Other Plastic Applications for the Inventive Colorants
a) Polyurethane
The colorant from example 1, above, was used to make a polyurethane foam according to the procedure of Example 1 in U.S. Pat. No. 5,731,398 to Milliken & Company. The finished foam product exhibited a pleasing red shade.
The same polyurethane production method was followed for the colorant of Example 2, above, and provided a pleasing blue shade.
The same thermoplastic production method was followed for the colorant of Example 8 above, and provided a pleasing violet shade.
Polyester Fabrics
The colorant from example 9 was finely powdered in a mortar and pestle and then used as a disperse dye to color polyester fabric. The dye (1.0 g) was mixed with a leveling agent (5.0 mL) (Millex™ DA-50, from ABCO), a sequestering agent (Trilon® BX, from BASF) (1.0 mL), acetic acid (4.5 mL) and water (ca. 500 mL) in a pressure vessel. A 6″×12″ piece of polyester fabric was added and the mixture heated with agitation to 280° F. for 30 minutes. The fabric exhibited a pleasing red shade after rinsing.
While specific features of the invention have been described, it will be understood, of course, that the invention is not limited to any particular configuration or practice since modification may well be made and other embodiments of the principals of the invention will no doubt occur to those skilled in the art to which the invention pertains. Therefore, it is contemplated by the appended claims to cover any such modifications that incorporate the features of the invention within the true meaning, spirit, and scope of such claims.
|
Colorants comprising a chromophore having two methine moieties attached to a benzodifuranone backbone, wherein said moieties optionally have at least one poly(oxyalkylene) chain, preferably at least two such chains attached thereto are provided. Such colorants exhibit excellent thermal stability, effective colorations, excellent low extraction rates, and effective lightfastness levels, particularly when incorporated within certain media and/or on the surface of certain substrates, particularly polyesters. The optional poly(oxyalkylene) chains also increase the solubility in different solvents or resins thereby permitting the introduction of such excellent coloring chromophores within diverse media and/or on diverse substrates as well as provides a liquid colorant which facilitates handling. Compositions and articles comprising such colorants are provided as are methods for producing such inventive colorants.
| 2
|
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. Pat. application No. 217,997, now abandoned, filed Jan. 14, 1972 by the same inventors in Group Art Unit 172 for Food Resembling Cheese and Process For Making Same.
BACKGROUND OF THE INVENTION
The field of art to which the invention pertains is a food product resembling cheese or, in other words, imitation cheese. The particular cheeses that are resembled are the pasta filata and cheddar types.
Applicants understand there are certain imitation cream cheeses on the market and know that imitation cream cheeses are described in U.S. Pat. No. 3,397,994 issued Aug. 20, 1968, entitled "Imitation Cream Cheese Spread Containing Polyunsaturated Fat", and in U.S. Pat. No. 3,397,995 also issued Aug. 20, 1968, and entitled "Edible Dietary Spread and Method of Making Same". However, Applicants were not aware of any imitation pasta filata or cheddar type cheese at the time of filing the parent application No. 217,997.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a food resembling pasta filata or cheddar type cheese and the process of making the same. A more particular object of the present invention is to provide such a food which is less expensive than real pasta filata or cheddar type cheese. The imitation cheeses of the present invention are particularly suitable for use in such dishes as enchiladas, pizzas, tacos, sandwiches, sauces and other prepared foods in place of ordinary cheese.
Other and further objects, features and advantages will be apparent from the following description of the invention given for the purpose of disclosure.
The present invention is based upon the discovery that a food resembling pasta filata or cheddar type cheese can be economically produced by forming a substantially gas-free homogeneous blend of (a) an emulsion of water with a fat having a Wiley melting point between about 90° and 110° F., the fat being about 12 to 35% of the food, (b) about 15 to 33% calcium caseinate, preferably about 25%, (c) up to about 5% ungelatinized flour, and (d) about 0.5 to 1.8% adipic, lactic, citric, or malic acid, or combinations of such acids, the food having a pH of about 4.8 to 5.7 and including appropriate coloring and flavoring materials. In some instances, the ungelatinized flour may be omitted.
In imitation cheddar-type cheese, there is normally included up to about 2% emulsifying salts, such as disodium phosphate and sodium aluminum phosphate.
"Substantially gas-free", as used herein, means that the product does not have air holes.
In practicing the method of the present invention, the fat is melted and then an emulsion of the fat with water is formed under subatmospheric conditions to remove air from the emulsion. The dry ingredients, which include the calcium caseinate, are blended with the emulsion under high shear mixing, a subatmospheric condition and at a temperature above the melting point of the fat to form a substantially gas-free homogeneous blend of the dry ingredients and the emulsion. The purpose of the subatmospheric condition is to prevent the inclusion of gas in the product. The mixing is done under high shear conditions so that the blending of the dry ingredients with the emulsion takes place completely and quickly. If thorough mixing does not take place quickly, at least two harmful effects are created. One is that the dry ingredients will form lumps surrounded by an oily film which are extremely difficult to break down. The second is that the emulsion will break down and the product will take on a "curdy" appearance rather than a homogeneous blend resembling a pasta filata or cheddar type cheese.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional side view of the Littleford-Lodige Model FM130D mixer identified later herein.
FIG. 2 is an end view of the structure of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fat may be any of the edible fats used in shortenings or margarine having a melting point between 90° and 110° F. The preferred fat is refined, bleached and deodorized soybean oil hydrogenated to a melting point of about 95° F. and present in an amount equal to about 22 to 24% of the product.
The preferred ungelatinized flour is tapioca flour.
A product to properly resemble cheddar-type cheese must have proper melt-down characteristics, and to resemble pasta filata-type cheese, for example mozzarella, must also have acceptable stringiness and/or breakdown. Both imitation cheeses need acceptable eating characteristics in cooked and uncooked conditions. To obtain the characteristics of both the pasta filata and cheddar type cheeses, it is necessary in the process of the present invention that, in addition to the fat and water emulsion, there also be included the calcium caseinate, the ungelatinized flour, the particular acid or acids, and the pH must be controlled within the ranges specified. In some instances, if a non-stringy pasta filata-type cheese with greater breakdown tendencies is desired, the ungelatinized flour may be omitted. The ungelatinized flour is used to promote stringiness and also to aid in the firmness of the product which affects its sliceability and shredability. When ungelatinized flour is included, the amount used is preferably between about 1 and 5% of the food.
Either adipic, lactic, citric or malic acids, or combinations of those acids must be included, but the exact chemical reason for this is not fully understood. Their function is to assist in the control of the pH range and to give proper firmness and melting qualities of the product when used on such materials as pizzas. The pH affects the flavor and the stringiness. If the pH is too high or too low, the food will not be stringy, and pasta filata-type cheese normally should be stringy. Also, the slightly acidic condition gives a desirable tart taste to the product. The preferred acid is adipic acid. The preferred amount of adipic acid in a mozzarella-type cheese is about 1.3% and in cheddar-type cheese is about 0.8%.
The acid next most preferable to adipic is lactic acid. Imitation cheese made with lactic acid, when compared to the same product made using adipic acid, has about the same flavor, but has more tendency to crust and burn, has slightly inferior melting properties, has a greater tendency to curdiness, and is not as reliable in reproducability.
Imitation cheese made with citric or malic acid, when compared to the same products made with adipic or lactic acid, have a generally satisfactory flavor, but their other properties are not nearly as favorable, that is, there is much more tendency to crust and burn, more inferior melting properties, greater tendency to curdiness, and less reliability in producability.
This requirement of 0.5 to 1.8% of the use of either adipic, lactic, citric, malic, or combinations thereof, is required, and Applicants are not aware of any other acid that can be substituted. For example, phosphoric, succinic and fumaric acids have been tried and found to be quite unsatisfactory.
For mozzarella-type imitation cheese, the pH of the product should be about 5.1 to 5.5, with about 5.1 being preferred. With a food resembling cheddar cheese, the pH should be about 4.8 to 5.7, with 5.1 being preferred.
In cheddar cheese, the inclusion of an effective amount, up to about 2%, of emulsifying salts to give desired characteristics of melting, shredding and matting. Particularly, they assist in the desirable flow of the melt of the cheese when it is heated on other foods. Preferably about 0.85% disodium phosphate is used.
In making the emulsion of fat and water, the preferred amount of water is approximately 46 or 47% of the weight of the final product. Water content depends on desired firmness of the final product and normally is between about 46 and 52%. Of course, conventional oil and water emulsifiers used in food products may be included. The most satisfactory apparatus known to Applicants to carry out the high shear mixing of the fat and water emulsion with dry ingredients including the calcium caseinate is a Littleford-Lodige high shear mixing vessel sold by Littlefore Brothers, Inc., Cincinnati, Ohio, U.S.A. The desired high shear mixing can be carried out with this equipment in less than four minutes, and preferably within two to three minutes. Referring now to the drawing, the Littleford-Lodige Model FM130D mixer includes a steam-jacketed cylindrical vessel 10 forming a generally horizontal cylindrical chamber 12 which is closed at both ends. A loading door 14 is on the top of the vessel and a discharging door 15 is at the bottom of the vessel 10 in line with the loading door 14. A vacuum line 16 communicates with the chamber 12 near the loading door 14 and a steam connection 20 is provided to admit steam to the steam jacket 21.
An axle 22 extends along the axis of the chamber 12. Extending radially from the axle 22 are a series of arms 24 on the outer end of each of which is a plow-shaped impeller (or mixing element) 26 contoured to fit the inner surface of the chamber 12. These plow-shaped impellers project material being mixed away from the inner surface of the chamber 12 and hurl it toward the axis of the chamber. Protruding from the lower wall of the vessel 10 and into the chamber 12 is a high speed blending chopper driven by a motor 30. The chopper rotates at high speeds of approximately 3,600 r.p.m. to break up agglomerates.
The following are examples of the present invention.
EXAMPLE 1
An imitation mozzarella cheese was prepared from the following ingredients:
______________________________________Dry Ingredients PercentCalcium caseinate 24.55Tapioca flour 3.00Salt (NaCl) 2.16Adipic acid 0.60Vitamins and minerals 1.47Sorbid acid 0.10Artificial cheese flavor 0.50Fat-Color BlendSoybean oil hydrogenated to aWiley melting point of about95° F. 21.29Lactylated monoglycerideemulsifier 0.05Red-orange coloring 0.011Liquid-Flavor BlendVarious cream, cheese, starterand butter flavors 0.23Water-Color BlendColoring 0.05Water q.s. to 100%______________________________________
It is not necessary that there be coloring in both the fat-color blend and in the water-color blend. Similarly, the flavors need not all be in the liquid-flavor blend. For example, some of the flavoring could be in the dry ingredients and preferably a small amount of imitation cheese flavor is included in the dry ingredients. The particular set of ingredients or blend in which the flavoring or coloring material is placed depends upon the choice of the operator and the characteristics of the particular flavor or coloring material.
If desired, especially to facilitate processing, a portion of the fat can be included in the dry ingredient mix.
The sorbic acid is used to inhibit mold growth when the product is stored under exposure to air.
In this example, the dry ingredients were formed into a dry blend mixture by mixing them in a large Hobart mixer Model M280 at No.2 speed for two minutes. The water-color mixture was prepared at 180° F. and put into a Littleford-Lodige Model FM130D mixer and held at that temperature by the stream jacket on the mixer. The fat-color blend was prepared at 160° and to this was added the liquid-flavor blend which, because of its small amount, need only be prepared at room temperature. This mixture was added to the contents of the Littleford-Lodige mixer and a vacuum of 20 inches of mercury was drawn on the mixer to remove the air entrapped in its contents. After about one minute of mixing at 180° F., the fat and water emulsion was formed. The vacuum was released and the dry blended mixture added to the mixer. A vacuum was again drawn to 20 inches of mercury and held during mixing at about 170° F. After about three minutes of mixing under these high shear conditions, the product, which had a pH of 5.3, was removed from the mixing vessel and packaged. After 3 days' storage at 40° F., it was sufficiently firm to shred or slice properly.
EXAMPLE 2
Using the process of Example 1, an imitation mozzarella cheese having a pH of about 5.1 was prepared from the following ingredients which did not include ungelatinized flour.
______________________________________Dry Ingredients PercentCalcium caseinate 24.65Salt (NaCl) 2.50Adipic acid 1.30Vitamins and minerals 1.47Sorbic acid 0.10Artificial cheese flavor 0.60Fat-Color BlendSoybean oil hydrogenated to aWiley melting point of about95° F. 22.7Red-orange coloring 0.007Liquid-Flavor BlendVarious cream, cheese, starterand butter flavors 0.26Water-Color BlendColoring 0.05Water q.s. to 100%______________________________________
EXAMPLE 3
Using the process of Example 1, an imitation cheddar cheese was prepared from the following ingredients:
______________________________________Dry Ingredients PercentCalcium caseinate 24.55Tapioca flour 0.20Salt (NaCl) 1.50Adipic acid 0.80Sorbic acid 0.10Cheese flavor 0.45Disodium phosphate 0.85Vitamins and minerals 1.47FatHydrogenated soybean oil havinga Wiley melting point of about95° F. 23.70Color-Flavor BlendApocarotenal color 0.005Various cream, cheese, starterand butter flavors 0.39Water q.s. to 100%______________________________________
This particular variety of imitation cheddar cheese had a pH of 5.1 and resembled natural current cheddar cheese often used in Mexican food dishes. It shredded properly without matting, making the product easy to use. It also melted properly when used in enchiladas which were heated at about 500° F. for three minutes. The melting was sufficient to enhance the eating properties but was not excessive.
EXAMPLE 4
This is an example using a mixture of citric and adipic acids. In this instance, the imitation cheese had 49.2% water, 22.5% calcium caseinate, 3% tapioca flour, 2% modified whey protein, 2% salt, 0.75% citric acid, 0.25% adipic acid, 20% hydrogenated soybean oil and various flavoring agents. The imitation cheese had good slicing and shredability characteristics and on pizzas it performed very well, having a good appearance, no crust and excellent flavor.
EXAMPLE 5
Here, citric acid was used without combining it with adipic, lactic or malic acid. In this example, the imitation cheese had 51.63% water, 1% vegetable gum, 24% calcium caseinate, 1% citric acid, 2.12% salt, 20% hydrogenated vegetable oil, and various artificial flavors. The finished product had good shredability, and when used on pizzas, had good string, very slight curd and a satisfactory appearance.
EXAMPLE 6
Here, lactic acid was used without combining it with adipic, citric or malic acid. In this example, the imitation cheese was comprised of 24.185% calcium caseinate, 3.0% tapioca flour, 0.5% modified whey protein, 2.15% salt, 0.1% sorbic acid, 0.5% artificial flavors, 0.75% lactic acid, 47.0% water and 21.5% hydrogenated vegetable oil, together with various artificial colors. The finished product had good melt, good string and good appearance on pizzas. The flavor was satisfactory although it was not as preferable as a cheese made with adipic acid.
EXAMPLE 7
This is an example using malic acid. This example is the same as Example 6 except that 1.3% malic acid was used in place of the lactic acid. The finished product had fairly good characteristics of sliceability and texture. It melted fairly well on pizzas and had a good appearance and breakdown with only a slight amount of curdiness, but in general was not as acceptable as an adipic acid control sample.
From the foregoing discussion, examples and description of the invention, it is apparent that the objects set forth herein as well as others have been achieved. Those skilled in the art will recognize that the principles of this invention may be applied in several ways, only a few of which have been exemplified here specifically.
|
A food resembling pasta filata cheese or cheddar cheese is produced by forming a substantially gas-free homogeneous blend of fat, water, calcium caseinate, ungelatinized flour and certain acids. The blend is formed under high shear mixing at subatmospheric conditions.
| 0
|
[0001] This is a continuation-in-part application of U.S. patent application Ser. No. 10/007,474, filed on Nov. 7, 2001, which is a divisional of U.S. patent application Ser. No. 09/389,507, filed on Sept. 3, 1999, now issued as U.S. Pat. No. 6,359,088, which claims the priority of U.S. Provisional patent application Ser. No. 60/102,706, filed on Oct. 1, 1998.
BACKGROUND OF THE INVENTION
[0002] It is highly desirable for pneumatic tires to have good wet skid resistance, low rolling resistance and good wear characteristics. It has traditionally been very difficult to improve the wear characteristics of a tire without sacrificing its wet skid resistance and traction characteristics. These properties depend, to a great extent, on the dynamic viscoelastic properties of the rubbers utilized in making the tire.
[0003] In order to reduce the rolling resistance and to improve the treadwear characteristics of tires, rubbers having a high rebound have traditionally been utilized in making tire tread rubber compounds. On the other hand, in order to increase the wet skid resistance of a tire, rubbers which undergo a large energy loss have generally been utilized in the tire's tread. In order to balance these two viscoelastically inconsistent properties, mixtures of various types of synthetic and natural rubber are normally utilized in tire treads. For instance, various mixtures of styrene-butadiene rubber and polybutadiene rubber are commonly used as a rubbery material for automobile tire treads.
[0004] It is conventionally believed to be desirable for styrene-butadiene rubber which is utilized in tire tread compounds to have a high level of vinyl content (1,2-microstructure). It is also generally desirable for the repeat units which are derived from styrene to be randomly distributed throughout the polymer chains of the rubber. To achieve these objectives, styrene-butadiene rubbers are often synthesized by solution polymerization which is conducted in the presence of one or more modifying agents. Such modifying agents are well known in the art and are generally ethers, tertiary amines, chelating ethers or chelating amines. Tetrahydrofuran, tetramethylethylene diamine (TMEDA) and diethyl ether are some representative examples of modifying agents which are commonly utilized.
[0005] U.S. Pat. No. 5,284,927 discloses a process for preparing a rubbery terpolymer of styrene, isoprene and butadiene having multiple glass transition temperatures and having an excellent combination of properties for use in making tire treads which comprises terpolymerizing styrene, isoprene and 1,3-butadiene in an organic solvent at a temperature of no more than about 40° C. in the presence of (a) tripiperidino phosphine oxide, (b) an alkali metal alkoxide and (c an organolithium compound.
[0006] U.S. Pat. No. 5,534,592 discloses a process for preparing high vinyl polybutadiene rubber which comprises polymerizing 1,3-butadiene monomer with a lithium initiator at a temperature which is within the range of about 5° C. to about 100° C. in the presence of a sodium alkoxide and a polar modifier, wherein the molar ratio of the sodium alkoxide to the polar modifier is within the range of about 0.1:1 to about 10:1; and wherein the molar ratio of the sodium alkoxide to the lithium initiator is within the range of about 0.01:1 to about 20:1.
[0007] U.S. Pat. No. 5,100,965 discloses a process for synthesizing a high trans polymer which comprises adding (a) at least one organolithium initiator, (b) an organoaluminum compound, (c) a barium alkoxide and (d) a lithium alkoxide to a polymerization medium which is comprised of an organic solvent and at least one conjugated diene monomer.
[0008] U.S. Pat. No. 5,100,965 further discloses that high trans polymers can be utilized to improve the characteristics of tire tread rubber compounds. By utilizing high trans polymers in tire tread rubber compounds, tires having improved wear characteristics, tear resistance and low temperature performance can be made. Such high trans polymers include, trans-1,4-polybutadiene, trans styrene-isoprene-butadiene terpolymers, isoprene-butadiene copolymers and trans-styrene-butadiene copolymers.
[0009] U.S. Pat. 6,103,842 discloses a process for synthesizing a random styrene-butadiene rubber having a high trans content by a process which comprises copolymerizing styrene and 1,3-butadiene under isothermal conditions in an organic solvent in the presence of a catalyst system which consists essentially of (a) an organolithium compound, (b) a barium alkoxide and (c) a lithium alkoxide.
SUMMARY OF THE INVENTION
[0010] This invention is based upon the unexpected discovery that a catalyst system which consists of (a) an organometallic compound of a metal selected from the group consisting of lithium, potassium, magnesium, sodium, aluminum, zinc and tin, (b) a calcium compound and (c) a lithium alkoxide, will catalyze the copolymerization of 1,3-butadiene monomer and styrene monomer into a styrene-butadiene copolymer having a random distribution of repeat units which are derived from styrene. Styrene-butadiene rubber made utilizing the catalyst system and techniques of this invention is highly useful in the preparation of tire tread rubber compounds which exhibit improved wear characteristics.
[0011] It is preferred for the organometallic compound to be a lithium, potassium, magnesium or sodium compound. Organolithium compounds are normally most preferred. The calcium compound will typically be a calcium carboxylate, a calcium phenolate, a calcium amine, a calcium amide, a calcium halide, a calcium nitrate, a calcium sulfate, a calcium phosphate or a calcium alcoholate. It is preferred for the calcium compound to be soluble in the organic solvent used as the polymerization medium. It is accordingly preferred for the calcium compound to be a calcium alcoholate, a calcium carboxylate or a calcium phenolate. It is typically most preferred for the calcium compound to be a calcium alcoholate (a calcium alkoxide).
[0012] Calcium compounds, which are insoluble in the organic solvent used as the polymerization medium, can also be utilized. However, such calcium compounds will typically be preformed by mixing them with the other catalyst components in the presence of a conjugated diene monomer, such as 1,3-butadiene or isoprene.
[0013] The polymerizations of this invention are normally conducted in the absence of organoaluminum compounds. A highly preferred catalyst system for the copolymerization of 1,3-butadiene monomer and styrene monomer consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide. The present invention accordingly specifically discloses a catalyst system which consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide.
[0014] The subject invention further discloses a process for synthesizing a random styrene-butadiene rubber having a high trans content by a process which comprises copolymerizing styrene and 1,3-butadiene under isothermal conditions in an organic solvent in the presence of a catalyst system which consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide.
[0015] The subject invention also reveals a process for synthesizing trans polybutadiene rubber having a vinyl content which is within the range of about 5 percent to about 15 percent by a process which comprises polymerizing 1,3-butadiene in an organic solvent in the presence of a catalyst system which consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide.
[0016] The present invention further reveals a catalyst system which consists essentially of (a) an organometallic compound of a metal selected from the group consisting of lithium, potassium, magnesium, sodium, aluminum, zinc and tin, (b) a calcium compound and (c) a lithium alkoxide.
[0017] The subject invention further reveals a styrene-butadiene rubber which is particularly useful in tire tread compounds, said styrene-butadiene rubber being comprised of repeat units which are derived from about 3 weight percent to about 50 weight percent styrene and from about 50 weight percent to about 97 weight percent butadiene, wherein at least 98 percent of the repeat units derived from styrene are in blocks containing less than 5 repeat units, wherein at least 40 percent of the repeat units derived from styrene are in blocks containing only 1 repeat styrene unit, wherein said rubber has a trans content which is within the range of 50 percent to 80 percent, wherein the rubber has a cis content which is within the range of 10 percent to 45 percent, wherein the rubber has a vinyl content which is within the range of 5 percent to 20 percent and wherein there are no segments of at least 100 repeat units within the rubber which have a styrene content which differs from the total styrene content of the rubber by more than 10 percent.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The polymerizations of the present invention will normally be carried out in a hydrocarbon solvent which can be one or more aromatic, paraffinic or cycloparaffinic compounds. These solvents will normally contain from 4 to 10 carbon atoms per molecule and will be liquid under the conditions of the polymerization. Some representative examples of suitable organic solvents include pentane, isooctane, cyclohexane, methylcyclohexane, isohexane, n-heptane, n-octane, n-hexane, benzene, toluene, xylene, ethylbenzene, diethylbenzene, isobutylbenzene, petroleum ether, kerosene, petroleum spirits, petroleum naphtha and the like, alone or in admixture.
[0019] In the solution polymerizations of this invention, there will normally be from 5 to 30 weight percent monomers in the polymerization medium. Such polymerization media are, of course, comprised of the organic solvent and monomers. In most cases, it will be preferred for the polymerization medium to contain from 10 to 25 weight percent monomers. It is generally more preferred for the polymerization medium to contain 15 to 20 weight percent monomers.
[0020] The solution styrene-butadiene rubbers made utilizing the catalyst system and technique of this invention are comprised of repeat units which are derived from 1,3-butadiene and styrene. These styrene-butadiene rubbers will typically contain from about 5 weight percent to about 50 weight percent styrene and from about 50 weight percent to about 95 weight percent 1,3-butadiene. However, in some cases, the amount of styrene included will be as low as about 3 weight percent. The styrene-butadiene rubber will more typically contain from about 10 weight percent to about 30 weight percent styrene and from about 70 weight percent to about 90 weight percent 1,3-butadiene. The styrene-butadiene rubber will preferably contain from about 15 weight percent to about 25 weight percent styrene and from about 75 weight percent to about 85 weight percent 1,3-butadiene. These styrene-butadiene rubbers typically have a melting point which is within the range of about −10° C. to about −20° C.
[0021] Styrene-butadiene copolymer resins containing from about 50 weight percent to about 95 weight percent styrene and from about 5 weight percent to about 50 weight percent 1,3-butadiene can also be synthesized utilizing the catalyst systems of this invention. Such copolymers having glass transition temperatures within the range of 7° C. to 70° C. can be used as toner resins.
[0022] In the styrene-butadiene rubbers of this invention, the distribution of repeat units derived from styrene and butadiene is essentially random. The term “random” as used herein means that less than 5 percent of the total quantity of repeat units derived from styrene are in blocks containing five or more styrene repeat units. In other words, more than 95 percent of the repeat units derived from styrene are in blocks containing less than five repeat units. A large quantity of repeat units derived from styrene will be in blocks containing only one styrene repeat unit. Such blocks containing one styrene repeat unit are bound on both sides by repeat units which are derived from 1,3-butadiene.
[0023] In styrene-butadiene rubbers containing less than about 30 weight percent bound styrene which are made with the catalyst system of this invention, less than 2 percent of the total quantity of repeat units derived from styrene are in blocks containing five or more styrene repeat units. In other words, more than 98 percent of the repeat units derived from styrene are in blocks containing less than five repeat units. In such styrene-butadiene rubbers, over 40 percent of repeat units derived from styrene will be in blocks containing only one styrene repeat unit, over 75 percent of the repeat units derived from styrene will be in blocks containing less than 3 repeat units and over 90 percent of the repeat units derived from styrene will be in blocks containing less than 4 repeat units.
[0024] In styrene-butadiene rubbers containing less than about 20 weight percent bound styrene which are made with the catalyst system of this invention, less than 1 percent of the total quantity of repeat units derived from styrene are in blocks containing 4 or more styrene repeat units. In other words, more than 99 percent of the repeat units derived from styrene are in blocks containing less than 4 repeat units. In such styrene-butadiene rubbers, over 60 percent of repeat units derived from styrene will be in blocks containing only one styrene repeat unit and over 90 percent of the repeat units derived from styrene will be in blocks containing less than 3 repeat units.
[0025] The styrene-butadiene copolymers of this invention also have a consistent composition throughout their polymer chains. In other words, the styrene content of the polymer will be the same from the beginning to the end of the polymer chain. No segments of at least 100 repeat units within the polymer will have a styrene content which differs from the total styrene content of the polymer by more than 10 percent. Such styrene-butadiene copolymers will typically contain no segments having a length of at least 100 repeat units which have a styrene content which differs from the total styrene content of the polymer by more than about 5 percent.
[0026] The polymerizations of this invention are initiated by adding (a) an organometallic compound of a metal selected from the group consisting of lithium, potassium, magnesium, sodium, aluminum, zinc and tin, (b) a calcium compound and (c) a lithium alkoxide to a polymerization medium containing the monomers to be polymerized. The polymerizations of this invention are typically initiated by adding an organolithium compound, a calcium alkoxide and a lithium alkoxide to a polymerization medium containing the styrene and 1,3-butadiene monomers. Such polymerization can be carried out utilizing batch, semi-continuous or continuous techniques.
[0027] The organolithium compounds which can be employed in the process of this invention include the monofunctional and multifunctional initiator types known for polymerizing the conjugated diolefin monomers. The multifunctional organolithium initiators can be either specific organolithium compounds or can be multifunctional types which are not necessarily specific compounds but rather represent reproducible compositions of regulable functionality.
[0028] The choice of initiator can be governed by the degree of branching and the degree of elasticity desired for the polymer, the nature of the feedstock and the like. With regard to the feedstock employed as the source of conjugated diene, for example, the multifunctional initiator types generally are preferred when a low concentration diene stream is at least a portion of the feedstock, since some components present in the unpurified low concentration diene stream may tend to react with carbon lithium bonds to deactivate the activity of the organolithium compound, thus necessitating the presence of sufficient lithium functionality so as to override such effects.
[0029] The multifunctional organolithium compounds which can be used include those prepared by reacting an organomonolithium compounded with a multivinylphosphine or with a multivinylsilane, such a reaction preferably being conducted in an inert diluent such as a hydrocarbon or a mixture of a hydrocarbon and a polar organic compound. The reaction between the multivinylsilane or multivinylphosphine and the organomonolithium compound can result in a precipitate which can be solubilized, if desired, by adding a solubilizing monomer such as a conjugated diene or monovinyl aromatic compound, after reaction of the primary components. Alternatively, the reaction can be conducted in the presence of a minor amount of the solubilizing monomer. The relative amounts of the organomonolithium compound and the multivinylsilane or the multivinylphosphine preferably should be in the range of about 0.33 to 4 moles of organomonolithium compound per mole of vinyl groups present in the multivinylsilane or multivinylphosphine employed. It should be noted that such multifunctional initiators are commonly used as mixtures of compounds rather than as specific individual compounds. Exemplary organomonolithium compounds include ethyl lithium, isopropyl lithium, n-butyllithium, sec-butyllithium, tert-octyl lithium, n-eicosyl lithium, phenyl lithium, 2-naphthyllithium, 4-butylphenyllithium, 4-tolyllithium, 4-phenylbutyllithium, cyclohexyl lithium and the like.
[0030] Exemplary multivinylsilane compounds include tetravinylsilane, methyltrivinylsilane, diethyldivinylsilane, di-n-dodecyldivinylsilane, cyclohexyltrivinylsilane, phenyltrivinylsilane, benzyltrivinylsilane, (3-ethylcyclohexyl) (3-n-butylphenyl)divinylsilane and the like.
[0031] Exemplary multivinylphosphine compounds include trivinylphosphine, methyldivinylphosphine, dodecyldivinylphosphine, phenyldivinylphosphine, cyclooctyldivinylphosphine and the like.
[0032] Other multifunctional polymerization initiators can be prepared by utilizing an organomonolithium compound, further together with a multivinylaromatic compound and either a conjugated diene or monovinylaromatic compound or both. These ingredients can be charged initially, usually in the presence of a hydrocarbon or a mixture of a hydrocarbon and a polar organic compound as a diluent. Alternatively, a multifunctional polymerization initiator can be prepared in a two-step process by reacting the organomonolithium compound with a conjugated diene or monovinyl aromatic compound additive and then adding the multivinyl aromatic compound. Any of the conjugated dienes or monovinyl aromatic compounds described can be employed. The ratio of conjugated diene or monovinyl aromatic compound additive employed preferably should be in the range of about 2 to 15 moles of polymerizable compound per mole of organolithium compound. The amount of multivinylaromatic compound employed preferably should be in the range of about 0.05 to 2 moles per mole of organomonolithium compound.
[0033] Exemplary multivinyl aromatic compounds include 1,2-divinylbenzene, 1,3-divinylbenzene, 1,4-divinylbenzene, 1,2,4-trivinylbenzene, 1,3-divinylnaphthalene, 1,8-divinylnaphthalene, 1,3,5-trivinylnaphthalene, 2,4-divinylbiphenyl, 3,5,4′-trivinylbiphenyl, m-diisopropenyl benzene, p-diisopropenyl benzene, 1,3-divinyl-4,5,8-tributylnaphthalene and the like. Divinyl aromatic hydrocarbons containing up to 18 carbon atoms per molecule are preferred, particularly divinylbenzene as either the ortho, meta or para isomer, and commercial divinylbenzene, which is a mixture of the three isomers, and other compounds such as the ethyl styrenes, also is quite satisfactory.
[0034] Other types of multifunctional lithium compounds can be employed such as those prepared by contacting a sec- or tert-organomonolithium compound with 1,3-butadiene, at a ratio of about 2 to 4 moles of the organomonolithium compound per mole of the 1,3-butadiene, in the absence of added polar material in this instance, with the contacting preferably being conducted in an inert hydrocarbon diluent, though contacting without the diluent can be employed, if desired.
[0035] Alternatively, specific organolithium compounds can be employed as initiators, if desired, in the preparation of polymers in accordance with the present invention. These can be represented by R(Li)x wherein R represents a hydrocarbyl radical containing from 1 to 20 carbon atoms, and wherein x is an integer of 1 to 4. Exemplary organolithium compounds are methyl lithium, isopropyl lithium, n-butyllithium, sec-butyllithium, tert-octyl lithium, n-decyl lithium, phenyl lithium, 1-naphthyllithium, 4-butylphenyllithium, p-tolyl lithium, 4-phenylbutyllithium, cyclohexyl lithium, 4-butylcyclohexyllithium, 4-cyclohexylbutyllithium, dilithiomethane, 1,4-dilithiobutane, 1,10-dilithiodecane, 1,20-dilithioeicosane, 1,4-dilithiocyclohexane, 1,4-dilithio-2-butane, 1,8-dilithio-3-decene, 1,2-dilithio-1,8-diphenyloctane, 1,4-dilithiobenzene, 1,4-dilithionaphthalene, 9,10-dilithioanthracene, 1,2-dilithio-1,2-diphenylethane, 1,3,5-trilithiopentane, 1,5,15-trilithioeicosane, 1,3,5-trilithiocyclohexane, 1,3,5,8-tetralithiodecane, 1,5,10,20-tetralithioeicosane, 1,2,4,6-tetralithiocyclohexane, 4,4′-dilithiobiphenyl and the like.
[0036] The calcium alkoxides which can be utilized typically have the structural formula:
R 1 —O—Ca—O—R 2
wherein R 1 and R 2 can be the same or different and represent alkyl groups (including cycloalkyl groups), aryl groups, alkaryl groups or arylalkyl groups. Some representative examples of suitable calcium alkoxides include calcium dimethoxide, calcium diethoxide, calcium diisopropoxide, calcium di-n-butoxide, calcium di-sec-butoxide, calcium di-t-butoxide, calcium di(1,1-dimethylpropoxide), calcium di(1,2-dimethyl-propoxide), calcium di(1,1-dimethylbutoxide), calcium di(1,10-dimethylpentoxide), calcium di(2-ethyl-hexanoxide), calcium di(1-methylheptoxide), calcium diphenoxide, calcium di(p-methylphenoxide), calcium di(p-octylphenoxide), calcium di(p-nonylphenoxide), calcium di(p-dodecylphenoxide), calcium di(α-naphthoxide), calcium di(β-naphthoxide), calcium (o-methoxyphenoxide), calcium (o-methoxyphenoxide), calcium di(m-methoxyphenoxide), calcium di(p-methoxy-phenoxide), calcium (o-ethoxyphenoxide), calcium (4-methoxy-1-naphthoxide) and the like. Cyclic compounds, such as calcium ditetrahydrofurfurylate, can also be utilized in the catalyst system.
[0037] Calcium alkoxides can be prepared using inexpensive starting materials using a relatively simple procedure. This is done by reacting calcium hydroxide, Ca(OH) 2 , with an alcohol of the formula ROH at a temperature which is within the range of about 150° C. to about 250° C. This reaction can be depicted as follows:
Ca(OH) 2 +2 ROH→Ca(OR) 2 +2 H 2 O
wherein R represents an alkyl group, an aryl group or an alkaryl group. R will preferably be a 2-ethylhexyl group, a nonylphenyl group, a dodecylphenyl group, a tetrahydrofurfuryl group or a furfuryl group. This reaction will preferably be conducted at a temperature which is within the range of about 175° C. to 200° C. with the alcohol acting as the solvent for the reaction. The reaction will normally be carried out at a temperature which is above the boiling point of the alcohol for a period of 2-3 hours. After the reaction has been completed, excess alcohol is removed by distillation under vacuum or evaporation. Then, the calcium alkoxide is recovered by dissolving it in a suitable organic solvent; such as, ethyl benzene, toluene or xylene.
[0038] The lithium alkoxide compounds which can be utilized have the structural formula:
LiOR
wherein R represents an alkyl group, an aryl group, an alkaryl group, an arylalkyl group or a hydrocarbon group containing at least one hetero atom selected from the group consisting of oxygen atoms and nitrogen atoms. The lithium alkoxide can be synthesized by reacting an organolithium compound, metallic lithium or lithium hydride with an alcohol. The organolithium compound, metallic or lithium hydride can be reacted with the alcohol at a molar ratio of 0.5:1 to 3:2. It is preferred for the alcohol to be reacted with an equal molar amount of the organolithium compound, metallic lithium or lithium hydride.
[0039] Some representative examples of alcohols which can be utilized in preparing the lithium alkoxide include methanol, ethanol, n-propyl alcohol, isopropyl alcohol, t-butanol, sec-butanol, cyclohexanol, octanol, 2-ethylhexanol, p-cresol, m-cresol, nonyl phenol, hexylphenol, tetrahydrofuryl alcohol, furfuryl alcohol, 3-methyltetrahydrofurfuryl alcohol, oligomer of tetrahydrofurfuryl alcohol, ethylene glycol monophenyl ether, ethylene glycol monobutyl ether, N,N-dimethylethanolamine, N,N-diethylethanolamine, N,N-dibutylethanolamine, N,N-diphenylethanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, N-butyldiethanolamine, N-phenyldiethanolamine, N,N-dimethylpropanolamine, N,N-dibutylpropanolamine, N-methyldipropanolamine, N-ethyldipropanolamine, 1-(2-hydroxyethyl)pyrrolidine, 2-methyl-1-(2-hydroxyethyl)pyrrolidine, 1-piperidineethanol, 2-phenyl-1-piperidineethanol, 2-ethyl-1-piperidinepropanol, N-β-hydroxyethylmorpholine, 2-ethyl-N-8-hydroxyethylmorpholine, 1-piperazineethanol, 1-piperazinepropanol, N,N'bis(β-hydroxyethyl)piperazine, N,N'-bis(Y-hydroxypropyl)-piperazine, 2-(β-hydroxyethyl)pyridine, 2-(γ-hydroxypropyl)pyridine and the like.
[0040] The molar ratio of the lithium alkoxide to the calcium alkoxide will be within the range of about 1:1 to about 20:1 and will preferably be within the range of 5:2 to 10:1. The molar ratio of the lithium alkoxide to the calcium alkoxide will most preferably be within the range of about 3:1 to about 5:1. The molar ratio of the alkyl lithium compound to the calcium alkoxide will be within the range of about 1:1 to about 6:1 and will preferably be within the range of 3:2 to 4:1. The molar ratio of the alkyl lithium compound to the calcium alkoxide will most preferably be within the range of 2:1 to 3:1.
[0041] The organolithium compound will normally be present in the polymerization medium in an amount which is within the range of about 0.01 to 1 phm (parts by 100 parts by weight of monomer). In most cases, from 0.01 phm to 0.1 phm of the organolithium compound will be utilized with it being preferred to utilize from 0.025 phm to 0.07 phm of the organolithium compound in the polymerization medium.
[0042] The polymerization temperature utilized can vary over a broad temperature range of from about 20° C. to about 180° C. In most cases, a temperature within the range of about 40° C. to about 120° C. will be utilized. It is typically most preferred for the polymerization temperature to be within the range of about 70° C. to about 100° C. The pressure used will normally be sufficient to maintain a substantially liquid phase under the conditions of the polymerization reaction.
[0043] Polar modifiers can be used to modify the microstructure of the rubbery polymer being synthesized. Ethers and amines which act as Lewis bases are representative examples of polar modifiers that can be utilized. Some specific examples of typical polar modifiers include diethyl ether, di-n-propyl ether, diisopropyl ether, di-n-butyl ether, tetrahydrofuran, dioxane, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, trimethylamine, triethylamine, N,N,N',N'-tetramethylethylenediamine (TMEDA), N-methyl morpholine, N-ethyl morpholine, N-phenyl morpholine and the like. Dipiperidinoethane, dipyrrolidinoethane, tetramethylethylene diamine, diethylene glycol, dimethyl ether, TMEDA, tetrahydrofuran, piperidine, pyridine and hexamethylimine are representative of highly preferred modifiers. U.S. Pat. No. 4,022,959 describes the use of ethers and tertiary amines as polar modifiers in greater detail.
[0044] The polymerization is conducted for a length of time sufficient to permit substantially complete polymerization of monomers. In other words, the polymerization is normally carried out until high conversions are attained. The polymerization can then be terminated using a standard technique. The polymerization can be terminated with a conventional noncoupling type of terminator (such as, water, an acid and a lower alcohol) or with a coupling agent.
[0045] Coupling agents can be used in order to improve the cold flow characteristics of the rubber and rolling resistance of tires made therefrom. It also leads to better processability and other beneficial properties. A wide variety of compounds suitable for such purposes can be employed. Some representative examples of suitable coupling agents include: multivinylaromatic compounds, multiepoxides, multiisocyanates, multiimines, multialdehydes, multiketones, multihalides, multianhydrides, multiesters which are the esters of polyalcohols with monocarboxylic acids, and the diesters which are esters of monohydric alcohols with dicarboxylic acids and the like.
[0046] Examples of suitable multivinylaromatic compounds include divinylbenzene, 1,2,4-trivinylbenzene, 1,3-divinylnaphthalene, 1,8-divinylnaphthalene, 1,3,5-trivinylnaphthalene, 2,4-divinylbiphenyl and the like. The divinylaromatic hydrocarbons are preferred, particularly divinylbenzene in either its ortho, meta or para isomer. Commercial divinylbenzene which is a mixture of the three isomers and other compounds is quite satisfactory.
[0047] While any multiepoxide can be used, liquids are preferred since they are more readily handled and form a relatively small nucleus for the radial polymer. Especially preferred among the multiepoxides are the epoxidized hydrocarbon polymers such as epoxidized liquid polybutadienes and the epoxidized vegetable oils such as epoxidized soybean oil and epoxidized linseed oil. Other epoxy compounds, such as 1,2,5,6,9,10-triepoxydecane, also can be used.
[0048] Examples of suitable multiisocyanates include benzene-1,2,4-triisocyanate, naphthalene-1,2,5,7-tetraisocyanate and the like. Especially suitable is a commercially available product known as PAPI-1, a polyarylpolyisocyanate having an average of three isocyanate groups per molecule and an average molecular weight of about 380. Such a compound can be visualized as a series of isocyanate-substituted benzene rings joined through methylene linkages.
[0049] The multiimines, which are also known as multiaziridinyl compounds, preferably are those containing three or more aziridine rings per molecule. Examples of such compounds include the triaziridinyl phosphine oxides or sulfides such as tri(1-ariridinyl)phosphine oxide, tri(2-methyl-1-ariridinyl)phosphine oxide, tri(2-ethyl-3-decyl-1-ariridinyl)phosphine sulfide and the like.
[0050] The multialdehydes are represented by compounds such as 1,4,7-naphthalene tricarboxyaldehyde, 1,7,9-anthracene tricarboxyaldehyde, 1,1,5-pentane tricarboxyaldehyde and similar multialdehyde containing aliphatic and aromatic compounds. The multiketones can be represented by compounds such as 1,4,9,10-anthraceneterone, 2,3-diacetonylcyclohexanone and the like. Examples of the multianhydrides include pyromellitic dianhydride, styrene-maleic anhydride copolymers and the like. Examples of the multiesters include diethyladipate, triethyl citrate, 1,3,5-tricarbethoxybenzene and the like.
[0051] The preferred multihalides are silicon tetrahalides (such as silicon tetrachloride, silicon tetrabromide and silicon tetraiodide) and the trihalosilanes (such as trifluorosilane, trichlorosilane, trichloroethylsilane, tribromobenzylsilane and the like). Also preferred are the multihalogen-substituted hydrocarbons (such as, 1,3,5-tri(bromomethyl)benzene and 2,4,6,9-tetrachloro-3,7-decadiene) in which the halogen is attached to a carbon atom which is alpha to an activating group such as an ether linkage, a carbonyl group or a carbon-to-carbon double bond. Substituents inert with respect to lithium atoms in the terminally reactive polymer can also be present in the active halogen-containing compounds. Alternatively, other suitable reactive groups different from the halogen as described above can be present.
[0052] Examples of compounds containing more than one type of functional group include 1,3-dichloro-2-propanone, 2,2-dibromo-3-decanone, 3,5,5-trifluoro-4-octanone, 2,4-dibromo-3-pentanone, 1,2,4,5-diepoxy-3-pentanone, 1,2,4,5-diepoxy-3-hexanone, 1,2,11,12-diepoxy-8-pentadecanone, 1,3,18,19-diepoxy-7,14-eicosanedione and the like.
[0053] In addition to the silicon multihalides as described hereinabove, other metal multihalides, particularly those of tin, lead or germanium, also can be readily employed as coupling and branching agents. Difunctional counterparts of these agents also can be employed, whereby a linear polymer rather than a branched polymer results. Monofunctional counterparts can be used to end cap the rubbery polymer. For instance, trialkyl tin chlorides, such as tri-isobutyl tin chloride, can be utilized to end cap the rubbery polymer.
[0054] Broadly, and exemplary, a range of about 0.01 to 4.5 milliequivalents of coupling agent are employed per 100 grams of monomer. It is preferred to utilize about 0.01 to about 1.5 milliequivalents of the coupling agent per 100 grams of monomer to obtain the desired Mooney viscosity. The larger quantities tend to result in production of polymers containing terminally reactive groups or insufficient coupling. One equivalent of treating agent per equivalent of lithium is considered optimum amount for maximum branching, if this result is desired in the production line. The coupling agent can be added in hydrocarbon solution (e.g., in cyclohexane) to the polymerization admixture in the final reactor with suitable mixing for distribution and reaction.
[0055] After the copolymerization has been completed, the styrene-butadiene elastomer can be recovered from the organic solvent. The styrene-butadiene rubber can be recovered from the organic solvent and residue by means such as decantation, filtration, centrification and the like. It is often desirable to precipitate the segmented polymer from the organic solvent by the addition of lower alcohols containing from about 1 to about 4 carbon atoms to the polymer solution. Suitable lower alcohols for precipitation of the segmented polymer from the polymer cement include methanol, ethanol, isopropyl alcohol, normal-propyl alcohol and t-butyl alcohol. The utilization of lower alcohols to precipitate the rubber from the polymer cement also “kills” the living polymer by inactivating lithium end groups. After the segmented polymer is recovered from the solution, steam-stripping can be employed to reduce the level of volatile organic compounds in the rubber.
[0056] There are valuable benefits associated with utilizing the styrene-butadiene rubbers of this invention in making tire tread compounds. For instance, the styrene-butadiene rubber of this invention can be blended with natural rubber to make tread compounds for passenger tires which exhibit outstanding rolling resistance, traction and tread wear characteristics. In cases where tread wear is of great importance, high cis-1,4-polybutadiene can also be included in the blend. In any case, the styrene-butadiene rubbers of this invention can be used to improve the traction, tread wear and rolling resistance of tires made therewith.
[0057] This invention is illustrated by the following examples which are merely for the purpose of illustration and are not to be regarded as limiting the scope of the invention or the manner in which it can be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.
[0058] Examples
[0059] The calcium-based catalyst of this invention can be used in the homopolymerization of 1,3-butadiene into polybutadiene (PBD), in the homopolymerization of isoprene into polyisoprene (PI), in the copolymerization of styrene and 1,3-butadiene into styrene-butadiene rubber (SBR) and in the terpolymerization of styrene, isoprene and 1,3-butadiene into styrene-isoprene-butadiene rubber (SIBR). The calcium-based catalyst system of this invention can be prepared in-situ or can be preformed.
[0060] Example 1
[0061] In this experiment a styrene-butadiene rubber was synthesized using the process and catalyst system of this invention. In the procedure used, a styrene/butadiene premix that contained 10 percent styrene and 90 percent 1,3-butadiene was charged in a one-gallon (3.785 liter) reactor equipped with a mechanical stirrer and under a blanket of nitrogen. Heat was applied to this reactor until the pre-mix temperature reached 75° C. At this point, catalyst was introduced. The catalyst included calcium tetrahydrofurfuryl alcohol (the calcium salt of tetrafydrofurfuryl alcohol which is hexane-soluble) which was introduced at a level of 1 mmole per 100 g of monomer. This was followed by the addition of 2 mmole of n-butyl lithium and 2 mmole of lithium t-butoxide, based on 100 g of monomer. It should be noted that the catalyst can be preformed or that the catalyst components can be added individually. The samples were taken at various time intervals and analyzed by gas chromatography (GC) analysis. The data showed that the 30/70 monomer composition in the pre-mix (monomer plus hexane) resulted in a copolymer having a constant composition of 30 percent styrene and 70 percent butadiene. Thus, a random copolymer was made throughout the polymerization. A monomer conversion of approximately 90 percent was reached after only one hour of polymerization time. The polymer was analyzed and was determined to have a glass transition temperature (Tg) of −31° C., a 20 percent bound 1,2-polybutadiene (vinyl)content and random styrene sequences. This polymerization with the calcium-based catalyst system offers the advantage of promoting a much faster rate of polymerization than can be attained utilizing calcium-based catalyst systems.
[0062] Comparative Example 2
[0063] The procedure utilized in Example 1 was repeated in this experiment except that the calcium tetrahydrofurfuryl alcohol was eliminated from the catalyst system. In this experiment it took over 15 hours to reach a monomer conversion of about 90 percent. Thus, this experiment shows that including calcium tetrahydrofurfuryl alcohol in the catalyst system greatly accelerates the rate of polymerization and reduces the time needed to reach a high monomer conversion. More specifically, it took only 1 hour to reach a monomer conversion of about 90 percent in Example 1 where the calcium tetrahydrofurfuryl alcohol was present in the catalyst system with it taking over 15 hours to reach the same level of conversion in this experiment where the catalyst system was void of calcium tetrahydrofurfuryl alcohol.
[0064] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.
|
The process and catalyst system of this invention can be utilized to synthesize a highly random styrene-butadiene rubber having a high trans content by solution polymerization. The styrene-butadiene rubber made by the process of this invention can be utilized in tire tread rubbers that exhibit improved wear characteristics. This invention more specifically reveals a catalyst system for use in isothermal polymerizations which consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide. The subject invention further discloses a process for synthesizing a random styrene-butadiene rubber having a low vinyl content by a process which comprises copolymerizing styrene and 1,3-butadiene under isothermal conditions in an organic solvent in the presence of a catalyst system which consists essentially of (a) an organolithium compound, (b) a calcium alkoxide and (c) a lithium alkoxide. An amine can also be added to the catalyst system to increase the molecular weight (Mooney viscosity) of the rubber.
| 2
|
BACKGROUND OF THE INVENTION
Metal framing systems for holding glass and various kinds of opaque panels have been in use for some time, both for store front applications and for light and heavy curtain walls. In store fronts and in light curtain walls, a trend has developed in the direction of making the elements of the framing systems as narrow as possible for aesthetic reasons. Typical narrow mullions presently being installed are about one and three fourths inches wide, i.e. the same width as "two-by-four" finished lumber. Problems are encountered in making mullions narrower than this width. First, panel installation (glazing) becomes more difficult because there is less "maneuvering room" in the glazing pockets prior to installation of the glazing gaskets. In addition, the narrowness of the mullion reduces the depth by which the mullion grips the panel (termed "glass bite") if a conventional extrusion profile is employed. Furthermore, the restricted space available in the hollow interior of a narrow mullion makes conventional joint forming techniques with internal brackets difficult to apply to produce a joint between vertical and horizontal mullions having adequate strength.
SUMMARY OF THE INVENTION
In accordance with the present invention, a wall framing system is provided in which the mullions may be as narrow as one inch or even somewhat less, while still providing easy panel installation, ample glass bite, and strong joints.
The system utilizes vertical mullions which are multi-part and which are assembled together in the course of glazing. The parts of the vertical mullion include the mullion proper (or mullion base piece), a mullion stop, and a mullion filler. The mullion proper is formed, preferably by extrusion of aluminum, in a generally rectangular shape, with opposed glazing pockets on the long sides of the rectangle, and with approximately one quadrant of the rectangle omitted. Stated differently, the mullion proper is formed with one complete glazing pocket on one side and one-half of a glazing pocket on the other. Both the complete and partial glazing pockets are provided with suitable protrusions or grooves for engaging and gripping resilient glazing gaskets.
The mullion stop is shaped for attachment to the mullion proper to bring it to full width on the narrow side where the omitted quadrant of the mullion proper is located. The mullion stop and the mullion proper are attached together by any convenient means which may be applied in the field, such as screws or rivets.
The mullion filler is shaped for attachment to the mullion proper and mullion stop to supply the remaining half of the second glazing pocket and the remainder of the long side of the mullion in the area where the omitted quadrant of the mullion proper is located. Thus the mullion stop and mullion filler together provide the quadrant of the mullion which was omitted from the mullion proper. The mullion filler, in its glazing pocket region, is provided with suitable protrusions or grooves for engaging and gripping resilient glazing gaskets. The preferred mode of attachment of the filler to the stop, and to the mullion proper, is by interlocking engagement with grooves and/or protrusions located on those parts.
Both the mullion stop and the mullion filler are attached to the mullion proper after the panel is positioned in the half-formed glazing pocket of the mullion proper. They are thus not in the way during positioning of the panel.
In accordance with another aspect of the invention, an improved joint structure is provided which is strong, easy to install, and adaptable to the various constructional situations encountered in a wall system, such as the meeting of a horizontal and a vertical mullion, or the meeting of a horizontal mullion and a vertical jamb.
In the joint structure, continuous splines or keys are formed on the upper and lower interior walls of the horizontal mullion. The structure also includes a joint pin of substantial diameter having keyways formed therein for engaging the splines of the mullion. The pin also has an axial bore so that it can be brought into abutment with a mullion wall and attached thereto by a screw passing through the wall and into the bore. In addition the pin is provided with a series of transverse screw holes, radially aligned with the keyways. In some joints, the joint pin is passed through one or both walls of the vertical mullion, through holes bored therein. The transverse screw holes are positioned along the length of the joint pin so that no matter which of the standard positions the pin is placed in -- abutting a vertical mullion, passing through one mullion wall, passing through both mullion walls, etc. -- there is a screw hole located a single pedetermined distance from the wall of the vertical mullion or jamb. Thus a worker installing the wall system can easily locate the proper position to drill an aligned hole in the horizontal mullion, and install a screw fastening the pin and horizontal mullion together.
From the foregoing, it can be seen that the principal object of the present invention is the provision of a superior narrow wall framing system, although it should be understood that various features of the invention can be applied advantageously to wall framing systems generally, including those which are not "narrow", as that term is used herein.
It is a further object of the invention to provide a wall system which is readily glazable.
A further object of the invention is the provision of a narrow wall framing system which nonetheless has a maximized glass bite.
Another object of the invention is the provision of a wall framing system, particularly a narrow system, having a novel joint system therein which is strong and simple to install.
The manner in which the foregoing objects and purposes, together with other objects and purposes, are accomplished may best be understood from the detailed description which follows, together with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic elevational view of a building front employing the wall framing system of the invention;
FIG. 2 is a cross sectional plan view of a typical vertical mullion of the invention, the section being taken on the line 2--2 of FIG. 1 and the scale being much enlarged in comparison with FIG. 1;
FIGS. 3, 4, and 5 are sequential cross sectional plan views of adjacent vertical mullions, showing sequential stages in the installation of a panel therebetween, the scale being somewhat reduced in comparison with FIG. 2, and the interior structure of the mullions being somewhat simplified for clarity;
FIG. 6 is a cross sectional plan view of a typical vertical jamb member, the section being taken on the line 6--6 of FIG. 1;
FIG. 7 is a cross sectional plan view of a vertical expansion mullion, the section being taken on the line 7--7 of FIG. 1;
FIGS. 8A and 8B are cross sectional plan views of vertical mullions modified to act as door frames for center-hung and edge hung doors respectively, the section being taken on the line 8--8 of FIG. 1;
FIG. 9 is a cross sectional elevational view of a typical horizontal mullion, the section being taken on the line 9--9 of FIG. 1;
FIG. 10 is an isometric view, partly broken out, of a joint pin constructed in accordance with the invention;
FIG. 11 is a fragmentary isometric view, partly broken away, of a typical joint between vertical and horizontal mullions, and showing the joint pin;
FIG. 12 is a very diagrammatic elevational view showing various positions of the joint pin of the invention with respect to a vertical mullion;
FIG. 13 is a cross sectional elevational view of a typical header, the section being taken on the line l3--13 of FIG. 1; and
FIG. 14 is a cross sectional elevational view of a typical horizontal sill, the section being taken on the line 14--14 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a building, designated generally as 20, which is constructed in part of masonry 21, with an opening in the front in which a wall system, designated generally as 22, constructed in accordance with the invention is installed. The wall system includes sills 23, vertical jamb members 24, headers 25, vertical mullions 26 (including an expansion vertical mullion 27), and intermediate horizontal mullions 28. Mounted in these frame members are panels 29, and door 30. Panels 29 may be made of glass or other suitable materials and may be transparent, translucent, or opaque. Panels of different kinds may be included in the same wall system.
Attention is next directed to FIG. 2, which shows in plan cross section a typical vertical mullion 26 constructed in accordance with the invention. As can be seen from that FIG. the vertical mullion 26 is generally rectangular in plan cross section with a long side 31 and a short side 32. The term "narrow" is used herein to designate the shortness of side 32. In the commercial form of the invention side 32 is one inch; it may be made even smaller, the lower limit being about three-fourths inch. The length of long side 31 is partly determined by strength considerations and partly by aesthetic considerations. In the commercial form of the invention side 31 is 41/2 inches, but it may be greater or less.
The vertical mullion 26 includes three metal parts: the mullion proper (or mullion base piece) 33; a mullion stop 34; and a mullion filler 35. It also includes four resilient glazing gaskets 36, formed of a suitable material such as extruded vinyl resin. Gaskets 36 are fitted to the mullion and directly grip panels 29.
As can be seen from FIG. 2, (and also FIGS. 3-5) the mullion proper 33 has a generally rectangular shape with one quadrant omitted. The omitted quadrant is the lower right hand quadrant as FIGS. 2-5 are drawn. On the left long side of mullion base piece 33, a glazing pocket 37 is formed. It is midway of the side in the embodiment shown in the drawings, but it may be displaced toward one end or the other if desired. Glazing pocket 37 has sides 38, and a floor 39. Protrusions 40 are formed in the glazing pocket 37 to create grooves 41 in which the glazing gaskets 36 are fitted.
On the other long side 31 of mullion proper 33, opposite glazing pocket 37, one half of a glazing pocket is formed. The half-pocket is designated 42 in the drawings. It includes a side wall 43 and shares floor 39 with glazing pocket 37. By utilizing common floor 39 for both glazing pockets, their depth is maximized in relation to the length of narrow side 32 of mullion proper 33. This in turn provides the maximum maneuvering room for panel edges during panel installation, and for maximum glass bite after fitting of the glazing gaskets.
As a consequence of omitting the lower right hand quadrant from the profile of mullion proper 33, it has a recessed side wall 44 which is substantially aligned with floor 39 of the glazing pockets.
The mullion stop 34 is T-shaped in cross section, with the leg 45 of the "T" being proportioned to fit against and be attached (as by screw 45a) to recessed wall 44 of the mullion proper. The arm 46 of the T is proportioned to extend across the narrow side of the overall mullion 26 and form the narrow face thereof. Arm 46 is provided with reentrant edge portions 47 and 48. Edge portion 47 fits in a small corner recess 49 in mullion proper 33, and edge portion 48 engages the mullion filler 35, as is discussed below. In this manner the joint lines between the mullion stop and the mullion proper and mullion filler respectively are placed in unobtrusive locations. If a joint line running midway of the narrow face of the mullion is considered unobjectionable, the mullion stop may have an L-shaped profile instead of a T-shaped profile.
Mullion filler 35 is generally U-shaped in cross section, the base 50 of the "U" being a portion of the overall mullion long side wall. One leg 51 of the U is a side wall of glazing pocket 42. It is formed with a glazing gasket protrusion 52, and an interlock protrusion 53, which locks in a groove 54 formed in the mullion proper. The other leg 55 of the U is proportioned to engage the mullion stop 34 near the base of leg 45, and has a small recess 56 which engages reentrant protrusion 48 of mullion stop 34.
With the foregoing description of the structure of a vertical mullion in hand, attention is now directed to FIGS. 3-5, which show successive stages in the installation of a panel between two such vertical mullions. For the sake of simplicity in illustration and discussion, FIGS. 3-5 do not show an intermediate horizontal mullion or a horizontal sill member, one or the other of which would normally run between the two vertical mullions shown in these FIGS.
As can be seen from FIGS. 3 and 4, the space into which the panel 29' is to be installed is bounded on the right by a vertical mullion 26 having its full glazing pocket 37 facing the space, and on the left by a vertical mullion 26 having its half-pocket 42 facing the space.
At the outset of the glazing operation, (FIG. 3), the gaskets are not installed on the mullions, nor are the mullion stop and mullion filler installed on the left mullion. The panel 29' is brought up to the space and pivoted so that its right hand edge is in full glazing pocket 37 of the right mullion. This position of the panel is shown in ghost outline in FIG. 3. Panel 29' is then pivoted clockwise about its right edge, which is maintained in pocket 37, until it reaches the position shown in full lines in FIG. 3, with its left edge in half-pocket 42. Since the right edge of panel 29' is deep in full pocket 37 throughout this movement, enough clearance is created at the left edge of panel 29' for it to clear recessed wall 44 and floor 39 of the half-pocket 42. In the next stage of installation, (FIG. 4), the panel is centered, if necessary, the interior glazing gaskets 36 are installed, and mullion stop 34 is attached, by screws 45a, to the mullion proper 33.
The last steps of panel installation are shown in FIG. 5, where it can be seen that the mullion filler 35 is locked into engagement with mullion proper 33 and mullion stop 34, and exterior glazing gaskets 36 are installed.
From the foregoing, it can be seen that it was the temporary absence of the lower right quadrant of mullion proper 33 (later supplied by stop 34 and filler 35) which made it possible to seat panel 29' in half-pocket 42, notwithstanding that full pocket 37 is only about one-half inch deep, and the panel is sized to have a glass bite of almost one-half inch.
FIG. 6 illustrates in cross section a vertical jamb member 24, which includes a base plate 57, and a main mullion piece 58. Both pieces are secured to masonry 21 by screws 59. The main mullion piece 58 is provided with a deep glazing pocket 60 which extends for substantially the full thickness of the jamb. This deep glazing pocket provides enough maneuvering room for positioning a panel even though the glazing pocket of the opposite vertical mullion is shallow, i.e. about one-half inch. Glazing gaskets 61 are the same in profile and means of mounting as gaskets 36.
FIG. 7 shows in cross section a vertical expansion mullion 27. It has substantially the same parts as standard vertical mullion 26, and these components are therefore given the same reference characters as were used in FIG. 2. However, mullion proper 33 is formed in two parts, designated 33a and 33b, which are movable laterally with respect to each other, gaskets 62 being mounted to accommodate the sliding of parts 33a and 33b relative to each other. In addition, mullion stop 34' is L-shaped instead of T-shaped, since a joint line is inherent on the narrow face of an expansion mullion. In long horizontal runs of wall framing system, considerable lateral stresses can build up, attributable to the coefficient of thermal expansion of the metal. Installation of expansion mullions 27 at intervals in such long runs accommodates for, and relieves, such stresses.
FIGS. 8A and 8B are cross sectional plan views showing modifications of vertical mullions 26 to act as door jambs. The basic structure of the mullions shown in FIGS. 8A and 8B is that shown in FIG. 2 and described above in connection therewith.
FIG. 8A illustrates mullion 26 employed as a jamb for center-hung door 63. Full glazing pocket 37 is filled by pocket filler 64, which is held in place by screws 65. FIG. 8B shows a mullion 26 employed as a jamb for edge-hung door 63'. Pocket filler 64' has an integral door stop 66, equipped with a gasket 67.
In FIG. 9 there is shown in vertical cross section a typical horizontal mullion 28 constructed in accordance with the invention. Mullion 28 is generally rectangular in profile with glazing pockets 68, 69 formed in its long sides. In order to provide maximum depth to the pockets to maximize glass bite, they have a common pocket floor 70. The glazing gaskets 71 are the same as those used on the vertical mullions previously described, and they are mounted in the same way.
Internally, horizontal mullion 28 is provided with four integral splines or keys 72 running longitudinally in the interior space on either side of the glazing pocket region of the mullion. Splines 72 are part of the joint forming system of the invention, which is discussed below in connection with FIGS. 10-12.
The joint pin of the invention is shown in isometric view, partly broken out, in FIG. 10, where it is designated 73. It is a pin of relatively large diameter with respect to the space available in the interior of horizontal mullion 28.
Joint pin 73 is provided with four keyways 74 running longitudinally thereof. When a joint pin is inserted into the interior of a horizontal mullion 28, keyways 74 slidingly engage splines 72 inside the mullion.
Pin 73 is provided with an axial bore 75 for receiving a screw driven through a mullion or jamb exterior wall against which the end of the pin has been placed in abutment. This mode of joint formation is used on some occasions in accordance with the invention, for example, to attach a horizontal mullion to a vertical jamb 24.
In other modes of use of the joint pin of the invention, the joint pin is abutted against the interior or exterior of recessed wall 44 of mullion proper 26, or against the interior of a side wall of the mullion proper, and again, the attachment is made by a screw driven into bore 75. For example, when a horizontal mullion abuts a door jamb midway of the height of the door (a situation not appearing on FIG. 1), one joint pin 73 is passed through a hole drilled in a side wall of the vertical mullion which is acting as the door jamb, and is abutted against the interior of the opposite side wall. The other joint pin is passed through a side wall of the vertical mullion and abutted against the interior of the recessed wall 44 of the mullion proper. At an expansion vertical mullion 27, one of the joint pins 73 is abutted against the exterior of recessed wall 44.
At a crossing of horizontal and vertical mullions, such as that occurring at 76 on FIG. 1, the joint pin 73 is passed though all walls of the vertical mullion, and positioned so that it extends into the horizontal mullions on each side of the vertical mullion.
From the foregoing it is apparent that the joint pin 73, in its various uses in the wall system, occupies a variety of lateral positions with respect to the side face of the vertical mullion or jamb with which it cooperates. In order to provide for securing the joint pin to the horizontal mullion 28, a series of predrilled holes are provided in the floors of keyway 74 of pin 73. These holes are so located along the length of pin 73 that for every standard position of the pin (some of which were discussed above), there is a hole aligned a predetermined distance from the side face of the vertical mullion. Thus an installer need only measure out this predetermined distance from the mullion to find the location to drill a hole in the face of the horizontal mullion and install a screw which penetrates into the aligned hole in pin 73.
This aspect of the invention is illustrated very diagrammatically in FIG. 12, where three pins 73 are shown in different standard positions with respect to mullion 26. In all three positions a hole 77 is aligned at a given predetermined distance, indicated by the dotted line 78, from the side face of mullion 26.
FIG. 11 illustrates the joint at the crossing 76 (FIG. 1) of a vertical mullion 26 and two horizontal mullions 28. A pair of joint pins 73, one of which is out of sight in the FIG. are passed through the walls of mullion 26, and into the interiors of horizontal mullions 28. Keyways 74 of the pin engage splines 72. One hole 77 is aligned at the standard predetermined distance, and a screw 79 is applied.
FIGS. 13 and 14 show in elevational cross section a header 25, and a sill 23, respectively. A consideration of these FIGS. will reveal that the same extrusion profiles are involved in each, thus reducing the number of parts involved in the system. Header 25 and sill 23 include a base piece 80, attached to masonry 21 by screws 81, and panel fillers 82, which snap interlock to base pieces 80. Glazing gaskets 83 are of the same kind as is employed in the remainder of the system, and are mounted in the same manner.
|
Disclosed is a narrow frame wall structure having panel gripping mullions formed of extruded metal. Typical vertical mullions comprise a mullion proper with a glazing pocket on one side and one half of a glazing pocket on the other side, a mullion stop attached to the mullion proper after installation of a panel, and a mullion filler snap-locked to the mullion proper and the mullion stop to provide the remaining half of the second glazing pocket, thereby providing easy glazing and adequate glass bite notwithstanding the narrowness of the mullion. Joints between vertical and horizontal mullions are formed with joint pins positioned internally of the horizontal mullions on internal splines, and abutting, passing into or through, the vertical mullion, with predrilled screw holes in the pin so located that a screw hole is positioned a predetermined distance from the side of the vertical mullion in every standard location of the pin.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a continuation-in-part of U.S. patent application Ser. No. 14/328,705, “Analyzing large data sets to find deviation patterns,” filed Jul. 11, 2014 [case 26649]; which is a division of U.S. patent application Ser. No. 13/249,168 (U.S. Pat. No. 8,782,087) filed Sep. 29, 2011; which is a continuation-in-part of U.S. patent application Ser. No. 12/944,554 (U.S. Pat. No. 7,933,878) filed Nov. 11, 2010; which is a continuation of U.S. patent application Ser. No. 12/787,342 (U.S. Pat. No. 7,849,062) filed May 25, 2010; which is a continuation-in-part of U.S. patent application Ser. No. 11/389,612 (U.S. Pat. No. 7,844,641) filed Mar. 24, 2006; which is a continuation-in-part of U.S. patent application Ser. No. 11/084,759 (U.S. Pat. No. 7,720,822) filed Mar. 18, 2005. U.S. patent application Ser. No. 13/249,168 is also a continuation-in-part of international application no. PCT/US 11/37956, filed May 25, 2011.
This application is also a continuation-in-part of U.S. patent application Ser. No. 13/310,783, “Analyzing data sets with the help of inexpert humans to find patterns,” filed Dec. 4, 2011 [case 19915].
This application is also a continuation-in-part of U.S. patent application Ser. No. 13/190,377, “Secure distributed storage of documents containing restricted information, via the use of keysets,” filed Jul. 25, 2011 [case 19329]; which is a continuation-in-part of U.S. patent application Ser. No. 13/103,883 filed May 9, 2011; which is a continuation-in-part of U.S. patent application Ser. No. 11/286,080 (U.S. Pat. No. 7,940,929) filed Nov. 23, 2005.
This application is also a continuation-in-part of U.S. patent application Ser. No. 13/080,603, “Automatically optimizing business process platforms,” filed Apr. 5, 2011 [case 18624].
The subject matter of all of the foregoing is incorporated herein by reference in their entirety.
BACKGROUND
The present invention relates to automated data analysis with the help of potentially untrained humans. In one aspect, it relates to leveraging structured feedback from untrained humans to enhance the analysis of data to find actionable insights and patterns.
Traditional data analysis suffers from certain key limitations. Such analysis is used in a wide variety of domains including Six Sigma quality improvement, fraud analytics, supply chain analytics, customer behavior analytics, social media analytics, web interaction analytics, and many others. The objective of such analytics is to find actionable underlying patterns in a set of data.
Many types of analytics involve “hypothesis testing” to confirm whether a given hypothesis such as “people buy more pizza when it is raining” is true or not. The problem with such analytics is that human experts may easily not know of a key hypothesis and thus would not know to test for it. Analysts thus primarily find what they know to look for. In our quality improvement work with Fortune 100 firms and leading outsourcing providers, we have often found cases where clear opportunities to improve a process were missed because the analysts simply did not deduce the correct hypothesis.
For example, in a medical insurance policy data-entry process, there were several cases of operators marking applicants as the wrong gender. These errors would often go undetected and only get discovered during claims processing when the system would reject cases such as pregnancy related treatment for a policy that was supposed to be for a man. The underlying pattern turned out to be that when the policy application was in Spanish, certain operators selected “Male” when they saw the word Mujer which actually means female. In three years of trying to improve this process, the analysts had not thought to test for this hypothesis and had thus not found this improvement opportunity. Sometimes analysts simply do not have the time or resources to test for all possible hypotheses and thus they select a small subset of the potential hypotheses to test. Sometimes they may manually review a small subset of data to guess which hypotheses might be the best ones to test. Sometimes they interview process owners to try to select the best hypotheses to test. Because each of these cases is subject to human error and bias, an analyst may reject key hypotheses even before testing it on the overall data. Thus, failure to detect or test for the right hypotheses is a key limitation of traditional analytics, and analysts who need not be domain experts are not very good at detecting such hypotheses.
Another limitation of traditional data analysis is the accuracy of the analysis models. Because the analysis attempts to correlate the data with one of the proposed models, it is critically important that the models accurately describe the data being analyzed. For example, one prospective model for sales of pizza might be as follows: Pizza sales are often correlated with the weather, with sporting events, or with pizza prices. However, consider a town in which the residents only buy pizza when it is both raining and there is a football game. In this situation, the model is unable to fit the data and the valuable pattern is not discovered. In one aspect of our invention, humans could recognize this pattern and provide the insight to the computer system.
A third limitation of traditional analysis is that the analysis is subject to human error. For example, many analysts conduct statistical trials using software such as SAS, STATA, or Minitab. If an analyst accidentally mistypes a number in a formula, the analysis could be completely incorrect and offer misleading conclusions. This problem is so prevalent that one leading analysis firm requires all statistical analyses to be performed by two independent analysts and the conclusions compared to detect errors. Of course, this is just one way in which humans can introduce error into the broad process of bringing data from collection to conclusion.
Finally, because humans cannot easily deal with large volumes of data or complex data, analysts often ignore variables they deem less important. Analysts may easily accidentally ignore a variable that turns out to be key. During an analysis of a credit card application process, it was found that the auditors had ignored the “Time at current address” field in their analysis as it was thought to be a relatively unimportant field. However, it turned out that this field had an exceptionally high error rate (perhaps precisely because operators also figured that the field was unimportant and thus did not pay attention to processing it correctly). Once the high error rate was factored in, this initially ignored field turned out to be a key factor in the overall analysis. Analysts also sometimes initially explore data to get a “sense of it” to help them form their hypotheses. Typically, for large datasets, analysts can only explore subsets of the overall data to detect patterns that would lead them to the right hypotheses or models. If they accidentally look at the wrong subset or fail to review a subset with the clearest patterns, they may easily miss key factors that would affect the accuracy of their analysis.
On the other hand, an emerging best practice in the world of business analytics is the practice of “crowdsourcing.” This refers to tapping a large set of people (the “crowd”) to provide insight to help solve business issues. For example, a customer might fill out a comment card indicating that a certain dress was not purchased because the customer could not find matching shoes. This can be a very valuable insight, but the traditional collection procedure suffers from several problems.
The first step in crowdsourcing is undirected social idea generation. Employees, customers, and others submit ideas and patterns that they have identified. Of course, any pattern that is not noticed by a human is not submitted and is therefore not considered in the analysis.
The next step is for someone to sort and filter all the submitted ideas. Because there are a large volume of suggestions, and it is impossible to know if the suggestions are valuable without further research, someone must make the decision on which ideas to follow up on. This can be based on how many times an idea is submitted, how much it appeals to the people sorting the suggestions, or any number of methods. The issue is that good ideas may be rejected and never investigated.
Once the selected ideas are passed to an analyst, he or she must decide how to evaluate the ideas. Research must be conducted and data collected. Sometimes the data is easily available, for example, if a customer suggests that iced tea sells better on hot days, the sales records can be correlated with weather reports. Sometimes the data must be gathered, for example, if a salesman thinks that a dress is not selling well due to a lack of matching shoes, a study can be performed where the dress is displayed with and without clearly matching shoes and the sales volumes compared. However, sometimes it is impossible to validate a theory because the corresponding data is not available.
Finally, the analysis is only as good as the analyst who performs it in the first place. An inexperienced analyst often produces much less useful results than an experienced analyst even when both work on the same data.
Thus there is a need for a solution which takes the strengths of the computer and the strengths of the humans and leverages both in a scalable manner. Such a solution could increase the effectiveness of analytics by decreasing the impact of human errors and human inability to select the correct hypotheses and models.
Further, there is a need for a scalable approach to crowdsourcing which does not suffer from the limitations of traditional crowdsourcing described above.
On the other hand, automated analysis also suffers from certain limitations. The software may not see that two different patterns detected by it are actually associated or be able to detect the underlying reason for the pattern. For example, in the policy data entry example described above, an automated analysis could detect that Spanish forms had higher error rates in the gender field but automated analysis may not be able to spot the true underlying reason. A human being however may suggest checking the errors against whether or not the corresponding operator knew Spanish. This would allow the analysis to statistically confirm that operators who do not know Spanish exhibit a disproportionately high error rate while selecting the gender for female customers (due to the Mujer=male confusion).
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, wherein like designations denote like elements, and in which:
FIG. 1 is block diagram illustrating a combined computer/human approach to finding patterns and other actionable insights in large data sets.
FIG. 2 illustrates an overview of various ways to display the state of underlying data or processed results at various points along the various analysis methods, according some embodiments.
FIGS. 3A-3E are screen shots illustrating the evolution of a story (an analysis project), according to some embodiments.
FIGS. 4A-4F are screen shots illustrating various advanced settings and options that allow a user to customize aspects of analysis, according to some embodiments.
FIGS. 5A-5C are screen shots illustrating the creation of a story by analyzing a data set, subject to the user's feedback (described above with reference to FIGS. 3 and 4 ), according to some embodiments.
FIGS. 6A-6B are user interfaces that enable a user to share ( FIG. 6A ) or download ( FIG. 6B ) a story, according to some embodiments.
FIGS. 7A-7F are screen shots illustrating various data transformation and manipulation features underlying analysis, according to some embodiments.
FIGS. 8A-8N are screen shots illustrating descriptive and interactive graphs that describe what is happening in a data set, according to some embodiments.
FIGS. 9A-9B are screen shots illustrating diagnostic graphs that highlight multiple factors that contribute to what is happening in a data set, according to some embodiments.
FIGS. 10A-10C are screen shots illustrating prescriptive graphs that recommend changes to improve what is happening in a data set, according to some embodiments.
FIGS. 10D-10K provide an example of prescriptive analysis performed on an underlying data set, according to some embodiments.
FIGS. 11A-11D are screen shots illustrating predictive graphs that contain an outcome of a predictive analysis, according to some embodiments.
FIGS. 12A-12C are screen shots illustrating analysis comparing two subsets of a data set, according to some embodiments.
FIG. 13 is a screen shot illustrating display of an underlying analysis method, according to some embodiments.
DESCRIPTION OF PREFERRED EMBODIMENTS
Introduction
FIG. 1 is block diagram illustrating a combined computer/human approach to finding patterns and other actionable insights in large data sets. For simplicity, most of the following discussion is in the context of finding meaningful patterns, but the principles illustrated can also be applied to identify other types of actionable insights. Steps 110 and 120 are largely based on automatic computer analysis. Step 130 is largely based on human analysis (e.g., crowdsourcing), preferably by relatively untrained humans. Optional step 140 is a more formal analysis, preferably by trained analysts, to test and refine the findings and suggestions of steps 110 - 130 .
In this context, “untrained” means little to no training in the statistical principles underlying the search for actionable insights. The term “statistically untrained” may sometimes be used. Thus, in a conventional approach, statistical analysts review the data, form hypotheses and design and run statistically significant experiments to test their hypotheses. These statistical analysts will generally be “trained humans” or “statistically trained humans.” On the other hand, consider a case where the process being examined is a loan underwriting process. Feedback may be solicited from humans ranging from data entry operators to those making final decisions on loan applications. These will generally be “untrained humans” or “statistically untrained humans” because they are not providing feedback on the statistical aspect of the search for actionable insights. Note that the term “untrained human” does not mean that these humans are unskilled. They may be highly trained in other areas, such as loan evaluation. They may even have enough training in statistics to play the role of a statistical analysis; they just are not playing that role in this context.
Steps 110 and 120 are the automatic analysis of large data sets and the automatic detection of potentially valuable and meaningful patterns within those data sets. We have previously disclosed multiple approaches to automatically analyzing data to detect underlying patterns and insights. Examples include U.S. Pat. No. 7,849,062 “Identifying and Using Critical Fields in Quality Management” that disclosed means to automatically detect underlying error patterns in data processing operations as well as pending patent application PCT/US2011/033489 “Identifying and Using Critical Fields in Quality Management” that disclose additional approaches to automatically analyzing data to detect underlying patterns. While some of these inventions were described in the context of data processing or human error patterns detection, the underlying methods are also applicable to a broad range of analytics. In U.S. patent application Ser. No. 13/249,168 “Analyzing Large Data Sets to Find Operator Deviation Patterns,” we specifically disclosed approaches that allowed the automatic detection of subsets of data with high p-values indicating the high likelihood that the specific subset contained some underlying patterns and that the corresponding data distribution was unlikely to have been random. Thus, the underlying patterns have a higher chance of leading to meaningful actionable insights. These approaches can be applied to analyses including but not limited to customer segmentation (psychographics), sales analysis, marketing campaign optimization, demand forecasting, inventory/resource/supply chain optimization, assortment/product mix optimization, causal analysis, fraud detection, overbilling detection, and risk analysis. All of the foregoing are incorporated by reference herein.
The output of such automated analysis 110 / 120 can be further enhanced by the addition of manual feedback 130 . Such feedback can be provided by statistically trained humans, however, certain types of extremely valuable feedback can be provided by statistically untrained humans. For example, a company's employees, customers, suppliers or even interested humans without special knowledge/experience may be able to provide valuable feedback that can enhance the automated analysis 110 / 120 .
For example, in the policy data entry example described above, an automated analysis 110 / 120 could detect that Spanish forms had higher error rates in the gender field but automated analysis may not be able to spot the true underlying reason. A human being however may suggest 130 checking the errors against whether or not the corresponding operator knew Spanish. As indicated by the feedback arrow 135 , this would allow the analysis 110 / 120 to statistically confirm that operators who do not know Spanish exhibit a disproportionately high error rate while selecting the gender for female customers (due to the Mujer=male confusion). In this way, actionable insights can be iteratively developed through a combination of computer analysis and statistically untrained human feedback.
One goal here is to minimize the need for expert knowledge, such as deep understanding of statistics, so that the scope of potential crowdsourcing contributors 130 is as broad as possible. At the same time, an additional goal is to make the opportunities for crowdsourcing feedback 135 sufficiently structured in nature, such that the overall process can be as automated as possible and does not require subjective human evaluation or processing of the crowdsourced feedback. A final optional goal is tying the crowdsourced feedback and the automated analytics tightly and interactively to the available data so that the analysis produces actionable insights backed by statistically valid evidence.
Automated Analysis
Various types of automated analysis have been described previously by the inventors. For example, in the context of document processing by operators, one goal may be to find documents that are similar in some way in order to identify underlying patterns of operator behavior. A search can be conducted for segments of the data which share as few as one or more similar field or parameter values. For example, a database of loan applications can be searched for applicants between 37 and 39 years of age. Any pair of applications from this sample might be no more similar than a randomly chosen pair from the population. However, this set of applications can be statistically analyzed to determine whether certain loan officers are more likely to approve loans from this section of the population.
Alternatively, it may not be necessary to find even one very similar parameter. Large segments of the population may be aggregated for analysis using criteria such as “applicants under 32 years old” or “applicants earning more than $30,000 per year.” Extending this methodology one step further, a single analysis can be conducted on the sample consisting of the entire population.
In addition, it is possible to analyze sets of data which do not contain all of the information that the operators use to make decisions. In the case of loan applications requiring a personal interview, it would be very hard to conduct a controlled experiment that includes the personal interview. It would also be difficult to search for “similar” interviews. However, we can still search for applications with some parameters similar, and aggregate the statistics across all interviews. It may not be possible to identify any single loan decision as incorrect or suspect, but if, for example, among applicants aged 26-28, earning over $32,000, one loan officer approves 12% of loans and another approves 74% of loans, there may be training or other issues.
These methods can be combined to find a diverse variety of samples to analyze. A sample might consist of the documents with each field similar to a given value for that field, or it might comprise the set of all the documents. In addition, some fields may be restricted to a small or large range, where other fields have no restriction. Each sample may be analyzed with statistical methods to determine whether operators are processing documents consistently.
There are several statistical hypothesis tests which may be appropriate for making this determination. If the output of the process is binary, such as a loan approval, and the number of documents in the sample under analysis is small, a test such as Fisher's Exact Test may be used. If the output is a number, such as a loan interest rate, and the sample is large, a Chi-Square Test may be used. These tests can be used to determine whether one operator is producing significantly differing output from the remainder of the operators. Alternately, the operators can be split into two groups and these tests can be used to determine whether the operators in the two groups are producing significantly differing output. All possible splits can be analyzed to find the one with the highest statistical significance. Alternately, these tests can be used to determine simply whether the distribution of operator output for this sample is significantly more unusual than what would be expected under the null hypothesis, i.e., all operators making decisions in the same manner.
If numerous statistical tests are conducted, it is expected that some of them will be statistically significant, even without any underlying pattern. It is important to search for p-values which are more extreme than would normally be sought. For example, if 1000 tests are conducted, we could require a p-value of 0.00005 rather than the typical 0.05. Alternately, we can split the data into two sets of data: a training set and a testing set. We can conduct a large number of tests on the training data, but may find that our lowest p-values are not statistically significant due to the large number of tests conducted. We can then use the results to construct new hypotheses and design a small number of new tests. These new tests can be conducted on the testing data set. Because only a few tests are being conducted, we would not need very extreme p-values to achieve significance. Alternately, we can use the results as a starting point for any other review process, including supervisor review of indicated historic documents. Rules can potentially also be created to automatically flag documents from this segment of the population, as they are processed, for additional review.
Another method for computing the statistical significance of complicated test statistics is as follows. We are testing against the null hypothesis that all operators behave in the same manner. Disproving this null hypothesis means there is some statistically significant underlying pattern to the behavior of the operators. For statistics where operators are separated into multiple groups under a grouping plan, we can randomly assign operators into groups repeatedly under multiple different grouping plans and re-compute the test statistic for each grouping plan. If the value for a specific grouping plan is higher than the value for 95% of randomized grouping plans then we have 95% confidence that our null hypothesis was incorrect. Of course, we cannot simply compute many random grouping plans and assert that the top few grouping plans are statistically significant. However, we can identify a possibly significant grouping plan by doing this for the training dataset, and see if that grouping plan is again in the best 5% of random grouping plans for the testing data set.
It should be noted that a statistical hypothesis test can be very useful for showing that one or more operators produce different output (or a different output distribution) for documents from the same section of the population. However, it may be more valuable to find sections of the population where the operator output difference is large, rather than merely statistically significant. Metrics other than statistical p-value can be used to determine which population sections require further study. One such metric is related to the variance in the means of the operators output. Because we only have access to a sample of the data, we typically cannot compute the actual means. We can instead compute an estimate of each of the means and use this to calculate an estimate of the variance in the means.
In a stable process where there were no deviations from the norm, the variance would be significantly lower than in a process with patterns of deviations from the norm. Any of these metrics, or others, can be used as the basis of a hill climb or other local search method to identify interesting samples of the population that would be most useful to analyze to detect underlying patterns of deviations from norms or fragmented norms. A key property of these metrics is that they are highest for the section of the document population that actually represents the variance in operator behavior. For example, if one operator is not approving loans from males aged 20-30, the metric should be higher for “males aged 20-30” than for “males aged 20-50” and “people aged 20-30.”
Local search methods operate by considering a given sample, and repeatedly modifying it with the goal of raising the metric. This continues until the metric is higher for the sample under consideration than for any nearby samples (a local optimum). The notion of proximity is complex for samples of the sort we are discussing. The “modify” step in the algorithm will change the restrictions defining the current sample. This can consist of widening or tightening the restriction on one field, or adding a restriction on a new field, or removing the restriction on a restricted field. For example, if we consider a sample consisting of “Loan applications from females aged 30-40” and calculate the metric to be X, we could then calculate the metric for “females”, “females aged 30-50”, “females aged 20-40”, “people aged 30-40”, and others. Each of these metrics will be compared to X and the search algorithm will continue.
Because the metrics are highest for samples with acute variances, samples obtained using parameter values which are responsible for the unusual behavior will have the highest scores. Much larger and much smaller samples will have lower scores. As the search algorithm runs, the sample under consideration will “evolve” to contain the features that are causing the discrepancy in operator processing while not containing unrelated random information. Of course, the search will cease on one local maximum. If the local search is repeated multiple times from random starting samples, many samples with peak metrics can be identified in the data.
The examples above were given in the context of forming hypotheses for patterns of operator behavior, but they can also be used to form hypotheses for other types of analysis. These hypotheses can then be further qualified 130 by humans.
Human Social Ideation
Referring to FIG. 1 , human feedback 130 is used to improve the hypotheses identified by the automated analysis 110 / 120 . Multiple forms of directed crowdsourced or social feedback can be supported. Examples include the following.
Voting of auto-detected patterns: Humans may simply review the auto-detected patterns or subsets of data with high p-values and vote that the specific pattern or subset is worth further exploration. The higher the number of votes a pattern gets, the more actionable or worthy of further exploration the pattern might be.
Tagging of auto-detected patterns: Humans may also tag the patterns or subsets with comments. For example, in an invoice processing scenario, certain operators might incorrectly process debits as credits. This error would show up in different ways. First, the amount for the line item would be positive instead of negative. Second, the transaction type would be marked incorrectly. And finally, the total amount for the invoice would be incorrect. While automated analysis might detect that the three patterns are highly correlated it might not have sufficient information to reveal that there is a causal relationship between the patterns. One or more humans however may tag the three different error patterns as part of a broader “debit/credit confusion” pattern. This would help the automated analysis detect the fact that a single underlying problem, operators confusing debits and credits, is the root cause behind these multiple patterns. Another tagging example could occur for an automated analysis that revealed that a certain bank was issuing very few loans below $10,000 and that this pattern had significant statistical evidence of being significant. A human might however know that the specific bank only serves multi-millionaires and thus rarely received loan applications for small amounts. The human could thus tag this pattern as not worth exploring due to this reason. If sufficient humans tagged the pattern the same way, the automated analysis may reduce the importance of the pattern despite the high statistical evidence.
Propose hypotheses: The analytics may reveal patterns but due to the lack of understanding of the complex real world systems, algorithms may not detect the right corresponding hypotheses. For example, the analysis may reveal that something statistically significant is happening which is causing a significantly lower sale of certain dresses in certain shops as opposed to other shops even though the dresses were displayed the same way in all stores on identical mannequins. A customer may point out that the dress material displays certain attractive characteristics when seen under florescent light and not under incandescent light. This would be an example of a hypothesis that an automated analysis probably would not identify and even human experts may have easily missed. However, given a specific pattern to focus on as a starting point, at least one of a sufficiently large number of crowdsourced helpers may detect this key pattern.
Filter/search data to find new slices with high p-values: Automated analysis might leverage various heuristics such as “hill climb” to detect the subsets with the highest p-values. However, humans, especially customers and employees, because of their unique understanding of the broader context may be able to find subsets of data with high p-values that automated analysis did not detect. Humans may also realize that certain subsets were actually related and propose more complex subsets that would have even higher p-values. Additionally, because of heuristics like bucketing, the automated analysis may have somewhat imprecisely defined the subset and unnecessarily included/excluded data points in the subset that did not/did relate to the underlying pattern in question. Humans may define the subset more precisely, either including related data points or excluding unrelated data points to increase the p-values. For example, the system might detect an unusual volume of sales between $20 and $30 during the March 1-15 time period. A customer might remember a promotion of a free gift with purchases over $25 during February 25 to March 12 and suggest this as a new subset to analyze, leading to an even higher p-value.
Propose external variables or datum to consider: A key limitation of automated analysis is the lack of awareness of the physical world or overall context. Humans may easily recommend the inclusion of additional variables, the inclusion of which simplifies or enables the detection of patterns. For example, if the automated analysis was evaluating the sale of pizzas, humans might suggest the inclusion of key causal variables such as the dates on which football games are held, or the local rainfall rates as these variables significantly affect the sale of home-delivered pizza. Similarly humans may simply provide additional specific information such as “This specific shop uses incandescent lights” rather than suggest an external variable to consider.
Suggest fields to combine during analysis: Certain patterns may be relatively complex, such as “if variable A is equal to x and variable B is greater than y but variable C is not equal to z, then a specific pattern is observed.” Such complex patterns may be difficult for automated analysis to detect short of expensive brute force analysis of an enormous number of possible scenarios. Humans, because of their enhanced understanding of the context, can more easily suggest such patterns.
Suggest breaking existing data into finer grained fields: Certain fields may represent overly aggregated data which hides underlying patterns. For example, if sales data is aggregated by day, a user may suggest that sales in the morning and in the evening should be tracked separately because different types of customers visit the shop during the morning as opposed to the evening and they exhibit different sales behavior patterns.
Suggest type of regression: Humans may have an instinct for the shape of the hidden data distribution. For example, humans may be asked to vote on whether the underlying pattern is linear, exponential, etc. They may also suggest combining certain variables during the analysis as specified in f above. In each of these cases, they are essentially suggesting the type of regression that the automated analysis should use.
Suggest experiments to detect or confirm patterns: In some cases, the humans may be aware of a pattern that cannot be confirmed from just the available data. For example, if a dress was not selling because customers could not imagine what kind of shoe they could wear with it, merely analyzing existing data may not be sufficient. However, human feedback may suggest that this hypothesis be tested by setting up floor displays with the specific dress and corresponding shoes or selling the dress and matching shoes together as a package. The results of this experiment would offer data that could confirm this hypothesis.
The previous section talks about auto-detected patterns or auto-detected subsets of data with high p-values. However, this method may be applied to other forms of automated, assisted, or manual data analysis as well. For example, there is no reason to believe that such social feedback would not be useful to an expert analyst performing a completely manual data analysis.
Collection of Human Feedback
Although feedback can be solicited as free-form text, there are several ways that we can structure the collection of feedback from customers and others. Structured as opposed to free-form feedback allows easer automated understanding of the feedback as well as enhanced clustering of feedback to determine cases where multiple humans have essentially provided the same feedback.
One method for collecting structured feedback involves having users select each word in a sentence from a drop-down of possible words. In this way they can construct a suggestion, comment, or other insight such as “I would purchase more shoes if they were red.” Each of the nouns and verbs can be altered but the sentence structure remains easy to analyze. The user could choose from insight templates such as “I would X if Y,” “I feel X when Y,” “I enjoy X when Y,” etc.
For cases where the feedback involves filtering/searching data to find new slices with high p-values, the structured interface can be similar to standard advanced search functionality. The criteria specified by the human can be immediately tested on all the data or a selected subset of the data and the p-value measured.
Another way to accept structured feedback is to ask the users to construct their sentence using a restricted language of selected nouns, verbs, and adjectives. These can be automatically analyzed by software algorithms such as statistical aggregation, Markov chains, and others to detect patterns.
If no other option allowed the user to express herself fully, she could compose her thoughts in free-form text. However, instead of having this text interpreted by humans, it could be analyzed by computer algorithms such as statistical aggregation, Markov chains, and others as described above.
Humans may be provided financial or other rewards based on whether their feedback was useful and unique. For example, in the filtering case, a user might be rewarded based on the feedback's usefulness, namely how much better the p-value of their specified subset was than the average p-values of the top 10 subsets previously detected by the software automatically or with the help of humans. A uniqueness criterion may also be easily applied to the reward formula such that a higher reward would be paid if the human-specified subset differed significantly from previously identified subsets. The uniqueness of a user specified set N as compared to each of the previously identified sets S t may be determined by a formula such as the following: (Number of elements in N−Number of element in N intersect S t )/(Number of element in N intersect S t ). Other uniqueness and usefulness criteria might be applied instead or in addition.
For feedback involving regression models or combinations of fields to be used in the model, a very similar approach combining usefulness and uniqueness can be used. Usefulness can be determined by the improvement in the “fit” of the model while uniqueness can be determined by whether a substantially similar model has already been submitted previously or detected automatically.
Alternate approaches to rewards may include the following for cases where humans are tagging or voting for a pattern. The first person to tag a pattern with a given phrase might be rewarded based on how many other users also tagged the same pattern with the same phrase. This motivates users to tag with the phrases that they think other users will tag with. Even a software algorithm that attempted to “game” this system would, if successful, provide valuable insight. Given that users would not know what phrases a given pattern has already been tagged with, or even whether a pattern has already been tagged, it would be difficult for a user to predictably game such a system to get unwarranted rewards. Rewards can be restricted to tags that are uniquely popular for this pattern, to avoid the possibility every pattern getting tagged with a trivial tag. Alternately, the reward can be reduced if a user provides lot of tags. Thus, users would have an incentive to provide a few tags that are good matches for the data rather than a lot of less useful tags in the hope that at least one of the tags would be a good match.
Most reward-incented systems rely on rewards which are delayed in time with respect to the feedback offered by users. Because this system as described can measure p-values interactively, rewards can be immediately awarded, significantly improving the perceived value of participating in the system and increasing participation.
The structured human feedback process may be transformed into games of various sorts. Various games related to human-based computation have been used to solve problems such as tagging images or discovering the three dimensional shape of protein structures. This is just one example of how using automated analysis to create a good starting point and then allowing a framework where different humans can handle the tasks most suited to their interests and abilities, can be more effective than either just automated or just expert manual analysis.
Existing approaches can be further improved in a number of ways. For example, one embodiment taps a human's social knowledge, something much harder for computers to emulate than specific spatial reasoning. Moreover, we tap the social knowledge in a structured machine-interpretable manner which makes the solution scalable. Humans excel at graph search problems such as geometric folding (or chess-playing) where there are many options at each step. Today, this gives people an advantage in a head-to-head competition, but with rapid advances in technology and falling costs, computers are rapidly catching up. In fact, computer algorithms are now widely considered to outperform humans at the game of chess. However, no amount of increased processor speed will enable a computer to compete in the arena of social cognizance and emotional intelligence. Socialization comes naturally to humans and can be effectively harnessed using our methods.
Additionally, various embodiments can be non-trivially reward based. By tying a tangible payment to the actual business value created, the system is no longer academic, but can encourage users to spend significant amounts of time generating value. Additionally, a user who seeks to “game” the system by writing computer algorithms to participate is actually contributing to the community in a valid and valuable way. Such behavior is encouraged. This value sharing approach brings the state of the art in crowdsourcing out of the arena of research papers and into the world of business.
Finally, some approaches allow humans to impact large aspects of the analysis, not just a small tactical component. For example, when a human suggests the inclusion of an external variable or identifies a subset with high p-value, they can change the direction of the analysis. Humans can even propose hypotheses that turn out to be the key actionable insight. Thus, unlike in the image tagging cases, humans are not just cogs in a computer driven process. Here, humans and computers are synergistic entities. Moreover, even without explicit collaboration, each insight from a human feeds back into the analysis and becomes available to other humans to build on. For example, Andy may suggest the inclusion of an external variable which leads Brad to detect a new subset with extremely high p-value, which leads Darrell to propose a hypothesis and Jesse to propose a specific regression model which allows the software to complete the analysis without expert human intervention. Thus, the human feedback builds exponentially on top of other human feedback without explicit collaboration between the humans.
Some humans may try to submit large volumes of suggestions hoping that at least one of them works. Others may even write computer code to generate many suggestions. As long as the computation resources needed to evaluate such suggestions is minimal, this is not a significant problem and may even contribute to the overall objective of useful analysis. To reduce the computational cost of the evaluation of suggestions, such suggestions may first be tested against a subset of the overall data. Suggestions would only be incorporated while analyzing the overall data if the suggestion enabled a significant improvement when used to analyze the subset data. To further save computation expenses, multiple suggestions evaluated on the subset data may be combined before the corresponding updated analysis is run on the complete data. Additionally, computation resources could be allocated to different users via a quota system, and users could optionally “purchase” more using their rewards from previous suggestions.
Feedback Loop
Once the feedback is received 135 , the initial automated analysis 110 / 120 may be re-run. For example, if the humans suggested additional external data, new hypotheses, new patterns, new subsets of data with higher p-values, etc., each of these may enable improved automated analysis. After the automated analysis is completed in light of the human-feedback, the system may go through an additional human-feedback step. The automated-analysis through human feedback cycle may be carried out as many times as necessary to get optimal analysis results. The feedback cycle may be terminated after a set number of times or if the results do not improve significantly after a feedback cycle or if no significant new feedback is received during a given human feedback step. The feedback cycle need not be a monolithic process. For example, if a human feedback only affects part of the overall analysis, that part may be reanalyzed automatically based on the feedback without affecting the rest of the analysis.
As the analysis is improved based on human feedback, a learning algorithm can evaluate which human feedback had the most impact on the results and which feedback had minor or even negative impact on the results. As this method clearly links specific human feedback to specific impacts on the results of the analysis, the learning algorithms have a rich source of data to train on. Eventually, these learning algorithms would themselves be able to suggest improvement opportunities which could be directly leveraged in the automated analysis phase.
The human feedback patterns could also be analyzed to detect deterministic patterns that may or may not be context specific. For example, if local rainfall patterns turn out to be a common external variable for retail analyses, the software may automatically start including this data in similar analyses. Similarly, if humans frequently combine behavior patterns noticed on Saturdays and Sundays to create a higher p-value pattern for weekends, the software could learn to treat weekends and weekdays differently in its analyses.
The software may also detect tags that are highly correlated with (usually paired with) each other. If a pattern is associated with one of the paired tags but not the other, this may imply that the humans simply neglected to associate the pattern with the other tag, or it may be a special rare case where the pattern is only associated with one of the usually paired tags. The software can then analyze the data to detect which of the two cases has occurred and adjust the analysis accordingly.
This overall feedback loop may occur one or more times and may even be continuous in nature where the analysis keeps occurring in real time and users simply keep adding more feedback and the system keeps adjusting accordingly. An example of this may be a system that predicts the movement of the stock market on an ongoing basis with the help of live human feedback.
During the crowdsourcing phase, certain data will be revealed to the feedback crowd members. Companies may be willing to reveal different amounts and types of data to employees as opposed to suppliers or customers or the public at large. Security/privacy can be maintained using different approaches, including those described in U.S. Pat. No. 7,940,929 “Method For Processing Documents Containing Restricted Information” and U.S. patent application Ser. No. 13/103,883 “Shuffling Documents Containing Restricted Information” and Ser. No. 13/190,358 “Secure Handling of Documents with Fields that Possibly Contain Restricted Information”. All of the foregoing are incorporated by reference herein.
Further Analysis
Once the automated analysis with human feedback is completed, the data could be presented to expert analysts 140 for further enhancement. Such analysts would have the benefit of the following:
lists of hypotheses detected automatically as well as proposed by humans; results of how well the data fit various regression models detected automatically as well as proposed by humans; specific subsets of data with high p-values, corresponding to automatically or manually detected patterns, and corresponding manually proposed causal links; votes and tags indicating agreement from communities such as customers or employees; and other valuable context information
Such information significantly ameliorates some of the key limitations of manual expert analysis such as picking the wrong hypotheses, the wrong models, ignoring key variables, reviewing the wrong subsets, etc.
The analyst's responsibilities can also be restricted to tasks such as slightly changing models, etc. or improving the way the data is analyzed rather than having to write complex code from scratch or figuring out which data sources need to be included in the analysis. By reducing the complexity and the “degrees of freedom” of the work the analyst has to perform, we significantly reduce the risk of human error or the impact of an analyst's experience on the final results. This may also enable superior analysis with lower cost analysts.
Given the nature of the automated analysis, the structured nature of the crowdsourced feedback, and the minimal optional involvement of expert analysts, such an analysis can be carried out much faster, at lower overall cost and higher overall accuracy and effectiveness than traditional methods.
Given the report-writing flexibility and freedom that analysts enjoy under traditional methods, it can be difficult to create scalable user-friendly reports with drill-down, expand-out, context-aware features and context specific data details. In essence, when an analyst writes custom code or analysis formulae to create analyses, the reports themselves have to be custom in nature and are difficult to build automatically without manual customization. However, the methodology specified above can restrict the expert analyst to configure, not customize. Due to the nature of the automated analysis, the structured feedback, and the limited expert configuration, the software solution is fully aware of all aspects of the report context and can automatically generate a rich context specific report with drill-down, expand-out, context specific data capabilities.
The system, as described in the present invention or any of its components, may be embodied in the form of a computer system. Typical examples of a computer system include a general-purpose computer, a programmed microprocessor, a micro-controller, a peripheral integrated circuit element, and other devices or arrangements of devices that are capable of implementing the steps that constitute the method of the present invention.
The computer system comprises a computer, an input device, a display unit and the Internet. The computer comprises a microprocessor. The microprocessor can be one or more general- or special-purpose processors such as a Pentium®, Centrino®, Power PC®, and a digital signal processor. The microprocessor is connected to a communication bus. The computer also includes a memory, which may include Random Access Memory (RAM) and Read Only Memory (ROM). The computer system also comprises a storage device, which can be a hard disk drive or a removable storage device such as a floppy disk drive, optical disk drive, and so forth. The storage device can also be other similar means for loading computer programs or other instructions into the computer system. The computer system also includes one or more user input devices such as a mouse and a keyboard, and one or more output devices such as a display unit and speakers.
The computer system includes an operating system (OS), such as Windows, Windows CE, Mac, Linux, Unix, a cellular phone OS, or a proprietary OS.
The computer system executes a set of instructions that are stored in one or more storage elements, to process input data. The storage elements may also hold data or other information as desired. A storage element may be an information source or physical memory element present in the processing machine.
The set of instructions may include various commands that instruct the processing machine to perform specific tasks such as the steps that constitute the method of the present invention. The set of instructions may be in the form of a software program. The software may be in various forms, such as system software or application software. Further, the software may be in the form of a collection of separate programs, a program module with a larger program, or a portion of a program module. The software might also include modular programming in the form of object-oriented programming and may use any suitable language such as C, C++ and Java. The processing of input data by the processing machine may be in response to user commands to results of previous processing, or in response to a request made by another processing machine.
Overview of BeyondCore
FIGS. 2-13 illustrate examples and implementations of various aspects of the analysis methodology and frameworks described above. For convenience, these examples and implementations will be referred to as BeyondCore. These examples concern the analysis of a data set for a process, where the term “process” is intended to include any system, business, operation, activity, series of actions, or any other things that can generate a data set. The data set contains observations of the process, which are expressed as values for the outcome of the process and for variables that may affect the process. Depending on the application, the data set may contain at least 100,000 observations, at least 1,000,000 observations or more. The outcome may be directly observed or it may be derived. Typically, the data set will be organized into rows and columns, where each column is a different outcome or variable and each row is a different observation of the outcomes and variables. Typically, not every cell will be filled. That is, some variables may be blank for some observations.
In one example, the process is sales for a company. The outcome is revenue. The variables might include store location, category of item sold, month when sale took place, promotion (if any), demographics of buyer (age, gender, marital status, income), etc. Another example may be patient claims where the outcome is the amount paid or the length of stay or whether the patient was readmitted, while the other variables may include demographics of the patient (age, gender, etc.), facility/hospital visited, diagnosis, treatment, primary physician, date of visit, etc. Yet another example may be logistics analysis where the outcome is whether or not a shipment was delayed or the amount paid for the shipment while the other variables are shipment type, weight, starting location, destination location, shipper details, weather characteristics, etc. Examples may involve almost any revenue cost or risk metric as well as other kinds of metrics and corresponding variables that may or may not impact the outcome.
Typically, the data set is initially processed to determine the impact of different variable combinations on the outcome. The variable combinations are defined by values for one or more of the variables. Examples of variable combinations include {item=camera}, {buyer gender=male}, {item=camera; month=November}, {item=television; buyer age=21 to 39; promotion=Super Bowl}, etc. Here, the semicolon indicates “and” so {item=camera; month=November} means the variable combination of item=camera and month=November.
The impact of each variable combination typically is determined by the behavior of a variable combination with respect to the outcome and by the population of the variable combination. In one approach, automated analysis learns the normative behavior for each variable combination as it relates to the outcome. For example it may learn that Men in California spend more while 18 to 25 year olds who buy over the Mobile channel spend less than usual in general (here amount spent is the outcome). But a specific transaction may be for a Male 18 to 25 years old from California who purchased goods over the Mobile channel. By observing the norm for each variable combination in isolation and in combinations across multiple transactions, we can learn the “net impact” (the behavior) of a variable combination. This is the positive or negative impact of the variable combination on the observed outcome, net of the impact of all other variable combinations that may also be affecting that specific transaction. This allows automated analysis to learn a behavior metric that is similar to obtaining a regression coefficient in a regression analysis, but which can be learned via the search-based approach described above with reference to FIG. 1 , instead of running a regression analysis. In an alternative approach, a type of regression analysis is run for the outcome with respect to all of the variable combinations being considered. For each variable combination, there will be a regression term (the impact) that equals the regression coefficient (the behavior) multiplied by the population. Behavior may also be measured in terms of correlation coefficients, net-effect impact net of all other variables, or any other suitable metric that captures how the variable combination affects the outcome or how the outcome trends as a function of the variable combinations. Population may also be measured in terms of counts (i.e., number of observations), whether or not something occurred, frequency/percentage of overall population, or relative frequencies of observations. The overall impact of a variable combination depends on both its behavior (i.e., how strongly does that variable combination affect the outcome) and its population (i.e., how much of that variable combination exists in the data set of interest). These impacts, behaviors and populations can then be used to analyze the data set in different ways.
Preferably, “all” possible variable combinations will be initially processed. However, in practice, there may be good reasons to limit the analysis to less than every theoretically possible combination. For example, some variable combinations may not have enough observations to yield a statistically reliable or meaningful result. In one approach, initial processing is applied to all variable combinations of up to N variables provided that the variable combination has a statistically meaningful sample (e.g., at least M observations). For example, behaviors for all variable combinations of between 2-10 variables may be determined for which the data set contains a statistically meaningful number of observations. In one approach, statistically meaningful is determined based on the number of observations (e.g., requiring at least M observations, where M is a predetermined integer). M=25 or greater are typical values. The total number of variable combinations considered may be greater than 200, greater than 1000, or even more. Alternatively, the variable combinations considered may represent a significant fraction of the total possible variable combinations, for example at least 50% of the total possible four-variable combinations. As another example, behaviors for at least one variable combination may be determined for every variable for which the data set contains a statistically meaningful number of observations (e.g., at least 1% of the observations). In some embodiments, the variable combinations considered represent a significant number (e.g., at least 10, or at least 25) or proportion (e.g., at least 50%) of the total variables of the data set.
As yet another example, due to time or compute limitations the analysis might consider 1000 variable combinations in the final model and may exclude any variable combinations that have less than 30 observations (because of statistical significance thresholds or privacy objectives such as not disclosing information on groups smaller than a certain size to prevent identification of specific people via the analysis). In other approaches, the processed variable combinations include at least 1,000,000 combinations of variables, or include combinations for at least 100 variables, or include variable combinations for every variable for which there is a statistically meaningful sample.
FIG. 2 illustrates an overview of various types of graphs that can be used to display the state of underlying data or processed results at various points along the analysis methods described above. A user can create an analysis project by specifying a data set and analysis parameters for analyzing the data.
Descriptive graphs 210 are graphs used in an analysis project (also referred to as a story). Typically, BeyondCore has looked at all the possible graphs (i.e., variable combinations) and automatically highlighted those that a user should see e.g., (highest statistical importance). BeyondCore also conducts statistical soundness tests and highlights the specific parts of each graph the user should focus on.
Predictive graphs 220 illustrate an outcome of predictive analysis that selects the Descriptive graphs 210 to be displayed as well as to make Prescriptive recommendations 240 . Expert users can access the predictive capabilities directly from the ‘Choose a graph’ feature.
Diagnostic graphs 230 highlight multiple unrelated factors (i.e., variable combinations) that contribute to an outcome or visual pattern displayed in a graph. For a Descriptive graph 210 , BeyondCore automatically checks for what other factors might be contributing to the pattern. For example, a hospital that is doing badly may actually have far more emergency patients and that is why it is doing badly. Diagnostic graphs 230 help ensure that the patterns the user focuses on are real and not accidents of the data.
Prescriptive graphs 240 provide a means for the user to communicate to BeyondCore which of the variables are actionable (things that can be changed easily) and whether the user wants to maximize or minimize the outcome. BeyondCore can then look at millions (typically) of possibilities for changing variables, conducts Predictive analysis, recommends specific actions, quantifies the expected impact, and explains the reasoning behind the recommendations.
BeyondCore Stories
FIGS. 3A-3E illustrate the evolution of a story (an analysis project) in BeyondCore. This is an example of the generation of rich context-aware reports based on structured feedback from untrained humans described previously. In some embodiments, “STORIES” is configured as a user's home page in BeyondCore.
Referring to FIGS. 3A-3B , a user can start a new analysis/project (e.g., via user interface element 310 ), called a Story, or access any previous Stories (e.g., via user interface element 315 ). When a user selects the ‘Create a New Story’ button (UI element 310 , FIG. 3A ) on the home page ( FIG. 3A ), the Select a Data Set page ( FIG. 3B ) is displayed. On the Select a Data Set page ( FIG. 3B ), the user can access his stories (UI element 320 ), access his data sets (UI element 325 ), upload his data file (UI element 330 ), use an existing data set (UI element 335 ), or connect to remote servers with data (UI element 340 ). For example, enterprise customers can upload data from a remote database or Hadoop.
FIG. 3C illustrates a user interface for selecting the business outcome (the variable) that the user wishes to analyze. This is typically the KPI or metric in the user's dashboards and reports, e.g. revenue or cost. This page lists all the numeric or binary (e.g. Male/Female) columns in the user's data that have sufficient variability. If the user does not see a variable that is expected, the user may verify that the variable has numerical values and not text. If a variable has only a few values (e.g. 1, 2, 5), BeyondCore will treat it as a categorical variable instead of numeric. In most cases this is desired and statistically appropriate. To change a variable from categorical to numeric, the user may go to the Data Setup page and manually filter or reformat data (see advanced options at FIG. 4A ). Returning to FIG. 3C , the user may click user element 345 to select the business outcome. (which would be the y-axis of the graph, or the number the user wants to predict).
FIG. 3D illustrates a scenario where the user may want to exclude extreme cases from his analysis. For example, the user may know that most of his sales are between $250 and $500. The user can set the maximum acceptable value to $500 to exclude data above $500 from the analysis, for example by specifying a range of acceptable values for the outcome (UI element 352 ). The user may additionally rename the outcome (UI element 350 ) or choose a different outcome (UI element 354 ).
FIG. 3E illustrates a user interface that allows a user to further customize a BeyondCore story. The user may edit the story name, row labels, column labels, and the like. For example, UI element 360 allows a user to specify a story title, UI element 362 allows a user to specify how BeyondCore should refer to a row in the data, UI element 364 enables the user to specify the unit of the y-axis of his graphs (the outcome variable), UI element 368 enables the user to access advanced options or further customize a story.
FIGS. 4A-4F illustrate various advanced settings and options that allow a user to customize how BeyondCore treats variables in the analysis, including ignoring specific variables. Referring to FIG. 4A , BeyondCore may automatically ignore variables (e.g., the ‘Customer’ variable) that are very sparse in information. As another example, an identification code that is unique for each row or observation may be ignored. The user may choose to undo the ignore (e.g., via UI element 410 ). The advanced setting of FIG. 4A also enables the user to rename variables (e.g., via UI element 412 ), specify advanced settings (e.g., via UI element 414 ), ignore a variable (e.g., via UI element 416 ), and the like.
FIG. 4B illustrates another example of advanced settings where the user can override BeyondCore's treatment of each variable to appropriately analyze text and categorical variables. For example, a user may Click All (UI element 420 ) to include all categories in the analysis, uncheck UI element 422 if he wants the data corresponding to the unchecked categories to be excluded from the analysis (rather than being included in an ‘Other’ category), uncheck a category (e.g., UI element 424 ) to exclude it from being specifically analyzed, or rename any category (e.g., UI field 428 ). If the user renames any two categories to the same name, they will be combined automatically. Smaller categories may be excluded ( 426 ) automatically by BeyondCore. UI element 430 enables the user to close the advanced settings window of FIG. 4B .
FIG. 4C illustrates yet another example of advanced settings where the user can override BeyondCore's automated categorizations to tailor the analysis of numeric variables. BeyondCore breaks numbers into categories, as is typically done when the user looks at numbers in categories. Either these are linear categories (0-9, 10-19), or are frequency-based such as deciles, percentiles, etc. By setting the categorization scheme up front, BeyondCore simplifies the analysis complexity and reduces privacy risk. The user may specify (e.g., via UI element 432 ) to exclude rows where this variable is lower than the specified Minimum or higher than the Maximum. The user may choose (e.g., via UI element 434 ) to set up the categories so they have the same number of rows (deciles, quartiles, etc.) or the same numeric width 0-9, 10-19, etc. The user may also set categories with fixed widths rather than categories based on number of transactions (e.g., via UI element 436 , and as explained further with reference to FIG. 4D ). The user may also specify (e.g., via UI element 438 ) how many categories should we split this variable into for graphs. UI element 440 enables the user to close the advanced settings window of FIG. 4C . FIG. 4D illustrates that the user may also set categories with fixed widths rather than categories based on number of transactions (e.g., via UI element 436 ). In this example, BeyondCore uses transaction count categorization as a default because it is the most useful approach statistically. However, the user may want to have fixed widths such as 10 year age groups (1-10, 11-20, 21-30, etc. . . . ). Toggling this box 436 changes that method of categorization.
FIG. 4E is an example of a user interface that enables a user to overrule the specific decisions BeyondCore automatically makes to appropriately analyze date variables. Often, it is important to test for cyclicity when analyzing date fields. For example, sales may jump on Saturdays, or in November. In traditional analysis, users have to apply pre-specified transformations to the data to detect/address cyclicity. With BeyondCore, the user may only need to specify at which detail level to look for cycles. It will automatically learn and adjust for cyclicity, even if the pattern is specific to an unrelated variable, like gender or state (e.g. men buy more on Friday and women on Saturday). For example, the user may specify whether to report the date variable (e.g., 442 ) by Date, Month, Quarter, etc. The user may specify the granularities 444 at which we should look for and report cyclical behavior. The user may specify to exclude rows where a variable (e.g., 446 ) is lower than the specified Minimum or higher than the Maximum.
FIG. 4F illustrates an example where a user may specify (via UI element 450 ) that BeyondCore should generate the simplest prediction model possible, even if it takes extra time. BeyondCore potentially looks at millions of variable combinations to create the best regression model based on the data. However, because business users do not always understand “net effect,” the BeyondCore model does not look like a traditional statistical model. For example, a model may include an effect for males and a separate effect for females rather than just a net effect for males. While the second approach creates a simpler model, it is sometimes more difficult for business users to understand. Expert users can specify “simplify prediction model” and BeyondCore automatically uses traditional term reduction approaches to craft a simpler prediction model for the data.
FIGS. 5A-5C illustrate the creation of a story by analyzing the user's data, subject to the user's specifications (described above with reference to FIGS. 3 and 4 ). Once the user has selected the outcome variable and made any desired adjustments, the user may click “create story” 510 ( FIG. 5A ) to create a story using the data previously provided. The status bar 520 ( FIG. 5B ) shows the status of the current stage of analysis as BeyondCore analyzes (all) possible variable combinations. The story page ( FIG. 5C ) informs the user of how confident BeyondCore is of the analysis based on the unique characteristics of the user's data, and lets the user either play the animated briefing 530 or read the story 540 . Playing the animated briefing 530 takes the user through the key insights in his data. Reading the story 540 provides an executive report. The story page also displays 550 the number of combinations for which there was sufficient data to analyze and points out the number of insights 560 and statistical relevance 570 . If BeyondCore says the relevance is LOW, it means the variability (noise) in the data was too high. The user may be able to address this by cleaning the data, increasing the amount of data he is analyzing or using the advanced setup page to filter out extreme cases from his data. Even though the relevance is low overall, certain specific graphs may still have sufficient significance.
FIGS. 6A-6B illustrate user interfaces that enable a user to share ( FIG. 6A ) or download ( FIG. 6B ) a story. FIG. 6A illustrates that a user can share the story with other users in the organization and either authorize them to view the story or edit the story as well. Any edits made by authorized users can be seen by every other user. The user can use the ‘History’ link below each graph to revert to his preferred version of the story. BeyondCore users can be grouped into organizations and, in some embodiments, users can share stories only with people within their organization. If a user does not see a specific user in their share screen, the user may confirm that the specific user has registered with BeyondCore and is in the same organization as the user himself. Additional options to include allowing or denying editing capabilities of story 610 , granting or revoking access to the story 620 , selecting users with whom he wants to share his story 630 (e.g., via a drop down list that includes every user in the viewing user's organization that has registered with BeyondCore), sharing the story 650 , and so on. Further, as illustrated in FIG. 6B , a user can download (e.g., via UI element 670 ) and email a static HTML version of the story to other licensed users in his organization. In some embodiments, only the main story (excluding the recommendations panel) is available through this HTML file. Users may also download the story in other formats such as PowerPoint, Word and pdf files.
FIGS. 7A-7F illustrate various data transformation and manipulation features included in BeyondCore and explained above. Referring to FIG. 7A , the user may ‘Change Data Format’ 710 to specify how his data should be treated. BeyondCore may guess the format of a variable (e.g., at 715 ), or the user may manually specify the format of a field (e.g., at 720 ). If the user has a numeric column that only has a few possible values (e.g. the only values are 0, 1, 1.5, 2, and 3) BeyondCore formats it as a text column instead of a number. This is because statistically such cases should be treated as categories and not as a number. If the user wants to use this column as an outcome though, the user may manually change the format to a Number. Also if a numeric field has a few non-numeric values (e.g. N/A) the user can use the Data Subset feature to exclude the rows with non-numeric values.
Referring to FIG. 7B , ‘Create Data Subset’ 725 allows a user to focus the analysis on a subset of his data. For example, the user may exclude 730 a selected column from the analysis, filter based on specified criteria 735 , specify filters for categorical variables 740 , and exclude rows 745 where a selected variable is below the minimum or above the maximum.
Referring to FIG. 7C , the user may ‘Add Derived Columns’ 748 which enables the user to create new variables based on the existing variables in his data, for example, calculating the ratio of two columns. The user may specify the variable to be transformed 750 , choose the transformation 755 , specify other criteria for the transformation 760 , and name the new derived column 765 .
Referring to FIG. 7D , the user may additionally ‘Add a Column from a Lookup Table’ 770 to combine data from multiple data sets (same as a database Join). The user interface of FIG. 7D shows the user all the tables 775 that the user had already loaded or pointed to from the BeyondCore server. The user may then choose a table that the user wants to look up data from 780 , specify the matching criteria (here the customer IDs have to match) 785 , and specify the variables the user wants to look up from the new table 790 .
Referring to FIGS. 7E-7F , the user may ‘Create a Grouped Table’ 792 to combine (tabulates) multiple rows in the dataset into a single one (same as a database Group By). The data is summarized and tabulated by the variable that the user chooses to ‘Group By’ 795 . The user can also specify how BeyondCore tabulates each of the other variables in his dataset based on the primary ‘Group By’ variable—for example, group by the combination of a selected variable and any other ‘Group By’ variable that the user may specify 795 - a , by an average of a selected variable for each distinct value of the ‘Group By’ 795 - b , the sum of a selected variable for each distinct value of the ‘Group By’ 795 - c , the minimum or maximum value of this variable for each distinct value of the ‘Group By’ 795 - d , and the like.
Animated Briefing (Descriptive and Interactive Graphs)
In one or more embodiments, a multi-screen reporting is generated to indicate which variable combinations have a largest estimated impact on deviations from the norm. In such embodiments, the multi-screen reporting may comprise an animated briefing comprising a sequence of graphs describing which variable combinations have a largest estimated impact on deviations from the norm. Alternatively or in addition, the multi-screen reporting comprises a multi-page text report describing which variable combinations have a largest estimated impact on deviations from the norm. In some embodiments, contents of the multi-screen reporting depend on a user's interaction with the multi-screen reporting. In some embodiments, the user's interaction with the multi-screen reporting are tracked. In some embodiments, the user's interaction with the multi-screen reporting are tracked in a manner that is auditable. In some embodiments, changes to the multi-screen reporting resulting from the user's interaction with the multi-screen reporting are sharable with other users.
FIGS. 8A-8N illustrate descriptive and interactive graphs that contain information complementary to the analyzed data displayed on the graph. The complementary information (such as an animated briefing) may be overlaid on the graph in the form of a descriptive visual overlay or provided along with the graph as an audio narrative, to provide additional insight into the methodology, analysis frameworks, and assumptions underlying the analysis that went into generating the graphs. Moreover the overlays provide guidance to the user on how to interpret the graphs and call out key insights in the graphs. These animated briefings augment the graph and provide a visual or oral walk-through that accompanies the graph.
Referring to FIG. 8A , for instance, an animated briefing walks users through the key insights of an analysis. In this example, the outcome is average revenue and one of the variables is state. FIG. 8A is a bar graph that illustrates average revenue for each of various states such as California, NY, Washington, Delaware, and so on. The graph visually emphasizes the states for which average revenue is significantly different (greater or less) than the average revenue for all states combined. The graph also visually deemphasizes the states for which average revenue is not significantly different from the average revenue for all states combined or for which the pattern is not statistically sound. This facilitates easy visualization of deviations from the overall norm for the dataset. This is an automatically generated slideshow. BeyondCore automatically provides the user guidance towards relevant insights, in this case creating “highlighted results” by making insignificant bars translucent and significant bars solid. In addition, the visual narrative guiding text 810 , 815 , and 820 may be displayed as legends to aid the user in interpreting these graphs. An audio narrative may be concurrently played to guide the user through the key insights. The progress bar 825 indicates the on-going or paused audio briefing and the pause/play button 835 facilitates starting or stopping the audio briefing.
Similar visual narrative guiding text 840 , 842 , and 845 are illustrated in FIG. 8B , and the progress bar 847 indicates the on-going or paused audio briefing. FIG. 8B is a bar graph that illustrates average revenue for females and for males—across all states (cross-hatched bars) and for the state of Florida alone (solid bars). These graphs are based on the analysis of different variable combinations. This graph allows for easy visualization of patterns of outcomes (average revenue, in this case), across multiple different variable combinations, thereby allowing for identification of deviations from normative behavior within subsets of data. In these examples, the narrative guiding text in blue boxes (such as 840 , 845 ) provide information about the screen, the narrative guiding text in orange boxes (such as 842 ) are actions taken in this example walk-through, and narrative guiding text in white boxes (none shown in FIG. 8B ) are other actions that could be taken.
As illustrated in FIGS. 8A-8B , two or more graphs in a multi-screen report (story) often are related to one another. One example is a parent-child relationship between two graphs, where a parent graph (e.g., FIG. 8A ) is for a first variable combination (various states) and a child graph ( FIG. 8B ) is for a second variable combination (states by gender) that is a subset of the first variable combination. The multi-screen animated briefing presents the two graphs, but also includes an explanation of the relationship between the parent graph and the child graph. Another type of relationship is a sibling relationship. Sibling graphs include the same variables but differ in a value of one of the variables. For example, in FIG. 8B , the right graph {state; gender=male} and the left graph {state; gender=female} are sibling graphs. They could be presented on different screens, in which case an automatic explanation noting the relationship would be more important.
The story page shows an executive report based on the results of the analysis. Illustrated in FIG. 8C are four main areas: Home Menu, Toolbar 850 , Story 854 , and Story Menu 852 . Toolbar 850 drives the Story Menu 852 and points to other actions of interest. In some embodiments, the story is shown as soon as the initial analysis is completed. The Story Menu 852 can take different views: table of contents or recommendations. The Story 854 enables the user to scroll through the story that BeyondCore has guided the user to and that the user has optionally actively updated. In some cases, the initial story may be shown even before certain complex computations are completed.
Referring to FIG. 8D , the story page shows an executive report based on the results of the analysis. FIG. 8D is a bar graph that illustrates average revenue for various states when the ages are 65-70 versus average revenue for various states for all ages. The graph of FIG. 8D may be considered a cousin graph of FIG. 8B , since the variable combinations of the graphs of FIG. 8B {state; gender} and variable combinations of the graphs of 8 D {state; age} contain the same variables except for one different variable (gender versus age). The solid bars emphasize the states for which the average revenue for ages 65-70 is significantly different from the average revenue for that same state for all ages. This representation and visual emphasis enable easy visual identification of statistical deviations from observed norms within the dataset. So in this case the software has already learned the norm that New York and Texas have slightly higher average revenues in general. However, customers aged 65 to 70 from New York have a significantly higher revenue than the norm for that state while similarly aged customers from Texas have a slightly lower revenue than the norm for Texas. While Washington also exhibits a slight difference in average revenue for this age group compared to the overall norm for this state, the difference is not statistically sound and may be immaterial or caused by factors other than age and state. The user can add graphs to the story from the ‘Recommendations’ pane and delete graphs from the ‘Table of Contents’ pane. The user may interact with the graphical user interface via icons 856 (for playing the animated briefing for this story), 857 (for sharing the story), 858 (to see the R code for the most recent prediction looked at), 859 (to skip to specific graphs in his story via the “table of contents”), 860 (to show/hide recommendations).
Referring to FIG. 8E , selecting the Table of Contents changes the Story Menu so that the user can change the order in which the graph appears in their story or remove a graph from their story. The graphs in the Table of Contents are typically in the following order:
(i) Single variable that best explains the variability in the outcome (best single predictor) (ii) Variable that in combination with the previous variable most improves the explanatory power (best two variable predictor) (iii) If appropriate, another variable that in combination with the first variable improves the explanatory power (iv) Next single variable that best explains the variability on its own (2nd best single predictor)
The Table of contents 864 shows graphs in order of appearance in the user's storyline. The user can interact with the graphs, for example via icon 862 (to delete the graph from their story).
Referring to FIG. 8F , the user can edit narrative text. The story includes automatically generated text that explains the key points in each graph. To edit this text, the user can click on the ‘edit link’ and replace the text. The animated briefing would automatically say the edited text the user provides. Each number such as {1} illustrated by 865 corresponds to a specific bar that will be highlighted at the time the corresponding text is spoken. Even though the text indicating the bar to be highlighted looks like ‘{ }’ in some embodiments, these are actually special characters that the user cannot type using their keyboard. If the user wants to add a tooltip on a specific bar, the user may copy over {#} from one of the existing tooltip texts and then edit it. In this case, the special characters will be copied over, that BeyondCore uses to indicate a tooltip, rather than just typing the { } using his keyboard.
FIG. 8G illustrates that selecting Recommendations from the Toolbar changes the Story Menu so that the user can add graphs to the story. BeyondCore recommends additional graphs for the user to see. These recommendations are related to the graph the user is currently looking at. The user may interact with the recommendations for example via user interface elements 866 (click on any recommendation to see the details or ‘Add to story’ using the link), 867 (click to show more graphs), 868 (click to start prescriptive), and 869 (click to create own graphs and use predictive model). When the user pauses on a graph in the report, BeyondCore performs several complex computations to recommend the appropriate additional graphs for the user to see. Because the recommendations are related to the graphs the user adds and the user sees, the story evolves based on the unique interaction between the user and the story. Two different users who started with the exactly same story might end up with completely different stories based on what BeyondCore learns based on their interactions with the story. Here which graphs the user deletes, which graphs they see/pause on and which recommended graphs they add, all serve as structured feedback from an untrained human.
FIG. 8H is another illustration of Descriptive graphs that are added automatically to the user's story. If they have multiple variables they will include a benchmark average (this is the learned norm for one of the variables and is used to explain how the learned norm for the combination of variables differs from the norm for the individual variables). Translucent bars are used in most graphs herein to show insignificant differences and solid bars to indicate significant differences. As described with reference to FIG. 8A , the visual narrative guiding text 870 - a , 870 - b , 870 - c , and 870 - d may be displayed as legends to aid the user in interpreting these graphs.
Referring now to FIG. 8I , BeyondCore automatically shows the user the most important graphs to review. However, the user can manually choose the type of graph the user wants to see, the corresponding variable combinations and see the corresponding graph. As illustrated, the user may click ‘Specify Graph’ 872 to open the pop-up window for manual analysis.
Referring to FIG. 8J , the user can manually choose any variable combination and instantaneously see the corresponding graph (because BeyondCore already evaluated all possible variable combinations and stored the corresponding metrics). The user may choose any of the options indicated by the instructive text 874 , 875 , and 876 shown in FIG. 8J . Referring to FIG. 8K , the user can specify which variables he is interested in (via menu 877 ) and BeyondCore shows the user the most statistically important graph (via selection of option 878 ) that involves at least one of the specified variables. In this case, only graphs involving either a state, a gender or an age group would be shown. Graphs involving none of these variables would not be shown. This allows the untrained human to focus the story on certain variables without having to know the precise hypothesis up front. For example, they may request a graph related to Gender in recommend descriptive and based on that BeyondCore may point out that Males and Females have very different buying patterns in Florida. Note that the untrained human did not have to know the hypothesis that gender has a significant effect in Florida, only that gender might be a useful variable to consider given the context of the analysis.
Referring to FIG. 8L , once a graph is recommended (in this case the combination of state and gender) the user can drill into the graph further. BeyondCore recommends the order in which to drill into the graph (in this case look at male first, then female, then Florida, then Arizona) based on the normative behaviors for each subset that BeyondCore has already learned and the relative explanatory power of such subsets as detected based on search based or hill-climb or other automatic evaluations described above. The user may select a drilldown 880 , focus on specified values 882 , choose a graph type 884 , and so on. Referring to FIG. 8M , the use has chosen two variables and BeyondCore will show the user the graph that was requested (in this case, the variables chosen are state and gender). The user can drill into the graph further. BeyondCore recommends the order in which the user should drill into the graph, for example, via text or other interactive prompts an 885 - a , 885 - b , 885 - c , 885 - d , 885 - e . FIG. 8N illustrates an Extreme Outcomes report which shows sub-groups of the data that have the most extreme average outcomes. The user can filter down to certain types of sub-groups to focus attention on groups relevant to his analysis. As indicated in the text guide 888 , for each identified group, the graph shows how much higher/lower is that group's average outcome than the overall average. As indicated in text prompt/guide 890 , these controls allow the user to focus on specific sub groups.
Diagnostic Graphs
FIGS. 9A-9B illustrate diagnostic graphs that highlight multiple unrelated factors that contribute to an outcome or visual pattern displayed in a graph. A diagnostic graph results from a diagnostic analysis performed on a dataset to analyze differences in an outcome between a data set for a process and a subset of the data set. For instance, referring to the graph of FIG. 9B , outcome value 925 represents the outcome for the data set and outcome value 927 represents the outcome for the subset {gender=male}. The diagnostic analysis and the resulting diagnostic graph then presents various contributing factors (represented as 926 - a , 926 - b , 926 - c , 926 - d , and 926 - e ) that caused or can explain a discrepancy ( 925 versus 927 ) between the outcome value for the data set and that for the subset. The contributing factors are those variable combinations for which the estimated contribution to the outcome additively explain (sums up to) the difference between the outcome for the data set and for the subset.
The subset is defined where one or more test variables, which may be user specified variables, take on specific trial values. Examples are given in Table 1 a below:
TABLE 1a
Examples of Subsets
Test Variable and Trial
Data Set
Subset
Value
Example 1
{All}
{Gender = Male}
Test Variables =
(based on
{Gender}
FIG. 9B)
Trial Values = {Male}
Example 2
{All}
{City = SF;
Test Variables = {City,
Campaign = Print}
Campaign}
Trial Values = {SF,
Print}
To determine the drivers of the differences between the data set and the subset, corresponding pairs of variable combinations are considered, where the test variables take the trial values in one of the variable combinations and are not specified in the other variable combination. Examples of pairs of variable combinations for Example 1 of Table 1 a are illustrated in Table 1b.
TABLE 1b
Examples of Corresponding Variable Combinations for Subset
{Gender = Male}
Variable
Variable Combination for Subset
Combination for Data Set
{Gender = Male}
Example
{All}
{Gender = Male}
Pair 1
Example
{State = FL}
{State = FL; Gender = Male}
Pair 2
Example
{State = CA; Campaign =
{State = CA; Campaign = Print;
Pair 3
Print}
Gender = Male}
For these pairs, the analysis estimates contributions of the pair to differences in the outcome between the data set and the subset, based on differences in the behaviors of the pair and also based on differences in populations of the pair. In one approach, for each pair, an outcome for each of the two variable combinations is computed as a product of the (a) behavior of that variable combination with respect to the outcome and (b) the population of the subgroup defined by that variable combination. The difference in outcomes for the two pairs is used to assess a contribution of the pair to differences in the outcome between the data set and the subset.
Differences in the outcome between the data set and the subset is reported based on the estimated contributions for the variable combinations, for example in the form of a diagnostic graph such as the one illustrated in FIG. 9B . Similarly, contributing factor 926 - a is due to the variable combination {Gender=Male}, which is example pair 1 in Table 1b above. Contributing factors 926 - b et al are due to other variable combinations.
The analysis preferably considers the impact of all other variable combinations on the observed outcome as well. The following is a snippet of a narrative text for a Diagnostic graph of different Facilities/Hospitals with the outcome being Excess Stay (how many days did the patient stay at the hospital greater than what was expected by the state based on the diagnosis of the patient):
“The following factors involving Facility is Hospital A may be related to an increase in Excess Stay:
Admission Type is Emergency occurs 45.4% of the time globally but it changes to 95.1% when it is known that Facility is Hospital A. Because of these cases, the Excess Stay increases by 0.6 Days per Transaction Payment Type is Medicare HMO occurs 8.5% of the time globally but it changes to 25.9% when it is known that Facility is Hospital A. Because of these cases, the Excess Stay increases by 0.2 Days per Transaction”
In this case, Facility Hospital A has a higher than average Excess Stay but the automated analysis has detected that this hospital has twice as many emergency cases than the norm across all hospitals and that it has three times the usual proportion of Medicare patients. Such deviations from the overall norm explain a total of 0.8 Days of the increase in Excess Stay.
Note that if the previously disclosed approach of learning the net normative behavior for each variable combination is used, calculating such a complex analysis can be achieved by just multiplying the observed net norms for each variable combination by the observed relative difference in population between the data set and the sub set. This significantly decreases the computational complexity of such an analysis.
As illustrated in FIG. 9A-9B , BeyondCore presents, to the viewing user, the story as soon as the initial analysis is completed and Descriptive graphs are available. It continues doing additional statistical tests to look for Diagnostic graphs and creates the models for Predictive and Prescriptive graphs. Once these steps are complete, a message (notification) 910 indicating ‘Regression Complete’ is displayed. Once this message (notification) 910 is displayed, Diagnostic graphs are available for viewing. The diagnostic graphs are not added automatically to a story. They are available for all Descriptive graphs and show up on the recommendation pane if appropriate. In some embodiments, the diagnostic graphs are displayed in a pop-up window 920 if the user selects a recommendation. The user may choose to include the graph in a story (e.g., by selecting the UI element 930 ).
For example, we can look at treatment decisions of doctors when faced with similar patients. In this example, rather than taking a single patient case and duplicating it for many doctors, we identify different patients whose cases are similar enough for the analysis at hand. For purposes of the analysis, there are naturally occurring “duplicates.” Let's say the vast majority of doctors prescribe a set of medicines within an acceptable level of difference in prescription details. However, some of them instead recommend surgery. This can be identified as a deviation from the norm.
The plurality vote and cluster analysis techniques described earlier can be applied here. The concepts of specified equivalencies (such as a table of equivalent medications) or learned equivalencies can be applied while determining the norm. Optionally we can look at a database of previously observed deviation patterns and predict whether a specific behavior is a benign variance or a significant error. Historic patterns of behavior for operators (same as “historic error rates”) can be further used for cases where there are multiple significantly sized clusters, to identify the true normative behavior. Classes of activities could be analogized to fields, and we could then apply the techniques used to consider different fields and the relative operational risk from errors in a given field. Similarly, a set of classes of activities that can be treated as a unit could be analogized to a document. Thus, each of the medical steps from a patient's initial visit to a doctor, to a final cure may be treated as a document or transaction. So, for example, pre-treatment interview notes, initial prescription, surgery notes, surgical intervention results, details of post-surgery stay, etc. would each be treated as a “field” and would have related weights of errors. The overall error E would be the weighted average of the errors in the various fields. As in the previously described methods, the occurrence of errors can be correlated to a set of process and external attributes to predict future errors. A database of error patterns and the corresponding historical root causes can also be generated and this can be used to diagnose the possible cause of an error in a field/class of activity. Continuing the analogy, the data on the error patterns of each operator, here a doctor or a medical team, can be used to create operator and/or field specific rules to reduce or prevent errors.
In another example, we can look at financial decisions of people with similar demographics and other characteristics. Let's say the vast majority of them buy a certain amount of stocks and bonds within an acceptable level of difference in portfolio details. However, some of them instead buy a red convertible. This might be a deviation from a norm and could be analyzed similarly.
The pattern of error E for a given operator over time can be used for additional analysis. Traditional correlation analysis predicts an outcome based on the current value of a variable based on correlation formulas learnt based on other observations. If the current value of the variable is 10, traditional correlation analysis will predict the same outcome regardless of whether the variable hit the value 10 at the end of a linear, exponential, sine, or other function over time. However, E can be measured for operators over time and the pattern of E over time (whether it was linear, exponential, random, sinusoidal, etc.) can be used to predict the future value of E. Moreover, one can observe how E changes over time and use learning algorithms to identify process and external attributes that are predictors of the pattern of changes in E over time. These attributes can then be used to predict the pattern of the future trajectory of the error E for other operators or the same operator at different points in time. Such an analysis would be a much more accurate predictor of future outcomes than traditional methods like simple correlation analysis.
One may also observe E for a set of operators with similar characteristics over time. In some cases, E of all of the operators in the set will shift similarly and this would be an evolution in the norm. However, in some cases, E for some of the operators will deviate from E for the other operators and form a new stable norm. This is a split of the norm. In the other cases, E for multiple distinct sets of operators will converge over time and this is a convergence of norms. Finally the errors E for a small subset of operators may deviate from E for the rest of the operators but not form a new cohesive norm. This would be a deviation of the norm. Learning algorithms may be used to find process and external attributes that are best predictors of whether a set of operators will exhibit a split, a convergence, an evolution or a deviation of the norm. Similar learning algorithms may be used to predict which specific operators in a given set are most likely to exhibit a deviation from the norm. Other learning algorithms may be used to predict which specific operators in a given set are most likely to lead an evolution or splitting or convergence of a norm. By observing E for such lead operators, we can better predict the future E for the other operators in the same set.
As described above, the error E here can be for data entry, data processing, data storage and other similar operations. However, it can also be for healthcare fraud, suboptimal financial decision-making, pilferage in a supply chain, or other cases of deviations from the norm or from an optimal solution.
Time Variation of the Diagnostic Graphs
In some embodiments, the behavior of a variable and its deviation from the norm may vary with time. In some embodiments, causes of time variations in a data set may be identified based on representations of the data set at two or more points in time. The data set is processed to determine behaviors for different variable combinations at different times with respect to the outcome. Time variations in the contributions of the variable combinations to the outcome are estimated. Table 2 illustrates examples of pairs of snapshots of the same variable combination taken at different time points.
TABLE 2
Examples of Variable Combinations at Different Times
Snapshot
Snapshot at first time instance
at second time instance
Example
{Gender = Male; City = NY}
{Gender = Male; City = NY}
Pair 1
Time = T1 (January 2010)
Time = T3 (February 2014)
Example
{Gender = Female; Mkt
{Gender = Female; Mkt
Pair 2
Cmpn = Print}
Cmpn = Print}
Time = T1 (January 2010)
Time = T3 (February 2014)
Such time variations may be estimated based on time variations in the behaviors of variable combinations and also based on time variations in populations of the variable combinations. The analysis may also determine whether the estimated time variations in the contributions of the variable combinations to the outcome represent deviations from a norm or evolutions of the norm. In one approach, for each time instance in the snapshot pairing, the net impact on the outcome for the variable combination is computed as a product of the (a) behavior of that variable combination with respect to the outcome at that time instance and (b) the relative population of the variable combination at that time instance. The difference in outcomes for the variable combination at the two time instances is used to assess time variations in the data set for the variable combination. Such analysis can be conducted across multiple or even all possible variable combinations using the approaches described herein. In one or more embodiments, an identification of whether the reported time variations represent deviations from a norm or evolutions of the norm, is received from the user. The determined behaviors for different variable combinations are adjusted based on whether reported time variations represent deviations from a norm or evolutions of the norm.
The automated analysis learns the normative behavior over time for different variable combinations. Then it continues collecting data. The data may not perfectly conform to the learned norms but may be within statistical tolerance. Over time, the analysis may encounter new data where the behaviors or relative populations for certain variable combinations start to deviate significantly from the learned norm. Such cases can be flagged to the untrained human who can intervene if this is a deviation from the norm, or who can indicate that this is a one time deviation from the norm that can be ignored (for example an impact on tourism because of the World Cup), or who can indicate that this is just an evolution of the norm, in which case the automated analysis can adjust its understanding of the normative behavior by updating the learned model based on the new data.
In one or more embodiments, determining behaviors for different variable combinations at different times with respect to the outcome comprises determining cyclical variations in behaviors for different variable combinations with respect to the outcome. In some embodiments, an identification of cyclical variations in behaviors is received from the user. In such embodiments, determining behaviors for different variable combinations at different times with respect to the outcome comprises accounting for such cyclical variations in behaviors for different variable combinations with respect to the outcome.
Prescriptive Graphs
FIGS. 10A-10C illustrate prescriptive graphs which, as explained above, provide a means to communicate to BeyondCore which variables are actionable (outcomes that a user can change easily) and whether the user may want to maximize or minimize said outcome. This is a form of structured input from an untrained human. BeyondCore then looks at typically millions of possibilities, conducts Predictive analysis, and recommends (via the Prescriptive graphs) specific actions, quantifies the expected impact, and explains the reasoning behind the recommendations. In other words, to conduct a Prescriptive Analysis the user may select whether to minimize or maximize an outcome (using the links in the recommendations pane).
In a first example, if marketing campaign (the currently selected variable 1005 ) is something the user can change easily to maximize revenue, the user would click on the ‘Start Analysis’ link 1010 below the ‘Maximize by Changing Marketing Campaign.’ Alternatively, the user may opt to minimize an outcome by selecting the ‘Start Analysis’ link 1020 below the ‘Minimize by Changing Marketing Campaign.’ The actionable variable may be a single variable or a combination of variables. Optionally the variable may only be actionable under certain circumstances (we can change price for most customers but not government customers). Such input is a form of structured input from an untrained human. In some embodiments, the identification of one or more actionable variables is received based on an analysis of the data set.
Referring to the Prescriptive graph of FIG. 10B , the user runs a prescription analysis. The Recommendations pane for that variable will show a rank-ordered list of things the user can do to effect the outcome variable. For example, a prescriptive analytics report 1025 is displayed in the recommendations pane 1028 of the report illustrated in FIG. 10B . BeyondCore determines which recommended action should be taken in the recommended situation to have the predicted result looking at potentially millions of similar cases where the actionable variable was different. BeyondCore adjusts for unrelated factors that made the two groups different (for example, one group might be older than the other, but that is unrelated to marketing campaigns).
Referring to FIG. 10C , each prescription recommends a specific action 1045 under specific circumstances 1050 and the precise anticipated/expected/predicted result (impact) of the change 1040 . Referring to the displayed result 1030 , in this example, 44.8% of print advertising for cameras was run in New York, and print did much worse than average in New York. Referring to the graphical illustration 1035 , average revenue for the benchmark (mobile when item is cameras) after we adjust for unrelated differences between the two cases (such as in which month the campaigns were run).
The illustration of prescriptive analysis herein is an instantiation of above-described techniques such as learning the normative behavior of subsets of the data, observing how the behavior changes as the subset is expanded or shrunk, leveraging accidental experiments in large volumes of data where two groups are similar expect for a few characteristics (in this case the difference is the actionable variable), automatically generating regression models based on the data, statistically adjusting for behaviors, and the like.
FIGS. 10D-10K provide an example of prescriptive analysis performed on an underlying data set to identify the potential impact on an outcome when a value of an actionable variable is changed under automatically identified specified circumstances, in some embodiments. In this example, BeyondCore analyzes “accidental experiments” by identifying corresponding pairs of “before change” and “after change” variable combinations which are the same or similar based on factors unrelated to the actionable variable but differ by the value of the actionable variable. If the objective is to maximize the outcome, the outcome for the after change subset would be higher than the corresponding before change subset. If the objective is to minimize the outcome, the outcome for the after change subset would be lower than the corresponding before change subset. For each of the identified pairs constituting the “accidental experiments,” the method predicts an impact of changing the actionable variables by applying (a) the behavior of the “after” variable combination to (b) a population of the “before” variable combination. In some embodiments, this is accomplished by computing a behavior difference between the behavior of the “before” and “after” variable combinations, and multiplying the behavior difference by the population of the “before” variable combination.
In the example of FIGS. 10D-10K , the outcome is average daily revenue and the actionable variable is marketing campaign. That is, the marketing campaign variable can take on different values—Print, Mobile, Social, etc.—and the user wants to investigate the predicted impact of changing marketing campaigns under certain situations. The data set also contains many other variables: city, item, month, etc. The prescriptive analysis recommends possible actions to change the marketing campaign.
It does this by analyzing the variable combinations. There are a large number of variable combinations involving the actionable variable (marketing campaign) in combination with the other variables. When a pair of variable combinations is the same except that the actionable variable takes on different values, this is an “accidental experiment” that can be used to predict the contribution of that variable combination to changing the actionable variable from one value to another value. Table 3 gives some examples of pairs of variable combinations that could be used to predict the impact of a candidate action.
TABLE 3
Examples of Pairs of Variable Combinations to Predict Impact of Candidates Changes
First Variable
Second Variable
Contributing Factor
Combination (“Before”)
Combination (“After”)
Example
Change Mktg Cmpn from
{Items = Headphones;
{Items = Headphones;
Pair 1
Social to Print, only for
Mktg Cmpn = Social}
Mktg Cmpn = Print}
items = Headphones
Example
Change Mktg Cmpn from
{Items = Headphones;
{Items = Headphones;
Pair 2
Print to Social, only for
Mktg Cmpn = Print}
Mktg Cmpn = Social}
items = Headphones (FIG.
10H)
Example
Change Mktg Cmpn from
{Mktg Cmpn = Print}
{Mktg Cmpn = Social}
Pair 3
Print to Social, for all
cases (FIG. 10I)
Example
Change Mktg Cmpn from
{Items = Headphones;
{Items = Headphones;
Pair 4
Print to Social, only for
City = NY; Mktg
City = NY; Mktg
items = Headphones and
Cmpn = Print}
Cmpn = Social}
City = NY (FIG. 10J)
For each pair, the predicted contribution to the impact is computed by applying the behavior of the second variable combination (or the difference in behaviors between the two variable combinations) to the population of the first variable combination. It should be noted that all possible pairs of variable combinations that involve the two different values of the actionable variable may be considered in this analysis. Thus, while calculating the impact of changing from Print to Social when item is Headphones, we would also apply the behavior of Social in each city to the corresponding frequency of each city for Print and apply the behavior of Social in each month to the corresponding frequency of each month for Print, and so on. This can be done for all accidental experiments and then different candidate actions can be compared to create a ranked list of the most effective actions. For example, consider the candidate action of changing Mktg Cmpn from Print to Social only for items=Headphones. This will be affected by the bottom three pairs in Table 3, in addition to any other pairs which (a) include Headphones and (b) where the only difference between the pair is changing Mktg Cmpn from Print to Social. Each of the candidate actions can be evaluated and then recommendations can be made.
The graph of FIG. 10D illustrates an analysis of a candidate change, where Mktg Cmpn is changed from Print to Social—under the circumstance that the item is Headphones. The graph of FIG. 10D illustrates measures of the outcome variable (average daily revenue, in this case) for different cases: average revenue 1055 for Headphones when the marketing campaign is Print, what the average revenue 1057 for Headphones could be if the cases where the marketing campaign was originally Print had been changed to Social instead, and the predicted impact 1056 of making only that change.
There may be other differences between the Print and Social variable combinations, such as differences in population distribution. Accounting for all of those additional differences results in the average revenue 1060 for Headphones when the marketing campaign is Social. FIG. 10D also shows the part 1058 of the differences in outcome that was due to unrelated factors (e.g., such as the percent of Print campaigns run in November was different than the percent of Social campaigns run in November) that cannot be impacted by changing the campaign type, and the part 1059 of the differences in averages that was due to factors that could not be explained by the analysis.
In this example, the recommendation 1061 is to change marketing campaign from Print to Social for item being Headphones. FIG. 10E lists additional recommendations 1062 . The top recommendation is to change marketing campaign from Print to Mobile for all cases. The second recommendation is to change marketing campaign from Print to Mobile for city being New York. The third recommendation is the one shown in FIGS. 10D-E .
FIGS. 10E-10K include a more detailed explanation of various variables or variable combinations that define constituent subgroups of the dataset that resulted in or influenced the impact that the action had on the outcome.
As shown in FIG. 10F , revenue 1055 is the starting point of the walk-through (revenue when marketing campaign is print; item is headphones). As shown in FIG. 10G , revenue 1057 is where the revenue could end up if the candidate change was made, i.e., if the observations where campaign was Print for Headphones had instead been Social. FIG. 10H illustrates the portion 1064 of the overall change that is due to changing from print to social specifically for Headphones, which affects 100% of the observations in the candidate change. FIG. 10I illustrates the portion 1065 of the overall change that is due to changing from print to social in general, irrespective of the item being headphones, which also affects 100% of the observations in the candidate change. FIG. 10J illustrates the portion 1066 of the overall change that is due to changing from print to social specifically for Headphones in New York, but note this factor only affects 43.9% of the observations in the candidate change.
FIG. 10K illustrates that a similar analysis can be made when comparing revenue 1057 and revenue 1060 , which accounts for differences in population between the two variable combinations. However, this difference is not actionable by just changing the values of the specified actionable variable.
Predictive Graphs
FIGS. 11A-11D illustrate predictive graphs, according to some embodiments. BeyondCore automatically creates a predictive model but the untrained user can manually choose specific variables to include or exclude from the model. Users can also specify any predictive scenario to evaluate. Referring to FIG. 11A , the user may select 1110 a what if scenario to view graphs comparing specified “what if” scenarios where BeyondCore compares the predicted outcomes for different values of a what-if variable under specified conditions. The user may also select 1120 to view visual representations of predictive models for specific variable combinations or select 1130 to view the coefficient terms of the regression model.
Referring to FIG. 11B , what-if scenario analysis enables a user to compare predicted outcomes for different values of a variable under specified conditions. The user interface may allow the user to select 1140 the variable that the user wishes to compare different outcomes for (e.g., in the example of 1140 , what acquisition channel should the user use?). The user may also choose 1145 the variables to constrain based on. The user may also click ‘View Graph’ 1150 to see the analysis. The user may also specify 1155 conditions under which the user wants to compare the what-if variable (in this case, Females with income between 61500 and 81500).
As illustrated in FIG. 11C , the Predictive Analysis shows the expected outcome under specified circumstances and explains the reasons behind the prediction. The user may additionally select variables to constrain based on 1160 , conditions 1165 for which to predict the outcome (in this case, Californian females who are 20 to 25 years old with income between 61500 and 81500), and an option to view the graph with the analysis 1170 . The graph itself includes the overall average 1175 - a , reasons behind the prediction 1175 - b (the user may hover or mouse over to see additional details), and predicted outcome 1175 - c . The prediction is based on the automatically learned features of the data set, the automated analysis approach for which has been described above.
Referring to FIG. 11D , the Regression Terms shows how each variable combination affects the expected outcome. These are the “coefficients” of the underlying regression model. For each identified group, 1180 shows how much it positively or negatively contributes to the predicted outcome. The controls 1185 allow the user to focus on specific sub groups.
Drivers of Difference
FIGS. 12A-12C illustrate a Drivers of Difference report which provides a rank-ordered list of factors that most impact the difference in average outcomes between selected groups. In the example illustrations of FIGS. 12B-12C , the drivers of difference analysis and resulting report ( FIG. 12C ) provide a tool for analyzing differences in an outcome (e.g., revenue, in this case, as shown on the Y-axis of FIG. 12C ) between a subset A from a data set (e.g., in this case, Group A: state=California 1245 ) for a process and a subset B from the same data set (e.g., in this case, Group B: state=New York 1250 ). The drivers of difference report may be provided as a type of diagnostic graph (e.g., by selecting 1210 in FIG. 12A ), or separately.
Referring to FIG. 12B , to access the Drivers of Difference page, the user chooses the groups to compare. The user may change the comparison variable 1220 , specify the first comparison group 1225 , and change the second comparison group 1230 . The user may also choose (e.g., by checking box 1235 ) to include or exclude factors that occur for only one of the two groups. Notification 1240 indicates that drivers of difference graphs have been prepared for the selected groups and are ready for viewing.
FIG. 12C includes an illustration of differences in outcome (revenue) between two subsets of data defined by two different values of a test variable (in this case “state”)—the two different values being California and New York. The difference in outcome (revenue) is decomposed by corresponding pairs of variable combinations defined by common values of other variables (Age, Acquisition Channel, Gender, Customer Status, and so on). Referring to FIG. 12C , the Drivers of Difference page provides a rank-ordered list 1255 of factors that most impact the difference in outcomes (in this case, revenue) between the selected groups (in this case, CA and NY). This analysis is performed by comparing corresponding variable combinations. Table 4 lists some of the variable combinations used in the analysis shown in FIG. 12C . Differences in behavior and population between the pairs can be evaluated for many different pairs. This can be used to determine which factors drive the differences between the two subsets.
TABLE 4
Examples of Pairs of Variable Combinations for Drivers of Difference
Contributing
Subset A Variable
Subset B Variable
Factor
Combination (CA)
Combination (NY)
Example
Age: 71 to 76
{Age = 71 to 76;
{Age = 71 to 76;
Pair 1
State = CA}
State = NY}
Example
Acq Ch: Paid
{Acq Ch = Paid
{Acq Ch = Paid
Pair 2
Search
Search; State = CA}
Search; State = NY}
Example
Acq Ch: Paid
{Acq Ch = Paid
{Acq Ch = Paid
Pair 3
Search;
Search; Gender =
Search; Gender =
Gender:
Female;
Female; State = NY}
Female
State = CA}
In some embodiments, this allows the user to ask questions like what were the key drivers for the difference in average revenue between last quarter and the current one and BeyondCore looks at all possible factors and points out things like we had 5% increase in sales transactions in Boston but the average price dropped by $5. Both the frequency and statistical impact of differences between the factors are considered in the analysis and are shown in the graphical plot of FIG. 12C . The graph of FIG. 12C illustrates markers for the first comparison group 1245 and for the second comparison group 1250 , and a rank-ordered list 1255 of the top differentiators between the groups. The user may interact with the graph and/or the ordered list displayed adjacent to the graph to show or hide a factor 1260 , scroll to view a next page of factors 1265 , change the comparison variable 1270 , change the first comparison group 1275 , or change the second comparison group 1280 .
Additionally, in some embodiments, techniques described herein (e.g., with reference to Drivers of Difference and Prescriptive Analysis) can be used to statistically back out the impact of the differences in population that may otherwise limit methods of A/B testing that rely on test and control sets having approximately identical population characteristics.
For example, when testing out two different marketing campaigns A and B on two groups of prospects X and Y, some methods of A/B testing may rely on X and Y having approximately the same percentage of 18 year olds and the same percentage of males. However, upon looking at variable combinations, such methods may be limited by discrepancies in populations of the variable combinations. For instance, the proportion of 18 year old men might be different in X and Y even though the two groups had substantially identical proportions of 18 year olds and of men individually. Under such circumstances, if the marketing campaigns A and B have a different impact for 18 year old men specifically, the A/B test may need to be redone after ensuring that the proportions of 18 year old men in both test groups are substantially the same.
In contrast, the techniques disclosed herein (e.g., with reference to Drivers of Difference and Prescriptive Analysis) can be used to statistically back out the impact of the differences in population for 18 year old men. Since the analysis model individually learns the behavior and population impact of each variable combination on the outcome being analyzed, the analysis can evaluate hypothetical questions and scenarios such as what would have been the outcome for marketing campaigns A and B if groups X and Y had substantially the same percentage of 18 year old men. This enables gleaning statistically sound results for A/B testing even when the population characteristics of X and Y may not be identical.
FIG. 13 illustrates illustrative code that could be used for the various models used to generate the graphs and stories described above. Clicking the R Formula button in the Toolbar exports the automatically generated model for the most recent Diagnostic, Predictive or Prescriptive graph the user has seen. This R code (e.g., of FIG. 13 ) can be used by experts to independently validate the model. The user can copy the R Code to a different development environment and further test or enhance the accuracy of the model. The model can be stored or shared publicly. This is beneficial for academic papers or regulatory/legal compliance.
While the preferred embodiments of the invention have been illustrated and described, it will be clear that it is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claims.
|
Methods for analyzing and rendering business intelligence data allow for efficient scalability as datasets grow in size. Human intervention is minimized by augmented decision making ability in selecting what aspects of large datasets should be focused on to drive key business outcomes. Variable value combinations that are predominant drivers of key observations are automatically determined from several competing variable value combinations. The identified variable value combinations can then be then used to predict future trends underlying the business intelligence data. In another embodiment, an observed outcome is decomposed into multiple contributing drivers and the impact of each of the contributing drivers can be analyzed and numerically quantified—as a static snapshot or as a time-varying evolution. Similarly, differences in observations between two groups can be decomposed into multiple contributing sub-groups for each of the groups and pairwise differences among sub-groups can be quantified and analyzed.
| 6
|
BACKGROUND OF THE INVENTION
The present invention pertains to replaceable cartridge type filters and, more particularly, to such a filter utilizing a reverse osmosis cartridge with an assembly for retaining the cartridge in the housing when it is removed for replacement.
Replaceable cartridge filters have been in used in water treatment systems for many years. A typical filter unit of this type utilizes an elongate, generally cylindrical housing or sump which is open at one end for the receipt of a replaceable filter cartridge, and the cartridge and the housing are demountably attachable to an enclosing end cap. The end cap may be a unitary cover or part of a header system for control of fluid flow into and out of the cartridge. The filter cartridge may include any of several well known kinds of filter media, and multiple housings and associated filter cartridges may be attached to a common header system for the serial removal of a wide variety of both suspended and dissolved contaminants from a liquid stream. The media used in filter cartridges varies widely, depending upon the contaminant to be removed, and such media include granular particulate materials, coarse sintered blocks, paper and plastic filters, and semi-permeable membranes.
One type of semi-permeable membrane or reverse osmosis (RO) filter cartridge utilizes a membrane which is spirally wrapped around a porous center tube and enclosed in an impervious cylindrical outer wrap. The opposite ends of the cartridge are open, with one of the ends receiving untreated incoming water under pressure and in which most dissolved solids are separated as the water passes through the semipermeable membrane and flows radially toward the porous center tube. The treated water (or membrane permeate) passes along the center tube to an outlet end. The untreated water containing the concentrated dissolved solids (known as the concentrate and commonly referred to as brine) passes out of the opposite end of the membrane cartridge. Such a cartridge typically includes a brine seal which is interposed between the outer cartridge wrap and the inside wall of the cartridge housing to prevent untreated water from bypassing the cartridge and mixing directly with the brine. However, in certain RO cartridge assemblies, such as an assembly in which the brine seal is located at one end of the element and the outlet for the brine flow is located at the opposite end of the element and housing, a volume of stagnant water is created between the OD of the element and the ID of the housing. This pool of stagnant water is not flushed by continuous flow through the element and therefore provides an area for the propagation of bacteria which, in turn, may lead to fouling by migration to active areas of the RO membrane surface. Depending on how a system is designed, the potential problem of pools of stagnant water, either on the untreated water side or the brine water side of the RO element, is a problem in all residential RO systems which utilize a brine seal.
The product water outlet in the typical RO cartridge comprises a cylindrical neck, which is typically an extension of the center product water tube, and is received in a cylindrical sleeve which forms part of the housing end cap and contains a product water discharge port. The interface between cartridge neck and the sleeve on the cap must be tightly sealed and one typical seal arrangement comprises a pair of axially spaced O-rings which are seated in annular grooves in the cartridge neck and which engage the inside wall of the sleeve in the cap. RO filter cartridges of the foregoing general type are shown, for example, in U.S. Pat. Nos. 4,645,601, 5,002,664, 5,082,557 and 5,266,195.
A typical application for a reverse osmosis membrane filter cartridge of the foregoing general types is in purifying tap water for drinking. As indicated, such a filter cartridge is commonly utilized in a series arrangement with other replaceable cartridge filters which remove from the untreated water other suspended and dissolved solids which cannot be removed by membrane separation. Such water treatment units are commonly mounted beneath a sink on which the tap is located or in another confined and typically somewhat restricted space. A number of problems relating to the replacement of filter cartridges generally and RO filter cartridges particularly have arisen with the use of these systems.
In multi-cartridge systems which typically include three units, manufacturer's like to utilize identical filter housings for simplicity in manufacturing and inventory, as well as to maintain a uniform product appearance. However, certain filter cartridges and often RO membrane cartridges, do not fit well in housings designed for other types of filter cartridges used in these multi-cartridge systems. As a result, special adapters, special covers, or special non-standard housings may have to be used. A specialized and relatively complex housing end cap is shown, for example, in the above identified U.S. Pat. No. 5,082,557. A specialized, non-standard housing is shown in U.S. Pat. No. 5,266,195.
Because RO filter cartridges must handle and provide an interface for three liquid flows, namely, untreated water, treated water, and brine, some means for accommodating the additional liquid flow, not present in other kinds of filter cartridges, must be utilized. In U.S. Pat. No. 5,002,664, the brine flow is accommodated by a special connection through the bottom of the RO cartridge housing. This complicates the construction of the unit, as well as the ease of filter replacement.
Another problem unique to filter cartridges having a neck on one end for the treated water outlet, which includes an O-ring seal arrangement engaging the cylindrical ID of a sleeve in the end cap, is that the tight seal which results causes the filter cartridge to hang up in the end cap when the housing is unscrewed from the end cap for removal and filter cartridge replacement. The filter housing must be slid downwardly along the entire length of the filter cartridge before the cartridge can be independently removed from its sealed attachment to the end cap or header. When operating in a confined space, such as under a kitchen sink, this lack of head space may present a serious obstacle to ease of replacement. This problem is addressed and solved in U.S. Pat. No. 4,645,601 by providing an integral cartridge and housing which are removed together. Such an arrangement, though convenient, is extremely uneconomical because the housing must be replaced each time the filter cartridge is replaced.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, a cartridge retaining assembly is used to hold the filter cartridge in place within the housing and to retain it in place when the housing is unscrewed or otherwise removed from the end cap or header for cartridge replacement. In an embodiment particularly adapted for small diameter RO filter cartridges, the cartridge retaining ring cooperates with a supplemental brine ring which adapts a conventional filter housing to receive a smaller diameter RO cartridge.
The cartridge retaining ring assembly of the present invention is particularly adapted for use with a filter cartridge of the type having a smaller diameter neck on one end which defines a liquid flow passage, and which cartridge is in use inserted into and contained in an open-ended housing. The housing is demountably and sealably attached to an enclosing end cap. The end cap, which may comprise a part of a multi-unit header, includes an integral sleeve which surrounds the neck of the cartridge in the attached position, and provides therewith a liquid-tight seal. The retaining ring assembly includes a retaining ring which is adapted to be placed on the end of the filter cartridge in the housing and around the cartridge neck. The retaining ring includes means for manually locking the ring to the housing to hold the cartridge in a fixed position within the housing. Thus, when the housing is demounted from the end cap, the filter cartridge neck is engaged by the retaining ring and pulled from the integral sleeve, against the resistance of the water-tight sealed interface, and the housing, cartridge and retaining ring are removable together.
The assembly, particularly when adapted to accommodate a conventional RO membrane cartridge, includes a brine ring which is attached to the inner wall of the housing adjacent the open end thereof. The brine ring has an outer wall which defines, with the cylindrical inner wall of the housing, a flow passage for one of the liquid fractions. The brine ring also has a cylindrical inner wall which is sealingly engaged by a brine seal on the cartridge element when the cartridge is inserted into the housing. The retaining ring locking means comprises interengaging connectors on the retaining ring and the brine ring. In its preferred construction, the brine ring comprise a tubular cylindrical sleeve, and the interengaging connectors comprise a pair of diametrically opposite slots in one end of the tubular sleeve and a pair of cooperating lugs on the retaining ring which are adapted to be received in the slots.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a vertical section through a filter cartridge showing the retaining ring assembly of the present invention in its operative installed position;
FIG. 2 is an enlarged detail of the upper portion of FIG. 1;
FIG. 3 is an exploded view of the upper portion of the housing, the replaceable filter cartridge, and the retaining ring assembly of the present invention;
FIG. 4 is a horizontal section through the filter unit taken on line 4--4 of FIG. 2;
FIG. 5 is a horizontal section taken through the unit on line 5--5 of FIG. 2; and
FIG. 6 is a partial perspective view of the interengaging connection between the retaining ring and brine ring of the retaining assembly of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, a replaceable filter cartridge 10 is contained inside a tubular housing 11 which is removably attached to an upper end cap 12. The particular filter cartridge 10 shown in the drawings, utilizes a semi-permeable membrane to remove dissolved solids from untreated water by reverse osmosis. The construction of the filter cartridge 10 is in all respects conventional and is of the type presently available from several manufacturers. The cartridge includes an interior spirally wound membrane 13 which may include an intermediate separator layer, all of which is shown schematically in FIGS. 1 and 2. The membrane 13 is wound around a central hollow product water tube 14, which extends the length of the cartridge 10, and is provided in its outer surface with a pattern of through holes 15. The membrane is closed by an impervious outer wrap 16 which may be plastic or any other suitable material. The upper end of the cartridge is provided with a brine seal 17 attached to the cylindrical outer wrap 16. The lower end of the cartridge has a central extension 18, and the opposite end has a small diameter cylindrical neck 20 both of which preferably comprise integral extensions of the interior product water tube 14. The neck 20 is provided with a pair of axially spaced annular grooves 21 in which are received sealing O-rings 22. The opposite axial ends of the cartridge 10, adjacent, respectively, the cylindrical neck 20 and the extension 18, are open to expose the membrane 13 to accommodate an incoming flow of untreated water and an outgoing flow of brine. The brine flow comprises the high volume concentrate of water and dissolved solids which does not pass through the semi-permeable membrane. Although membrane filter cartridges of the type used in this invention may accommodate untreated water and brine water flows through either end, the cartridge in the present embodiment is oriented with the untreated water inlet 23 on the upper end and the brine water outlet 24 on the lower end.
The filter housing 11 is of conventional molded plastic construction, which includes an elongated cylindrical side wall 25 and a closed bottom end 26. The open, upper end of the housing has an enlarged diameter end portion 27 with a threaded ID adapted to engage a correspondingly threaded OD on a cylindrical boss 28, which depends downwardly from the underside of the end cap 12. In this embodiment, the end cap comprises the lower portion of a multi-unit header which, as indicated previously, may accommodate several different types of filter units, each of which is contained in a housing similar to housing 11, threadably attached to a similar cylindrical boss 28. As is well known in the industry, the remainder of the header (not shown) includes a pattern of passageways and valves to accommodate the flow of water through the system.
Referring also to FIG. 3, the filter cartridge 10 is inserted vertically downwardly into the open upper end of the housing 11 until the center tube extension 18 on the lower end of the cartridge engages and rests upon the upper edge of a cartridge support 31 on the bottom end 26 of the housing. To provide a sealing surface for the cartridge brine seal 17, the housing 11 is provided with a brine ring 32. The brine ring is made of suitable plastic separately from the housing, but is permanently attached thereto. The brine ring 32 comprises a generally cylindrical tubular sleeve 33 to the outer wall of which are attached four equally spaced axial ribs 34. As shown in FIGS. 1 and 2, the axial ribs 34 are shorter in length than the tubular sleeve 33 and terminate somewhat short of the upper end thereof. The ribs are sized to tightly engage the inner wall 35 of the housing when the brine ring is initially pressed into the housing, the insertion of which may be aided by providing the lower ends of the ribs with chamfered ends 36. The brine ring 32 is permanently secured in place by sonic welds 37 or other permanent joints at the interface between the ribs 34 and the inner wall 35.
The brine ring sleeve 33 has a smooth cylindrical inner wall 38 which engages the brine seal 17 on the filter cartridge as the latter is inserted into the housing. The outer surface of the brine ring sleeve 33 is spaced radially inwardly of the inner wall 35 of the housing by the axial ribs 34. This space defines a brine flow passage 39 as will be described in greater detail below.
With the filter cartridge 10 in place within the housing 11, the housing could be threadably connected to the mating threads on the cylindrical boss 28 of the end cap or header 30. As the threaded attachment takes place, the cylindrical neck 20 at the upper end of the cartridge is inserted into a downwardly depending cylindrical sleeve 40 formed integrally with the end cap and located concentrically within the cylindrical boss 28. The O-rings 22 engage the inner wall of the sleeve 40 and provide a liquid tight seal. Simultaneously, the upper end of the cylindrical tubular sleeve 33 forming the main body of the brine ring 32 moves into the interior of the cylindrical boss 28 and adjacent the cylindrical interior wall 41 thereof. The upper end of the brine ring sleeve 33 is provided with a pair of axially spaced annular grooves in which are seated a pair of O-ring seals 42 which sealingly engage the interior wall 41 of the boss. A large diameter O-ring 43 is seated on an annular shoulder 44 at the base of the threaded ID on the open end of the housing 11. As the threaded housing comes into full engagement with the threaded boss 28, a lower annular face 45 on the boss compresses the large diameter O-ring 43 against the shoulder 44 to provide an additional liquid seal.
When it is desired to replace the filter cartridge 10 in the assembly thus far described, the housing 11 is unscrewed from the cylindrical boss 28. However, the tight seal provided by the O-rings 22 bearing against the cylindrical sleeve 40 typically causes the filter element to hang up and remain in place as the housing is removed. As a result, after the housing has been completely unthreaded from the end cap or header 30, it must be withdrawn the full axial length of the filter cartridge 10, and then the filter cartridge removed separately by pulling it axially downward to withdraw the cylindrical neck 20 from the sleeve 40 in the header. This problem is eliminated by the use of a retaining ring 46 which operates in conjunction with the brine ring 32 to hold the filter cartridge 10 in place when the housing is removed.
Referring also to FIGS. 4-6, the retaining ring 46 has an annular cylindrical body 47 sized to slip without interference into the cylindrical inner wall 38 of the brine ring sleeve 33. The upper end of the retaining ring 46 is provided with a pair of diametrically opposed lugs 48 which extend radially outwardly. The lugs are sized to cooperate with slots 50 formed in the upper end of the cylindrical, tubular sleeve 33 of the brine ring 32. Each of the slots 50 includes an offset recess 51 at the bottom of the slot, also sized to receive a lug 48. After a new filter cartridge 10 has been inserted into the housing 11, in the manner previously described, but before the housing is threaded onto the cylindrical boss 28, the retaining ring 46 is placed around the cylindrical neck 20 on the cartridge and into the cylindrical tubular brine ring sleeve 33. The lugs 48 are caused to enter the slots 50, and, when bottomed therein, the ring 46 is turned on its axis to cause the lugs to enter the recesses 51, thereby holding the ring 46 in position. The unitary subassembly of the housing 11, filter cartridge 10, brine ring 32, and retaining ring 46 is then threaded onto the cylindrical boss 28, as previously described. When the filter cartridge is to be replaced, the housing 11 is unthreaded in a manner previously indicated. However, as the housing moves axially away from the end cap during unthreading, the underside of the retaining ring 46 comes into contact with the upper end of the filter cartridge 10 (which has not moved axially downwardly because of the tight fit of the O-rings 22). Because of the engagement of the retaining ring 46 with the upper end of the filter cartridge, further unscrewing of the housing and consequent axial downward movement will carry the filter cartridge with the housing, allowing the entire assembly to be removed as soon as the housing is completely unthreaded and without the necessity of any further downward axial movement.
The filter cartridge is removed from the housing by first removing the retaining ring 46, by turning the latter slightly on its axis and withdrawing the lugs 48 from the slots 50. To facilitate manual attachment and removal of the retaining ring, the inside surface is provided with a pair of finger tabs 52. To provide additional bearing surface for the ring and the top of the filter cartridge, the lower edge of the cylindrical body portion 47 of the ring is provided with a pair of sector shaped flats 53, as best seen in FIGS. 3 and 4.
As is shown in the drawings, in the installed position, the lower surface of the retaining ring and flats 53 are spaced slightly above the upper inlet end 23 of the cartridge. This permits a more uniform flow of incoming water to all areas of the inlet end of the cartridge 10.
In either embodiment of the foregoing arrangement, in addition to facilitating removal of the filter cartridge with the housing, the assembly also allows the use of a standard size housing 11 modified only by the addition of the brine ring 32. Instead of the lugs 48 and slots 50, the retaining ring and brine seal could be provided with mating threads to accommodate the interconnection. Referring to FIGS. 1 and 2, the three liquid flows accommodated by the assembly are all directed to the upper end thereof. This allows the use of a header arrangement 30, particularly useful in a multi-unit filter assembly of the type described in the background discussion above.
Untreated water is directed into the unit via an inlet port 54 in the header 30 which communicates directly with the open annular space between the cylindrical boss 28 and the cylindrical center sleeve 40. The untreated water flows under system pressure past the open interior of the retaining ring 46 and into the inlet end 23 of the filter cartridge. The treated water (or membrane permeate) travels downwardly and generally radially inwardly and into the center product water tube 14, from which it passes axially upwardly through the cylindrical neck 20 and out of an outlet port 55 in the header. The liquid brine (or membrane concentrate) flows downwardly and out of the brine water outlet 24 at the bottom of the cartridge. From there, the brine flows upwardly between the cylindrical side wall of the housing and the outer surface of the filter cartridge, through the brine flow passage 39 between the housing wall and the brine ring 32, into an annular slot 56 in the cylindrical boss 28, and upwardly out through a brine port 57. The header 30 is typically provided with additional overlying sealed layers which define a pattern of passages for controlling the flows to and from the various ports 54, 55 and 57.
Referring particularly to FIG. 1, it is important to note that the flow path for the brine does not have any areas of stagnant water which are not regularly flushed and in which bacteria growth may occur. The brine flow path, described in the preceding paragraph, is completely flushed by the brine flow whenever the system is operated. There are no pockets where stagnant water may accumulate and lead to the fouling problems previously described.
|
A retaining ring assembly for a reverse osmosis filter cartridge includes a removable retaining ring inserted into the cartridge housing after insertion of the cartridge, the retaining ring including a demountable locking connection with the housing. When the housing is subsequently removed to replace the cartridge, the retaining ring forces the cartridge from its tightly sealed connection to the end cap or header, allowing the cartridge to be easily removed with the housing. Preferably, the housing includes a special brine ring adapted to cooperate with a conventional cartridge brine seal, the brine ring providing connection for the retaining ring and defining with the housing a brine flow passage.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of international patent application no. PCT/DE2009/001588, filed Nov. 11, 2009 designating the United States of America and published in German on May 20, 2010 as WO 2010/054635, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 10 2008 056 872.4, filed Nov. 12, 2008, which likewise is incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to a damper unit, particularly for a drive train of a motor vehicle, which damper unit comprises two components connected to each other for co-rotation, and an axially elastic element disposed in between them.
Damper units of the foregoing type are used, for example, for damping axial vibrations and for compensating for angular misalignments between two shafts. One variant of such damper units has become become known as Hardy disks or flexible disks. DE 9313417 U1 discloses a corresponding construction of the such a damper unit. In this case two radially extended flange components disposed on a shaft component or another component which transfer the rotation of the shaft are rotationally connected over the circumference thereof to an elastic disk made, for example, of a rubber/steel netting mesh. The elastic disk serves as a damper for absorbing torsional vibrations and compensating small angular misalignments between the components associated with the flange components. In order to be able to transfer the required torque with a damping unit of this type, the diameter of the elastic disk must be dimensioned in accordance with the circumferential forces which act upon the elastic disk so that it is necessary to provide the damper unit with a diameter that is many times the diameter of the shaft and allow for the damper unit of increased diameter in the corresponding installation space. Axial length compensation is not possible with such types of damper units. Two shaft sections are connected to each other by helical gears, so as to be displaceable, for example, as disclosed in the patent specification DE 611 129. Similarly, published German patent application no. DE 195 25 271 A1 also describes a connection of shaft components, in which a sliding displacement of the shaft components relative to each other is likewise facilitated via a thread.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a damper unit for a shaft, which damper unit has a smaller diameter.
Another object of the invention is to provide a small diameter damper unit for jointed shaft, particularly a longitudinal drive shaft and/or lateral drive shaft in a drive train of a motor vehicle.
A further object is to provide a smaller diameter damper unit which enables length compensation of a shaft.
These and other objects are achieved in accordance with the present invention by providing a damper unit disposed particularly in a drive train of a motor vehicle between two components connected to each other for co-rotation, the two components being axially displaceable, at least to a limited extent, relative to each other and an axially elastic element being disposed between the two components, which elastic element is loaded or compressed by a thread-like rotational movement of the two components relative to each other. By virtue of a damper unit constructed in this way, the axially elastic element is loaded in the axial and not in the circumferential direction in order to transfer the required torque. As a result, the damper unit can be constructed with a substantially smaller diameter than flexible disks, for example, with a diameter that is at the most twice, preferably only one and a half times the diameter of a shaft or two shaft sections, on or between which the damper unit is mounted, respectively. Such a damper unit is also able to provide length compensation since an axial displacement is achieved by the threads due to a slight rotation of the shaft when the two components are subjected to axial load. Due to the transfer of torque, a driven shaft or two shaft sections comprising an interposed damper unit are therefore always pre-stressed axially. In the case of a reversal of torque direction, it shall be understood that the axial length of the damper unit is limited by the corresponding installation situation. Apart from being suitable for the mounting of two components between two shaft sections (for example, parts of a multi-part drive shaft), the proposed damper unit is also well-suited for connecting an end of a shaft to a further component such as a differential or a swivel joint, for example, for driving a wheel via a lateral drive shaft. It should be understood that a small angular misalignment of two shafts can also be compensated by providing appropriate play between the threads of the two components.
A first one of the two components of the damper unit comprises a sleeve-like molded recess in which the axially elastic element is received and with which the second of the two components engages via an axial projection. A partial thread is arranged between the molded recess and the projection. A slight thread-like rotation of the molded recess and the projection compresses the axially elastic element in the axial direction. In one embodiment, the pitch of the partial thread is designed such that the axially covered distance is large relative to the torsion angle in that the axial component of the partial thread is much larger than the circumferential component. As a result, the partial thread in one embodiment comprises less than one thread turn. This means that the pitch of the partial thread is less than one, preferably less than a quarter of the circumference. Depending on the required elasticity and the consequently selected elasticity of the axially elastic element, the maximum torsion angle of the two components relative to each other can range, for example, from a few degrees to 90°. Longitudinal grooves having a circumferential component are provided in the axial projection and the sleeve-shaped molded recess so as to be distributed around the respective circumferences thereof. At least one ball is mounted in each of the mutually opposing longitudinal grooves, which thus form pairs. The balls disposed in the mutually opposing longitudinal grooves enable a rolling movement between the two components connected to each other for co-rotation. In one embodiment, the balls are retained in a ball cage. Such a rolling movement can be achieved in a simpler, and thus more low-force and low-loss manner as compared to the prior art. In this way a reduced degree of wear is also achieved.
In a simple case, the partial thread may comprise a standard screw mechanism comprising mutually engaging screw-thread sections. It has proved advantageous if the partial thread is formed of a ball-screw segment.
An additional preferred embodiment of the damper unit can comprise an axial projection that comprises a central opening, in which a receiving component comprising a radially expanded rim is mounted, the axially elastic element being received between an end face of the axial projection and the rim, and the rim being supported axially against an end face of the sleeve-like molded recess. In this way, the axially elastic element can be annular in shape and at the same time centered inwardly in the radial direction. The bearing surfaces of the two components may be in the form of axial supporting surfaces, and the sleeve-shaped molded recess may be produced, for example, by a forming process or by machining. To better fit the bearing surfaces of the flange of the receiving component and the sleeve-shaped molded recess, the bearing surfaces can be conical in shape. In order to prevent friction between the receiving component and the axial projection, a small play can be provided between these two components. Alternatively or additionally, the surfaces coming into contact with each other can be machined, for example, ground and/or provided with lubricants. An intermediate disk or washer can be disposed between the end-face contact surface of the axial projection and the axially elastic element. The material used and treatment of the intermediate washer can be selected independently of the material and treatment, such as hardening, required for the axial projection, and should be chosen to satisfy the requirements for loading the axially elastic element. Furthermore, the intermediate washer can be provided for rotationally decoupling the axially elastic element from the axial projection when, for example, the friction between the axially elastic element and the intermediate washer is selected to be greater than the friction between the axial projection and the intermediate washer.
Depending on the application for which the damper unit is used, the axially elastic element may be disposed between the two components in a pre-stressed form or with play. For example, an annular component made of an elastic material such as rubber, reinforced rubber or plastic and mixtures of the same known as composites or mixtures with other inorganic substances can be used as the axially elastic element. An annular component of this type can have a volume in the unstressed or merely pre-stressed state of the two components that is smaller than an installation volume or operating volume. For example, a substantially cylindrical operating volume can be provided, whereby the annular component exhibits a substantially circular cross-section. By virtue of the axial load, displacement forces which depend on the axial compression distance can thus be provided in accordance with the designed volume for displacing the elastic annular component so that performance characteristics of the damper unit that vary throughout a range of geometric relationships can be achieved, particularly in conjunction with a varying design of the pitch of the partial thread. For example, after the operating volume, which decreases with increasing axial force, has been completely filled by the compressed damper element, a particularly rigid second-stage characteristic and thus a hard, but not metallic, stop can be achieved after the elastically damped axial distance is used up.
Alternatively or additionally, a spring unit made of steel or comparable materials can be used as the axially elastic element. This spring unit can be at least in the form of a helical compression spring or a coil-spring set comprising helical springs disposed radially one inside the other or disposed serially, as a result of which a damper unit having multi-stage characteristics unit can be realized. In the case of springs that are fully compressed, a hard stop can likewise be achieved. Furthermore, the spring unit can comprise a set of axially arranged plate springs or diaphragm springs. Corresponding characteristics of the damper unit can be realized by selecting diaphragm springs with appropriate characteristic performance curves.
The object of the invention is further achieved by providing a jointed shaft, particularly a longitudinal drive shaft or a lateral drive shaft in the drive train of a motor vehicle, in which at least one axially elastic element is mounted between two shaft components, or on at least one end of the shaft, and/or between one end and a subsequent constant velocity joint or the like. Alternatively or additionally, provision is made for a damper unit according to any one of the preceding embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in further detail hereinafter with reference to illustrative embodiments shown in the accompanying drawing figures, in which:
FIG. 1 shows a section of a damper unit comprising an axially elastic element made of an elastic material;
FIG. 2 is an exploded view of the damper unit of FIG. 1 ;
FIG. 3 is a sectional view of an alternative embodiment of a damper unit, which comprises an axially elastic element in the form of a diaphragm-spring set;
FIG. 4 is an exploded view of the damper unit of FIG. 3 ;
FIG. 5 is an exterior view of the damper units of FIGS. 1 to 4 , and
FIG. 6 is a sectional view of a jointed shaft comprising a damper unit according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a section of a damper unit 1 comprising a first component 2 and a second component 3 each respectively associated with drive side or a driven side of a shaft. The first component 2 comprises a sleeve-shaped molded recess 4 , in which an axial projection 5 of the second component 3 engages. When stressed axially, the two components 2 , 3 can rotate relative to each other along a partial thread 6 , and in so doing, they compress the axially elastic element 7 , which in the illustrative embodiment is made of an elastic material, for example, an elastomer such as rubber, plastic such as VITON ®, EPDM, inorganic elastomers or combinations thereof. The elastic material may be suitably reinforced, for example, by glass fibers, carbon addition and/or metal additives.
A ball-screw segment 8 that enables a low-friction rotation of the two components 2 , 3 in order to compress the axially elastic element 7 is used for the partial thread 6 in the illustrative embodiment shown. For this purpose, longitudinal grooves 9 , 10 having a circumferential component are disposed in the molded recess 4 and on the axial projection 5 , respectively, which longitudinal grooves force a screwing motion of the two components when the components are subjected to axial load, and this screwing motion causes the axially elastic element 7 to be compressed in the axial direction. Depending on the configuration of the pitch of the longitudinal grooves 9 , 10 and on the elastic properties of the axially elastic element 7 , it is possible to predetermine a corresponding characteristic of the damper unit 1 .
In the illustrative embodiment shown the axially elastic element 7 in the form of an annular component 11 is supported on one side against the end face 12 of the axial projection 5 by an intermediate washer 13 bearing, and on the other side by a radially expanded rim 14 of a receiving component 15 . The receiving component 15 is mounted in a central opening 16 of the axial projection 5 . The boundary surfaces between the inner circumference of the opening 16 and the outer circumference of the receiving component 15 can exhibit selective friction for adjusting the hysteresis of the damper unit 1 . In order to prevent friction, however, the boundary surfaces are preferably provided with play, or are coated with a low-friction coating and/or lubricated and/or machined, for example, in a grinding process. The receiving component 15 is supported by the rim 14 axially against an end face 17 of the axial molded recess. The bearing surfaces or supporting surfaces 18 , 19 between the rim 14 and the end face are shaped conically.
When the components 2 , 3 are loaded axially relative to each other, the intermediate ring 13 slides, preferably relative to the end face 12 of the axial projection 5 , so that the annular component 11 is prevented from rolling on the intermediate washer 13 and possibly being subjected to wear. For this purpose, the contact surface between the intermediate washer 13 and the end face 12 can be treated appropriately, for example, by being provided with a low-friction coating and/or lubricated and/or machined in order to prevent friction.
The annular component 11 has a substantially circular cross-section and is mounted in a preferably cylindrical working chamber 20 . In its unstressed state, the annular component 11 has a smaller volume than the working chamber 20 so that when the two components 2 , 3 are loaded relative to each other, for example, as a result of axial vibrations or axial impact, the annular component is initially deformed elastically and fills in the free corners, which may be rounded. In this way, a slightly rising characteristic curve is realized as the annular component is subjected to increasing load until the volume of the working chamber 20 , which decreases axially as the load increases, is substantially completely filled. Thereafter, the stiffness of the annular component, and thus the characteristic curve, increases sharply so that an essentially two-stage damping performance characteristic can be achieved.
FIG. 2 is an exploded view of the damper unit 1 shown in FIG. 1 comprising the first component 2 which may be produced by a forming process, and the second component 3 which may be produced from of a pipe section. The longitudinal grooves 9 , 10 are introduced, for example impressed, in the two components 2 , 3 . Balls 21 that are received in a ball cage 22 are guided in the longitudinal grooves 9 , 10 . The receiving component 15 , which receives the annular component 11 and the intermediate washer 13 and then the axial projection 5 of the second component 3 , is mounted in the sleeve-shaped molded recess 4 .
FIG. 3 shows an illustrative embodiment of a damper unit 1 a that is slightly modified as compared to the damper unit 1 shown in FIG. 1 . In this case, the axially elastic element 7 is formed by a diaphragm-spring set 23 comprising an arrangement of individual diaphragm springs 24 . The diaphragm-spring set 23 can be adapted by variable selection of the stiffness of the diaphragm springs 24 and a variable number of diaphragm springs 24 in order to realize the desired multi-stage characteristics of the damper unit 1 a. Diaphragm springs 24 that are completely compressed can be provided to obtain a characteristic curve having a particularly steep gradient.
FIG. 4 is an exploded view of the damper unit 1 a shown in FIG. 3 comprising an axially elastic element 7 that is modified as compared to the exploded view of the damper unit 1 shown in FIG. 2 and that is equipped with individual diaphragm springs 24 that form the diaphragm-spring set 23 .
FIG. 5 is an exterior view of the damper unit 1 a that is identical to the exterior view of the damper unit 1 . For connection to a shaft (not shown) or a shaft member, the two components 2 , 3 each comprise a sleeve-shaped flange 25 , 26 , with which the shaft forms a positive interlock. For this purpose, the respective shaft or the corresponding shaft section can be joined to the flange, welded, screwed to the same or attached thereto in some other manner. The outer diameter of the damper units 1 , 1 a can be kept small due to the smaller dimensions assumed by the axially elastic element 7 ( FIGS. 1 and 3 ) as a result of the axial loading thereof and the transfer of torque via the longitudinal grooves 9 , 10 and the balls 21 so that the outer diameter of the damper is only slightly larger than the diameter of the shafts to be received in the flanges 25 , 26 .
FIG. 6 shows a jointed shaft 100 —more particularly, a drive shaft—which comprises a damper unit 1 of the invention. Two articulated joints 101 comprising internal teeth 102 for connection to additional vehicle components are provided on the sides of the jointed shaft. The damper unit 1 is sealed by roll bellows 103 on the side, at which a shaft section extends into the damper unit in the form of an inner hub. This shaft section—the central shaft section in the drawing—also has a displacement unit 104 , which is provided here, for example, for assembly or crash purposes. Alternatively, an additional displacement unit 104 is not provided in the case of a damper unit 1 that also enables an axial displacement. If a displacement unit 104 is provided, expansion bellows 105 comprising reinforcing rings 106 are provided in this embodiment for the purpose of sealing. Both seals 103 , 105 can also be of identical construction.
One or more jointed shafts 100 having the construction shown here or a modified construction can be installed in a multi-part shaft. Installation of multiple jointed shafts is possible, for example, in a two-part shaft with a center bearing.
The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents.
|
A damper unit ( 1 ) composed of two parts ( 2, 3 ) which are connected to rotate with one another and between which an axially elastic element ( 7 ) is disposed. Such damper units are used particularly for axial damping and for compensating slight axial misalignments of shafts in drive trains. To improve such damper units, particularly with respect to their external diameters, the axially acting energy storage device is compressed by a rotational movement produced by threads upon axial loading of the two parts.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates generally to improvements to LED strip lamps consisting of an emitting diode and an extruded electrode, which is connected to a current supplying conductor, and especially to direct connection to an electrical current supplying conductor. Purposes are to provide an LED lamp and circuitry featuring high heat dissipation efficiency, and free placement capability in or on support means; elimination of need for a printed circuit board associated with the LED; and improved production methods.
Conventional LEDs generally incorporate a substrate, a light emitting part including a light emitting layer formed on a laminated nitride semiconductor on a substrate, and an electrode which protrudes behind or at a rim of the light emitting part, connected to a current supplying conductor of a current supplying cable. The said conventional LED is generally known as respects a current supplying conductor connected to a current supplying cable that needs special form in its configuration to secure firm connection between the electrode provided at the backside of the light emitting part and the current supplying conductor. Also, wire bonding is used to connect the electrode and current supplying conductor. Wire bonding is also used to connect between another electrode and the current supplying conductor.
As for general LEDs and referring to FIG. 15 herein, light emitting part (a) is covered by transparent polymer (d) which is encapsulated, and two electrode wires (b), (c) protrude from polymer (d). The LED secures insulation between light emitting part (a) and electrode wires (b), (c) as by encapsulation of light emitting part (a). Also, by increasing the optical size of transparent polymer (d), the internal reflection prospects of the transparent polymer are decreased, and output emission from transparent polymer (d) to the exterior is increased. Further, by changing the configuration and dimensions of transparent polymer (d), the LED can control internal reflection, and spectral angle of outer reflection.
However, in a conventional LED, it is difficult to transport or transfer generated heat fully to the local environment, as from the light emitting part, as current is supplied to the LED; and placement of multiple LEDs at a high density mounting is not practical, so the placement positions of LEDs are limited. Also, as stated in P.H06-275865, the current supplying conductor is continually made of solid metal, so the position of LED placement cannot be changed once connection is made to the current supplying conductor, lead wire being used as current supplying conductor. However such a lead wire is coated with insulation material, so that it is difficult to obtain better heat transportation, which leaves the high temperature issue unsettled. Further, light emission is all-directional and dispersion of emission makes it difficult to intensify the light beamed toward a specific direction unless a reflective mirror or other means of collection of light is used, and this complicates structure and increases manufacturing cost.
SUMMARY OF THE INVENTION
The purpose of the present invention is to improve the LED strip lamp and its manufacturing method, by solving the above stated problems, as by increasing heat dissipation capability, also needed are ways of high density LED mounting, contributing to free placement design, and contributing to free placement design, and adjustment of LED positioned after their connections to conductors.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is an outline of an embodiment of this invention;
FIG. 2 is an enlargement of a diode connecting part on a current supplying conductor;
FIG. 3 is a backside view of an LED;
FIG. 4 is an enlarged view of a diode connecting part on a current supplying conductor;
FIG. 5 is a view of a second embodiment of this invention;
FIG. 6 is a view showing second embodiment LED placement position adjustment;
FIG. 7 is a wall-eyed drawing for a third embodiment of this invention;
FIG. 8 is a side view of a fourth embodiment of this invention;
FIG. 9 is a plan view of the fourth embodiment;
FIG. 10 is a view of a fifth embodiment;
FIG. 11 is a plan view of the fifth embodiment;
FIG. 12 is a plan view of a sixth embodiment;
FIG. 13 is a cross section showing a seventh embodiment;
FIG. 14 is a side view of the seventh embodiment;
FIG. 15 shows conventional LED structure;
GLOSSARY
1 , 10 , 14 , 80 LED (Emission part), 11 , 12 extruded (shaped) electrode;
2 , 3 , 5 , 6 Current supplying conductor, 20 , 30 , 70 Connecting part;
21 , 13 , 31 , 51 , 61 Insulating paint layer;
22 , 32 , 52 , 62 Conducting wire (core wire), 50 , 60 (Exposed electrode);
7 , 81 Current supplying cable, 71 Groove peeled;
81 , 111 , 112 Reflective surface, 113 , 114 Exposed electrode;
301 Reflective pedestal, 302 Electric wire, 303 Wire bonding;
an Emitting part, b, c Electrode wire, d Transparent polymer
GENERAL DESCRIPTION OF INVENTION
To achieve the abovementioned purposes, the invention includes provision of an LED strip lamp consisting of an emitting diode and an extruded electrode, as claimed, having insulating paint coated wire which forms the core wire of the metal rod wire serving as current supplying conductor, and formation of a diode connecting part by local removal of an insulating paint layer. It is fixed directly to the diode connecting part on the current supplying conductor by die bonding or other fixing means. This contributes to a high reflective rate and intensity of LED light reflected toward the opposite direction of the core wire by virtue of the exposed metal surface of the metal core wire on a diode connecting part on a current supplying conductor. Also, a printed circuit board is not needed, and placement range, in length, can be determined freely as the LED is connected directly (by die bonding) to the current supplying conductor as by direct fixing of the LED to the diode connecting part on the current supplying conductor, by die bonding or other fixing means.
Also, the current supplying conductor (insulating paint coated wire) provides the feature of flexibility, so that the LED strip lamp can be deformed in not only two-dimensions but also in three-dimensions and set or installed at any desired position for placement as well as adjustment of emission range.
Also, by selecting insulating paint coated wire (enamel wire, magnet wire) for the current supplying conductor, efficiency of heat dissipation from the current supplying conductor is heightened and a large amount of heat generated at the LED is transported to the local environment, and the operating temperature of the LED can be decreased, whereby light emitting efficiency of the LED is enhanced, and spacing of LED placement positions becomes closer, whereby mounting density become higher. Also, insulating paint coated wire for the current supplying conductor contributes to inexpensive material, less cost, and reduction of manufacturing cost. As included in the following claims, the core wire of current supplying conductor is typically made of aluminum wire rod which has high heat conducting and transportation capability, and the rod can be connected directly to the LED, so that much larger amounts of heat generated by the LED become efficiently dissipated to the local environment.
As stated in the claims, two or more current supplying conductors may be aligned and stranded together with current supplying cable, for carrying an electrode on the current supplying conductor as by removing a portion of the insulating painted layer, providing a connecting part at an appropriate position on one sidewall, and a firm connection to exposed electrode (connection) of the current supplying conductor is assured. As included in the claims, with formation of a tube-shaped helical current supplying cable by winding, providing a groove on the outer surface of the tube-shaped helical current supplying cable, and mounting an exposed electrode to the core wire at the base of groove, and by adjusting of distance between exposed electrodes in reference to stretching of tube-shaped helical wire, placement positions of the LEDs can be easily determined, optionally. By stretching or shrinking of current supplying cable wound helically, the distance of adjacent LEDs on the strip lamp can be determined at any desired interval by stretching or shrinking. Still more, by the tilting the direction of the groove formed on insulating paint, about the centerline of tube-shaped helical wire, intervals of electrodes can be expanded or contracted.
As appears in the claims, on one sidewall of each of two current supplying conductors aligned and joined together with two current supplying cables, a concave reflector or reflectors are supported lengthwise of the direction of a current supplying cable, and by formation of a flatted exposed electrode extending in the length direction of the current supplying cable along the edge of the reflector, and by direct connection of the shaped or extruded electrode of the LED to a diode connecting part on current supplying cable by soldering or other means, LED light emission is reflected by such reflectors provided on both sides of the current supplying conductor, and strong light flux is obtained by collecting and beaming of a narrow width of light. The reflector can be made of aluminum or inexpensive material, so that manufacturing cost of the reflector is reduced, high heat transfer or transportation rate is obtained, and high emitting light efficiency can be assured.
As appears in the claims, an exposed electrode is formed, by removing insulating paint layer on one sidewall of current supplying cable to form a notch to expose the core wire with two current supplying conductors which are aligned and stranded together, and by direct connection of the extruded electrode of the LED to the exposed electrode of the current supplying cable at the notch by soldering or other means. It is located at the bottom of a V-shaped or U-shaped reflector of which both opposite sidewalls extend toward or face the open direction. LED light emission is reflected by such reflectors provided on both sides of the current supplying conductor, and strong flux with formation of a narrow width beam of light is provided. The reflector is made of aluminum or inexpensive material, so that manufacturing cost of the reflector or reflectors is reduced, high heat transportation or transfer rate is obtained, and high emitting light efficiency is assured.
One end of the current supplying conductor can be deformed or crushed and expanded toward the axial direction, to form a disk-shaped pedestal, with wire crossing the axis of the current supplying conductor. By placing one or more exposed electrodes of LEDs on the pedestal, LED light emission is reflected and collected by the pedestal, so there is no need to provide a reflective mirror, and simple structure makes available and directed strong emission of light. Further, the nature of the aluminum conductor allows extensive shaping, and much larger pedestal diameters can be formed as compared with conductor diameter. Also, as the materials of the conductor and pedestal are the same, heat dissipation rate is high, so heat generated from LEDs is transported efficiently to the local environment. Plural pedestals are typically combined in a concentric circle type cluster placing an electric wire in the center, so that LED light emission is reflected and collected on each pedestal; thus high intensity of light can be obtained by this provided simple structure.
DETAILED DESCRIPTION OF INVENTION
For the first embodiment of this invention, refer to FIG. 1 through FIG. 3 . FIG. 1 shows an LED strip lamp that employs a light emitting diode (emission part) 1 and current supplying conductors 2 and 3 connected or to be connected to LED 1 . Insulating paint coated wire (examples being Enamel wire, magnet wire) is used for current supplying conductor 2 and 3 .
As shown in FIG. 2 , using insulating paint coated wire (ex. Enamel wire, magnet wire) as current supplying conductor 2 , and 3 . Insulating paint layers 21 , 31 on connecting parts 20 , 30 are removed enabling connection to extruded electrodes 11 , and 12 of LED 1 (see FIG. 3 ), inside conducting wires (core wires) 22 , 32 being exposed.
As shown in FIG. 3 , LED 1 employs a substrate, emitting part 10 including an emitting layer on laminated nitride semiconductor layers, and extruded or shaped polygonal electrodes 11 , 12 provided on the backside of emitting part 10 . Extruded or shaped electrodes 11 , 12 are connected directly to diode connecting parts 20 , 30 , respectively, on current supplying conductors 2 , 3 and the extruded electrodes (drawing omitted) on LED 1 are connected to conducting wires (core wires) 22 and 32 of the above stated current supplying conductors 2 , 3 , respectively as by die bonding. Distance L (see FIG. 3 ) between electrodes 11 , 12 of LED 1 and distance W (see FIG. 2 ) between current supplying conductors 2 , 3 are indicated by almost the same dimensions.
Connecting parts 20 ( 30 ), as shown in FIG. 4 , are provided by locally removing one side of insulating painted layer 21 ( 31 ) on current supplying conductor 2 ( 3 ) (embodiment shows upper side), whereby top surface of conducting wire 22 ( 32 ) is exposed and formed. Diode connecting part 20 ( 30 ) has the function of a reflective surface, so exposed portion of conducting wire (core wire) 22 ( 32 ) is needed to provide enough room for reflection.
With this structure, the extruded or shaped electrode of the LED is directly connected (die bonding) to current supplying conductor (insulating paint coated wire, namely, enamel wire, magnet wire), so that an associated printed circuit board is no longer needed and distance of LED placement positions can be designed, freely and arbitrarily. Also, a current supplying conductor (insulating paint coated wire, magnet wire) can be plastically deformed at any desired length or configuration in not only two-dimensional but also in three-dimensional forms; therefore LED placement, namely, LED strip lamp placement, is done or made possible at any desired positions. Also, with selection of enamel wire or magnet wire for insulating paint coated wire of current supplying conductor, efficiency of heat dissipation from current supplying conductor is high, and a large amount of heat generated at the LED is transported or transferred to the local environment. The operating temperature of the LED can be decreased, thus emitting light efficiency of the LED is enhanced, and spacing of successive LED placement positions is closer whereby placement density becomes higher. Also, because of direct connection of the LED to the diode connecting part, which is exposed on conducting wire (core wire) of current supplying conductor, the diode connecting part becomes or produces a reflective surface, the effect of collecting light being enhanced, so that additional provision or preparation of a reflective mirror or mirrors is not needed. Further, insulating paint coated wire (ex. enamel wire, magnet wire) for the current supplying conductor, contributes to low cost of material and reduction of manufacturing cost.
In the first embodiment, FIGS. 2 and 3 show current supplying conductors and two extruded electrodes of the LED when the extruded (or polygonally shaped) electrodes are increased to three or more, the same number of current supplying conductors being provided and each polygonally shaped or extruded electrode is connected to a corresponding current supplying conductor. For example, a single emitted color of Red or Blue of the LED requires two each of the LED extruded electrodes and current supplying conductors, and for a dual color LED, three each of the LED extruded electrode and current supplying conductors will be required (or 4 each); and for a triple color LED, four each of the LED extruded electrodes and current supplying conductors will be required (or 6 each); and when three or more current supplying conductors are used, they should be aligned and joined together; also, the diode connecting part is provided by removing (notching) insulating paint on one side wall of the current supplying conductor. The mounting part of the LED can be formed as an electrode.
For the second embodiment, as shown in FIG. 5 and FIG. 6 , two current supplying conductors 5 , 6 are aligned and joined together (for example helically) to form a current supplying cable 7 , which forms tube-shaped helical wire (see FIG. 4 ) as by winding. By locally removing insulating paint layer or layers 51 , 61 , where the mounting part of the LED is to be connected, the notched exposed part 50 , 60 is formed, exposing the inside of conducting wire 52 , 62 , the exposed part or parts 50 , 60 providing a diode connecting part or parts connected to a mounting part or parts of the LED, respectively.
The outer surface of the helically wound current supplying cable 7 , forms a straight line of grooves or notches 71 lengthwise of the axis of the tube-shaped helical wire, and by removing insulating paint layer portions of 51 , 61 to expose the core wire 52 , 62 at the bottom of grooves or notches, diode connecting parts 50 , 60 are formed. With two diode connecting parts 50 , 60 as provided, a diode connecting part 70 on the current supplying cable 7 is provided. Current supplying cable 7 can be stranded by use of the plural number of wires.
When the width of a current supplying cable 7 is sufficient the polygonally formed or extruded electrode of the LED is connected to the connecting part 70 of the current supplying cable 7 , and corresponding electrodes of individual LEDs are connected to electrodes 50 , 60 of individual LEDs respectively, in a row. On the other hand, if the width of the current supplying cable is not wide enough, the helical wire 7 consisting of two current supplying cables 5 , 6 , can be axially stretched, as in FIG. 6 , and the shaped electrodes of corresponding LEDs are then connected to parts 50 , 60 of connecting part 70 , respectively, as by die bonding or other means.
This described structure makes it possible for adjustment of positioning of LED placement, as at any desired distances, axially, and assures firm connection between LEDs and current supplying cable (current supplying conductor).
By expansion and contraction of helical current supplying cable, the distances between successive LED strip lamps can be adjusted and determined at any desired distances. (Different sections of the helix can be stretched by selected different amounts, to differentially shift LED position or positions). Further, by changing the angularity of the formed grooves about the centerline of the helix, the distances between electrodes is also adjustable. Helical winding of current supplying cable is of great advantage for heat dissipation, and tighter windings provide better transfer or transportation of heat.
A third embodiment is shown in FIG. 7 . Two current supplying conductors 100 and 110 are joined together as at insulating paint layer 13 , with formation of a parabola shape 111 or composite curved surface inwardly of insulating paint layer 13 . Reflective surfaces 111 , 112 , are at opposite sides of LED 14 , placed on insulating paint layer 13 , as shown. A pair of mounting parts are provided underneath LED 14 , and connected to current supplying conductors 113 , 114 by die bonding or other means.
Although the outer surface of the current supplying conductor or conductors 11 , 12 is coated by the insulating paint layer 13 , the reflective surfaces 111 and 112 are provided by locally removing the insulating paint layer to locally expose current supplying conductor 11 , 12 , or by potting reflective paint. At the edges of both reflective surfaces 111 , 112 bounding or surrounding the insulating paint layer 13 , the diode connecting part 113 , 114 is formed, and which extends in a straight line along with the edge or edges of reflective surfaces 111 , 112 . A mounting part is provided underneath of one or more LEDs 14 connected to adjacent diode connecting parts 113 , 114 . This enables connection of a current supplying conductor with single conductive unit to one pole, and connection of a separate conductive wire to another pole, which is connected to the LED. With this structure, light emission from the LED is reflected by reflective surfaces on a current supplying conductor provided at both sides of the LED, and strong light flux along with a collected narrow width beam of light are obtained. Also, by forming the current supplying conductor to be larger, high heat dissipation efficiency is obtained, and this protects the LED from objectionable high temperature, whereby more effective light emission is enabled.
The fourth embodiment is shown in FIGS. 8 and 9 . By locally removing insulating paint on one sidewall of current supplying cable 81 (upper part of FIG. 8 ) for two or more current supplying conductors combined together, an LED diode connecting part (not shown) is formed by exposing a conductor surface. A desired number of LEDs 80 is connected to such surfaces by die bonding or other means, inwardly of reflector walls 82 forming a V-shape in cross section. With this structure, as in the third embodiment, light emission from the LED or LEDs is reflected by reflective surfaces on current supplying conductors provided at both sides of each LED, and concentrated, narrow width of flux output is obtained. The reflector is typically made of aluminum or other metal, so that manufacturing cost of the reflector is reduced and high heat dissipation efficiency obtained. Note the row of LEDs in FIG. 9 .
Referring now to FIGS. 10 , and 11 , the fifth embodiment is shown. One extreme end of current supplying conductor 300 , which is made of aluminum or copper, is crushed or deformed (flattened) in the long length direction of conductor 300 to form a disk-shaped reflective pedestal 301 , and the extruded or shaped electrode of LED 14 is connected to the reflective pedestal 301 carrying one or more LEDs 14 . The opposite end of conductor 300 is connected to one pole of a power supply. The ratio of diameter D of the reflective pedestal 301 and diameter d of conductor 300 , referred to as deformation ratio D/d, is 4 to 6 in this embodiment. The electrode of each LED 14 is connected by wire bonding to conductive wires 302 and 303 , connected to another pole of the power supply.
Using this structure, a reflective pedestal formed and obtained by flattening and extending the end of the conductor for collecting light emitting from the LED, so there is no need to provide an extra reflective mirror. This simple structure makes available strong and efficient flux projection. Also, by using aluminum for the material of conductor, a larger diameter D of the reflective pedestal is available compared with diameter d of the conductor, since aluminum is readily deformable. Further, the reflective pedestal and wire lead are typically made of the same material, so that the rate of heat conductivity is high, and heat transfer cooling of the LED are promoted. By making the reflective pedestal surface concave, greater concentration of collected light is enabled, and strong flux obtained. By setting the deformation rate of the reflective pedestal at D/d=4−6, enhanced LED mounting space is secured.
The sixth embodiment shown in FIG. 12 provides plural reflective pedestals 301 in a cluster. Electric wire 302 is located in the center of the cluster. Conductive wire 302 is connected to electrodes of LEDs 14 as by wire bonding 303 . Light emission from each LED is reflected and collected by each pedestal, and the simple structure makes available the obtaining of a large intensity of beamed light because of the locations of the plural pedestals.
The seventh embodiment is shown in FIG. 13 . Three or more current supplying conductors (insulating paint coated wires) 91 , 92 , 93 are stranded together to form a polygon cluster in cross section (embodiment shows triangle) and provides a current supplying cable, as a one piece unit. Such a polygon may include a square (4 conductors), hexagon (6 conductors) and others.
Current supplying cable 90 , as shown in FIG. 14 as including current supplying conductor 91 , conductor 92 appearing in FIG. 13 as aligned, with the outer surface of each current supplying conductor being locally removed to expose the core wires or at 101 and 102 . This provides the first diode connecting part or parts. FIG. 14 also shows current supplying conductors 92 and 93 as aligned, and outer surface locally removed to expose the core wires, to provide the second diode connecting part 102 , note axial shifting of 101 relative to 102 . The third diode connecting parts 103 on 93 are shown as shifted in position relative to 101 and 102 .
This structure enables shifted placement of different color LEDs in the current supplying cable 90 , as in a selected variety of arrangements for emitting different colors and mixing. Use of stranded current supplying cable is also enabled. Also, since the current supplying cable consists of a plural number of current supplying conductors, they can be plastically deformed and the arrangement of LED placement can be freely made as well as free arrangement of color matching and LED positioning.
EFFECT OF INVENTION
In summary, the invention provides for:
An LED strip lamp comprising a diode and a shaped or extruded electrode, using insulating paint coated wire such as enameled wire as a current supplying conductor, by locally removing an insulating paint layer to expose the core wire of current supplying conductor enabling direct connection (die bonding) of a mounting part of the LED to the current supplying conductor (insulating paint coated wire) PC boards are not needed and distances of LED placement positions are selectable. Also, the current supplying conductor (insulating paint coated wire) can be deformed to desired configuration as in two or three dimensions. Furthermore, the current supplying conductor made of insulating paint coated wire (enamel wire, magnet wire) provides high efficiency of heat dissipation and efficient transfer of heat generated from LEDs to the local environment. As a result less temperature rise of LEDs and enhanced light emission efficiency are provided. High density of LED placement positions is also available. In addition, material and production cost are reduced because of the use of insulating paint coated wire for the current supplying conductor.
As in claim 2 , use of current supplying cable, which is aligned and joined together with two or more current supplying conductors, and a diode connecting part on an exposed local sidewall region of the current supplying cable, assures firm connection with the diode connecting part on the current supplying cable. As in claim 3 , a helical wire may be provided by winding of the current supplying cable, with a groove located at the outer surface of current supplying cable, the core wire exposed at the bottom of groove or notch to provided an exposed electrode. Stretching of the helical wire adjusts distance between diode connecting parts so that desired placements of LEDs at any desired intervals can be selected. By expansion or contraction of the current supplying cable of helical wire axially of the helix distances in between adjacent LEDs can be controlled at any desired length. Changing the rotary tilt of groove locations about that centerline of helical wire, also serves to control the spaces between electrodes.
As in claim 4 , on a sidewall of the current supplying cable, aligned and joined together with two current supplying conductors, a concave reflector is provided to extend along long length direction of current supplying cable, providing a flattened exposed extending edge of the reflector. Direct connection of the formed electrode of the LED to the current supplying cable, as by soldering or other means, enables strong flux to be obtained, with collection of a narrow width of light and reflection of emitting light from the LED at reflecting surfaces provided at both sides of LED. One highly advantageous reflector is made of aluminum or other metals, reducing the reflector cost and providing high heat dissipation efficiency. High light emitting efficiency is also achieved.
With respect to claim 5 , exposing the core wire by locally removing one sidewall of the insulating painted layer of current supplying cable, which was formed by aligning and flatly joining together two current supplying conductors, enables a direct connection of extruded shaped electrode of the LED to the exposed electrode of current supplying cable as by soldering or other means. That connection is typically placed inside of or between V shaped reflector sidewalls. Emission of LED light is reflected by the reflective surfaces of the current supplying conductors provided at opposite sides of the LED enabling provision of strong flux along with collected narrow width of light.
As in claim 7 , formation of a disk shaped reflective pedestal extending crosswise of the axis line of the current supplying conductor enables connection of the exposed electrode of or electrodes of one or more LEDs to a pedestal. Emitted light of the LED is collected at a reflective surface of the pedestal, so there is no need to provide any extra reflective mirror, is and simple construction enables strong light protection. Also, the conductor consists of aluminum with advantages referred to above. Further, the lead wire and reflective pedestal may consist of the same metallic material, and continuous formation, so that the rate of heat dissipation is high with efficient heat to local environment.
As in claim 8 , multiple reflective pedestals can be clustered together with an electric wire in the center of the cluster, light emission of each LED being collected and reflected by each reflective pedestal. A large intensity of light is thereby obtained, with simple construction.
As in claim 9 , three or more insulating paint coated wires used as current supplying conductors are aligned and combined together to form a one piece unit forming a polygon in cross section. By locally exposing the core wire on the outer surface of each current supplying cable and by shifting the position of diode connection part controlled placement of different color light emitting LEDs is enabled, and a variety of arrangements for emitting color is also made available using stranded current supplying cable. Also, current supplying cable may consist of a plural number of current supplying cables, combined together to be plastically deformed whereby the arrangement of LED placement is freely accomplished as well as free arrangement of color matching and LED positions.
Referring to claim 9 , the location of diode connecting part on the core wire exposed on outer side of current supplying cable, by combining 3 or more current supplying conductors of insulating paint coated wires which are aligned and stranded together to form one piece unit, forming a polygon on cross section, is shifted away each other on each sidewall. By twisting current supply cable, a variety of placement of emitting color can be achieved at desired position. Also, the plural number of current supplying conductor is combined together, so plastically deformed arrays, arrangement of LED position can be done freely as well as matching color and emitting position.
|
LED strip lamp comprising a light emitting diode and extruded electrodes characterized in that a shaped electrode of that LED is fixed directly to a diode connecting part on a current supplying conductor, by die bonding or other fixing means, an insulating painted layer on the current supplying conductor being locally absent, exposing a core wire, wherein the current supplying conductor comprises a metal wire rod having said insulating painted layer thereon.
| 5
|
[0001] This application claims priority from copending provisional application serial No. 60/335,822, filed on Dec. 5, 2001, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a novel highly thermally stable anhydrous crystalline polymorphic form of venlafaxine hydrochloride, methods for the preparation thereof, and its use.
BACKGROUND OF THE INVENTION
[0003] Venlafaxine (1-[2-(dimethylamino)-1-(4-methoxyphenyl)ethyl]cyclohexanol) and its therapeutically acceptable salts (collectively referred to as venlafaxine herein) are inhibitors of monoamine neurotransmitter uptake, a mechanism associated with clinical antidepressant activity. This mechanism has also been associated with reproductive function by affecting indirectly the hypothalamic-pituitary-ovarian axis. It is believed that venlafaxine's mechanism of action is related to potent inhibition of the uptake of the monoamine neurotransmitters serotonin and norepinephrine. To a lesser degree, venlafaxine also inhibits dopamine reuptake. However, it has no inhibitory activity on monoamine oxidase.
[0004] In contrast to classical tricyclic antidepressant drugs, venlafaxine has virtually no affinity for muscaranic, histaminergic, or adrenergic receptors in vitro. Pharmacologic activity at these receptors is associated with the various anticholinergic, sedative, and cardiovascular effects seen with the tricyclic antidepressant drugs.
[0005] Hypothalamic amenorrhea in depressed and non-depressed human females may also be treated with venlafaxine as taught in U.S. Pat. No. 5,506,270.
[0006] U.S. Pat. No. 5,530,013 teaches that venlafaxine induces cognition enhancement and treats cognitive impairment in a mammal.
[0007] U.S. Pat. No. 5,744,474 discloses that venlafaxine can treat urinary incontinence in humans.
[0008] More recently, as discussed in U.S. Pat. No. 5,916,923, venlafaxine has been found to treat, prevent, and control obesity, generalized anxiety disorder, post-traumatic stress disorder, late luteal phase disphoric disorder (premenstrual syndrome), attention deficit disorder (with and without hyperactivity), Gilles de la Tourette syndrome, bulimia nervosa, and Shy Drager Syndrome in mammals (e.g., humans).
[0009] Extended release formulations of venlafaxine are disclosed in U.S. Pat. No. 6,274,171 and International Patent Publication No. WO 94/27589. As discussed in U.S. Pat. No. 6,274,171, venlafaxine hydrochloride is known to exist in two polymorphic forms, Forms I and II. Characteristic X-ray powder diffraction patterns for Forms I and II are shown in FIGS. 2 and 3, respectively.
SUMMARY OF THE INVENTION
[0010] The present invention provides a novel anhydrous crystalline polymorph of venlafaxine hydrochloride. This crystalline polymorph is more thermally stable than known forms of venlafaxine hydrochloride. While forms I and II of venlafaxine hydrochloride have melting points of 209 and 211° C. (ΔH=125.8 and 130.3 J/g), respectively, the melting point of the crystalline polymorph of the present invention is about 219° C. (ΔH=116 J/g). Because of this stability, a mixture of various polymorphs of venlafaxine hydrochloride can be formed into a pure form of this new polymorph. Furthermore, residual solvents used in the preparation of this new polymorph or the precursor venlafaxine hydrochloride can be easily removed.
[0011] The crystalline polymorph of the present invention exhibits characteristic XRPD peaks (expressed in degrees 2θ) at about 5.67, 7.28, 9.14, 9.67, 10.77, 11.31, 14.01, 14.54, 14.85, 15.48, 15.81, 16.17, 16.94, 17.68, 18.02, 18.48, 19.29, 19.69, 20.46, 20.74, 21.86, 22.33, 22.67, 22.95, 23.17, 24.06, 24.61, 25.13, 26.62, 26.97, 27.64, 28.25, 29.01, 29.96, 31.01, 31.61, 32.75, 34.54, 35.50, 35.95 and 36.91.
[0012] The crystalline polymorph of the present invention can be administered to a mammal to treat depression (including, but not limited to, major depressive disorder, bipolar disorder, and dysthymia), fibromyalgia, anxiety, panic disorder, agorophobia, post traumatic stress disorder, premenstrual dysphoric disorder (premenstrual syndrome), attention deficit disorder (with and without hyperactivity), obsessive compulsive disorder (including trichotillomania), social anxiety disorder, generalized anxiety disorder, autism, schizophrenia, obesity, anorexia nervosa, bulimia nervosa, Gilles de la Tourette Syndrome, vasomotor flushing, cocaine and alcohol addiction, sexual dysfunction (including premature ejaculation), borderline personality disorder, chronic fatigue syndrome, urinary incontinence, pain (including, but not limited to, migraine, chronic back pain, phantom limb pain, central pain, neuropathic pain such as diabetic neuropathy, and postherpetic neuropathy), Shy Drager Syndrome, or Raynaud's syndrome. The crystalline polymorph can also be administered to prevent relapse or recurrence of depression, to induce cognitive enhancement, to treat cognitive impairment, and in regimens for cessation of smoking or other tobacco uses. Additionally, the crystalline polymorph can be administered to treat hypothalamic amenorrhea in depressed and non-depressed human females. These methods involve administering to a mammal (e.g., a human) in need thereof an effective amount of the crystalline polymorph of the present invention or a mixture of venlafaxine polymorphs that contains the crystalline polymorph of the present invention. Preferably, the venlafaxine is administered orally.
[0013] Another embodiment is a pharmaceutical composition comprising the crystalline polymorph of the present invention and, optionally, a pharmaceutically acceptable carrier or diluent. Typically, the pharmaceutical composition comprises an amount of the crystalline polymorph effective to treat depression or any of the aforementioned indications in an animal, such as a mammal (e.g. human). According to one preferred embodiment, the pharmaceutical composition comprises at least about 20, 30, 40, 50, 60, 70, 80, 90, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% by weight of the crystalline polymorph of the present invention, based upon 100% total weight of venlafaxine hydrochloride in the pharmaceutical composition. According to another preferred embodiment, the pharmaceutical composition comprises at least about 20, 30, 40, 50, 60, 70, 80, 90, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% by weight of the crystalline polymorph of the present invention, based upon 100% total weight of venlafaxine hydrochloride in the pharmaceutical composition.
[0014] The pharmaceutical composition may be incorporated into a dosage form, such as a tablet or capsule.
[0015] The crystalline polymorph of the present invention can be prepared by heating venlafaxine hydrochloride of form I or II or mixtures thereof to a temperature of at least about 197° C. and more preferably at least about 200° C. According to one embodiment, the venlafaxine hydrochloride is heated to about 200° C. Generally, the venlafaxine hydrochloride is heated for at least about 60 minutes and more preferably for at least about 150 minutes. The crystals formed may be recovered by any method known in the art.
[0016] Another embodiment is a method of preparing a substantially pure crystalline polymorphic form of venlafaxine hydrochloride. The method includes obtaining the venlafaxine hydrochloride crystalline polymorph of the present invention in substantially pure form and then converting the substantially pure venlafaxine hydrochloride into another polymorphic form, such as form I. The substantially pure venlafaxine hydrochloride product can be incorporated into pharmaceutical compositions and dosage forms as known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a characteristic X-ray Powder Diffraction (XRPD) pattern of the anhydrous venlafaxine hydrochloride crystalline polymorph of the present invention.
[0018] [0018]FIG. 2 is a characteristic XRPD pattern of Form I of venlafaxine hydrochloride.
[0019] [0019]FIG. 3 is a characteristic XRPD pattern of Form II of venlafaxine hydrochloride.
[0020] [0020]FIG. 4 is a differential scanning calorimetry (DSC) scan of the anhydrous venlafaxine hydrochloride crystalline polymorph of the present invention carried out in a sealed pan at a scan rate of 10° C./minute from 25 to 240° C. under a nitrogen purge.
[0021] [0021]FIG. 5 is a thermogravimetric analysis (TGA) of the anhydrous crystalline polymorph of the present invention heated from 28 to 238° C. at a scan rate of 10° C./minute under a nitrogen purge.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The term 37 about” generally means within 10%, preferably within 5%, and more preferably within 1% of a given value or range. With regard to a given value or range in degrees 2θ from XRPD patterns, the term “about” generally means within 0.2° 2θ and preferably within 0.1°, 0.05°, or 0.01° 2θ of the given value or range. Alternatively, the term “about” means within an acceptable standard error of the mean, when considered by one of ordinary skill in the art.
[0023] The term “treat” as used herein refers to preventing, ameliorating, controlling, or curing the desired symptoms or disorders.
[0024] The term “venlafaxine hydrochloride” as used herein refers to racemic mixtures of R and S-venlafaxine and their optically pure enantiomers. The crystalline polymorph of the present invention may be R, S, or a racemic mixture of R and S-venlafaxine hydrochloride.
[0025] The crystalline polymorph has an XRPD pattern substantially identical to that shown in FIG. 1. Peak locations and intensities for the XRPD pattern in FIG. 1 are provided in Table 1 below.
TABLE I Characteristic XRPD Peaks (expressed in degrees 2θ) D-spacing in Angstrom (Å) and Intensities of Diffraction Lines in CPS for the Polymorphic Form of Venlafaxine Hydrochloride Degrees 2θ d (Å) I (Counts per Second (CPS) 5.67 15.57 309.09 7.28 12.14 828.73 9.14 9.67 766.93 9.67 9.14 262.26 10.77 8.21 303.39 11.31 7.82 728.55 14.01 6.31 224.07 14.54 6.09 807.87 14.85 5.96 887.19 15.48 5.72 830.41 15.81 5.60 617.50 16.17 5.48 357.33 16.94 5.23 728.55 17.68 5.01 338.29 18.02 4.92 312.91 18.48 4.80 753.93 19.29 4.60 1069.82 19.69 4.50 963.51 20.46 4.34 866.61 20.74 4.28 1084.34 21.86 4.06 365.61 22.33 3.98 187.75 22.67 3.92 259.14 22.95 3.87 240.39 23.17 3.84 343.83 24.06 3.70 264.69 24.61 3.62 403.19 25.13 3.54 498.24 26.62 3.35 479.23 26.97 3.30 783.01 27.64 3.23 338.01 28.25 3.16 294.56 29.01 3.08 452.07 29.96 2.98 237.53 31.01 2.88 348.88 31.61 2.83 478.42 32.75 2.73 332.38 34.54 2.60 347.78 35.50 2.53 338.55 35.95 2.50 315.92 36.91 2.43 221.30
[0026] In particular, the peaks (expressed in degrees 2θ) at about 5.67, 7.28, 9.14, 9.67, 10.77, 14.01, 14.54, 16.17, 19.69, and 20.74 are unique to this crystalline polymorph. The crystalline polymorph also has a melting endotherm, according to differential scanning calorimetry, at 219° C.
[0027] The crystalline polymorph of the present invention is useful for treating, preventing, or controlling depression and the aforementioned indications. The appropriate dosage amounts for an animal can be determined by methods known in the art. Generally, a therapeutic effective amount for the desired purpose is administered. The dosage of the crystalline polymorph of venlafaxine hydrochloride disclosed herein is generally from about 75 to about 300 mg per day.
[0028] The crystalline polymorph can be formulated into a pharmaceutical composition. Preferably, the pharmaceutical composition comprises an amount of the crystalline polymorph of venlafaxine hydrochloride effective to treat the desired indication in an animal, such as a human. According to one preferred embodiment, the pharmaceutical composition comprises at least about 20, 30, 40, 50, 60, 70, 80, 90, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% by weight of the crystalline polymorph of venlafaxine hydrochloride, based upon 100% total weight of venlafaxine hydrochloride in the pharmaceutical composition. According to another embodiment, the pharmaceutical composition comprises at least about 20, 30, 40, 50, 60, 70, 80, 90, 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, or 99.9% by weight of the crystalline polymorph of venlafaxine hydrochloride, based upon 100% total weight of crystalline venlafaxine hydrochloride in the pharmaceutical composition.
[0029] The pharmaceutical composition can also be substantially free or completely free of other crystalline polymorphs of venlafaxine hydrochloride, such as Forms I and II. The terms “substantially free” and “substantially pure” include those pharmaceutical compositions that contain less than 0.01, 0.1, 0.2, 0.3, 0.4, 0.5, 1 or 2% by weight of other crystalline polymorphs, such as Form I or II or both, based upon the total weight of pharmaceutical composition (or alternatively based upon on the total weight of venlafaxine hydrochloride in the pharmaceutical composition).
[0030] According to one embodiment, the pharmaceutical composition contains from about 25 to about 350 mg of the crystalline polymorph of venlafaxine hydrochloride. More preferably, pharmaceutical compositions of the present invention contain 75 mg, 150 mg or 225 mg of the crystalline polymorph of venlafaxine hydrochloride.
[0031] The pharmaceutical composition may also include one or more pharmaceutically acceptable carriers or diluents and excipients. The term “excipient” includes, but is not limited to, those materials that are acceptable for use in pharmaceutical formulations, and are added to the formulation to promote the stability and viability of the formulation, such as binders, bulking agents, clarifying agents, buffering agents, wetting agents, lubricants, sweeteners, and flavoring agents. Suitable excipients include, but are not limited to, cellulose, ethyl cellulose, gelatin, hydroxypropyl methylcellulose, iron oxide, titanium dioxide, lactose, magnesium stearate, and sodium starch glycolate. Suitable pharmaceutically acceptable carriers, diluents, and excipients also include those described in Remington's, The Science and Practice of Pharmacy, (Gennaro, A.R., ed., 19 th edition, 1995, Mack Pub. Co.) which is herein incorporated by reference. The phrase “pharmaceutically acceptable” refers to additives 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 an animal, such as a mammal (e.g. a human).
[0032] According to one preferred embodiment, the pharmaceutical composition is an extended release formulation, such as that described in U.S. Pat. No. 6,274,171, which is herein incorporated by reference. For example, an extended release formulation may comprise spheroids comprised of the crystalline polymorph of the present invention, microcrystalline cellulose, and, optionally, hydroxypropyl-methylcellulose The spheroids are preferably coated with a film coating composition comprised of ethyl cellulose and hydroxypropylmethylcellulose.
[0033] The pharmaceutical composition may be a dosage form, such as a liquid (e.g., elixirs and suspensions), capsule, pill, or tablet. The pharmaceutical compositions and the crystalline polymorph of venlafaxine hydrochloride may be administered to animals, including, but not limited to, mammals (e.g. humans), orally, intravenously, intramuscularly, parenterally intraperitoneally, subdermally, buccally, subcutaneously, transdermally, topically, rectally, vaginally, or intranasally. Preferably, the composition is administered orally.
[0034] The crystalline polymorph of the present invention can be prepared by heating venlafaxine hydrochloride of form I or II or mixtures thereof to at least about 197° C. and more preferably at least about 200° C. According to one embodiment, the venlafaxine hydrochloride is heated to about 200° C. Generally, the venlafaxine hydrochloride is heated for a time sufficient to form the crystalline polymorph of the present invention. Preferably, the venlafaxine hydrochloride precursor is heated for at least about 60 minutes and more preferably for at least about 150 minutes. The crystalline polymorph may be prepared in substantially pure form by heating the venlafaxine hydrochloride precursor for a sufficient amount of time.
[0035] Venlafaxine hydrochloride may be prepared by any method known in the art including, but not limited to, the methods described in U.S. Pat. Nos. 4,535,186 and 4,761,501 and International Patent Publication Nos. WO 00/32555, WO 00/32556, and WO 01/07397, all of which are hereby incorporated by reference.
[0036] The crystals formed may be recovered by any method known in the art, such as filtration, centrifugation, or with a Buchner style filter, Rosenmund filter, or plates and frame press. Typically, the crystals are recovered as solids.
[0037] The crystalline polymorph can be converted into Form I by recrystallizing it in ethyl acetate in ethanol (e.g., 80% ethyl acetate in ethanol).
[0038] As discussed above, substantially pure forms of the crystalline polymorph can be prepared such as by heating one or more forms of venlafaxine hydrochloride to about 200° C. for a sufficient time. The substantially pure crystalline polymorph can be used to prepare other substantially pure crystalline polymorphic forms of venlafaxine hydrochloride, such as form I, by the methods described above. The substantially pure venlafaxine hydrochloride product can be incorporated into pharmaceutical compositions and dosage forms as known in the art.
EXAMPLES
[0039] The following examples are illustrative and are not meant to limit the scope of the claimed invention. The venlafaxine hydrochloride which is used as a raw material in the example below can be prepared by any method known in the art.
Example 1
Preparation of Anhydrous Venlafaxine Hydrochloride
[0040] About 100 mg of venlafaxine hydrochloride of Form II was put in a glass vial, flushed with nitrogen gas and then sealed by heat. The sealed vial was put in an oil bath at about 200° C. (197° C. to 200° C.) for 1 hour or until the shape of the crystals changed to form cream-white crystals.
Example 2
Preparation of Anhydrous Venlafaxine Hydrochloride
[0041] The procedure in Example 1 was repeated with 500 mg of venlafaxine hydrochloride of Form II, except the vial was left in the oil bath for 2.5 hours instead of 1 hour.
Example 3
Preparation of Anhydrous Venlafaxine Hydrochloride
[0042] The procedure in Example 1 was repeated, except an aluminum vial was used instead of a glass vial.
Example 4
X-Ray Powder Diffraction (XRPD)
[0043] XRPD was performed on the crystalline polymorph of venlafaxine hydrochloride of the present invention under dry conditions with a Scintag X2 X-Ray Diffraction System Model 00-A02, available from Thermo ARL of Ecublens, Switzerland. The XRPD instrument had the following parameters:
Scan Type: Normal Start Angle: 3 degrees Stop Angle: 40 degrees Number of Points: 1851 points Step Size: 0.02 degrees Datafile Resolution: 1600 Scan Rate: 0.04 Scan Mode: Step Wavelength: 1.540562 Diffraction Optics: Detector: Type: Fixed Slits X2 Configuration: No Tube: Type: Fixed Slits X2 Configuration: No
[0044] The results are shown in FIG. 1.
[0045] This procedure was repeated for Forms I and II of venlafaxine hydrochloride.
[0046] The results for Forms I and II are shown in FIGS. 2 and 3, respectively.
Example 5
Intrinsic Dissolution Rate
[0047] The intrinsic dissolution rates of Form II and the crystalline polymorph of the present invention were determined as follows. Pellets of venlafaxine hydrochloride were prepared by compressing 100 mg of each material in a die (Wood's apparatus) at 1000 psi for 1 minute with a Carver press. The pellets produced were then fitted into a dissolution apparatus (Vankel 7010 equipped with a Cary 300 Ultraviolet/Visible Spectrophotometer) which resulted in a single exposed surface area of 0.5 cm 2 . The dissolution rate in 900 mL of water was determined by USP 23 (1995), section 711, page 1791 (Dissolution, apparatus 2 ), with a rotation speed of 100 rpm at 37° C. The dissolution media was circulated through a 1.0 cm path microflow cell at a flow rate of 10 mL/minute. Ultraviolet absorbance was recorded at 220 nm.
[0048] Both Form II and the crystalline polymorph of the present invention exhibited dissolution rates of 24.7 mg/cm 2 -minute.
Example 6
Differential Scanning Calorimetry (DSC)
[0049] DSC measurements on the anhydrous venlafaxine hydrochloride crystalline polymorph of the present invention were carried out in a sealed pan at a scan rate of 10° C./minute from 25° C. to 240° C. under a nitrogen purge with a Pyris I DSC available from Perkin-Elmer of Shelton, Conn. The DSC scan is shown in FIG. 4.
[0050] [0050]FIG. 4 shows one endotherm at 221° C. (heat of fusion is 116 J/g), which was the melting of the anhydrous venlafaxine hydrochloride. The onset melting temperature for the venlafaxine hydrochloride was 219° C.
Example 7
Thermogravimetric Analysis (TGA)
[0051] A sample of the venlafaxine hydrochloride crystalline polymorph of the present invention was heated from 28 to 238° C. at a scan rate of 10° C./minute in a Pyris I TGA, available from Perkin-Elmer of Shelton, Conn., under a nitrogen purge. The results are shown in FIG. 5. The sample lost little weight until it was heated near the melting point of venlafaxine hydrochloride.
[0052] The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description and the accompanying figures. Such modifications are intended to fall within the scope of the appended claims. It is further to be understood that values are approximate, and are provided for description.
[0053] Patents, patent applications, publications, procedures, and the like are cited throughout this application, the disclosures of which are incorporated herein by reference in their entireties. To the extent that a conflict may exist between the specification and a reference, the language of the disclosure made herein controls.
|
This invention relates to a highly thermally stable novel anhydrous crystalline polymorphic form of venlafaxine hydrochloride, methods for the preparation thereof, and its use.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application claims a benefit of U.S. Provisional Application No. 61/366,877 filed on Jul. 22, 2010, which is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to wine storage devices. More particularly, the present invention relates to an apparatus for storing and dispensing wine from collapsible, reusable containers.
[0003] For many years, wine has remained one of the most popular drinks to accompany a meal, and as such, is made available not only at home, but at a vast number of restaurants. It is therefore important for a restaurant to keep in stock ample quantities of wine to meet the demand of its customers. However, as wine has historically been stored within glass 750-mL bottles, not only are there increased shipping costs associated with the use of glass bottles, but stocking a restaurant with such wine requires certain space requirements. Alternatively, certain types of wine have been made available by means of portable fluid containers, for example flexible 3- to 10-liter bladders of wine contained within a cardboard box, sometimes referred to as “wine-in-a-box” or simply “box wine”. While such containers cut down on shipping costs, there are still storage considerations to take into account, as well as other inherent setbacks. For instance, as the box itself must be placed within a refrigeration unit to keep the wine chilled, the refrigeration space required for the box must be considered. Further, and regardless if a bottle or portable fluid bladder is used, once opened, the shelf-life of the wine decreases rapidly due to oxidation. While bottles of wine typically have to be consumed within a day or so, “wine-in-a-box” products currently available typically last only about a week. More importantly, though, as wine is considered by many to be a premium product, “wine-in-a-box” does not do well from a marketing standpoint as it has been perceived by the purchasing public to be an inferior product or inferior means of storage as opposed to glass bottles. For this reason alone, many vintners have avoided providing wines in this fashion, preferring instead to stick with glass bottles.
[0004] There exist in the art several examples of devices which have attempted to provide a means for storing box wine in an aesthetically pleasing manner. However, limitations exist in such examples as conventional devices have been shown to be quite difficult to change between spent wine bladders and new ones. For example, U.S. Pat. No. 7,434,705 requires that a front end housing containing a dispensing spout be removed before a spent bladder of wine can be replaced with a full bladder of wine. It has been shown in the field that this mechanism is difficult to employ.
[0005] Currently, there exists a need in the art to provide an aesthetically pleasing wine dispensing mechanism for use in conjunction with reusable bladders of wine which provides a quick, easy and efficient means of changing between spent and full bladders. There also exists a need in the art to provide a wine dispensing mechanism which assists in preserving unused quantities of wine after opening longer than what is currently available.
BRIEF SUMMARY OF INVENTION
[0006] In accordance with the present invention, an apparatus is provided for refrigerating and dispensing pre-packaged wine. The apparatus includes a housing formed substantially in the shape of an aesthetically pleasing miniature wine barrel which holds a removable insert containing between approximately 3 and 10 liters of wine within a collapsible bladder. The housing includes a first circumferential wall, a front face and removable rear panel. A spigot for selectively dispensing the wine is supported by and positioned through the front face. The insert is disposable within the housing through the rear portion with the panel removed. A telescoping conduit in fluid communication with the spigot extends from the front face of the housing to the rear thereof for connection with the insert proximate the rear of the housing. The conduit is positionable between a first retracted position and a second extended position, which facilitates in connecting the bladder thereto.
[0007] In replacing a spent bladder, the user removes the rear cover and pulls the insert out slightly such that the connection between the conduit and the insert is easily accessible to the user. This extends the conduit from the first retracted position to the second extended position. The user can then disconnect the spent insert from the conduit, fully remove the spent insert, which can then be replaced by a full insert. The full insert is connected to the conduit and then fully positioned within the housing, which positions the telescoping conduit from the second extended position to the first retracted position. The panel can then be replaced and the apparatus is ready to again dispense wine.
[0008] To optionally cool the wine, an electric heat pump extends through an aperture contained within a bottom portion of the housing. The heat pump is capable of expelling thermal energy contained within the housing to keep the wine cool relative to a higher ambient temperature. To facilitate in the cooling of the wine, a thermally conductive shroud is provided which is supported by a thermal conductive block in communication with the heat pump. The shroud is configured to receive and support the insert. Both the shroud and the insert have an angled floor which permits the wine to be gravitationally urged toward the rear of the housing where the conduit fluidly connects to the bladder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following figures are used herein in conjunction with the specification to assist in understanding the invention. The Figures are as follows:
[0010] FIG. 1 is a perspective view of a wine storage and dispensing apparatus in accordance with a first embodiment of the present invention.
[0011] FIG. 2 is a side-view of the wine storage and dispensing apparatus in accordance with the first embodiment of the present invention.
[0012] FIG. 3 is a cross-sectional view of the wine storage and dispensing apparatus as taken along lines A-A in FIG. 2 .
[0013] FIG. 4 is a cross-sectional view of the wine storage and dispensing apparatus as taken along lines B-B in FIG. 2 .
[0014] FIG. 5 is a cross-sectional view of the wine storage and dispensing apparatus of the present invention with an insert partially removed.
[0015] FIG. 6 is a side-view of the wine storage and dispensing apparatus in accordance with a second embodiment of the present invention.
[0016] FIG. 7 is a partial cross-sectional side view of a dispensing system in accordance with the present invention.
[0017] FIG. 8 is a cross-sectional view of a telescoping conduit in accordance with the present invention.
[0018] FIG. 9 is an exploded perspective view of a reusable container in accordance with the present invention.
[0019] FIG. 10 is a side profile view of the reusable container in accordance with the present invention.
[0020] FIG. 11 is a perspective view of the first and second embodiments of the wine dispensing apparatuses of the present invention supported by a rotatable stand.
DESCRIPTION OF THE INVENTION
[0021] A wine storage and dispensing apparatus of the present invention is generally indicated at 100 in FIGS. 1 through 4 . The apparatus 100 includes a housing structure 102 , preferably an aesthetically shaped miniature wooden wine barrel, for placement on or near a bar in areas where wine would normally be dispensed. However, it should be noted that alternative shapes for the housing structure are well within the scope of the present invention, including non-exhaustive examples of semi-circular barrels with flat bottoms, rectangular boxes or the like. The wine barrel 102 includes a front face 104 which supports a spout or spigot 106 for selectively dispensing wine. A removable back panel 108 attaches to the wine barrel 102 by means of a latching mechanism 110 . The specific latching mechanism 110 employed is not critical in practicing the invention, and those skilled in the art will recognize that other mechanisms than those illustrated will suffice.
[0022] The apparatus 100 further includes an optional thermoelectric heat pump 112 for cooling wine contained within the barrel 102 . The thermoelectric heat pump 112 for use with the present invention includes a solid-state active heat pump which transfers heat from one side 114 of the device to the other side 116 against a temperature gradient with the consumption of electrical energy. A heat sink 117 effectuates dissipation of heat into the air. As best illustrated in FIGS. 3 through 5 , the thermoelectric heat pump 112 is positionable through an aperture 118 contained in an under portion of the housing. As it is contemplated that in most situations the a ambient temperature of the room or restaurant where the apparatus 100 will be dispensing wine will be greater than optimal wine dispensing temperatures of between 45 and 65 degrees Fahrenheit, the heating portion 116 of the thermoelectric cooler seats outside of the barrel 102 , enabling any generated heat to dissipate into the outside air. Attached to the cooling side 114 of the heat pump is a thermally conductive block 120 , preferably constructed of a metallic material such as aluminum. However, any material having a thermal conductivity greater than about 100 watts per meter Kelvin (W/(m*K)) is well within the scope of the present invention. The thermoelectric heat pump 112 further includes a control unit and electric transformer (not shown) for activating and controlling the temperature of the block 120 and shroud 122 , which in turn controls the temperature of the wine. Exemplary thermoelectric heat pumps 112 for use with the present invention include those as made available by Pacific Supercool, Ltd. of Bangkok, Thailand or SOS Prescott of Prescott, Wis. However, one skilled in the art will recognize that the use of similar thermoelectric heat pumps by other manufacturers are well within the scope of the present invention.
[0023] To increase the efficiency and the consistency of the manner in which heat is conducted out of the wine barrel 102 , and to provide for a more consistent temperature therein, the metallic shroud 122 is provided. The shroud 122 seats upon and engages the conductive block 120 . The metallic shroud includes a base plate 124 attached to the conductive block 120 , as well as a semi-circular wall 126 extending along longitudinal edges of the base plate 124 . Insulation 125 may be provided between the shroud 122 and the inner wall 128 of the barrel. Further, thermal electric compound 127 , such as thermal grease, may be optionally included between the conductive block 120 and the inner wall 128 , as is illustrated in FIG. 5 . The shroud 122 is designed to support a removable plastic insert 130 containing a collapsible bladder 132 of wine.
[0024] As mentioned, use of the thermoelectric heat pump 112 is optional and the present invention can be practiced without such a device, as is illustrated in alternative embodiment 200 in FIG. 6 . However, for purposes of this description, similar parts from apparatus 100 and alternative apparatus 200 will be given similar references, and any differences between the two embodiments will be explicitly stated. As such, unless otherwise noted, description of one is meant to include description of the other for similar parts and operation.
[0025] To transfer the wine contained within the bladder 132 positioned within the insert 130 , a liquid transfer mechanism 134 is provided. As illustrated in FIG. 7 , the liquid transfer mechanism 134 includes the spigot 106 in fluid communication with a telescoping conduit 136 , which in turn fluidly connects to a quick connector 138 . The spigot 106 , as made available by Artisan Barrels of Oakland, Calif., threadably attaches to a first segment 140 of the telescoping conduit 136 , wherein a seal is formed by means of a washer 141 . As illustrated in FIG. 8 , the telescoping conduit includes the first segment 140 into which slidably disposes a second segment 142 , as denoted by arrow 143 . The second segment 142 is therefore of a lesser diameter than the first segment 140 . Both the first segment 140 and the second segment 142 are preferably constructed of a rigid material, for example stainless steel. The second segment 142 is slidably positionable relative to the first segment 140 to increase or decrease the overall length of the telescoping conduit 136 , the importance of which will become apparent shortly. In order to prevent leakage of liquid when passing therethrough, and to prevent the intrusion of any unwanted material therein, the second segment 142 includes a flange 144 extending circumferentially and slidably engaging an inner surface 146 of the first segment 140 . Additionally, an O-ring 148 is positionable within a groove contained in the first segment 140 . The O-ring 148 abuts against an outer surface 150 of the second segment 142 , which further enhances the seal between the first segment 140 and the second segment 142 .
[0026] The quick connect 138 is preferably a VITOP® BAG-IN-BOX® quick connect as made available by the Smurfit Kappa Group of Eperny, France. The quick connect 138 includes a male and female connector, 152 and 154 respectively. The female connector 154 connects to the second segment 142 by means of a flexible length of tubing 156 . The tubing 156 is preferably anti-microbial to prevent the intrusion of micro-organisms into the wine which can lead to the spoilage thereof. The male connector 152 attaches to the bladder 132 and seats within an aperture 158 contained within the insert 130 . The telescoping conduit 136 , as well as the connecting tube 156 and a portion of the quick connect 138 , is disposable within a circular channel 160 contained within the conducting block 120 as illustrated in FIGS. 3 and 4 .
[0027] Referring now to FIG. 9 , the removable insert 130 is constructed from plastic and includes a substantially flat rectangular floor 162 containing the circular aperture 158 for receiving the male connector 152 . A semi-circular wall 164 extends from opposing longitudinal sides of the bottom 162 . The semi-circular wall 164 and bottom 162 are joined on a first end by an end-wall 166 . A removable cap 168 is securable to a second end portion of the bottom 162 and semi-circular wall 164 . The insert 130 houses the collapsible bladder 132 which is fillable with liquid, which in this case includes wine. The male connector 152 fluidly communicates with the bladder 132 and provides the wine to the liquid transfer mechanism 134 when connected thereto. Both the end wall 166 and removable cap 168 include a semi-circular design with a bottom flat portion such that the insert conforms to the shape of the barrel 102 and is disposable within the shroud 122 . In order to facilitate gravitational draining of the bladder contents during use, the cap 168 includes a larger circular radius x than a circular radius of the end-wall y, giving the semi-circular wall 164 a frusto-conical configuration. With the end-wall 166 and cap 168 being positioned substantially parallel to one another, the floor 162 therefore is positioned at a declining angle from the end-wall 166 as the floor 162 proceeds towards the cap 168 relative to the top of the semi-circular wall 164 , as illustrated in FIG. 10 . As the shroud 122 is configured to receive the insert 130 , it should be understood that the base plate 124 also includes a corresponding declination.
[0028] As is known in the art, the bladder 132 may is constructed of a flexible material such that it may collapse upon itself when the contents therein are drained. Such materials can include metallic sheeting or plastic formed to provide a hermetically sealed interior. To fill the bladder 132 , all air is first evacuated after which the wine is introduced therein. Upon being filled, the bladder 132 is injected with an overpressure of an inert gas, such as Argon, to prevent oxygenation of the wine and thereby extend shelf life. Further, by filling the bladder 132 with an inert gas, it has been discovered that the wine can remain unspoiled after opening for a much longer time than is observed within conventional wine-in-a-box methods. Instead of less than two weeks, which is typical for a conventional device, the wind dispensing apparatus 100 of the present invention can prevent oxygenation and spoiling of the wine after opening for up to eight weeks.
[0029] It is intended that either the vintner or the wine wholesaler fills the bladders 132 with wine, along with the overpressure of inert gas prior to sealing the bladder 132 within the insert 130 . The insert 130 thereby provides a protecting structure to prevent the bladder 132 from being punctured during transit or use. The vintner or wholesaler then ships the insert, or a plurality of inserts, directly to the restaurant when they can be stored until needed for dispensing.
[0030] In operation, the apparatus 100 or 200 containing an insert with wine contained therein is positioned within a restaurant, home or other suitable place where it is convenient to dispense the wine into individual glasses when so desired. Upon depleting the contents of a bladder 132 , whereby the wine insert needs to be replenished, the back cover 108 of the housing 102 is removed. As illustrated in FIG. 6 , the user pulls the insert 130 partially from the shroud 122 , causing the second segment 142 of the telescoping conduit to withdraw from the first segment 140 and allowing the user access to the quick connector 138 . The user then removes the male connector 152 from the female connector 154 , whereby the insert 130 is fully removable from the shroud 122 and the housing 102 . A new insert containing a full bladder of wine is then partially disposed within the barrel and the shroud. The male connector 152 , which comes already connected to the bladder 132 , is then attached to the female connector 154 and the insert 130 is pushed fully within the shroud 122 with the telescoping conduit 136 decreasing in overall length. The back cover 108 is replaced and the apparatus 100 or 200 is again ready to dispense the wine through the spigot 106 . Upon activating the thermoelectric heat pump 112 , the wine within the insert 130 is storable at a constant temperature for up to 8 weeks.
[0031] Another advantage of the present invention is that it permits ease of operation in an aesthetically pleasing manner without undue hardship in exchanging inserts. As illustrated in FIG. 11 , apparatus 100 , apparatus 200 , or both, can be positioned on a rotatable stand 180 , which in turn can be set up on a table, bar top or other suitable location. The stand may include a rotatable base 182 , which when the wine in the bladder goes empty, can simply be rotated around to give a person access to the rear of the housing without having to lift and move the housing itself. A depleted insert can be exchanged with a full insert in the manner as previously described, whereafter the stand can be rotated back to its desired position.
[0032] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
|
An apparatus for storing and dispensing wine comprises a housing formed substantially in the shape of a wine barrel. The housing including a circumferential wall, a first closed end and a second open end. A spigot for selectively dispensing wine is supported by and positioned through the first closed end of the housing. A removable insert disposable within the housing through the second open end contains a collapsible bladder of wine. A wine dispensing port is contained within the bladder and insert. With the insert positioned within the housing, the port is positioned proximate the second open end thereof. A conduit in fluid communication with the spigot extends from the first closed end toward the second open end. Upon disposing the insert within the housing, the conduit is connectable to the port wherein the wine can be selectively dispensed from the spigot.
| 5
|
FIELD OF THE INVENTION
The present invention relates to a means or device for delivery of flowable media, especially of lubricants, with a pump which can be driven by a motor and which forms a component of a line system.
BACKGROUND OF THE INVENTION
In known means of this type, under certain unfavorable operating conditions the danger exists that malfunctions, for example, a drop of delivery output, pump overload, or even its failure will occur. These difficulties can occur especially when overly low oil temperatures occur as lubricating oils are being delivered in a lubricant circuit. These operating states prevail, for example, during cold running phases of certain systems, or occur in wind power plants under winter conditions that can last over longer time intervals. The corresponding strong increase in the viscosity of the lubricating oils to be delivered leads at least to a reduction of the delivery output, resulting in danger to the assigned machinery system, or in less favorable cases leads to overloading or even failure of the pump. This situation in turn entails corresponding subsequent damage to the pertinent system.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a means or device for delivering flowable media, especially lubricants, with operating reliability ensured even when very low temperatures of the line system and the medium to be delivered prevail.
This object is basically achieved by a means or device where heat transfer to the pump housing from the outside is provided. If necessary, a direct temperature increase can take place in the critical, i.e., fault-susceptible area of the line system, specifically directly on the pump. The heating of the pump housing also leads to a corresponding temperature increase of the delivered medium. This heating of the delivered medium causes a corresponding temperature increase of the entire pertinent line system, including an increase of a possible overly low oil temperature in a lubricant circuit.
In especially advantageous exemplary embodiments, at least one heating element is in the form of a self-regulating electrical resistance element with a positive temperature coefficient, for example, in the form of a PTC heating element. Commercially available PTC heating elements include doped polycrystalline ceramic with barium titanate as the base material. These PTC elements ensure rapid heat-up, have good self-regulation behavior, and thus, have a long service life, since there is no danger of overheating due to the self-regulating properties. The use of such PTC elements is also especially advantageous because these elements can automatically maintain a desired temperature level, without control means or temperature sensors being necessary.
Preferably, the housing of the pump has more than one flat outside wall section, to each of which one PTC element is assigned.
Preferably, the PTC heating elements are assigned to those outside wall sections of the housing that are spatially adjacent to the inside displacement elements of the pump. This piston arrangement leads to especially effective and prompt heat-up in the desired region which is critical against insufficient temperatures.
In exemplary embodiments in which on the pump housing fluid input and output define the start and end of the inner pump flow path and in which displacement elements are placed at the same height or coaxial with the input and output on end walls of the pump housing, preferably with the PTC heating element on the side walls joining the end walls and placed at the height of the fluid input and output. This placement yields especially specific heat-up in the area of the inner flow path of the pump.
In advantageous exemplary embodiments, the carrier for the PTC heating elements is an aluminum sheet adjoining the pertinent outside wall sections for heat transfer. The outer side of that sheet adjoins the PTC heating elements made in a flat construction. This support of the PTC heating elements ensures especially good heat transfer to the pump housing.
In this connection, the carrier can be made U-shaped with U-legs extending parallel to one another to form one collar of the two opposing outside side wall sections of the pump housing. On the outside of each U-leg, one PTC heating element is provided.
The PTC heating elements for their part can be held in contact with the U-legs by an enclosure attached to the outside of the U-legs and made from highly heat-conductive metallic material.
The efficiency of the means or device is especially good when the pump housing is surrounded with heat-insulating jacketing, leaving its pump shaft and fluid input and output exposed. Heat losses to the vicinity are then for the most part prevented. This jacketing, with the housing being, for example, cast round, prevents not only heat exit to the outside, but also forms protective jacketing preventing direct access to the PTC heating elements.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a perspective view of a pump according to one exemplary embodiment of the present invention;
FIG. 2 is a front elevational view, looking at the end wall of the pump housing, with its components surrounding the side walls being shown cutaway or in section;
FIG. 3 is a perspective view of part of a carrier forming the collar of the side walls of the pump housing with PTC heating elements located on its outside and their electrical connecting means;
FIG. 4 is a side elevational view of the carrier part of FIG. 3 ;
FIG. 5 is a front elevational view of the carrier part of FIG. 3 ;
FIG. 6 is a bottom plan view drawn roughly in actual size of a metallic enclosure with a PTC heating element of flat construction held in it; and
FIG. 7 is a side elevational view in section of the metallic enclosure taken along line VII-VII of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show a pump 1 , with a pump housing 3 which has a fluid input or inlet 9 provided with a connecting flange 7 on the front end wall. Diametrically opposite fluid input 9 on the rear wall (not shown) in the figures a corresponding fluid output or outlet 10 is placed at the same height (coaxially aligned) with the fluid input (inlet) 9 . Within the flow path of the pump 1 between the fluid input 9 and fluid output (outlet), a gear pair forms the displacement elements, i.e., the pump 1 is an outside gear pump with a drive shaft 11 located on the top of the housing. As is best shown in FIG. 1 , the pump housing 3 is surrounded with heat-insulating jacket 13 , leaving exposed the areas of the fluid input 9 , of the housing top with the drive shaft 11 , and of the area of the fluid output (not shown). Jacket 13 can be a cast or foamed jacket.
FIG. 2 shows the part of the jacket 13 including the side walls 15 of the pump housing 3 extending between the end or front wall 5 and the rear wall. In a vertically cut representation between the side walls 15 and the jacket 13 a U-shaped carrier 17 is provided.
FIGS. 3 to 5 show the carrier 17 in greater detail. The carrier 17 is shaped from aluminum sheet, and has two U-legs 19 intended to make contact with the side walls 15 of the pump housing 3 and defining or extending in planes parallel to one another. A PTC element unit 21 shown schematically in FIGS. 3 to 5 is attached to the outside of each U-leg 19 . U-legs 19 of carrier 17 are connected by a crosspiece 23 enclosing the bottom of the pump housing 3 . An electrical connecting means or connector 25 is provided on crosspiece 23 for supplying electrical power to PTC heating elements of PTC element units 21 .
FIGS. 6 and 7 show details of the PTC element units 21 . Each of the element units 21 is provided with its own PTC element 29 in the form of a flat cuboid. The PTC element 29 is located in an enclosure 31 made in the form of a round disk of metal with good heat conductivity and provided with profiling. The enclosure 31 has central profile 33 forming a receiving channel 37 in which the PTC element 29 is fixed by a heat-resistant adhesive film strip 39 , in the exemplary embodiment a Kapton® strip. The bottom 35 of the enclosure 31 is intended for contact with the pertinent U-leg 19 . On either side of the receiving channel 37 , profiles 41 of low height with a round mounting hole 43 and an oblong hole 45 are provided for forming a screw connection between the enclosure 31 and the pertinent U leg 19 . Carrier 17 mounts PTC heating elements 29 at the height of the fluid input 9 and the fluid out output.
Connecting wires 27 intended for power supply of the PTC element 29 are connected in the manner conventional for PTC elements 29 to the flat metal electrodes provided thereon. In the end area bordering the PTC element 29 , the connecting wires 27 are surrounded by a silicone insulating tube 47 . Moreover the transition area between the end of the connecting wires 27 provided with the insulating tube 47 can be sealed with rubber in the area bordering the PTC element 29 .
The enclosure 31 attached to the pertinent U-leg 19 of the carrier 17 forms a heat conducting plate for transfer of the heat generated by the PTC element 29 to the aluminum sheet of the pertinent U-leg 19 adjoining the pertinent side wall 15 of the pump housing 3 as a heat transfer agent. This thermal coupling makes it possible using the self-regulating characteristic of the PTC heating element 29 to maintain the desired temperature during changing operating states on the pump housing 3 , without the need for control electronics for this purpose.
The present invention is described above using the example of an outside gear pump, but can be used likewise in pumps of a different design, for example, for inside gear pumps, screw pumps, vane cell pumps, radial piston pumps or in pumps with a different operating principle. In any case, it is advantageous to attach the pertinent PTC heating elements to the respective pump housing in a position such that there is good thermal coupling to the pertinent inner displacement elements. While the present invention is explained using one example in which two element units 21 with one contained PTC element 29 each are used, there could be a different number of PTC elements 29 , and other designs different from the flat execution can be used, for example, PTC elements with a round or rectangular cartridge shape.
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
|
A device for delivery of flowable media, especially of lubricants, includes a pump ( 1 ) driven by a motor and forming a component of a line system. At least one heating element ( 21 ) activated by energy supply is located outside of the housing ( 3 ) of the pump ( 1 ) in a position enabling heat transfer to the housing ( 3 ).
| 5
|
This application is a continuation of application Ser. No. 08/237,215, filed May 3, 1994 now abandoned.
FIELD OF THE INVENTION
This invention relates to methods of applying finishes to garments. More particularly, this invention relates to improved methods for applying an even and uniform coating of specialty finishes on the garments using a cellulose-type based carrier and to a gel composition for practicing the method. Cellulose-type based carrier is hereafter defined to include cellulose-type based carriers, as well as, natural gums such as starch, guar, xanthium, gharia, sodium alginate, locust bean gum, carboxymethyl cellulose, and hydroxypropyl cellulose, and synthetic gums such as polyacrylates.
BACKGROUND OF THE INVENTION
The textile industry has long used a variety of mechanical and chemical operations to give fabrics and garments their ultimate feel and performance characteristics. Recently, the textile industry has seen tremendous growth in the development of new finishes for garments, such as Prewash, Soft Hand, Stonewash, Bleach, Acid Wash, Garment Dye, and combinations thereof. With growth of new finishes for garments, the textile industry has also seen the reintroduction or resurgence of garments with durable press, shrink-proof, water-repellent, fire-retardant and soil release agents, and other specialty finishes.
For illustration purposes, the background will focus on the techniques and problems with applying durable press finishes to garments. A durable press finish allows a fabric or garment to be washed and dried by conventional methods and still recover or retain an ironed appearance without pressing. The same or similar techniques used in applying durable press finishes are also used in applying other finishes. Therefore, the background's focus on durable press finishes is not intended to limit the presently disclosed invention in any manner.
For many years, the textile industry has had applied durable press finishes to cotton and cotton blended fabrics. This finishing is done by the application and curing of one or more resins including melamine formaldehyde, urea formaldehyde, polycarboxylic acids, and dimethyloldihydroxyethylene urea. A finishing technique using formaldehyde is disclosed in U.S. Pat. No. 3,275,402 which relates to imparting crease recovery properties to cellulose fabrics by impregnating the fabrics (in the presence of water) with formaldehyde, a water-soluble metal salt, and a polymeric film forming stiffening material capable of reacting with formaldehyde, and curing the impregnated material to cross-link the cellulose and bond the film forming material to the cellulose.
The two standard techniques for applying durable press finishes to fabrics are the pre-cured technique and the post-cured technique. The pre-cured technique involves applying a pre-cured resin finish by padding on the finish, framing to width and drying on a finish frame (pin or clip), and curing in an oven. The post-cured technique is the same as the pre-cured technique except the curing step is omitted to prevent the finishing resin from cross-linking with the cotton. After a garment is made from post-cured fabric, it can be pressed and then cured in the pressed configuration so that creases, pleats, seams, belt loops, etc., maintain their "new" look and the panels of the garment remain smooth even after repeated laundering.
Whether using the pre-cured or post-cured technique on garments, the finishing resins are currently applied through the use of industrial washers. However, one of the primary problems with applying the finish is that durable press resins lack affinity for cotton. Thus, these durable press resins do not exhaust to the fabric as may certain dyes and chemicals. Therefore, using an industrial washing machine to apply resins is inefficient because it is necessary to run a liquor ratio (weight of liquid to weight of garments) of at least 4:1 in order to achieve uniform saturation. Assuming that the garments will be extracted to between about 50 to 100% percent total add on, four to eight times more resin has to be in the bath than is accepted by the garment. For example, if 5.0% resin is needed to achieve a desired finish, 40.0% resin would have to be added to a washer (assuming a 4:1 liquor ratio and extracting to 50.0% total add on). Since such large amounts of resins are necessary, it would be advantageous to recover the resin which is not accepted by the garment. However, it has been found that reclaiming the resin leads to contamination. Thus, most resins are wasted rather than recovered which makes this technique of applying finishing resin very costly.
In an attempt to overcome the inefficiency of using a washer for applying finishes to garments, other methods have been devised including the "Dip & Drip" method and the use of manufactured foam.
The "Dip & Drip" method is a slight improvement over the washer method. In this method, garments are collected in a water permeable bag, dipped in a resin finish mix, allowed to drip the excess finish back into the mix tank applicator, and then extracted. While the amount of unused finish mix has been greatly reduced, it is still a significant problem.
The method of using manufactured foam entails entraining the resin within a foam. Although manufactured foams are generally applied to piece goods by continuously metering a predetermined amount of foam on to the surface of the piece good, manufactured foams can also be applied using the washer method. Using a manufactured foam to apply finishes to garments does reduce waste, however the use of manufactured foam requires strict control of many process parameters and the purchase of expensive foaming equipment. A further disadvantage is that the finish may be distributed in a random and uneven fashion. Although this random and uneven distribution may be advantageous when it is desirable to create a blotchy effect on the fabric, such as when applying a dye to achieve a certain pattern, it is a disadvantage when applying finishing, such as durable press, shrink-proof, water-repellent, fire-retardant and soil release agents, and other specialty finishes, where coating the fabric evenly and smoothly is essential.
To truly become efficient, garment producers need a way to apply finishes to garments with no special equipment that distributes the finish evenly and smoothly with minimal or no wasted resin.
OBJECTS OF THE INVENTION
A primary object of this invention is to provide a composition and a method for coating fabrics of various fibers with a variety of finishing.
It is a further object of this invention to provide a composition and a method for coating fabrics which minimizes or eliminates any wasted finishing.
It is still a further object of this invention to provide a composition and a method for coating fabrics which results in even distribution of the finishing onto any fabric surface.
It is yet a further object of this invention to provide a composition and a method to achieve a smooth and even coating of the finishing onto fabric without having to recover unused finishing.
It is yet a further object of this invention to provide a composition and a method to achieve a smooth and even coating of the finishing onto fabric without having to recover unused finishing using standard garment production equipment.
The above and other objects, features and advantages of this invention will be apparent in the following detailed description of illustrative embodiments thereof.
SUMMARY OF THE INVENTION
This invention relates to improved methods for applying an even and uniform coating of a specialty finishing on garments using a cellulose-type based carrier and to a gel composition for practicing the method.
To overcome the numerous disadvantages of known finishing compositions and methods, cellulose-type based carriers mixed with solvents were developed to provide a cellulose-type based carrier with a specific rheology to carry specialty finishes with restricted wetting properties. The restricted wetting properties allow the cellulose-type based carrier to tumble with garments using an industrial washing machine or a tumbler, thereby spreading uniformly and wetting out the garments.
Of course, the viscosity and flow characteristics of the carrier depend on the components chosen and the amount used. Additionally, it is understood that the viscosity and flow characteristics of the carrier need to be adjusted according to fiber type and weight of the garment. However, excellent results have been achieved by using a mixture of hydroxyethylcellulose (HEC) and water.
The HEC/water mixture slowly hydrates to form a gelatinous substance (HEC gel) with a viscosity of about 12,000 cps which behaves as a lubricant and has a long flow rheology. Moreover, when the HEC gel is mixed with additional water or other liquids, the HEC gel does not immediately become homogeneous. A homogeneous solution is only formed after a considerable amount of time with high shear mixing.
Therefore, the HEC gel has characteristics which are advantageous for use as a carrier in applying a finish. The HEC gel has lubricant properties, long flow characteristics, slow hydration, and low solids content. These characteristics enable the HEC gel to spread evenly and uniformly on wet garments. Additionally, these characteristic permit the use of conventional garment treatment equipment, such as an industrial washing machine or a tumbler.
Although it is understood that numerous application methods can be utilized, the following is a general method for applying finishing to garments with a cellulose-type based carrier. First, a cellulose-type based carrier is formed, such as the HEC gel discussed above, with a specialty finishing added to form a carrier/finish mixture. Second, the garments are saturated with water. Third, the carrier/finish mixture is introduced to the garments and the garments are agitated. Fourth, the garments are tumble dried with subsequent cooling thereof. Finally, the garments are pressed and cured.
The present invention has achieved a composition and a method of using the composition for applying finishing on garments which is superior to any prior art teaching. The present invention achieves an even and uniform distribution of finishing, results in all or virtually all of the finishing being accepted by the garment (i.e. no waste problem), and requires no special equipment to apply the finishing. Additionally, it is surprising to find that despite the cellulose-type based carrier used, the performance of the finish and fabric texture and feel are not adversely affected.
A further advantage of the present invention is that this composition and method is not limited to cellulose-fiber containing fabrics nor is it limited to durable press resin as a finishing. This composition and method can be used in combination with any fabric and with any specialty finishing.
DETAILED DESCRIPTION OF THE INVENTION
As discussed previously, this invention relates to improved methods for applying an even and uniform coating of a specialty finishing on garments using a cellulose-type based carrier and to a gel composition for practicing the method.
Hydroxyethylcellulose (HEC) mixed with water has been found to produce a desirable cellulose-type based carrier for specialty finishes. A carrier/finish mixture is most preferably produced by mixing between about 0.5 to 5 wt % hydroxyethylcellulose, between about 5 to 50 wt % self-catalyzed modified glyoxal reactant (durable press finish), between about 0 to 15 wt % cationic-silicone softener (optional component to improve the texture and feel of the garment), and the remainder between about 45 to 94.5 wt % being water. This mixture slowly hydrates to form a gelatinous substance (HEC gel) with a viscosity of between about 11,000 to 13,000 cps which behaves as a lubricant and has a long flow rheology. Moreover, after the HEC gel has been formed it becomes somewhat hydrophobic, such that is takes a considerable amount of mixing at high shear to add additional water or other liquids.
Therefore, the HEC gel has characteristics which are advantageous for use as a carrier in applying a finish. The HEC gel has lubricant properties, long flow characteristics, slow hydration, and low solids content. These characteristics enable the HEC gel to spread evenly and uniformly on wet garments. Additionally, these characteristics permit the use of conventional garment treatment equipment, such as an industrial washing machine or a tumbler.
As discussed above, the present invention also relates to improved methods for applying an even and uniform coating of a specialty finishing on garments using a cellulose-type based carrier. It is understood that numerous application methods can be utilized to apply the cellulose-type based carrier, however the following is a preferred method for application. First, a cellulose-type based carrier is formed, such as the HEC gel discussed above, with a specialty finishing added to form a carrier/finish mixture. Second, the garments are immersed in water within a conventional washer, then the water is extracted in order to maintain between about 50 to 70% moisture in the garments. Third, an effective amount of carrier/finish mixture is added to the garments in the washer and the washer is run without additional water for between about 5 to 25 minutes. Fourth, the garments are tumble dried between about 140° to 180° F. with subsequent cooling thereof. Fifth, the garments are pressed on a hot-head press at a sufficient temperature and for a sufficient time to configure the garments prior to curing. Lastly, the garments are cured in a curing oven at between about 290° to 330° F. for between about 5 to 25 minutes.
It is to be understood that when reference is made to a garment herein it is meant that the garment is formed from any type of fabric. Thus, this invention is not limited to a cellulose-fiber containing fabric. In addition, one can substitute any type of finishing for this method as well as any type of gelatinous material as a carrier.
It is to be understood that the present process is not limited to garments, thus, piece goods may be used in place of the garments.
The type of finishing agents used in conjunction with this process are commercially available and may be selected according to the contents of the garments and weight used in fabricating the garments.
The following example is being presented not as a limitation but to illustrate and provide a better understanding of the invention, as well as to illustrate the importance of certain steps utilized in the present process.
EXAMPLE
A cellulose-type based carrier and finish mixture was produced by mixing 1.75% hydroxyethylcellulose, 20.00% Freedom Reactant 834™ (durable press finish--Freedom Reactant 834™ is a self-catalyzed modified glyoxal reactant supplied by Freedom Textile Chemicals Co., Charlotte, N.C.), 3.00% Romene Soft SS™ (optional component to improve the garment texture and feel--Romene Soft SS™ is a cationic-silicone softener blend from Hopkins Chemical Incorporated), and 75.25% water.
Eight pounds of garments made from 71/2 oz. all cotton twill fabric were loaded into a conventional washer. The garments were rinsed in a sufficient quantity of water to completely saturate the garments for five minutes. Next, the water was extracted from the garments to leave approximately 60% moisture within the garments resulting in a garment weight after extraction of 12.8 pounds. The washer was then run without additional water for approximately two minutes to untangle the garments. Once the garments were untangled, 2 pounds of the cellulose-type based carrier and finish mixture were added to the garments in the washer and the washer was run without additional water for 15 minutes resulting in a garment weight of 14.8 pounds. It was observed that after 5 minutes the garments were approximately 95% covered and after the full 15 minutes, the garments were totally and evenly covered.
The differential between the weight of the garments before and after the addition of the cellulose-type based carrier and finish mixture was 2 pounds. This showed that all or virtually all of the cellulose-type based carrier and finish mixture was accepted by the garments with no waste.
The garments were then transferred to a conventional tumble dryer and run at 160° F. until dry and then tumbled until cool. The garments were then pressed on a hot-head press at a sufficient temperature and for a sufficient time to configure the garments prior to curing. Lastly, the garments were cured in an oven at 310° F. for 15 minutes.
The cured garments were then tested by AATCC Test Method 143-1992 for crease retention and fabric smoothness. The AATCC Test Method 143-1992 is designed for evaluating the smoothness appearance of flat fabric and seams, and the retention of pressed-in creases in garments and other textile products after repeated home laundering. The textile end product items are subjected to standard home laundering practices and evaluated using a standard lighting and viewing area by rating the appearance of specimens in comparison with appropriate reference standards.
The rating for the AATCC Test Method 143-1992 are as follows:
SA-1 Crumpled, creased and severely wrinkled appearance.
SA-2 Rumpled, obviously wrinkled appearance.
SA-3 Mussed, nonpressed appearance.
SA-3.5 Fairly smooth, but nonpressed appearance.
SA-4 Smooth, finished appearance.
SA-5 Very smooth, pressed, finished appearance.
The results on the test garments were SA-4 ratings. Additionally, fabric samples were taken from the cured garments and subjected to resin identification dyeing. This dyeing showed the resin to be fixed evenly to the fabric.
It is understood that the invention is not restricted to the detailed description of the invention, which may be modified without departure from the accompanying claims.
|
This invention relates to methods of applying finishes to garments. More particularly, this invention relates to improved methods for applying specialty finishing on the garments using a cellulose-type based carrier and to a carrier/finish composition for practicing the method which achieves a smooth and even coating of the finishing onto fabric without having to recover unused finishing and which can be accomplished using standard garment production equipment.
| 3
|
This is a continuation-in-part of U.S. Pat. application Ser. No. 493,074 filed July 30, 1974, entitled "Duplex Cut Film Holder" , now abandoned.
The present invention relates generally to a photographic film sheet holder, and more particularly to improvements for such a holder which significantly facilitate the insertion therein and removal therefrom of so-called cut film sheets.
In the use of a photographic film sheet holder, it is highly desirable that the film sheet be very easily and readily inserted in the holder preparatory to photographic exposure of the film sheet and, thereafter, that it be readily and easily removed therefrom. In typical holders, either for rigid photographically sensitized plates or flexible cut-to-size film sheets, one end of the four-sided frame which defines or bounds the film-receiving compartment is appropriately moved to a clearance position so that the plate or film sheet can be inserted into the compartment. After this positioning of the film is achieved, the temporarily removed frame member is then again moved back into holding contact with the film sheet or plate, as the case may be. Exemplifying a typical photographic plate holder as just described is the plate holder which is the subject of U.S. Pat. No. 620,373. In the contemplated method of inserting and removing the film plate or sheet using a typical prior art holder as just described, it is of course necessary that in order to provide access to the film-receiving compartment to move one of the frame members to a sufficiently remote clearance position so that there is no interference or obstacle presented to inserting the film or plate into the compartment and removing it therefrom. The cost of constructing a prior art holder is increased as well as rendered more complicated because of the requirement to allow for movement of one of the frame members between its clearance and film-holding operative positions.
Broadly, it is an object of the present invention to provide an improved holder for a cut film sheet overcoming the foregoing and other shortcomings of the prior art. Specifically, it is an object to provide a film sheet holder in which the film sheet is manually positioned therein beneath film-holding projections which bound the film-receiving compartment, and then these projections are advantageously additionally used to subsequently accurately guide the film sheet through movement which results in its complete engagement on all four sides. That is, in accordance with the present invention, the film sheet has an initial position within the holder which is readily achieved manually, and subsequently said film sheet is provided with additional movement into an appropriate operative mounted position within the frame. In this connection and most important, the movement which the film sheet partakes of to assume its mounted position is accurately controlled and achieved by using to advantage the frame structure which holds the film sheet in place within the holder during the contemplated photographic use of the holder.
A photographic film sheet holder demonstrating objects and advantages of the present invention includes a pair of opposite side frames and an end frame which cooperate with each other to define a three-sided frame housing bounding a film-receiving compartment. Positioned, as by a friction fit or the like, to each of these frames are a corresponding pair of opposite side frame inserts and an end frame insert, all of which inserts have a film-holding lip extension means thereon projected into the film-receiving compartment in a strategic location about the periphery thereof for establising holding contact with a film sheet that is inserted into the compartment. Further, each of the lip extension means on the opposite side inserts has adjacent one end a film-inserting slot of a sufficient length and size which facilitates the insertion of the film sheet through the slot into the compartment. Initially, the inserted film assumes a position in which it is slidably held beneath the length of the lip extension means which extends beyond the film-inserting slots of the side inserts. Completing the holder is a slidably disposed positioning member which is mounted in spanning relation across the open end of the three sided frame, which member is movable from a clearance position through a film sheet positioning stroke into the compartment. Accordingly, the positioning member establishes pushing contact against an end of the film sheet and urges this film sheet during the positioning stroke into a final operative position in the compartment in which the peripheral edges of the film sheet are all appropriately and properly engaged, said engagement being with the lip extension means not only on the opposite side inserts but also on the bottom insert which the end of the film sheet is advantageously positioned beneath as a result of the movement thereof during the referred to positioning stroke.
BRIEF DESCRIPTION OF THE DRAWING
In the various figures of the drawing like reference characters designate like parts. In the drawing:
FIG. 1 is a perspective view of the double cut film holder comprising the present invention with portions broken away;
FIG. 2 is a fragmentary, sectional, elevational view taken along line 2--2 of FIG. 1;
FIG. 3 is a fragmentary, sectional plan view taken along line 3--3 of the FIG. 2;
FIG. 4 is a side elevational view, partially broken away, illustrating the method of use of the present invention;
FIG. 5 is a fragmentary elevational view, in section, illustrating an alternative embodiment of the present invention;
FIG. 6 is an elevational view partially broken away and partially in section, illustrating still another alternative embodiment of the present invention; and
FIG. 7 is a fragmentary, sectional, elevational view taken along line 7--7 of FIG. 6.
METHOD OF INSERTING AND REMOVING THE CUT FILM SHEET
Before proceeding with a detailed description of the construction of a preferred embodiment of a holder according to the present invention, it is believed that it would be helpful to describe, particularly in connection with FIGS. 1-4, the contemplated method in which a film sheet 34 is inserted and removed from the holder 10. It is this insertion and removal, in a significantly faciliated manner, which constitutes the essence of the within invention. In this connection, and as will be described in detail subsequently, holder 10 is constructed to include, at least in part, a four sided frame, which bounds a centrally located film-receiving compartment 11. Three of these frame members, namely side frames 12 and 14, and end frame 26, function primarily as mountings for inserts 40, 42 and 18 which, in turn, have appropriate structural features for engaging with the peripheral edges of the cut film sheet 34 which is inserted in the compartment 11. The fourth frame member 16 primarily serves as a mounting for pins 62 of a slidably disposed member 64 which is movable between a clearance position and an operative position with respect to the film-receiving compartment 11. The effect of these positions will soon become apparent.
As is perhaps best shown in FIG. 3, the insert 42 for frame 12 and the insert 40 for frame 14, each has a central groove 44 or a centrally disposed partition plate 30 and, more important each said insert has a lip 48 therealong which extends into the film-receiving compartment 11. It is the overhang of these lip extensions 48 along the peripheral edges of the film sheet which effectively hold the same in place during use of the holder 10.
The lip extensions 72 of the insert 18 for the frame 26 can be more readily seen in FIG. 1, to which figure reference should be made. Also, as clearly shown in this figure, bottom portions of the lip extensions 48 of the inserts 40 and 42, namely the ends thereof adjacent to the frame member 26, are removed to provide insert openings 47 into the film-receiving compartment for the cut film sheet. Thus, as clearly shown in FIG. 4, the cut film sheet 34 is readily inserted through the insert slots 47 into the film-receiving compartment 11 so that the side edges of the film sheet are strategically located beneath lip extensions 48 which extend forwardly of the film-inserting slots 47. During insertion of the film sheet 34, it will be understood that the pins 60 are in their retracted position and that therefore member 64 is also in its fully retracted position, all as is clearly shown in FIG. 4. It is contemplated that film sheet 34 be inserted to the fullest extent possible beneath the side lip extensions 48 which, of course, would be when the film end 35 abuts against the transversely oriented member 64. Once this is achieved, pins 60 are then depressed which has the desired result of urging the member 64 through movement from right to left as viewed in FIG. 4, which movement may properly be characterized as a film sheet positioning stroke 61 in that it effectively moves the opposite end of the film sheet, namely that designated 37, into a desirable position in which it is projected beneath the overhanging lip extension 72 of insert 17. During this positioning stroke, it should be noted that the side lip extensions 48 are advantageously used as movement-guiding means for the film sheet to insure that the film end 37 moves properly beneath the end lip extension 72. In this way, the film sheet 34 readily assumes an operative position within the holder 10 in which all four peripheral edges are properly engaged or confined against movement.
After photographic exposure of the film sheet 34, the removal thereof from the holder 10 is also achieved in a simple faciliated manner. From the description already provided, it should be readily understood that the removal procedure is essentially the reverse of the procedure used for inserting the film. More particularly, the pins 60 are withdrawn thereby correspondingly withdrawing or retracting the member 64. Film sheet 34 is then readily manually removed from left to right, as viewed in FIG. 4, which has the effect of moving the film end 37 into an area coextensive with the slots 47. In this accessible position, the user can readily grasp the film end 37 and then complete the removal of the film sheet 34 from the beneath the side lip extensions 48.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now particularly to FIGS. 1 and 2. It will be seen that the double cut film holder 10 comprising the present invention includes right and left-hand side rails 12 and 14 which are identical to each other and of which only one will be described in the interest of brevity. There are also provided an upper transverse end rail 16 as well as a lower transverse end rail 26. Upper, front and rear retaining plates 20 and 22 are used to secure the upper end rail 16 and the two side rails 12 and 14 by means of any suitable fasteners such as indicated by the reference characters 24. The lower end rail 26 is secured to the side rails 12 and 14 by any appropriate means. Also shown in FIG. 1 is the opaque central partition plate 30, the front and rear sheets of cut film 32 and 34, respectively, as well as the front and rear dark slides 36 and 38, respectively.
The construction of the duplex cut film holder 10 comprising the present invention will now be described in further detail in conjunction with FIG. 2 and with FIG. 3. Turning first to FIG. 3 it will be seen that the side rail 12 is provided with a centralized, vertically extending friction fitting insert or inner guide rail 42. A first central groove 44 of relatively narrow width is framed along the length of the inner guide rail 42 in order to accept the vertical side edges of the central partition plate 30. A second, wider groove 46, which defines the previously noted lip extensions into the compartment 11 or inner and outer legs 48 and 50, is also formed in the inner guide rail 42 so that the side edge of the cut film sheets 32 and 34 may be positioned between the legs 48 and the central partition plate 30 and the legs 50 and the central partition 30, respectively.
It should be noted at this time that the inner side rails 42 may be formed integrally with their respective outer side rails 12 and 14. If this alternative construction is followed then of course the grooves 40 could be eliminated but the grooves 44 and the legs 48 and 50 would still be necessary in order to receive the central partition plate 30 and to define recesses for accepting the sheets of cut film 32 and 34. It will also be noted in FIG. 3 that a second groove 52 is formed in the outer side rail 12 in order to define, in cooperation with the legs 48 and 50 of the inner guide rail 42, a pair of inner and outer channels for receiving the dark slides 36 and 38.
Referring now to FIG. 2 it will be seen that the upper end rail 16 is provided with an inverted, generally U-shaped or V-shaped light trap which includes a transverse, resilient spring-like member 54 that is covered with a black cloth 56. The light trap may be secured to the underside of the upper end rail 16 in any suitable manner. The upper end rail 16 is also provided with two vertically extending bores 58 that are arranged to slidably receive vertically oriented pins 60 and 62. A vertically displaceable, transversely oriented film clamp member 64 is secured to the lower end of each of the pins 60 and 62 for movement together therewith. As shown for example in FIG. 2, the inner edge of the clamp member 64 is provided with a transverse groove or channel 66 for receiving the upper transverse end of the central partition plate 30 and the two sheets of cut film 32 and 34. As shown best in FIG. 2 the light trap 54, 56 effectively seals the space or recess formed between the front and rear dark slides 36 and 38, respectively, and the inner and outer surfaces of the transverse clamp member 64.
As also shown in FIG. 2, the lower, transverse end rail 26 is also provided with an insert 18 having a first central groove 68 that extends transversely. That is, the groove 68 extends between the side rails 12 and 14 of the film holder 10 in order to receive the lower transverse edge of the central partition plate 30. A second transverse groove 70 is also formed in the lower guide rail 18 in order to define transversely extending front and rear lip extensions or legs 72 and 74 whereby the lower edge of the cut film sheets 32 and 34 may be positioned, respectively, between the leg 72 and the central partition plate 30 and the leg 74 and the central partition plate 30. The lower edge of the dark slides 36 and 38 are received, respectively, in the spaces defined by the outer and inner surfaces of the lower end rail insert 18 and the respective, oppositely facing, opposed surfaces of the U-shaped channel member 26.
At this time it should be noted that recesses 76 and 78 are formed respectively, on the front and rear surfaces of the central partition plate 30 proximate the lower end thereof. It should also be noted at this time that the legs 48 and 50 of the inner guide rail 42 terminate at a location that is spaced upwardly of the lower end rail 18 to provide the previously noted slots 47 communicating with the film-receiving compartment 11. The purpose for this construction will now be described in connection with FIG. 4.
The sheets or cut film 32 and 34 are unloaded from the holder 10 by pulling the pins 60 and 62 in an upward direction such as shown in FIG. 1 or to the right as shown in FIG. 4. The pins 60 and 62 slide loosely within the bores 58 formed in the upper end rail 16 and thereby pull the film clamp member 64 in the same direction. When the pins 60 and 62 are pulled as just described, the base of the transverse, film engaging groove 66 will then be displaced from the upper edge of the central partition plate 30 as well as the upper edges of the cut sheets of film 32 and 34. With the dark slides 36 and 38 drawn out in the usual manner the cut sheets of film may then be moved upwardly (FIG. 1) or to the right (FIG. 4) so that they once again abut the base of the groove 64 in the clamp member 64. The lower edge of the cut film 32 and 34 may then be grasped as shown in FIG. 4 and lifted out. To facilitate the grasping operation, the recesses 76 and 78 are formed in the central partition plate 30. To further facilitate this operation the legs 48 and 50 of the inner guide rails 42 terminate at a location spaced upwardly from the lower guide rail 18, as described above and as shown for example in FIG. 4.
The loading of the film uses just the reverse sequence of operation. That is, the pins 60 and 62 are initially in their outward or upper position and the dark slides are either completely removed or in their outward positions. The cut sheets of film 32 and 34 may then be deposited on the opposing surfaces of the central partition plate 30 and oriented in the channels defined by the legs 48 and 50 of the inner guide rails 42 and the opposed surfaces of the central partition plate 30. The pins 60 and 62 are then moved downwardly (FIG. 1) or inwardly (FIG. 4) and the dark slides are inserted in their usual manner.
An alternative embodiment designated by the reference character 10' is shown in FIG. 5. Where the components of the FIG. 5 embodiment are the same as the embodiment shown in FIGS. 1-4, primed reference characters will be used. The basic difference between the first and second embodiments resides in the construction of the displaceable film clamp member. Whereas in the first embodiment shown in FIGS. 1-4 a single film clamp member 64 was used for both sheets of cut film 32 and 34, the embodiment shown in FIG. 5 utilizes separate front and rear film clamp members 80 and 82. The pin 60' is secured to the front film clamp member 80 while the pin 62' is secured to the rear film clamp member 82. In the embodiment shown in FIG. 5 the pins 60' and 62' are manipulated separately in order to load and unload the cut sheets of film 32' and 34' whereas in the first described embodiment of FIGS. 1-4 both pins 60 and 62 are moved simultaneously.
All other constructional features of the embodiment shown in FIG. 5 are the same as that shown and described in connection with the embodiment of FIGS. 1-4.
Another alternative embodiment of the present invention is illustrated in FIGS. 6 and 7. Whereas in the first and second described embodiments the displaceable film clamp member was located at the top end of the cut film holder either 10 or 10' in the embodiment shown in FIG. 6 and in FIG. 7 a lower film clamp member, generally, designated by the reference character 84 is employed. The lower film clamp member 84 is comprised of a transversely positioned film clamp bar 86 along the upper, transverse edge of which is formed a central groove 87 for receiving the central partition plate 30'. Front and rear legs 88 and 90 are also formed in the upper transverse edge of the film clamp member 86 in a spaced parallel relationship to the central groove 87 in order to receive the front and rear sheets of cut films 32' and 34', respectively. Positioned intermediate the lower transverse surface of the film clamp bar 86 and the upper, opposed surface of the lower end rail 18' is a bowed, leaf spring 92 that normally urges the bar 86 in an upward direction, to a first position. In order to utilize the embodiment shown in FIG. 6 and in FIG. 7, the dark slides 36' and 38' are moved upwardly and the film clamp bar 86 is moved downwardly against the force of the bowed leaf spring 92. This action frees the lower transverse edge of the sheets of cut film 32 and 34 so that they may be lifted out in the manner described hereinabove. The loading operation of this last mentioned embodiment is just the opposite of the unloading operation which was just described.
From the foregoing description and from the drawing it will be evident that an improved double cut film holder has been provided which contributes to greatly facilitated loading and unloading of the cut film 32, 34. This is achieved by providing the film with an initial easily manually achieved position, wherein it is inserted against the retracted member 64, and then using the closing movement 61 of this member into the compartment 11 to complete the positioning of the film, wherein it is inserted beneath the bottom lips or legs 72, 74. As already noted, during this insertion, the side lips or legs 48, 50 properly guide the film so that it cannot fail to be projected beneath the legs 48, 50.
There has been disclosed heretofore the best embodiment of the invention presently contemplated. However, it is to be understood that various changes and modifications may be made thereto without departing from the spirit of the invention. three-sided film-holding
|
A holder for so-called cut photographic film sheets into which the inserted film sheet is provided with an initial position that is readily manually achieved. Specifically, the sides of the film sheet during insertion are advantageously located beneath the overhang of lip structures which project from opposite sides into the film-receiving compartment of the holder. Thereafter, the frame of the holder is closed about the film sheet and, in the process, the film sheet assumes a final mounted position in the holder in which all four peripheral edges thereof are properly confined against movement.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to European Application 12194042.3 filed Nov. 23, 2012, the contents of which are hereby incorporated in it entirety.
FIELD
[0002] The invention is related to a boiler, typically a circulating fluidized bed boiler (CFB), which comprises a fluidized bed heat exchanger. Circulating fluidized bed boilers include a reactor where the solid particles are fluidized and where chemical reactions and/or combustion reactions can take place. The circulating fluidized regime enhances the mixing of particles along with potential exothermic or endothermic chemical reactions.
[0003] The operating principle of a fluidized bed heat exchanger is relatively simple: hot solids are brought into a chamber, in which they are fluidized with air or re-circulated flue gas as a slowly bubbling fluidized bed. Heat exchanger elements, often in the form of tube coils following a boustrophedon path, are located inside this fluidized bed and are fed with a coolant fluid.
[0004] The tube coils have to be maintained by supports. It is known to use a sliding connection with supports allowing differential movements between the tubes and the supports. The drawback of this sliding connection is that gaps and wearing associated therewith may occur.
[0005] It is also known to use shims. However, this solution requires high construction skills to install all the different parts of the fluidized bed heat exchanger without gaps along with the difficulty to assess the good execution of the work afterwards.
SUMMARY
[0006] Thus, an object of the present invention is to provide a boiler having a fluidized bed heat exchanger as to solve the above-described problems.
[0007] The object mentioned above is accomplished by a boiler comprising a fluidized bed heat exchanger, the heat exchanger including a plurality of tubes forming a tube bundle, each tube following a vertical boustrophedon path, the tubes being supported by at least two vertical supporting devices, typically at least two separate vertical supporting devices, placed on both sides of the tube bundle.
[0008] In the boiler of the invention, every vertical supporting device comprises at least two vertical supports for fixing the tubes, typically at least two separate vertical supports.
[0009] Thus, the fixation of the tubes on the vertical supports prevents local vibrations and possible abrasions resulting therefrom. Using at least two supports by device makes it possible to split the amount of efforts.
[0010] The boustrophedon path of each tube can comprise horizontal portions, two consecutive horizontal portions being linked together by a vertical portion thus forming a bend between the horizontal portions.
[0011] One supporting device can be located on the left side of the tube bundle and one supporting device can be located on the right side of the tube bundle.
[0012] The vertical supports can be vertical tubes.
[0013] The tubes forming the vertical supports can be cooled or uncooled.
[0014] For at least one supporting device, at least one horizontal portion—preferably each horizontal portion—of each tube of the heat exchanger is preferably fixed to only one vertical support of the supporting device.
[0015] For each supporting device, at least one horizontal portion—preferably each horizontal portion—of each tube of the heat exchanger is preferably fixed to only one vertical support of the supporting device.
[0016] For at least one supporting device, two consecutive horizontal portions of at least one tube—preferably each tube—of the heat exchanger are preferably not fixed to the same vertical support of the supporting device.
[0017] For each supporting device, two consecutive horizontal portions of at least one tube—preferably each tube—of the heat exchanger are preferably not fixed to the same vertical support of the supporting device.
[0018] For each supporting device, each tube of the heat exchanger is preferably fixed to only one vertical support of the supporting device and, for each supporting device, two consecutive horizontal portions of each tube of the heat exchanger are preferably not fixed to the same vertical support of the supporting device.
[0019] The boiler can comprise a furnace in which combustion of solid particles is sustained and the fluidized bed heat exchanger can be placed outside the furnace.
BRIEF DESCRIPTION OF DRAWINGS
[0020] Other features and advantages of the invention will become apparent from the following description of an embodiment of the invention given by way of a non-limiting example only, and with reference to the accompanying drawings, in which:
[0021] FIG. 1 is a diagram of a boiler according to the invention with a furnace, a separator member and an external dense fluidized bed,
[0022] FIGS. 2 through 4 are perspective views of a heat exchanger of the external dense fluidized bed,
[0023] FIGS. 5 and 6 show fixations of the tubes of the heat exchanger,
[0024] FIGS. 7 to 10 show different fixation embodiments of the tubes of the heat exchanger.
DETAILED DESCRIPTION
[0025] FIG. 1 illustrates a boiler that includes a furnace 1 in which combustion of solid particles is sustained. The top of the furnace 1 is connected to a separator member 2 via an extraction duct 12 which conveys the flue gases and the recycled particles.
[0026] The separator member 2 , e.g. a cyclone, delivers the gas to a flue duct 20 leading off from its top, and it delivers the particles to a recycling duct 23 which leads into an external dense fluidized bed 3 that is placed outside the furnace 1 . The recycling duct 23 is generally provided with a siphon and with lagging. The external bed 3 is provided with a first heat exchanger 3 A, and which, in this example, is in the form of a nest of tubes that zigzag in vertical planes, following a boustrophedon path, so that the long tube segments are preferably horizontal. The first heat exchanger 3 A is fed with a coolant fluid, e.g. water, via an inlet 39 .
[0027] The outlet 30 of the heat exchanger 3 A can be connected to a second heat exchanger 3 B which can be located in the furnace 1 .
[0028] The remainder of the description is dedicated to the support of the heat exchanger 3 A. It is to be noted that the invention is not limited to external fluidized bed heat exchangers but can also be used with other fluidized bed heat exchangers.
[0029] As illustrated in FIG. 2 , and in FIG. 3 in a perspective view, the heat exchanger 3 A includes a plurality of tubes 7 (four tubes in this example) zigzagging in a vertical plane. The tubes 7 can be of a square or circular cross-section. The serpentine tubes 7 follow each a boustrophedon path. Boustrophedon is a kind of bi-directional text, mostly seen in ancient manuscripts and other inscriptions. Every other line of writing is flipped or reversed, with reversed letters. Rather than going left-to-right as in modern English, or right-to-left as in Arabic and Hebrew, alternate lines in boustrophedon must be read in opposite directions. The name “boustrophedon” is taken from the Greek language. Its etymology is from bous, “ox” and strephein, “to turn”, because the hand of the writer goes back and forth like an ox drawing a plough across a field and turning at the end of each row to return in the opposite direction (i.e., “as the ox ploughs”). In this way, the tubes path goes alternately from right to left and from left to right.
[0030] Two or more distinct supporting devices 41 , 42 separated by an empty space realize the support of the fluidized bed heat exchangers bundle tubes. One device 41 is located on the left side of the exchanger and the other device 42 is located on the right side of the exchanger. Each device 41 , 42 comprises at least two vertical supports 411 , 412 ; 421 , 422 separated by an empty space and which are two close hanger tubes along with alternately welded interference clamps supports, which position can be adapted according to mechanical calculation results. The hanger tubes 411 , 412 ; 421 , 422 may be cooled, as is the case in the High Temperature Superheater (HTS) bundles. Alternatively, the hanger tubes 411 , 412 ; 421 , 422 may be uncooled, as is the case in the Intermediate Temperature Superheater (ITS) bundles.
[0031] FIG. 4 illustrates the fixation points 6 between the tubes 7 and the vertical tubes 411 , 412 , 421 , 422 .
[0032] As illustrated in FIG. 5 , the fixations 6 of the tubes 7 being represented by circles, for each supporting device 41 , 42 , each horizontal portion of each exchanger tube 7 is preferably fixed to only one vertical tube of the supporting device 41 , 42 . This allows to decrease the bending stresses in the exchanger. Also for a decreasing of the bending stresses, as illustrated in FIG. 6 , for each supporting device 41 , 42 , two consecutive horizontal portions of a tube 7 (i.e. an horizontal portion of the tube placed before one bend of the boustrophedon path and the horizontal portion placed after the bend) are preferably not fixed to the same vertical tube.
[0033] A first fixation embodiment which is consistent with these preferred conditions is shown on FIG. 7 . On the left side, the first supporting device 41 comprises two vertical supports 411 , 412 , i.e. one left support 411 and one right support 412 . In the same manner, on the right side, the second supporting device 42 comprises two vertical supports 421 , 422 , i.e. one left support 421 and one right support 422 . The tube bundle comprises five tubes 71 to 75 . The tubes 71 , 72 , 73 , 74 , 75 follow a boustrophedon path including four bends A,B,C,D. Naturally, the number of tubes and the number of bends are given by way of example, and a person skilled in the art can choose a different number of tubes and bends.
[0034] If one considers tube 71 (i.e. a tube numbered N), this tube 71 is connected before the bend A to the right support 412 of the first supporting device 41 and after the bend A to the left support 411 of the first supporting device 41 . After the bend A, the tube 71 is then connected before the bend B to the left support 421 of the second supporting device 42 and after the bend B to the right support 422 of the second supporting device 42 . The same connection mode is then repeated: the tube 71 is connected before the bend C to the right support 412 of the first supporting device 41 and after the bend C to the left support 411 of the first supporting device 41 . The tube 71 is then connected before the bend D to the left support 421 of the second supporting device 42 and after the bend D to the right support 422 of the second supporting device 42 .
[0035] The tubes 73 and 75 (i.e. tubes numbered N+ 2 ) are connected in the same way as for the tube 71 (a tube numbered N).
[0036] According to this first embodiment, the tubes 72 and 74 (i.e. tubes numbered N+1) are connected in the opposite way, i.e. a connection of a tube N to the right support 412 of the first supporting device 41 is replaced for a tube N+1 by a connection to the left support 411 of the first supporting device 41 and vice versa. In the same manner, a connection of a tube N to the right support 422 of the second supporting device 42 is replaced for a tube N+1 by a connection to the left support 421 of the second supporting device 41 and vice versa.
[0037] A second embodiment is shown on FIG. 8 . According to this embodiment, all the tubes 71 to 75 are connected before the bend A to the right support 412 of the first supporting device 41 . Thus, all the tubes 71 to 75 are connected after the bend A to the left support 411 of the first supporting device 41 . In the same manner, all the tubes 71 to 75 are connected before the bend B and after the bend A to the right support 422 of the second supporting device 42 . Thus, all the tubes 71 to 75 are connected after the bend B to the left support 421 of the second supporting device 42 .
[0038] FIGS. 9 and 10 show a third and a fourth embodiment, respectively. Thus, one skilled in the art is taught that various configurations can be carried out. These configurations are consistent with the two conditions illustrated in FIGS. 5 and 6 , i.e. 1) for at least one supporting device, and preferably for both supporting devices, each horizontal portion of an exchanger tube is fixed to only one vertical tube of the supporting device, and 2) for each supporting device, and preferably for both supporting devices, two consecutive horizontal portions of an exchanger tube (i.e. an horizontal portion of the tube placed before one bend of the boustrophedon path and the horizontal portion placed after the bend) are fixed to a different vertical tube of the supporting device.
|
The invention relates to a fluidized bed heat exchanger. The heat exchanger includes a plurality of tubes forming a tube bundle. Each tube follows a vertical boustrophedon path. The tubes are supported by at least two vertical supporting devices placed on both sides of the tube bundle. Every vertical supporting device includes at least two vertical supports for fixing the tubes.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates generally to agricultural implements and, more particularly, to an apparatus for recollecting residual commodity from a fill hopper of an air seeder filling system.
An air seeder is an agricultural implement that is commonly used to plant usually a seed crop in a large field. Air seeders typically have centrally located hoppers for seed and fertilizer which distributes them through an air stream to individual seed rows. It is convenient to fill, easy to clean out and move. Any crop that can be grown from seeds—which might vary is size from oilseeds to corn, can be sewn by an air seeder.
The seed and fertilizer hoppers are usually carried on a large cart located behind or in front of the seeder. The air stream is created by a high capacity fan mounted on the cart which blows air through pipes located under the grain and fertilizer tank. Seed and fertilizer are metered out from the hoppers by a meter wheel that is turning in a ratio set by the operator for the proper seed rate or seed density. The seeds enter the pipe in the airstream and follow the pipes which terminate in the seedbed. Openers pulled through the soil make the opening where the seeds are placed. They are made of steel in the shape of points, discs or cultivator shovels. Once placed in the seed bed, the air is blown out the opening in the soil and the seed and fertilizer remain. The seeder can then pack the soil tight to retain moisture near the seed and harrow the furrows so the field is not rough.
A typical air seeder has an agricultural commodity cart (“air cart”) comprising at least one, and commonly two, three or more tanks for carrying various agricultural products like seed and fertilizer. Although not always present, commonly there is a conveyor mounted on the cart for transferring agricultural product (“commodity”) from transport vehicles into the tanks. It is commonly seen as more convenient to mount a conveyor on the cart rather than on each transport vehicle, or maneuver a portable conveyor as a separate implement altogether.
The conveyor is typically mounted on a pivot mechanism configured to allow it to be moved from a transport position, where the bottom end of the conveyor is raised for transport, to an operating position where the bottom end is lowered to receive a commodity from the transport vehicle, and is typically resting on the ground. The pivot mechanism also allows the conveyor to be maneuvered so that a spout on the upper discharge end of the conveyor can be maneuvered to direct the commodity from the conveyor into the filling hatch for each tank. Cart loading conveyors commonly include a hopper at the bottom intake end to receive agricultural product from the transport vehicle. Conventional cart conveyors typically comprise simply a straight tube with an auger inside to convey the product, and the hopper is simply mounted on the lower end.
It is generally desirable to clean out the hopper when changing from one agricultural product to another in order to minimize contamination of the tanks with different agricultural products. On conventional cart conveyors, it is often possible to simply rotate the hopper on the conveyor tube such that the hopper is oriented downward. The auger can then be rotated in reverse so that material in the tube falls out of the lower end of the tube and into the inverted hopper and onto the ground. Other approaches include a hopper constructed with a cleanout port in the bottom of the hopper so that the auger can be reversed and the majority of material will fall out the cleanout port onto the ground. Some manual pushing of material is typically required to completely clean out the hopper.
These conventional approaches to emptying the fill hopper are generally effective in removing the residual commodity, these approaches are wasteful in that the residual product is simply casted onto the ground. To avoid this waste, many end-users will place a pail or similar collector on the ground and raise the fill hopper above the pail. To empty to the residual commodity into the pail, the fill hopper must be reoriented, i.e., tilted, so that the residual commodity runs out of the fill hopper and into the pail. This tilting of the fill hopper can be laborious and awkward as the fill hopper is generally heavy and bulky and, thus, difficult to maneuver. And, depending on the amount of residual commodity in the fill hopper, repositioning the fill hopper can be particularly cumbersome. Similarly, the pail, which is commonly a larger container, i.e., 20 L, can also be difficult to maneuver.
SUMMARY OF THE INVENTION
The present invention is directed to a fill hopper for an air seeder conveyor. The fill hopper is configured such that a pail can be removably mounted to the fill hopper. The pail mounts to the fill hopper so that when the fill hopper is raised and rotated, the pail will move with the fill hopper.
A number of different mounting structures may be used to removably mount the pail to the hopper. In one embodiment, the hopper has hooks that enable the bail of the pail to be hung on the hopper. The hooks are positioned such that the pail is substantially horizontal, i.e., parallel to the base of the hopper, when the hopper is in the being-filled (“operating”) position. The hooks are positioned so that the pail sits tightly against the sidewall of the hopper when the hopper is in the operating position. When the hopper is rotated to an upright position, the pail remains hooked to the hopper and thus rotated from the horizontal position referenced above to a vertical or upright position. In this position, the residual commodity from the hopper will empty into the pail. After the fill hopper is empty, slack between the pail and fill hopper can be introduced by lowering the conveyor slightly and unhooking the bail from the hopper. The pail can then be emptied in a commodity saving fashion and reconnected to the fill hopper or a new pail could be hooked onto the fill hopper.
Therefore, in accordance with one aspect of the invention, a hopper of a commodity conveyor apparatus for use with an agricultural implement is provided. The hopper has a bin configured to hold a volume of a granular commodity. The bin is movable between a first position at which the bin can be loaded with the granular commodity and a second position at which residual granular commodity can be recovered from the bin. The hopper further has a fill opening formed in the bin and adapted for loading the granular commodity into the bin when the bin is in the first position. A discharge opening is configured to be flow-coupled to the commodity conveyor apparatus and a pail is removably attached to the bin for recovering the residual granular commodity from the bin when the bin is in the second position.
In accordance with another aspect of the invention, a commodity conveying apparatus for use with an air seeding implement is provided. The apparatus comprises a conveyor having an intake end for receiving a granular commodity and a discharge end for passing the granular commodity into a seed hopper of the air seeding implement. A feed hopper is pivotally attached to the discharge end of the conveyor, and is pivotal between a commodity conveying position and a commodity recapture position that is upright relative to the commodity conveying position. The apparatus further comprises a bucket having a handle and a catch that captures the handle for removably attaching the bucket to the feed hopper. The catch maintains attachment of the bucket to the feed hopper when the feed hopper is pivoted from the conveying position to the recapture position.
The invention may also be embodied in a method. The method is directed to recapturing residual granular commodity from a feed hopper of a conveying apparatus of an air seeding implement, and comprises attaching a pail to the feed hopper. The pail has an annular wall extending between an open top and a closed bottom surface collectively defining an annular interior. The method also includes tilting the feed hopper to an inclined position in which the closed bottom surface of the pail rests atop the ground and residual granular commodity in the feed hopper falls through the open top of the pail and into the annular interior of the pail.
Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.
In the Drawings:
FIG. 1 is an isometric view of an air cart having a cart mounted conveyor apparatus in the transport position;
FIG. 2 is an isometric view of the air car with the cart mounted conveyor apparatus in the loading position;
FIG. 3 is an enlarged view of a free end of the conveyor apparatus showing a fill hopper with a pail removably attached thereto according to the present invention;
FIG. 3A is a partial exploded view of the fill hopper taken along line 3 A- 3 A of FIG. 3 ;
FIG. 4 is a top plan view of the fill hopper;
FIG. 5 is a side elevation view of the fill hopper in an operating position;
FIG. 6 is a side elevation view of the conveyor apparatus with fill hopper rotated to an upright position to place the hopper-mounted pail atop the ground; and
FIG. 7 is a side elevation view of the conveyor apparatus with the fill hopper further rotated to empty residual commodity into the pail.
DETAILED DESCRIPTION
FIGS. 1-2 illustrate a commodity cart loading conveyor apparatus 10 having a commodity cart 12 comprising a tank 14 . In the illustrated example, the cart 12 has three tanks 14 . It is understood however the cart 12 could have fewer than three tanks or more than three tanks. Each tank 14 has a fill hatch 16 located at a top portion of the cart 12 . The cart 12 is typically attached to a seeding tool bar (not illustrated) that is operative to receive the agricultural commodities, e.g., seed and/or fertilizer, carried in the tank 14 through a system of air ducts, and deposit the material in the soil. Such carts are typically pulled either directly behind or sometimes directly ahead of such a tool bar.
The cart loading conveyor apparatus 10 has an auger 18 inside a conveyor tube 20 . As known in the art, the conveyor tube 20 provides an elongate enclosure through which commodity can be conveyed from a fill hopper 22 to the fill hatch 16 .
The conveyor tube 20 is mounted to the cart 12 such that the conveyor tube 20 can be moved from a transport position, shown in FIG. 1 , to a filling position, shown in FIG. 2 . In the transport position, the conveyor tube 20 is raised off the ground 24 . In the filling position, the conveyor tube 20 is rotated outward and downward so that fill hopper 22 sits atop the ground 24 . When the fill hopper 22 is sitting on the ground 24 , commodity can be loaded into the fill hopper 22 from a transport vehicle (not shown). In the transport position, the conveyor tube 20 extends generally rearward with the fill hopper 22 raised above the ground 24 . In the filling position, the upper (discharge) end 26 of the conveyor tube 20 is centered slightly above a fill hatch 16 . In a preferred embodiment, the upper end 26 of the conveyor tube 20 includes a chute 28 that extends generally downward into the opening defined by the fill hatch 16 . The conveyor tube 20 can be moved fore and aft to align the chute 28 with the fill hatch 16 of the tank 14 to be filled.
With additional reference to FIGS. 3 and 3A , the fill hopper 22 is pivotally attached to the lower end 30 of the conveyor tube 20 . An actuator 32 is interconnected between the lower end 30 of the conveyor tube 20 and the fill hopper 22 , and is operable to pivot the fill hopper 22 away from the conveyor tube 20 , as will be described more fully below, during emptying of the fill hopper 22 .
With additional reference to FIGS. 4 and 5 , a container, which in the illustrated embodiment is a pail 34 , is removably attached to the fill hopper 22 by a pair of hooks 36 , 38 . The pail 34 has a cylindrical container 40 defined by an annular wall 42 extending from a disc-shaped base 44 to an open end 46 . Near the open end 46 of the cylindrical container 40 is attached a bail 48 . The bail 48 is attached to the cylindrical container 40 in a conventional manner and thus is movable between a lowered position in which the bail 48 rests against the outer surface of the annular wall 42 or a raised position in which the bail 48 is centered above the open end 46 , such as for carrying. The pail 34 can be mounted to the fill hopper 22 by hanging the bail 48 on the pair of hooks 36 , 38 .
The fill hopper 22 is comprised of a bin 50 defined by a pair of sidewalls 52 , 54 , front wall 56 , and rear wall 58 . The walls are interconnected to form an inverted tetrahedron shaped cavity 60 . An auger 62 is rotatably mounted to the front wall 56 within the cavity 60 is operable to feed commodity from the bin 50 to the auger 18 in the conveyor tube 20 . It is desirable that the intake for a conveyor be screened to sieve the commodity and prevent entry into the cart 12 of lumps or foreign objects that could plug the tubes that carry the commodity. Accordingly, a sieve screen or grate 64 is attached to the upper end of the bin 50 .
Mounted just below the sieve screen 64 is a plate 66 to which the hooks 36 , 38 are mounted. Each hook has a shank 68 that extends uprightly from the plate 66 to a bend 70 that turns downward to form a catch 72 . A gape 74 is defined between the catch 72 and the shank 68 , and is sized to receive the bail 48 when the pail 34 is hung on the fill hopper 22 . The hooks extend through a respective space (not numbered) in the sieve screen 64 . Additionally, the hooks 36 , 38 are mounted to the plate 66 so that the distance therebetween results in the pail 34 being held snuggly against the front wall 56 of the bin 50 when the pail 34 is hooked onto the fill hopper 22 , as best shown in FIG. 5 . As further shown in FIG. 5 , when the fill hopper 22 is in the filling position, e.g., the sieve screen 64 parallel to the ground 24 , the pail 34 is also oriented parallel to the ground 24 . That is, the open end 46 and the base 44 of the pail 34 are perpendicular to the ground 24 .
The pail 34 latches tightly onto the bin 50 which holds the relative position of the pail 34 to the fill hopper 22 when the fill hopper 22 is rotated from the filling position shown in FIG. 5 to the upright position shown in FIG. 6 . The fill hopper 22 is rotated relative to the conveyor tube 20 by actuator 32 , which in one embodiment is a hydraulic acutator comprised of a hydraulic cylinder 76 and a ram 78 . The ram 78 is connected to a linkage 80 that is connected to rear wall 58 . The linkage 80 includes an inner arm 82 that is connected to the ram 78 and an outer arm 84 that is connected to the rear wall 58 . The inner arm 82 is connected to the outer arm 84 by a pivot pin 86 . Thus, as the ram 78 is extended, the outer arm 84 rotates downward (clockwise in the figure), which causes the bin 50 to be roated to a generally downward position. It will be appreicated that the conveyor tube 20 must be raised slightly to lift the fill hopper 22 off the ground 24 so that there is ample room between the fill hopper 22 and the ground 24 for the fill hopper 22 to rotate downward to vertically orient the fill hopper 22 .
As also shown in FIG. 6 , when the fill hopper 22 is rotated to the upright position, the base 44 of the pail 34 is parallel to the ground 24 and thus conveyor tube 20 can be lowered so that the pail 34 sits on the ground 24 . In this position, the open end 46 of the pail 34 is effectively below the front wall 56 (lower wall in FIG. 6 ) of the bin 50 , which allows residual commodity in the fill hopper 22 to flow by gravity and/or counter-rotation of auger 62 into the pail 34 .
Turning now to FIG. 7 , it is contemplated that the fill hopper 22 could be rotated further, which results in the fill hopper 22 being in an over-rotated or past-upright position but the pail 34 still securely seated on the ground 24 . Permitting limited over-rotation of the fill hopper 22 may improve the capture of residual commodity from the fill hopper 22 by enabling any residual commodity that is sitting against the front wall 56 of the bin 50 to be gravitationally fed into the pail 34 .
After the fill hopper 22 is emptied, the conveyor tube 20 may be lowered slightly so that the otherwise snug fit between the bail 48 and the hooks 36 , 38 can be released. This allows a user to remove the bail 48 from engagement with the hooks 36 , 38 and unhook the pail 34 from the fill hopper 22 . The pail 34 can then be emptied and then hooked again to the fill hopper 22 or a new pail could be hooked to the fill hopper 22 .
While the present invention has been described with respect to hooks for facilitating the temporary attachment of the pail to the fill hopper, it is understood that other types of latching structures could be used.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
|
A hopper of a commodity conveyor apparatus for use with an agricultural implement has a bin configured to hold a volume of a granular commodity. The bin is movable between a first position at which the bin can be loaded with the granular commodity and a second position at which residual granular commodity can be recovered from the bin. The hopper further has a fill opening formed in the bin and adapted for loading the granular commodity into the bin when the bin is in the first position. A discharge opening is configured to be flow-coupled to the commodity conveyor apparatus and a container is removably attached to the bin for recovering the residual granular commodity from the bin when the bin is in the second position.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of devices which protect an athlete's teeth while the athlete is engaged in a sporting activity such as playing football.
2. Description of the Prior Art
In general, there are many devices known in the prior art which are used to protect an athlete or a person while the athlete or person is engaged in a sporting activity. In one sporting activity such as football, the person engaged in playing football wears many protective devices to protect various body parts of the person such as shoulder pads, leg guards, and a helmet which has bars in front to protect the person's face during physical contact while playing football.
One of the most sensitive parts of a person's body are the person's teeth. There frequently are violent collisions between persons engaged in the game of football, such as a running back being tackled by a defensive player or a wide receiver being hit by a defensive player. During these collisions, it is very easy for one or more teeth to be knocked out or otherwise damaged such as being chipped or cracked. To help protect teeth and reduce the occurrence of damage to teeth, devices such as mouth guards have been developed. In the prior art, one type of mouth guard is a dental tray which is conformed to the shaped of a person's upper teeth and is worn in the mouth to protect the upper teeth. The mouth guard rests against the person's lower teeth to also protect the person's lower teeth. Many mouth guards are separate pieces which are taken out of the person's mouth after a play is run and either carried in the person's hand or pressed into a portion of the helmet worn by the person and is then reinserted into the mouth immediately prior to the beginning of the next play. One problem with a hand held mouth guard is that holding it in the person's hand or retaining it on the person's helmet leads to many germs coming in contact with the mouth guard which is then placed into a person's mouth where the germs come in direct contact with the person's teeth ands gums and can create an infection and disease in the person.
To avoid the above problem, mouth guards have been designed which are attached to a strap. The strap is attached to the mouth guard at one end and attached to a bar of the football helmet at the other end. This design eliminates the problem of having to carry the mouth guard in the person's hand or squeezing it into a portion of the helmet because the person does not have to carry the mouth guard after a play and the mouth guard hangs down from the strap. However, while solving one problem, this strap design presents a possibly even greater problem. During the violent collisions which occur when football is played, a person's helmet can be knocked off. With the strap attached to a bar of the helmet and to the mouth guard, when the helmet is knocked off the person's head, the strap and mouth guard are forced to travel with the helmet. Since the mouth guard is carried in the person's mouth during this activity, there is a significant risk that when the mouth guard and strap go flying with the football helmet, the person's teeth can be severely damaged or knocked out.
Therefore, there is a significant need for a mouth guard which protects a person's teeth and eliminates the problem of having to carry the mouth guard in the person's hand between football plays and at the same time reduces the problem associated with a mouth guard attached to a strap and a football helmet where a person's teeth can be knocked out if the helmet goes flying off the person's head during a collision.
SUMMARY OF THE INVENTION
The present invention is a mouth guard which is worn to protect a person's teeth when the person is engaged in a sports activity such as football. A strap which has a quick release mating member at each end interconnects the mouth guard with a bar on a helmet worn by the person. One quick release mating member is removably connected to a bar on the helmet and the other quick release mating member is removably connected to a receiving member in the mouth guard. In the event of a collision between participants in the sport which results in the helmet flying off the person's head, one or both of the quick release members will disengage the strap from either the bar on the helmet, the mouth guard, or both to thereby avoid damage to the person's teeth.
It has been discovered, according to the present invention, that for a mouth guard which is connected by a strap to a bar on a football helmet, in order to prevent injury to a person's teeth, it is necessary to provide means to either disengage the mouth guard from the strap or disengage the strap from the football helmet during a collision which results in the football helmet flying off the person's head.
It has also been discovered, according to the present invention, that if a connecting strap has a quick release engagement member such as a clip at one end which is removably received into a mating receiving member in the mouth guard and the strap is connected at its opposite end to a protective helmet, then in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, the quick release engagement member will disengage from the receiving member in the mouth guard so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It has further been discovered, according to the present invention, that if a connecting strap has a quick release engagement member such as an engagement clip at one end which is removably received onto to portion of a protective helmet such as a face bar and the strap is connected at its opposite end to a mouth guard, then in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, the quick release engagement clip will disengage from the portion of the helmet to which it is attached so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It has also been discovered, according to the present invention, that if a connecting strap has a quick release engagement member at one end which is removably received into a mating receiving member in the mouth guard and the opposite end the strap has a quick release engagement member which is removably received onto to portion of a protective helmet such as a face bar, then in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, either the quick release engagement member at one end of the strap will disengage from the mouth guard, or the quick release engagement member at the opposite end of the strap will disengage from the helmet, or both quick release engagement members will respectively disengage from the mouth guard and the helmet so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It has also been discovered, according to the present invention, that if the quick release engagement member at the end of the strap connected to the helmet has a widened surface, then a logo or other decoration can be placed on the surface of the quick release engagement member.
It has additionally been discovered, according to the present invention, that if the quick release engagement member received in the mouth guard has a widened surface connected to the engagement member at the location opposite to where it is received within the mouth guard, a decorative logo or other decoration can be placed on the surface so that the mouth guard is not connected to any strap but instead has a decorative element in addition to a protective element.
It has also been discovered, according to the present invention, that if the mouth guard has a quick release engagement cavity which extends through the entire width of the mouth guard, then when the clip is not inserted, the cavity provides a breathing hole for the user when the mouth guard is held between the user's teeth. In addition, if there is at least one additional opening extending through the mouth guard, then a breathing hole is formed in the mouth guard even when the clip is inserted into the cavity in the mouth guard.
It has further been discovered, according to the present invention, that if the mouth guard has attached at its front end a transversely extending female clip member which can be removably attached to a potion of a protective helmet such as a face mask bar, then if the mouth guard is used by itself without an attaching strap, after a play is over the player can removably attach the mouth guard to a face mask bar while the next play is being called and in this way the mouth guard does not have to be held in the player's hand and the mouth guard will not be lost between plays. When the next play is called, the mouth guard is once again inserted into the player's mouth and held between the player's teeth. The female connecting means will not interfere with the user's ability to play football as the protruding female attaching means extends only for a short distance in front of the mouth guard and does not come in contact with a face mask bar during a play.
It is therefore an object of the present invention to prevent injury to a person's teeth from a mouth guard which is connected by a strap to a bar on a football helmet by providing means to either disengage the mouth guard from the strap or disengage the strap from the football helmet during a collision which results in the football helmet flying off the person's head.
It is also an object of the present invention to prevent injury to a person's teeth from a mouth guard connected to one end of a strap and at the opposite end the strap is connected to a protective helmet, by incorporating a quick release engagement member such as a clip at one end of the strap which is removably received into a mating receiving member in the mouth guard and the strap is connected at its opposite end to a protective helmet, so that in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, the quick release engagement member will disengage from the receiving member in the mouth guard so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It is further an object of the present invention to prevent injury to a person's teeth from a mouth guard connected to one end of a strap and at the opposite end the strap is connected to a protective helmet, by incorporating a quick release engagement member such as a clip at one end of the strap which is removably connected to a portion of a protective helmet so that in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, the quick release engagement clip will disengage from the portion of the helmet to which it is attached so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It is additionally an object of the present invention to prevent injury to a person's teeth from a mouth guard connected to one end of a strap and at the opposite end the strap is connected to a protective helmet, by incorporating a quick release engagement member such as a clip at one end of the strap which is removably received into a mating receiving member in the mouth guard and incorporating a quick release engagement member at the opposite end of the strap which is removably received onto to portion of a protective helmet such as a face bar, so that in the event of a collision during a sporting event where the helmet is caused to be removed from a person's head, either the quick release engagement member at one end of the strap will disengage from the mouth guard, or the quick release engagement member at the opposite end of the strap will disengage from the helmet, or both quick release engagement members will respectively disengage from the mouth guard and the helmet so that the mouth guard remains in the person's mouth and thereby prevents injury to the person's teeth.
It is another object of the present invention to provide a widened surface on the quick release engagement member at the end of the strap connected to the helmet so that a logo or other decoration can be placed on the surface of the quick release engagement member.
It is an additional object of the present invention to provide a widened surface on the quick release engagement member which is received in the mouth guard so that a decorative logo or other decoration can be placed on the surface so that the mouth guard is not connected to any strap but instead has a decorative element in addition to being a protective element.
It is also an object of the present invention to provide a mouth guard having a quick release engagement cavity which extends through the entire width of the mouth guard, so that when the clip is not inserted, the cavity provides a breathing hole for the user when the mouth guard is held between the user's teeth. In addition, if there is at least one additional opening extending through the mouth guard, then a breathing hole is formed in the mouth guard even when the clip is inserted into the cavity in the mouth guard.
It is a further object of the present invention to provide a mouth guard which has attached at its front end a transversely extending female clip member which can be removably attached to a potion of a protective helmet such as a face mask bar, so that if the mouth guard is used by itself without an attaching strap, after a play is over the player can removably attach the mouth guard to a face mask bar while the next play is being called and in this way the mouth guard does not have to be held in the player's hand and the mouth guard will not be lost between plays. When the next play is called, the mouth guard is once again inserted into the player's mouth and held between the player's teeth. The female connecting means will not interfere with the user's ability to play football as the protruding female attaching means extends only for a short distance in front of the mouth guard and does not come in contact with a face mask bar during a play.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG. 1 is a perspective view of a person wearing a protective helmet and illustrating the present invention double quick release mouth guard assembly with the mouth guard in the person's mouth and with a strap interconnecting the quick release mechanisms with one quick release engagement member removably received in the mouth guard and the second quick release engagement member removably connected to a face bar on the protective helmet;
FIG. 2 is a top plan view of a strap with a quick release engagement member which will be received in a mouth guard at one end of the strap and a quick release engagement member which will be removably attached to a portion of a protective helmet at the other end of the strap;
FIG. 3 is a left side elevational view of the quick release engagement member which will be removably attached to a portion of a protective helmet;
FIG. 4 is a right left side elevational view of the quick release engagement member which will be removably attached to a portion of a protective helmet;
FIG. 5 is a front elevational view of one embodiment of the quick release engagement member which will be removably attached to a portion of a protective helmet showing a widened surface onto which a logo or other decoration can be placed;
FIG. 6 is a front elevational view of an alternative embodiment of the quick release engagement member which will be removably attached to a portion of a protective helmet;
FIG. 7 is an exploded view showing the quick release engagement member removed from a bar of a face mask of a helmet and a quick release engagement member removed from a receiving member of a mouth guard;
FIG. 8 is a top plan view of the present invention double quick release mouth guard assembly with one quick release engagement member removably received within a mouth guard and one quick release engagement member removably received on a face mask bar of a helmet;
FIG. 9 is a bottom plan view of the present invention double quick release mouth guard assembly with one quick release engagement member removably received within a mouth guard and one quick release engagement member removably received on a face mask bar of a helmet;
FIG. 10 is a top perspective view of the present invention double quick release mouth guard assembly with one quick release engagement member removably received within a mouth guard and one quick release engagement member removably received on a face mask bar of a helmet;
FIG. 11 is an exploded view of an alternative embodiment of the present invention which is a decorative mouth guard;
FIG. 12 is a perspective view of an alternative embodiment of the present invention which is a decorative mouth guard;
FIG. 13 is a front elevational view of an alternative embodiment of the present invention which is a decorative mouth guard; and
FIG. 14 is a bottom plan view of another alternative embodiment of the present invention which is a mouth guard having an attaching mean such as a female clip member extending from the mouth guard.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
Referring to FIGS. 2 through 10 , there is illustrated the present invention double quick release mouth guard assembly 10 . The assembly includes an elongated interconnecting strap member 12 have a first end 14 and a second end 16 . By way of example only, the strap member 10 can have a length “L” of approximately 145 millimeters and can be made out of flexible material such as nylon webbing.
Attached to the first end 14 of strap member 12 is a first quick release engagement member 20 which is comprised of a male clip member 22 having a generally elongated shaped upper sidewall 24 and a generally widened frustum shaped end 26 with lips 26 A which extend to either side of the sidewall 24 , both sidewalls terminating in a flat leading edge 28 . Spaced apart from the male clip member 22 is a stop collar 30 . By way of example, the length “L 2 ” of the male clip member 22 can be approximately 12.5 millimeters.
Referring particularly to FIGS. 7 and 10 , a mouth guard 60 has a body 62 having a teeth receiving tray 64 surrounded by a circumferential exterior sidewall 66 and a circumferential interior sidewall 68 . In use, the mouth guard 60 is placed into a user's mouth so that the user's teeth rest on receiving tray 64 and are surrounded by circumferential exterior sidewall 66 and circumferential interior sidewall 68 . The front 70 of mouth guard 60 has a receiving cavity 72 in the body 62 of the mouth guard 60 at a location below the teeth receiving tray 64 , and preferably extending through the entire width of the mouth guard. The shape of the receiving cavity 72 conforms to the shape of the male clip member 22 . As best illustrated in FIGS. 7 , 8 and 9 , the male clip member 22 is inserted into receiving cavity 72 so that the stop collar 30 lies adjacent the front 70 of mouth guard 60 and lips 26 A help secure the clip member 22 within the receiving cavity 72 . The fit between male clip member 22 and receiving cavity 72 , even with the securing lips 26 A, is a loose press fit. In the event of a tugging force on the strap 12 ; the male clip member 22 will immediately come loose from and be pulled out of the receiving cavity 72 in mouth guard 60 . When the male clip member 22 is not inserted into the receiving cavity 72 , then the receiving cavity provides a breathing opening in the mouth guard. Additional openings 72 A and 72 B extend through the mouth guard 60 on either side of cavity 72 so that breathing holes are provided even when the clip member 22 is inserted into receiving cavity 72 . It is also within the spirit and scope of the present invention to have at least one extra breathing hole 72 A or 72 B.
Referring to FIGS. 2 , 7 , 8 , 9 and 10 , attached to the second end 16 of strap member 12 is a second quick release engagement member 32 which is comprised of a female clip member 34 . As best illustrated in FIGS. 3 and 4 the female clip member 34 has a rear wall 36 terminating in an outwardly extending leading end 38 . The rear wall 36 supports rounded wall 40 which extends from the approximate midpoint 42 of rear wall 36 in a generally arcuate fashion for approximately 180 degrees and then extends in an outwardly extending leading end 44 which extends away from outwardly extending leading end 38 . The rounded wall 40 defines an interior cavity 46 which is bounded by rear wall 36 and rounded wall 40 with an opening 48 between rear wall 36 and rounded wall 40 and the locations 37 which is the areas where rear wall 34 begins its outwardly extending leading end 36 and the area 41 where the rounded wall 40 begins its outwardly extending leading end 44 . The opening or gap 46 is sized to be slightly smaller than a face bar 140 of a protective helmet such as a football helmet 100 so that when the female clip member 34 is pressed against a face bar 140 , as illustrated in FIGS. 1 , 7 , 8 , 9 and 10 , the face bar snaps into interior cavity 46 and is retained therein. In the event of a tugging action on the strap 12 , the face bar 140 will be immediately pulled out of cavity 46 and released from male clip member 34 .
Referring to FIGS. 5 and 6 , the second quick release engagement member 32 can have a widened surface 50 on the body 52 of second quick release engagement member 32 which widened surface 50 extends on the side of rear wall 36 opposite to the wall from which the rounded wall 40 extends so that a logo or other decoration can be placed on widened surface 50 as illustrated in FIG. 5 . Alternatively, as illustrated in FIG. 6 , the rear wall 36 can occupy most of the surface area 54 of the body 52 . At the end opposite the male clip member 34 , the body 52 has a receiving slot 56 for receiving the second end 16 of strap 12 .
The present invention is illustrated in use in FIG. 1 . The helmet 100 which by way of example is a football helmet is worn around a person's head. The person 200 wears the helmet 100 on the person's head 210 so that the person's face 220 can look through the opening 110 in the helmet 100 . The helmet 100 includes a multiplicity of protective members such as face bars 120 , 130 , 140 and 150 . The purpose of the face bars is to protect the person's face 220 so that body parts of an opposing player do not contact the person's face 220 . When playing a sport, the person opens the person's mouth 230 and places the mouth guard 60 therein so that when the mouth guard 60 is placed into a user's mouth 230 , the user's teeth rest on receiving tray 64 and are surrounded by circumferential exterior sidewall 66 and circumferential interior sidewall 68 .
The first quick release engagement member 20 is placed into the receiving cavity 72 of mouth guard 60 in the manner previously described and second quick release engagement member 32 is placed onto one of the face mask bars 120 , 130 or 140 in the manner previously described with the strap 12 positioned between the person's mouth 230 and the face mask bars 120 , 130 and 140 with the strap hanging down below the helmet as illustrated in FIG. 1 .
When the person is engaged in a heavy contact sport such as football, violent collisions frequently occur. When such violent collisions occur, the helmet 100 is sometimes knocked off the person's head 210 . When the helmet 100 is caused to be removed from the person's head in this violent way, the strap 12 has a tugging force imparted on at least one end 14 or 16 and sometimes on both ends 14 and 16 depending on the nature of the force, the location where the force impacts the helmet 100 , etc. If the tugging force on the strap 12 is at the location of the first end 14 , the first quick release engagement member 20 is released from the cavity 72 of mouth guard 60 in the manner previously described and the mouth guard 60 remains in the person's mouth while the helmet 100 and strap fly away. If the tugging force on the strap 12 is at the location of the second end 16 , the second quick release engagement member 32 is released from the face mask bar 120 , 130 or 140 in the manner previously described and the mouth guard 60 remains in the person's mouth while the helmet 100 flies away. The strap 12 is still attached to the mouth guard 60 . If the fore is at both locations 14 and 16 , both the first quick release engagement member 20 is released from the cavity 72 in the mouth guard 60 and the second quick release engagement member 32 is released from the face mask bar 120 , 130 , or 140 . The mouth guard 60 remains in the person's mouth while the helmet 100 flies way and the strap 12 falls to the ground.
While the first quick release engagement member has been illustrated with a male member 22 inserted into a female cavity 72 in the mouth guard 60 , it will be appreciated that it is within the spirit and scope of the present invention for the first quick release engagement member to have a female receiving member with the mouth guard 60 having a male connecting member extending from it. Similarly, the second quick release engagement member can be attached to any part of the helmet 100 and not only to a face mask bar.
In an alternative embodiment of the present invention, the mouth guard 160 is used to protect the person's teeth and functions additionally as a decorative embodiment. Referring to FIGS. 11 through 13 , the mouth guard 160 has a receiving cavity 172 . An engagement member 132 has at one end male clip member 134 having a shape which conforms to the shape of the receiving cavity 172 . Extra breathing holes 172 A and 172 B are on either side of the receiving cavity 172 . At its opposite end, the engagement member 132 has a widened surface area 150 onto which a logo or other decoration 151 can be placed. In its completed assembled condition as illustrated in FIG. 12 , the mouth guard 160 is retained in a person's mouth to protect a person's teeth as previously described and the widened surface 150 with decorative logo 151 is in front of the person's mouth to provide a decorative feature to the mouth guard. In this embodiment, the mouth guard 160 protects the person's teeth and serves a decorative function as well. It is not connected to any strap or to a face mask bar.
In a second alternative embodiment of the present invention, the mouth guard 120 is used to protect a person's teeth and also contains a protruding attaching means 234 which enables the entire mouth guard and attaching means to be removably attached to a portion of a protective helmet such as a face mask bar between plays when the mouth guard is not retained in the user's mouth. Referring to FIG. 14 , a second alternative of the mouth guard 160 is shown. The embodiment of the mouth guard 260 has the same internal components of the previous embodiments including a teeth receiving tray surrounded by a circumferential exterior sidewall and a circumferential interior sidewall so that in use, the mouth guard 260 is placed into a user's mouth so that the user's teeth rest on the teeth receiving tray and the teeth are surrounded by the circumferential exterior and interior sidewalls.
The bottom plan view of FIG. 14 shows the attaching means 232 comprised of a female clip member 234 . As illustrated in FIG. 14 the female clip member 234 has a rear wall 236 terminating in an outwardly extending leading end 238 . The rear wall 236 supports rounded wall 240 which extends from the approximate midpoint 242 of rear wall 236 in a generally arcuate fashion for approximately 180 degrees and then extends in an outwardly extending leading end 244 which extends away from outwardly extending leading end 238 . The rounded wall 240 defines an interior cavity 246 which is bounded by rear wall 236 and rounded wall 240 with an opening 248 between rear wall 236 and rounded wall 240 and the locations 237 which is the areas where rear wall 234 begins its outwardly extending leading end 236 and the area 241 where the rounded wall 240 begins its outwardly extending leading end 244 . The opening or gap 246 is sized to be slightly smaller than a face bar 140 of a protective helmet such as a football helmet 100 so that when the female clip member 234 is pressed against a face bar 140 , as illustrated in FIGS. 1 , 7 , 8 , 9 and 10 , the face bar snaps into interior cavity 246 and is retained therein.
As illustrated in FIG. 14 , the rear wall 236 has a proximate end 243 which is attached to and preferably molded into the front 270 of the mouth guard 260 so that the female clip member 234 extends transversely to the front of the mouth guard. Through use of this second alternative embodiment of a mouth guard 260 , after a play is over the player can removably attach the mouth guard to a face mask bar while the next play is being called and in this way the mouth guard does not have to be held in the player's hand and the mouth guard will not be lost between plays. When the next play is called, the mouth guard is once again inserted into the player's mouth and held between the player's teeth. The female connecting means will not interfere with the user's ability to play football as the protruding female attaching means extends only for a short distance in front of the mouth guard and does not come in contact with a face mask bar during a play.
While shown oriented parallel to the body of the mouth guard, the attaching means 232 can be rotated 90 degrees to the orientation illustrated in FIG. 14 .
Defined in detail, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet having at least one face mask bar of a given diameter, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) a first quick release engagement member attached to the first end of said interconnecting strap member and comprised of a male clip member having a generally elongated shaped upper sidewall and a generally widened frustum shaped end terminating in a flat leading edge with ends having lips extending from the sidewall, with a stop collar on the interconnecting strap member and spaced apart from and adjacent to the of the end of the male clip member remote from the flat leading edge; (c) said mouth guard having a body having a teeth receiving tray surrounded by a circumferential exterior sidewall and a circumferential interior sidewall, the body having a front portion beneath the teeth receiving tray having a receiving cavity within said body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that when the male clip member is inserted into the receiving cavity, a loose press fit is formed, the mouth guard having at least one additional breathing hole extending through it; (d) a second quick release engagement member attached to the second end of the interconnecting strap and further comprised of a body having means to attached the body to the strap at one end of the strap and a female clip member at the other end of the body, the female clip member having a rear wall terminating in an outwardly extending leading, the rear wall supporting a rounded wall which extends from the approximate midpoint of the rear wall in a generally arcuate fashion and then extends in an outwardly extending leading end which extends away from the outwardly extending leading end of the rear wall, an opening between the rear wall and the rounded wall leading to an interior cavity between the rear wall and the rounded wall, the interior cavity sized to be slightly smaller than the diameter of the face mask bar so that when the female clip member is inserted onto the face mask bar of the helmet there is a loose press fit between the face mask bar and the interior cavity; and (e) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the male clip member of the first quick release engagement member is removably inserted into the receiving cavity of the mouth guard and the interior cavity of the male clip member of the second quick release engagement member is removably attached to the least one face mask bar of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, depending on the location on the impact force, the first quick release engagement member will be released from the mouth guard and/or the second quick release engagement member will be released from the face mask bar so that the mouth guard remains in the person's mouth.
Defined broadly, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet having at least one face mask bar of a given diameter, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) a first quick release engagement member attached to the first end of the interconnecting strap member and comprised of a male clip member with a stop collar on the interconnecting strap member and spaced apart from the male clip member; (c) the mouth guard having a body having a teeth receiving tray surrounded by a circumferential exterior sidewall and a circumferential interior sidewall, the body having a front portion beneath the teeth receiving tray having a receiving cavity within the body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that when the male clip member is inserted into the receiving cavity, a loose press fit is formed; (d) a second quick release engagement member attached to the second end of the interconnecting strap and further comprised of a body having means to attach the body to the strap at one end of the strap and a female clip member with a receiving interior cavity at the other end of the body, the interior cavity sized to be slightly smaller than the diameter of the face mask bar so that when the female clip member is inserted onto the face mask bar of the helmet there is a loose press fit between the face mask bar and the interior cavity; and (e) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the male clip member of the first quick release engagement member is removably inserted into the receiving cavity of the mouth guard and the interior cavity of the female clip member of the second quick release engagement member is removably attached to the least one face mask bar of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, depending on the location on the impact force, the first quick release engagement member will be released from the mouth guard and/or the second quick release engagement member will be released from the face mask bar so that the mouth guard remains in the person's mouth.
Defined more broadly, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) a first quick release engagement member attached to the first end of the interconnecting strap member and comprised of a male clip member of a given shape; (c) the mouth guard having a body having teeth receiving means, the body having a front portion beneath the teeth receiving means having a receiving cavity within the body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that when the male clip member is inserted into the receiving cavity, a loose press fit is formed; (d) a second quick release engagement member attached to the second end of the interconnecting strap and further comprised of a body having means to attach the body to the strap at one end of the strap and means to removably attach the second quick release engagement member to a portion of the helmet so that a loose press fit is formed between the attachment means and the helmet and (e) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the male clip member of the first quick release engagement member is removably inserted into the receiving cavity of the mouth guard and the attachment means of the second quick release engagement member is removably attached to a portion of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, depending on the location on the impact force, the first quick release engagement member will be released from the mouth guard and/or the second quick release engagement member will be released from the helmet so that the mouth guard remains in the person's mouth.
Defined even more broadly, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) a first quick release engagement member attached to the first end of the interconnecting strap member and comprised of a male clip member of a given shape; (c) the mouth guard having a body having teeth receiving means, the body having a front portion beneath the teeth receiving means having a receiving cavity within the body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that when the male clip member is inserted into the receiving cavity, a loose press fit is formed; (d) means to attach the second end of the interconnecting strap to a portion of the helmet; and (e) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the male clip member of the first quick release engagement member is removably inserted into the receiving cavity of the mouth guard and the second end of the interconnecting strap is attached to a portion of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, the first quick release engagement member will be released from the mouth guard so that the mouth guard remains in the person's mouth.
Defined even more broadly, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) a first quick release engagement member attached to the first end of the interconnecting strap member and having a quick release interconnecting means; (c) the mouth guard having a body having teeth receiving means, the body having a mating quick release interconnecting means so that when the interconnecting means of the first quick release engagement member and the mouth guard are connected, a loose press fit is formed; (d) means to attach the second end of the interconnecting strap to a portion of the helmet; and (e) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the interconnecting means of the first quick release engagement member and interconnecting means the mouth guard are removably interconnected and the second end of the interconnecting strap is attached to a portion of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, the first quick release engagement member will be released from the mouth guard so that the mouth guard remains in the person's mouth.
Defined even more broadly, the present invention is a mouth guard assembly to be used in conjunction with a protective helmet, the mouth guard assembly comprising: (a) an elongated interconnecting strap member having a first end and a second end; (b) the mouth guard having a body having teeth receiving means, the body attached to the first end of the interconnecting strap; (c) a quick release engagement member attached to the second end of the interconnecting strap and further comprised of a body having means to attach the body to the strap at the second end of the strap and means to removably attach the second quick release engagement member to a portion of the helmet so that a loose press fit is formed between the attachment means and the helmet; and (d) the mouth guard assembly worn in a person's mouth while a person wears the helmet on the person's head so that the first end of the strap is attached to the mouth guard and the attachment means of the second quick release engagement member is removably attached to a portion of the helmet so that in the event of an impact force which causes the helmet to be removed from the person's head, the quick release engagement member at the second end of the interconnecting strap will be released from the helmet so that the mouth guard remains in the person's mouth.
Defined even more broadly, the present invention is a mouth guard assembly comprising: (a) a first engagement member comprised of a male clip member at one end and a widened surface on the other end; and (b) the mouth guard having a body having a teeth receiving tray surrounded by a circumferential exterior sidewall and a circumferential interior sidewall, the body having a front portion beneath the teeth receiving tray having a receiving cavity within the body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that when the male clip member is inserted into the receiving cavity, a loose press fit is formed.
Defined even more broadly, the present invention is a mouth guard assembly comprising: (a) a first engagement member comprised of a male clip member at one end and a widened surface on the other end; and (b) the mouth guard having a body having a teeth receiving tray, the body having a front portion beneath the teeth receiving tray having a receiving cavity within the body at its front portion, the shape of the receiving cavity conformed to the shape of the male clip member so that the male clip member is inserted into the receiving cavity.
Defined even more broadly, the present invention is a mouth guard assembly comprising: (a) a first engagement member comprised of a first mating means at one end and a widened surface on the other end; and (b) the mouth guard having a body having a teeth receiving tray, the body having a second mating means which is joined to the first mating means so that the widened surface area rests in front of the mouth guard.
Defined alternatively, the present invention is a mouth guard assembly comprising: (a) a mouth guard with a body having a teeth receiving tray and a front edge; and (b) an attaching means attached to the mouth guard and extending transversely to the front edge so that the attaching means can be removably attached to a face mask bar of a protective helmet.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.
|
The present invention is a mouth guard which is worn to protect a person's teeth when the person is engaged in a sports activity such as football. A strap which has a quick release mating member at each end interconnects the mouth guard with a bar on a helmet worn by the person. One quick release mating member is removably connected to a bar on the helmet and the other quick release mating member is removably connected to a receiving member in the mouth guard. In the event of a collision between participants in the sport which results in the helmet flying off the person's head, one or both of the quick release members will disengage the strap from either the bar on the helmet, the mouth guard, or both to thereby avoid damage to the person's teeth.
| 0
|
TECHNICAL FIELD
The present invention relates to an injection device having several automatic functions such as automatic penetration, automatic injection and automatic safety means for preventing from accidental needle sticks and in particular an injection device capable of handling medicament in fluid form having high viscosity.
BACKGROUND ART
The present invention relates to injection devices for injecting medicament in fluid form having high viscosity which means that these devices require high forces in order to press the fluid through a needle when injecting the medicament.
Auto-injectors, or pen-injectors have been on the market for many years. One of the first auto-injectors was developed for war-times, which was activated by pressing the injector against a body part for activating it. The main concern was to have the medicament injected as fast as possible, without much concern for the patient or for handling safety aspects. During the recent years some medicaments have been developed such that these have to be injected by the patients themselves. Therefore, depending on the intended use and type of medicament, it has also been developed injection devices having a varying degree of automatic functions to facilitate the injection of medicaments in a reliable and safe way for patients and even for trained personnel; e.g. physicians, nurses.
Auto-injector devices having an automated injection function often comprises a housing, a spirally wound compression spring acting on a plunger rod which in its turn acts on a stopper inside a medicament container for expelling the medicament through an attached needle to the container. Normally, one end of the spring is often abutting an inner end surface of the housing, which means that the housing has to be dimensioned to the force of the spring. When fluids with high viscosity are to be injected using an auto-injector, high forces are required to expel the medicament through a fine needle. Consequently, the spring becomes very large both regarding the diameter of the wound spring and also the diameter of the thread of the wire. The size of the spring means that the device becomes large, and for some applications and customers, such sizes of the devices are not acceptable.
A solution to said problem is disclosed in document EP 1 728 529 which discloses a medicament delivery device arranged with an energy accumulating member, e.g. a flat spiral spring, capable of providing an output torque to a plunger rod driving member which is adapted to engage a threaded plunger rod. The rotation of the plunger rod driving member due to the output torque of the spring rotates the plunger rod and allows said rod to be driven forwardly within a medicament container for expelling said medicament. When said device is used as an injection device; a user e.g. a patient, a physician or trained personal; has to penetrate the needle manually. Though, said device comprises a needle shield sleeve for activating the injection step and for covering the needle after the medicament has been injected, some users experience this manually penetration as an unpleasant step.
A solution to this problem is disclosed in document U.S. Pat. No. 5,104,380 which discloses an injection device having a rotatable dose metering cap which compresses a coil spring. When a dose is to be injected, a latch body is pressed against an injection site such that a compression spring can be decompressed for performing an auto-penetration. That action also brings a drive gear out of engagement permitting the coil spring to unwind and thereby rotating a drive plunger rod. Said rotational movement is accompanied by axial movement to cause medicament to be discharged from a cartridge and injected through a needle. This design cannot be utilised when larger forces for injecting a high viscous medicament are required. This design also requires an extra latch body comprising an extra spring for auto-penetration, which increases the physical size and manufacturing cost for such device.
DISCLOSURE OF THE INVENTION
The aim of the present invention is to provide injection device having several automatic functions as automatic penetration, automatic injection and automatic safety means for preventing accidental needle sticks and in particular an injection device capable of handling medicament in fluid form having high viscosity without increasing the size of the injector in any substantive way.
This aim is obtained with an injector according to the features of claim 1 . Preferable embodiments of the invention are the subject of the dependent claims.
According to a main aspect of the invention it is characterised by an injection device comprising a housing, a container holder arranged within said housing having a container adapted to contain medicament to be delivered through a needle attached to the container and a stopper sealingly and slidable arranged inside said container, an energy accumulating member arranged in the interior of the device and adapted to accumulate energy, plunger drive means comprising a plunger rod driving member connected to said energy accumulating member and threadly engaged to a plunger rod which is arranged with a proximal end in contact with said stopper, such that when said plunger rod driving member is rotated due to an output torque from the energy accumulating member, the plunger rod ( 40 ) is urged towards the proximal end of the device, characterized in that said device further comprises container driver means arranged and designed to be fixedly connected to the container holder and to be releasably connected to the plunger rod, such that when said plunger rod is urged towards the proximal end of the device, the container holder is moved a predetermined distance towards the proximal end of the device whereby a needle penetration is performed and whereupon the continuous movement of said plunger rod forces said container driver means to be released from said plunger rod whereby an injection is performed.
According to another aspect of the invention, said container driver means is connected to the plunger drive means in a snap-on fit manner for releasing said container driver means from said driver means and thereby said container holder from the force that urges it towards the proximal end of the device, directly after the needle penetration is performed.
According to yet another aspect of the invention, said container driver means comprises resilient members arranged in snap-on fit manner in an annular groove on said plunger rod for releasing said container driver from said plunger rod directly after the needle penetration is performed and for allowing said container driver to slide over said plunger rod when said plunger rod continues to be driven towards the proximal end of the device inside said container for expelling the medicament through said needle.
According to another aspect of the invention, said plunger drive means further comprises non-rotating means arranged and designed to be engaged to longitudinal guiding means on the plunger rod for urging the plunger rod to move linearly inside said container towards the proximal end of the device.
According to a further aspect of the invention, said device further comprises holding means capable of acting on said plunger drive means for holding said energy accumulating member in a loaded state.
According to yet another aspect of the invention, it further comprises actuating means capable of acting on said holding means for releasing said energy accumulating member and thereby said plunger drive means.
According to a further aspect of the invention, it further comprises a needle shield sleeve arranged slidable in said proximal housing capable of acting on said actuating means when said needle shield sleeve is pressed against an injection site.
According to yet an aspect of the invention, said actuating means further comprises a resilient means for urging said needle shield sleeve towards the proximal end of the device when said device is removed from the injection site.
According to yet an aspect of the invention, said device further comprises a locking means for locking said needle shield sleeve against moving towards the distal end of the device when said device is removed from the injection site.
The advantages with the present invention are several. Because the device is arranged with an energy accumulating member which provides a torque force, a large force can be obtained. The device is thus capable of handling liquid medicament having high viscosity, without the device having to be large and bulky, and thus not very attractive to users.
Also, the device requires only one energy accumulating member for performing both an automatic penetration and an injection function.
These and other aspects of and advantages with the present invention will become apparent from the following detailed description and from the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
In the following detailed description of the invention, reference will be made to the accompanying drawings, of which
FIG. 1 is a cross-sectional view of an injector according to the present invention in a state when delivered to a user,
FIG. 2 is a cross-sectional view of the injector of FIG. 1 where penetration has been initiated,
FIG. 3 is a cross-sectional view of the injector of FIG. 1 where penetration has been completed,
FIG. 4 is a cross-sectional view of the injector of FIG. 1 where injection has been completed,
FIG. 5 is a cross-sectional view of the injector of FIG. 1 where the injector has been withdrawn from the injection site, and
FIG. 6 is an exploded view of the injector of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
In the present application, when the term “distal part/end” is used, this refers to the part/end of the injection device, or the parts/ends of the members thereof, which under use of the injection device is located the furthest away from the medicament injection site of the patient. Correspondingly, when the term “proximal part/end” is used, this refers to the part/end of the injection device, or the parts/ends of the members thereof, which under use of the injection device is located closest to the medicament injection site of the patient.
The embodiment of the injector shown in the drawings comprises a housing having a proximal housing 10 and a distal housing 100 , an elongated needle shield sleeve 11 , a container driver 30 , a plunger rod 40 , a plunger rod driving member 50 , a helical spring 60 , an actuating sleeve 70 and an energy accumulating member 80 . The proximal housing 10 being an elongated tube-shaped comprising of two sections: a proximal section and a distal section, wherein the distal section has a diameter that is larger than the diameter of the proximal section. The elongated needle shield sleeve 11 comprises of three sections: a proximal section a middle section and a distal section, wherein the distal section has a diameter that is larger than the diameter of the middle section and the middle section has a diameter that is larger than the diameter of the proximal section, as seen in FIG. 6 . Said elongated needle shield sleeve 11 is slidably arranged within said elongated housing, wherein a portion of the proximal end of said needle shield sleeve protrudes out of the proximal housing 10 , which is pressed against the injection site during use, as will be described below. Further said needle shield sleeve comprises in the circumference of its distal section resilient tongues 15 .
Inside the needle shield sleeve a medicament container holder 12 is arranged and inside the container holder a container 20 , e.g. a cartridge, a syringe or the like, is arranged containing medicament to be delivered through a needle 22 attached to the container and a stopper 23 sealingly and slidable arranged inside said container. Moreover, the distal part of the container holder is arranged with tongues 13 having inwardly directed ledges 14 , as seen in FIG. 6 .
Between the tongues 13 of said medicament container holder 12 , a funnel-shaped annular member 30 , hereinafter called container driver, is arranged. Said container driver comprises in its proximal end and in its outer surface one outwardly directed annular ledge 31 which cooperates with the ledges 14 of the container holder creating a snap-on fit between these components. From the proximal end of said container driver extends at least two resilient members 32 , e.g. tongues, legs; towards the distal end, wherein each member 32 comprises an inwardly directed ledge 33 .
The plunger rod 40 is provided in the interior of the injection device, running along the longitudinal axis of said device. Said plunger rod comprises two of sections: a distal section 42 and a proximal section 41 , wherein the distal section has a diameter that is smaller than the diameter of the proximal section, wherein the distal section has a length that is larger than the length of the proximal section and wherein the distal section is threaded and comprises longitudinal guiding means 44 . Moreover, an annular groove 43 is arranged at the distal end of the proximal section 41 of said plunger rod 40 wherein said annular groove 43 cooperates with the ledges 33 of said container driver 30 creating a snap-on fit between these components. Further, the proximal end of the proximal section 41 is in contact with the stopper 23 in the medicament container.
The threaded distal section 42 of the plunger rod 40 is screw threaded in the interior of the plunger rod driving member 50 . Said driving member 50 comprises of two sections: a distal section 52 and a proximal section 51 , wherein the distal section 52 has a diameter that is smaller than the diameter of the proximal section 51 and a length than is larger than then length of the proximal section 51 . Further, the proximal section 51 comprises outwardly protruding flanges or teeth 53 , as seen in FIG. 6 .
In a preferred embodiment, the distal housing 100 comprises of three housings: a first half distal housing 110 , a second half distal housing 120 and a third distal housing 130 adapted to house the plunger rod driving member 50 , a helical spring 60 , the actuating sleeve 70 and the energy accumulating member in the form of e.g. a flat spiral spring 80 , a helical torque spring.
Said first half distal housing 110 comprises of two sections: a distal section 112 and a proximal section 111 , wherein the distal section has a diameter that is larger than the diameter of the proximal section. The distal section 112 is divided from the proximal section 111 by a member, which comprises a disc-like part 114 in its distal end and a coaxially part 115 in its proximal end forming a cylindrical space, in which said helical spring 60 is arranged having its distal end supported against the disc-like part 114 . Said coaxially part 115 comprises outwardly protruding flanges 116 on its outer surface and a through going hole 117 adapted to house a portion of the distal 52 section of the plunger rod driving member 50 . At least two of said outwardly protruding flanges 116 have resilient arms 118 .
Said second half distal housing 120 comprises of two sections: a distal section 122 and a proximal section 121 , wherein the distal section 122 has a diameter that is larger than the diameter of the proximal section 121 . Further, said second half distal housing 120 also comprises a proximal end wall 123 having a two crescent apertures 124 and a through going hole 125 provided with non-rotating interior means (not shown) adapted to travel along the longitudinal guiding means 44 of the plunger rod 40 .
The third distal housing 130 also comprises a distal section 132 and a proximal section 131 , wherein the distal section 132 has an inner diameter that is smaller than the inner diameter of the proximal section 131 . The distal section 132 is thus adapted to house a portion of the distal 52 section of the plunger rod driving member 50 and the proximal section 131 is adapted to house the flat spiral spring 80 . Said flat spiral spring 26 is provided with outer holding means in order to be connected to the proximal section 131 of the third distal housing 130 and with inner holding means in order to be attached to the distal section 52 of the plunger rod driving member 50 . Moreover, in a preferred embodiment, the proximal section 131 of the third distal housing 130 is arranged to be manually rotatable between the distal sections 112 and 122 .
The actuating sleeve 70 comprises of two sections: a distal section 72 and a proximal section 71 , wherein the distal section 72 is a ring and the proximal section are two tongues 71 ′, 71 ″. Both sections 71 , 72 arranged between the first half distal housing 110 and the second half distal housing 120 . The distal section 72 has an outer diameter that is smaller than the outer diameter of the proximal section 71 forming two support walls 74 where the proximal end of the helical spring 60 is supported. Said tongues 71 ′, 71 ″ extends towards the proximal end of the device through the crescent apertures 124 of the second half distal housing 120 and comprises on its outer surface some ledges that mates with resilient tongues 15 of the needle shield sleeve 11 . Further, said sections 71 and 72 comprises inwardly directed ledges forming slots 73 , as seen in FIG. 6 , which mate the outwardly protruding flanges 53 of the plunger rod driving member 50 and the outwardly protruding flanges 116 of the first half distal housing 110 .
The device is intended to function as follows. When the device is delivered to a user, in a preferred embodiment, the flat spiral spring 80 has been already loaded at the manufacturing site. In another embodiment the flat spiral spring 80 is loaded by the user through rotating the third distal housing 130 . Further, a protective cap (not shown) is arranged at the proximal end of the device. The protective cap comprises a sheath (not shown) covering the needle in a sterile way. When the cap is removed, so is also the sheath. This also causes the needle shield sleeve 11 to move towards the proximal end of the device and protrude somewhat at the proximal end of the injector, FIG. 1 .
The injector is now ready to use. The proximal end of the needle shield sleeve 11 is pressed against the injection site, whereby the needle shield sleeve is pushed towards the distal end of the device, FIG. 2 . Since the needle shield sleeve is connected to the actuating sleeve 70 , the latter is also moved towards the distal end of the device, whereby the helical spring 60 is compressed and the inwardly directed ledges forming slots 73 of the actuation sleeve 70 and the outwardly protruding flanges 53 of the plunger rod driving member 50 are brought out of engagement whereby the plunger rod driving member 50 is released for rotation due to the energy accumulated in the flat spiral spring 80 . The rotation of the plunger rod driving member 50 will rotate the plunger rod 40 , and due to the non-rotating interior means provided in the through going hole 125 adapted to travel along the longitudinal guiding means 44 of the plunger rod 40 , the plunger rod is linearly urged towards the proximal end of the device without rotation.
When the plunger rod is linearly urged towards the proximal end of the device, the medicament container holder 12 is also urged towards the proximal end of the device, due to the engagements 14 , 31 , 32 , 43 between the medicament container holder 12 , the container driver 30 and the plunger rod 40 . The movement of the medicament container holder 12 causes the automatic penetration of the needle 22 into the injection site.
The needle 22 is completely penetrated until the proximal end of the medicament container holder 12 comes into contact with the transition part between the proximal section and the middle section of the needle shield sleeve 11 . The torque force of the spring 80 will continue to drive the plunger rod further towards the proximal end of the device inside the container pressing the stopper 23 in order to start expelling the medicament through the passage of the needle 22 . Said movement takes out of contact the inwardly directed ledges 33 of the container driver 30 which cooperates with the annular groove 43 of the plunger rod 40 for releasing the container driver from the plunger rod and thereby the container/container holder from the force that urges it towards the proximal end of the device. The container driver slides over along the plunger rod as said plunger rod continues to move towards the proximal end of the device. The injection is completed when the stopper is at the proximal end of the container, FIG. 4 .
The device may now be removed from the injection site. The spring 60 acting on the actuation sleeve 70 will cause the needle shield sleeve 11 to move forward, FIG. 5 , since the needle shield sleeve is connected to the actuating sleeve, thereby covering the needle. The resilient arms 118 are thus free to flex out radially whereby they come into contact with the distal wall of the actuation sleeve 70 and thereby locking said needle shield sleeve 11 such that said needle shield sleeve 11 cannot be pushed again towards the distal end of the device.
The device is now ready to be discarded.
It is to be understood that the embodiment described above and shown in the drawings is to be regarded only as non-limiting examples of the present invention and that it may be modified within the scope of the patent claims.
|
The present invention relates to an injection device comprising a housing ( 10, 100 ), a container holder ( 12 ) arranged within said housing having a container ( 20 ) adapted to contain medicament to be delivered through a needle, plunger drive means ( 40 ), an energy accumulating member ( 80 ) adapted to accumulate and transfer energy to said plunger drive means wherein said device further comprises container driver means ( 30 ) arranged and designed to be connected to the plunger drive means and to the container holder for holding the container and its needle stationary within said housing before said energy is provided to the drive means and for urging the container towards the proximal end of the device when said energy is provided to the drive means whereby a needle penetration and respectively an injection are performed.
| 0
|
TECHNICAL FIELD
The present invention relates to a coding apparatus, a decoding apparatus, a coding method and a decoding method.
BACKGROUND ART
Patent Literature (hereinafter, referred to as “PTL”) 1 discloses a technique that enables efficient encoding of speech signals or music signals in a super-wide band (SWB) (typically, 0.05 to 14 kHz band). This technique has been standardized by ITU-T (see, for example, NPL1 and NPL2). In this technique, a low band part (a band of, for example, up to 7 kHz) of an input signal such as a speech signal or a music signal is encoded by a core coding section while a high band part (a band higher than, for example, 7 kHz) is encoded by an extension band coding section.
In general, the core coding section uses CELP (code excited linear prediction) coding. Meanwhile, the extension band coding section performs encoding in the frequency domain using information encoded by the core coding section. More specifically, the extension band coding section uses a spectrum (decoded low band spectrum) obtained as a result of decoding a narrowband signal in the low band part (not higher than 7 kHz) encoded by the core coding section and transforming the decoded narrow-band signal into MDCT (modified discrete cosine transform) coefficients (spectrum), for encoding for the high band part (a band higher than 7 kHz; hereinafter referred to as “extension band”).
At the time of encoding for the extension band, first, the decoded low band spectrum generated by the core coding section is normalized using a spectrum power envelope (hereinafter referred to as “envelope”). More specifically, the low band part including the decoded low band spectrum is divided into a plurality of sub-bands, and energy (sub-band energy) is calculated for each sub-band. Next, the sub-band energy is smoothened in order to smooth energy fluctuations in the frequency domain. Next, a spectrum included in each sub-band is normalized using the smoothened sub-band energy. The extension band coding section makes a search to find bands that are highly correlated with each other from the spectrum (normalized spectrum) obtained as described above and an extension band spectrum in the input signal and encodes information indicating the highly-correlated bands as a lag. Also, the extension band coding section copies the highly-correlated band in the low band part to the extension band in order to use the highly-correlated band in the low band part as a spectrum fine structure (frequency-based fine structure) in the extension band. Then, the extension band coding section calculates a gain between the spectrum fine structure and the extension band spectrum and encodes the gain.
As a result of the above processing being performed, an extension band spectrum is generated from a low band spectrum.
The reason for normalizing the low band spectrum when an extension band spectrum is generated from a low band spectrum in an input signal is as follows. In general, a low band spectrum has very large energy bias, and a high band, i.e., extension band, spectrum has small energy bias. In other words, in the high band part, high peaks are less likely to appear locally compared to the low band part, and thus, copying a signal having a high peaking property to the high band part (extension band) may result in sound quality deterioration. Therefore, in a coding apparatus, a low band spectrum is normalized because encoding can be performed more efficiently when correlation between the low band spectrum and an extension band spectrum is calculated after energy bias in the low band spectrum is removed to flatten (normalize) the low band spectrum.
NPL 3 discloses a related technique in which transform coding is used in a core coding section. In this related technique, an MPEG (Moving Picture Experts Group) AAC (Advanced Audio Coding) method is used in the core coding section. Also, extension band coding is performed using a SBR (spectral band replication) method, which is different from the extension band coding method described above.
CITATION LIST
Patent Literature
PTL1
Japanese Translation of PCT Application Laid-Open No. 2009-515212
Non-Patent Literature
NPL1
ITU-T Standard G.718 Annex B, 2008
NPL2
ITU-T Standard G.729.1 Annex E, 2008
NPL3
Martin Dietz, Lars Liljeryd, Kristofer Kjörling, Oliver Kunz, “Spectral Band Replication, a novel approach in audio coding,” Preprint 5553, 112th AES Convention, Munich, 2002.
SUMMARY OF INVENTION
Technical Problem
In NPL 1 and NPL 2, CELP coding is used in the core coding section. CELP coding has the advantage of enabling very efficient speech signal coding and providing excellent coding performance, but has the disadvantage of having insufficient music signal coding performance.
However, in order to encode an SWB signal with a sampling rate of 32 kHz, it is necessary to enhance the music signal encoding performance. In this case, in the core coding section, transform coding may be used instead of CELP coding. In general, in transform coding, a spectrum is encoded using a limited number of pulses, and thus, the low band spectrum will be expressed by a discrete pulse train.
If such spectrum expressed by a discrete pulse train is segmented into sub-bands and energy in each sub-band is calculated and smoothened to estimate an envelope as in NPL 1 and NPL 2, parts of the spectrum that are necessary to correctly calculate the energy in each sub-band are insufficient. For this reason, the coding apparatus may estimate an envelope that is different from the shape of an original envelope (that is, the envelope of the input signal). If the coding apparatus performs normalization of the low band spectrum using the incorrect envelope calculated as described above, the spectrum resulting from the normalization is not flat and may include extremely-large amplitudes.
When a spectrum of a speech signal or a music signal is observed, in the high band part, almost no high peaks appear locally compared to the low band part. Thus, if a low band part having a high peaking property is copied to a high band part, a spectrum having an excessively-high peaking property is generated in the high band part, resulting in sound quality deterioration. As described above, a low band spectrum having no flat characteristic may adversely affect the quality of sound in the extension band, which is generated using the low band spectrum.
An object of the present invention is to provide a coding apparatus, a decoding apparatus, a coding method and a decoding method that copy a low band part having a sufficiently-lowered peaking property to a high band part (extension band) to prevent generation of a spectrum having an excessively-high peaking property in the high band part, thus enabling generation of a high-quality extension band spectrum.
Solution to Problem
A coding apparatus according to an aspect of the present invention includes: a first coding section that encodes a low band part of an input signal including at least one of a speech signal and a music signal to generate first encoded data, the low band part being equal to or lower than a predetermined frequency; a normalization section that normalizes a first spectrum to generate a normalized spectrum, the first spectrum being obtained by decoding the first encoded data; a band searching section that makes a search to find a particular band having a largest correlation value between the normalized spectrum and a second spectrum that is a spectrum in a high band part of the input signal, the high band part being higher than the predetermined frequency; a gain calculating section that calculates a gain between the second spectrum and a third spectrum that is a spectrum obtained by copying the normalized spectrum in the particular band to the high band part; and a second coding section that encodes information including the particular band and the gain to generate second encoded data, in which the normalization section includes: a largest value searching section that makes a search to find a largest value in amplitude of the first spectrum in each of a plurality of sub-bands resulting from division of the low band part; and an amplitude normalization section that normalizes the first spectrum included in each of the sub-bands using the largest value in the amplitude of the sub-band to obtain the normalized spectrum.
A coding apparatus according to an aspect of the present invention includes: a transforming section that transforms an input signal including at least one of a speech signal and a music signal into a frequency domain to generate an input signal spectrum; a first bit allocating section that determines a number of bits to be allocated to each of sub-bands resulting from division of an entire band of the input signal spectrum using predetermined bandwidth; a first coding section that encodes the input signal spectrum using the allocated bits to generate first encoded data; a second bit allocating section that determines a number of bits to be allocated to each of sub-bands resulting from division of a spectrum in a low band part of the input signal spectrum using a predetermined bandwidth, the low band part being lower than a predetermined frequency; a second coding section that encodes the spectrum in the low band part of the input signal spectrum using the allocated bits to generate second encoded data, the low band part being lower than the predetermined frequency; a third coding section that encodes a spectrum in a high band part of the input signal spectrum to generate third encoded data, the high band part being higher than the predetermined frequency; a determination section that analyzes a number of bits to be consumed for encoding the spectrum in the high band part of the input signal spectrum to obtain determination information, the high band part being higher than the predetermined frequency; and a switching section that performs switching to select the first coding section alone or a combination of the second coding section and the third coding section to encode the input signal spectrum, according to the determination information, for each frame.
A decoding apparatus according to an aspect of the present invention includes: a first decoding section that receives as input first encoded data generated by encoding a low band part of an input signal including at least one of a speech signal and a music signal in a coding apparatus and that decodes the first encoded data to generate a first spectrum, the low band part being equal to or lower than a predetermined frequency; a normalization section that normalizes the first spectrum to generate a normalized spectrum; and a second decoding section that receives as input the normalized spectrum and second encoded data generated in the coding apparatus and that decodes the second encoded data to generate a second spectrum, in which: the second encoded data contains information indicating a particular band having a largest correlation value between an encoding-side first spectrum that is a spectrum in a high band part of the input signal in the coding apparatus and an encoding-side second spectrum resulting from normalization of a spectrum generated by decoding the first encoded data in the coding apparatus, the high band part being higher than the predetermined frequency, and information indicating a gain calculated between the encoding-side first spectrum and an encoding-side third spectrum that is a spectrum obtained by copying the encoding-side second spectrum in the particular band to the high band part; and the normalization section includes a largest value searching section that makes a search to find a largest value in amplitude of the first spectrum in each of a plurality of sub-bands resulting from division of the low band part, and an amplitude normalization section that normalizes the first spectrum in each of the sub-bands using the largest value in the amplitude of the sub-band to generate the normalized spectrum.
A coding method according to an aspect of the present invention includes: encoding a low band part of an input signal including at least one of a speech signal and a music signal to generate first encoded data, the low band part being equal to or lower than a predetermined frequency; normalizing a first spectrum to generate a normalized spectrum, the first spectrum being obtained by decoding the first encoded data; making a search to find a particular band having a largest correlation value between the normalized spectrum and a second spectrum that is a spectrum in a high band part of the input signal, the high band part being higher than the predetermined frequency; calculating a gain between the second spectrum and a third spectrum that is a spectrum obtained by copying the normalized spectrum in the particular band to the high band part; and encoding information including the particular band and the gain to generate second encoded data, in which, the normalizing of the first spectrum further includes: making a search to find a largest value in amplitude of the first spectrum in each of a plurality of sub-bands resulting from division of the low band part; and normalizing the first spectrum included in each of the sub-bands using the largest value in the amplitude of the sub-band to obtain the normalized spectrum.
A decoding method according to an aspect of the present invention includes: receiving as input first encoded data generated by encoding a low band part of an input signal including at least one of a speech signal and a music signal in a coding apparatus and decoding the first encoded data to generate a first spectrum, the low band part being equal to or lower than a predetermined frequency; normalizing the first spectrum to generate a normalized spectrum; and receiving as input the normalized spectrum and second encoded data generated in the coding apparatus and decoding the second encoded data to generate a second spectrum, in which: the second encoded data contains information indicating a particular band having a largest correlation value between an encoding-side first spectrum that is a spectrum in a high band part of the input signal in the coding apparatus and an encoding-side second spectrum resulting from normalization of a spectrum generated by decoding the first encoded data in the coding apparatus, the high band part being higher than the predetermined frequency, and information indicating a gain calculated between the encoding-side first spectrum and an encoding-side third spectrum that is a spectrum obtained by copying the encoding-side second spectrum in the particular band to the high band part; and the normalizing of the first spectrum to generate a normalized spectrum further includes making a search to find a largest value in amplitude of the first spectrum in each of a plurality of sub-bands resulting from division of the low band part, and normalizing the first spectrum in each of the sub-bands using the largest value in the amplitude of the sub-band to generate the normalized spectrum.
Advantageous Effects of Invention
According to the present invention, a low band part having a sufficiently-lowered peaking property is copied to a high band part (extension band) to prevent generation of a spectrum having an excessively-high peaking property in the high band part, which in turn, enables generation of a high-quality extension band spectrum.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram illustrating a configuration of a coding apparatus according to Embodiment 1 of the present invention;
FIG. 2 is a diagram illustrating how a band searching section in the coding apparatus according to Embodiment 1 of the present invention operates;
FIG. 3 is a block diagram illustrating a configuration of a decoding apparatus according to Embodiment 1 of the present invention;
FIG. 4 is a diagram illustrating how an extension band decoding section in the decoding apparatus according to Embodiment 1 of the present invention operates;
FIG. 5 is a block diagram illustrating an internal configuration of a sub-band amplitude normalizing section according to Embodiment 1 of the present invention;
FIG. 6 is a diagram illustrating envelope calculation processing according to the related art;
FIG. 7 is a diagram illustrating a normalized low band spectrum according to the related art;
FIG. 8 is a diagram illustrating a normalized low band spectrum according to Embodiment 1 of the present invention;
FIG. 9 is a block diagram illustrating a configuration of a coding apparatus according to Embodiment 2 of the present invention;
FIG. 10 is a block diagram illustrating a configuration of a decoding apparatus according to Embodiment 2 of the present invention;
FIGS. 11A and 11B are diagrams illustrating envelope calculation processing and a harmonic-emphasized normalized low band spectrum according to Embodiment 2 of the present invention;
FIG. 12 is a block diagram illustrating a configuration of a coding apparatus according to Embodiment 3 of the present invention;
FIG. 13 is a block diagram illustrating a configuration of a decoding apparatus according to Embodiment 3 of the present invention;
FIG. 14 is a block diagram illustrating a configuration of a coding apparatus according to Embodiment 4 of the present invention;
FIG. 15 is a block diagram illustrating a configuration of a decoding apparatus according to Embodiment 4 of the present invention;
FIG. 16 is a block diagram illustrating an internal configuration of a spectrum envelope normalizing section in the coding apparatus according to Embodiment 4 of the present invention;
FIG. 17 is a diagram illustrating how a band searching section in a coding apparatus according to Embodiment 5 of the present invention operates;
FIG. 18 is a diagram illustrating how an extension band decoding section in a decoding apparatus according to Embodiment 5 of the present invention operates;
FIG. 19 is a diagram illustrating how an input signal spectrum is divided into a plurality of sub-bands in a coding apparatus according to Embodiment 6 of the present invention;
FIG. 20 is a block diagram illustrating a configuration of the coding apparatus according to Embodiment 6 of the present invention;
FIG. 21 is a diagram illustrating a configuration of a mode determining section in the coding apparatus according to Embodiment 6 of the present invention;
FIG. 22 is a block diagram illustrating a configuration of a decoding apparatus according to Embodiment 6 of the present invention; and
FIG. 23 is a block diagram illustrating an internal configuration of a spectrum envelope normalizing section in a coding apparatus according to Embodiment 8 of the present invention.
DESCRIPTION OF EMBODIMENTS
In the present invention, in a codec with which a coding apparatus that generates a spectrum in an extension band (extension band spectrum) using a spectrum in a low band part (low band spectrum), the low band spectrum is divided into a plurality of sub-bands and the spectrum in each sub-band is normalized using a largest value in amplitude of the spectrum included in the sub-band. Consequently, even if the low band spectrum is a discrete spectrum, generation of an extremely-large amplitude in the low band spectrum is prevented, which in turn, enables provision of a flat normalized low band spectrum. Consequently, the coding apparatus copies the low band part having a sufficiently-lowered peaking property to the extension band, preventing generation of a spectrum having an excessively-high peaking property in the extension band, enabling generation of an extension band spectrum of high quality sound.
Each embodiment of the present invention will be described below with reference to the accompanying drawings. The coding apparatus and decoding apparatus according to the present invention cover any of speech signals, music signals and signals that are mixtures thereof, as input/output signals.
Embodiment 1
FIG. 1 is a block diagram illustrating a configuration of coding apparatus 100 according to Embodiment 1.
Coding apparatus 100 in FIG. 1 includes time-frequency transform section 101 , core coding section 102 , sub-band amplitude normalizing section 103 , band searching section 104 , gain calculating section 105 , extension band coding section 106 and multiplexing section 107 . In the present embodiment, core coding section 102 encodes a low band part (low band spectrum) of an input spectrum that is input to coding apparatus 100 , the low band part being of a frequency equal to or lower than a predetermined frequency, and extension band coding section 106 encodes a spectrum in a high band of the input spectrum, the high band being higher than the band subjected to the encoding by core coding section 102 (band higher than the predetermined frequency; hereinafter referred to as “extension band”).
Time-frequency transform section 101 transforms an input time-domain signal (including a speech signal or/and a music signal) into a frequency-domain signal and outputs a spectrum of the resulting input signal to core coding section 102 , band searching section 104 and gain calculating section 105 . Here, the below description will be given on the premise that MDCT is employed for time-frequency transform processing in time-frequency transform section 101 . However, time-frequency transform section 101 may use an orthogonal transform such as FFT (fast Fourier transform) or DCT (discrete cosine transform) for transform from the time domain to the frequency domain.
Core coding section 102 encodes a low band spectrum in the input signal spectrum input from time-frequency transform section 101 to generate encoded data. Core coding section 102 performs the encoding using transform coding. Core coding section 102 outputs the generated encoded data to multiplexing section 107 as core-encoded data. Also, core coding section 102 outputs a core-coding low band spectrum obtained by decoding the core-encoded data, to sub-band amplitude normalizing section 103 .
Sub-band amplitude normalizing section 103 normalizes the core-coding low band spectrum received as input from core coding section 102 to generate a normalized low band spectrum. More specifically, sub-band amplitude normalizing section 103 divides the core-coding low band spectrum into a plurality of sub-bands, and a spectrum in each sub-band is normalized using a largest value in amplitude (absolute value) of the spectrum in the sub-band. Sub-band amplitude normalizing section 103 outputs a normalized low band spectrum obtained as a result of the normalization processing to band searching section 104 and gain calculating section 105 . Details of a configuration and operation of sub-band amplitude normalizing section 103 will be described later.
Band searching section 104 , gain calculating section 105 and extension band coding section 106 perform processing for encoding a spectrum in the extension band of the input signal spectrum (input extension band spectrum).
Band searching section 104 makes a search to find particular bands in the input signal spectrum input from time-frequency transform section 101 , the particular bands having a largest value of correlation between the input extension band spectrum, and the normalized low band spectrum input from sub-band amplitude normalizing section 103 . Then, band searching section 104 outputs information indicating the found particular bands (the relevant band in the normalized low band spectrum (copy source) and the relevant band in the extension band (copy destination)) (referred to as lag or lag information) to gain calculating section 105 and extension band coding section 106 .
FIG. 2 is a diagram illustrating how band searching section 104 operates. In band searching section 104 , a spectrum corresponding to each of lag candidates provided in advance (as an example, four candidates of L0 to L3 in FIG. 2 ) is extracted from the input normalized low band spectrum. The spectrum to be extracted is a spectrum with a starting point located at a position shifted from reference frequency f0 by a given sample value expressed by the lag candidate, the spectrum having a bandwidth that is the same as that of the input extension band spectrum (entirety or part of the extension band). The extracted spectrum is output to correlation value calculating section 104 a as a candidate spectrum for correlation value calculation. In this example, four types of candidate spectrums are subject to correlation value calculation.
Correlation value calculating section 104 a calculates a correlation value between each of the candidate spectrums identified according to the respective lag candidates and the input extension band spectrum and outputs a lag candidate exhibiting a highest correlation value in the correlation values to gain calculating section 105 and extension band coding section 106 as information indicating the particular bands.
Gain calculating section 105 determines a spectrum obtained as a result of copying the normalized low band spectrum in the relevant particular band found as a result of the search in band searching section 104 to the extension band, as a spectrum fine structure (frequency-based fine structure). Then, gain calculating section 105 calculates a gain between the obtained spectrum fine structure and the input extension band spectrum received as input from time-frequency transform section 101 . Gain calculating section 105 outputs information indicating the calculated gain to extension band coding section 106 . Gain calculating section 105 basically calculates a gain so that energy of a signal copied from a normalized low band spectrum corresponds to (or is close to) energy in the extension band of the input signal spectrum. Examples of the simplest gain calculation method include a method in which energy in an extension band of an input signal spectrum is divided by energy of a signal copied from a normalized low band spectrum and the square root of the value obtained as a result of the division is employed as a gain.
Extension band coding section 106 encodes the information indicating the particular bands, which is input from band searching section 104 , and also encodes the gain input from gain calculating section 105 . Extension band coding section 106 outputs encoded data generated as a result of encoding the particular bands and the gain to multiplexing section 107 as extension-band encoded data.
Multiplexing section 107 multiplexes the core-encoded data received as input from core coding section 102 and extension-band encoded data received as input from extension band coding section 106 and outputs the resulting encoded data.
Next, decoding apparatus 200 according to the present embodiment will be described. FIG. 3 is a block diagram illustrating a configuration of decoding apparatus 200 .
Decoding apparatus 200 illustrated in FIG. 3 includes demultiplexing section 201 , core decoding section 202 , sub-band amplitude normalizing section 203 , extension band decoding section 204 and frequency-time transform section 205 .
Demultiplexing section 201 separates encoded data received as input into core-encoded data and extension-band encoded data. Demultiplexing section 201 outputs the core-encoded data to core decoding section 202 and outputs the extension-band encoded data to extension band decoding section 204 .
As described above, core-encoded data is encoded data obtained as a result of encoding a low band part of an input signal (including a speech signal or/and a music signal), the low band part being not higher than a predetermined frequency, being encoded in coding apparatus 100 . Also, extension-band encoded data contains: information indicating particular bands having a largest correlation value between a spectrum (input extension band spectrum) of a high band part in an input signal (including a speech signal or/and a music signal), the high band part being higher than the predetermined frequency, and a normalized spectrum; and information indicating a gain between a spectrum obtained as a result of copying the normalized spectrum in the relevant particular band to the high band part (spectrum fine structure) and the input extension band spectrum.
Core decoding section 202 decodes the core-encoded data received as input from demultiplexing section 201 to generate a core-coding low band spectrum. Core decoding section 202 outputs the generated core-coding low band spectrum to sub-band amplitude normalizing section 203 and frequency-time transform section 205 .
Sub-band amplitude normalizing section 203 normalizes the core-coding low band spectrum received as input from core decoding section 202 to generate a normalized low band spectrum. Sub-band amplitude normalizing section 203 outputs the generated normalized low band spectrum to extension band decoding section 204 . The configuration and operation of sub-band amplitude normalizing section 203 are the same as those of sub-band amplitude normalizing section 103 illustrated in FIG. 1 , which will be described later, so that a detailed description thereof will be omitted.
Extension band decoding section 204 performs decoding processing using the normalized low band spectrum received as input from sub-band amplitude normalizing section 203 and the extension-band encoded data received as input from demultiplexing section 201 to obtain an extension band spectrum. Extension band decoding section 204 decodes the extension-band encoded data to obtain lag information and a gain. Extension band decoding section 204 identifies a predetermined band in the normalized low band spectrum, which is to be copied to the extension band, based on the lag information, and copies the predetermined band in the normalized low band spectrum to the extension band. Next, extension band decoding section 204 multiplies a spectrum resulting from the predetermined band in the normalized low band spectrum being copied to the extension band, by the decoded gain to obtain the extension band spectrum. Then, extension band decoding section 204 outputs the obtained extension band spectrum to frequency-time transform section 205 .
FIG. 4 is a diagram illustrating how extension band decoding section 204 operates. Extension band decoding section 204 first determines a starting point of a normalized low band spectrum used for copy to the extension band, based on the lag information. Since FIG. 4 indicates an example where lag information L1 is obtained, the starting point of the normalized low band spectrum is located at f1.
Next, extension band spectrum generating section 204 a in extension band decoding section 204 extracts a spectrum included in a bandwidth that is the same as that of an input extension band spectrum (entirety or part of the extension band), from the starting point to generate an extension band spectrum (before multiplication by the gain).
Frequency-time transform section 205 first combines the core-coding low band spectrum input from core decoding section 202 and the extension band spectrum input from extension band decoding section 204 to generate a decoded spectrum. Next, frequency-time transform section 205 performs an orthogonal transform of the decoded spectrum to transform the decoded spectrum into a time-domain signal and outputs the time-domain signal as an output signal.
Next, a configuration and operation of sub-band amplitude normalizing section 103 in coding apparatus 100 will be described in detail below.
Sub-band amplitude normalizing section 103 removes energy bias in the core-coding low band spectrum received as input from core coding section 102 to obtain a normalized low band spectrum. Here, in order to remove energy bias in a spectrum, in general, the spectrum is normalized by calculating an envelope of the spectrum and spectrum parts in each band are divided by a representative value in the envelope for the band. In NPL 1 and NPL 2, also, a low band spectrum is normalized using a technique that is similar to the above.
However, in a case where core coding section 102 uses transform coding and a low bit rate is provided, a low band spectrum is expressed by a discrete pulse train. It is difficult to obtain a correct envelope from a discrete pulse train representing a low band spectrum. Thus, if a low band spectrum is normalized using such incorrect envelope obtained from the low band spectrum, the energy bias remains in the normalized low band spectrum, resulting in the problem of a spectrum part having an extremely-large amplitude remaining in the spectrum. If a search is made to find a band having a large correlation value between such normalized low band spectrum and an input extension band spectrum to copy a part of the normalized low band spectrum in the band having the large correlation value to an extension band, a signal having a high peaking property, which is intrinsically not generated in the extension band (high band part), is generated on the high band side, resulting in substantial sound quality deterioration.
Therefore, in the present embodiment, as a method for removing energy bias, sub-band amplitude normalizing section 103 calculates a largest amplitude value in absolute value of the low band spectrum in each sub-band (hereinafter referred to as “sub-band largest value”) and the spectrum in each sub-band is normalized using the sub-band largest value calculated in the sub-band. Consequently, the largest values in absolute value of the spectrums in respective sub-bands after the normalization sub-band become uniform throughout the sub-bands. Consequently, no spectrum part having an extremely-large amplitude exists in the normalized low band spectrum.
FIG. 5 illustrates a configuration of sub-band amplitude normalizing section 103 that provides the above processing. Sub-band amplitude normalizing section 103 illustrated in FIG. 5 includes sub-band dividing section 131 , largest value searching section 132 and amplitude normalizing section 133 .
Sub-band dividing section 131 divides a band including a core-coding low band spectrum input from core coding section 102 (that is, a low band part) into a plurality of sub-bands and outputs the spectrum in each of the obtained sub-bands to largest value searching section 132 and amplitude normalizing section 133 as a sub-band divisional core-coding low band spectrum. For simplicity, a case where sub-band dividing section 131 divides an entire band of a core-coding low band spectrum at even intervals will be described below. Also, in the below description, “w” represents a bandwidth (sample count) of each sub-band. For example, one sub-band may include eight samples (w=8).
Largest value searching section 132 makes a search to find a largest value in amplitude (absolute value) of the sub-band divisional core-coding low band spectrum input from sub-band dividing section 131 in each of the plurality of sub-bands (that is, a sub-band largest value in each sub-band). Largest value searching section 132 outputs the sub-band largest value in each sub-band to amplitude normalizing section 133 . Hereinafter, M[j] is used to represent a j-th core-coding low band spectrum, S is used to represent the number of sub-bands and “s” represents a sub-band index. In this case, sub-band largest value Mmax[s] in sub-band s can be expressed by Equation (1) below.
[1]
M max[ s ]=max(abs( M[j ])), w *( s− 1)< j<w*s , 1 ≦s≦S (Equation 1)
Amplitude normalizing section 133 normalizes the sub-band divisional core-coding low band spectrums input from sub-band dividing section 131 using the sub-band largest values in the respective sub-bands, which have been received from largest value searching section 132 , to obtain a normalized low band spectrum. In other words, amplitude normalizing section 133 normalizes the sub-band divisional core-coding low band spectrums in the respective sub-bands using the sub-band largest values in the sub-bands, respectively. For example, normalized low band spectrum Mn can be expressed by Equation 2 below.
[
2
]
Mn
[
j
]
=
M
[
j
]
(
M
max
[
s
]
+
ɛ
)
,
w
*
(
s
-
1
)
<
j
<
w
*
s
,
1
≤
s
≤
S
(
Equation
2
)
In Equation 2, ε represents a minimal value to avoid division by zero. Amplitude normalizing section 133 can perform the above processing for each of the sub-bands to obtain a normalized low band spectrum.
Next, the operation of sub-band amplitude normalizing section 103 described above will be described with reference to FIGS. 6, 7 and 8 .
FIG. 6 illustrates an example of envelope calculation processing in the related art. In FIG. 6 , the abscissa axis represents frequency and the ordinate axis represents spectrum power. In FIG. 6 , a band (low band part) that is subject to encoding (range of encoding) by a core coding section is divided into six sub-bands SB0 to SB5. In other words, a band (extension band) that is higher than SB5 in FIG. 6 is subject to encoding (range of encoding) by an extension band coding section. Also, the curved dashed line in FIG. 6 indicates an envelope of an input signal spectrum (input signal envelope).
Furthermore, in FIG. 6 , it is assumed that the core coding section has encoded spectrum parts at positions p0 to p10 by means of transform coding. In FIGS. 6, 7 and 8 , the encoded spectrum parts are illustrated in terms of spectrum power. As illustrated in FIG. 6 , it is difficult to calculate a correct envelope (dashed line in FIG. 6 ) from a discrete spectrum (core-coding low band spectrum: spectrum parts at positions p0 to p10). For example, in FIG. 6 , the estimated envelope indicated by the curved solid line (envelope obtained from the core-coding low band spectrum) is different from the input signal envelope indicated by the curved dashed line.
FIG. 7 illustrates an example of a normalized low band spectrum calculated from an estimated envelope (incorrect envelope) in the related art, which is indicated as spectrum power. In FIG. 7 , symbols that are the same as those in FIG. 6 represent the same in FIG. 6 . If a low band spectrum is normalized using an incorrect envelope, as illustrated in FIG. 7 , in the normalized low band spectrum, variations in spectrum amplitude in the respective sub-bands become large. For example, in FIG. 7 , the spectrum amplitudes in sub-bands SB3 and SB5 are larger than the spectrum amplitudes in sub-bands SB0 and SB1. In particular, if an extremely-incorrect envelope is estimated in a band, the spectrum in the band has extremely large power compared to the spectrums in the other bands.
On the other hand, FIG. 8 illustrates a normalized low band spectrum obtained by sub-band amplitude normalizing section 103 in the present embodiment, which is indicated as spectrum power. In FIG. 8 , symbols that are the same as those in FIG. 7 represent the same in FIG. 7 .
In sub-band amplitude normalizing section 103 , largest value searching section 132 makes a search to find a sub-band largest value in each of sub-bands SB0 to SB5. For example, as illustrated in FIG. 8 , largest value searching section 132 identifies spectrum part (p1) having a largest amplitude value from among spectrum parts (p0 and p1) included in SB0 as a sub-band largest value for SB0. Likewise, as illustrated in FIG. 8 , largest value searching section 132 identifies a spectrum part (p2) having a largest amplitude value from among spectrum parts (p2 and p3) included in SB1 as a sub-band largest value for SB1. Largest value searching section 132 also identifies spectrum parts (p5, p7, p8 and p10) each having a largest amplitude value as sub-band largest values for respective sub-bands SB2 to SB5 illustrated in FIG. 8 .
Next, amplitude normalizing section 133 normalizes the spectrum included in each sub-band (sub-band divisional core-coding low band spectrum) using the sub-band largest value for the sub-band. For example, amplitude normalizing section 133 normalizes spectrum parts p0 and p1 in SB0 illustrated in FIG. 8 using the relevant sub-band largest value (amplitude value of spectrum part p1). Likewise, amplitude normalizing section 133 normalizes spectrum parts p2 and p3 in SB1 illustrated in FIG. 8 using the relevant sub-band largest value (amplitude value of spectrum part p2). The same applies to SB2 to SB5.
As a result, a spectrum having a largest amplitude in each sub-band certainly has a value of 1.0. In FIG. 8 , also, spectrum parts each having the largest amplitude have spectrum power of 1.0. However, here, no effects of minimal values as countermeasures for division by zero are taken into account. In other words, in all of sub-bands SB0 to SB5 illustrated in FIG. 8 , the respective largest amplitude values after normalization are uniformed to be the same value (1.0).
Consequently, the characteristics of the spectrum can be made flat through the sub-bands, and thus, no spectrum part having an extremely-large amplitude can be generated. In other words, sub-band amplitude normalizing section 103 can obtain a normalized low band spectrum that is highly correlated with an extension band spectrum (in general, a spectrum whose frequency characteristics are flat compared to those of a low band spectrum). In other words, sub-band amplitude normalizing section 103 can transform a core-coding low band spectrum generated as a result of an input signal spectrum being encoded and decoded by core coding section 102 into a normalized low band spectrum whose characteristics are flat. Consequently, coding apparatus 100 can obtain a normalized low band spectrum that is highly correlated with an extension band spectrum, enabling enhancement in sound quality in the high band.
The details of the configuration and operation of sub-band amplitude normalizing section 103 have been described above.
As described above, according to the present embodiment, in sub-band amplitude normalizing section 103 of coding apparatus 100 , largest value searching section 132 makes a search to find a largest amplitude value in each of the plurality of sub-bands of a core-coding low band spectrum, the sub-bands being obtained by dividing a low band part of an input signal, the low band part being not higher than a predetermined frequency (sub-band largest value), and amplitude normalizing section 133 normalizes the core-coding low band spectrum in each sub-band using the sub-band largest value of the sub-band. Then, coding apparatus 100 encodes an extension band spectrum using the normalized core-coding low band spectrum (normalized low band spectrum).
Consequently, even if a core-coding low band spectrum obtained as a result of encoding by core coding section 102 is a discrete spectrum, coding apparatus 100 prevents generation of a spectrum part having an extremely-large amplitude, enabling provision of a normalized low band spectrum whose characteristics are flat. Consequently, in the normalized low band spectrum, no spectrum part having an extremely-large amplitude exists, and thus, coding apparatus 100 copies a spectrum in a low band part having a sufficiently-lowered peaking property to a high band part (extension band), whereby generation of a spectrum having an excessively-high peaking property in the extension band (high band part) can be prevented, which in turn, enables generation of a high-quality extension band spectrum.
Embodiment 2
As described above, when encoding a spectrum in an extension band (high band part) of an input signal, a coding apparatus uses a spectrum resulting from a normalized low band spectrum being copied to the extension band as a spectrum fine structure. This can be regarded as utilizing a harmonic structure in a spectrum in a low band part of an input signal. In other words, provision of a clearer decoded signal can be expected by emphasizing the harmonic structure in the spectrum in the low band part of the input signal.
Therefore, in the present embodiment, a case where a harmonic structure in a normalized low band spectrum obtained in Embodiment 1 is emphasized further will be described.
FIG. 9 is a block diagram illustrating a configuration of coding apparatus 300 according to the present embodiment. In coding apparatus 300 illustrated in FIG. 9 , components other than harmonic emphasizing section 301 are the same as those of coding apparatus 100 ( FIG. 1 ) according to Embodiment 1 and thus are provided with reference numerals that are the same as those of coding apparatus 100 , and a description thereof will be omitted herein.
Harmonic emphasizing section 301 emphasizes a harmonic structure in a normalized low band spectrum received as input from sub-band amplitude normalizing section 103 and outputs the normalized low band spectrum with the harmonic structure emphasized (harmonic-emphasized normalized low band spectrum) to band searching section 104 and gain calculating section 105 .
In other words, band searching section 104 makes a search to find a particular band (a band having a largest correlation value) using the harmonic-emphasized normalized low band spectrum and an input extension band spectrum. Also, gain calculating section 105 calculates a gain between a spectrum obtained as a result of the harmonic-emphasized normalized low band spectrum in the particular band being copied to the extension band (spectrum fine structure) and the input extension band spectrum.
FIG. 10 is a block diagram illustrating a configuration of decoding apparatus 400 according to the present embodiment. In decoding apparatus 400 illustrated in FIG. 10 , components other than harmonic emphasizing section 401 are the same as those of decoding apparatus 200 ( FIG. 3 ) according to Embodiment 1, and thus, are provided with reference numerals that are the same as those of decoding apparatus 200 and a description thereof will be omitted here. Also, the configuration and operation of harmonic emphasizing section 401 are the same as those of harmonic emphasizing section 301 illustrated in FIG. 9 , and thus, a detailed description thereof will be omitted.
Next, details of the harmonic structure emphasis processing in harmonic emphasizing section 301 will be described.
As described above, core coding section 102 encodes a low band spectrum only in a small number of pulses when the bit rate is low. In this case, spectrum parts having large energy can preferentially be encoded. Also, spectrum parts having large energy can be highly likely to be important spectrum parts forming a harmonic structure. Furthermore, spectrum parts (spectrum parts having high energy) forming a harmonic structure are supposed to be discretely distributed.
Based on the above, harmonic emphasizing section 301 leaves a spectrum part having a large amplitude in each sub-band of a normalized low band spectrum (spectrum part corresponding to a sub-band largest value in each sub-band) and removes spectrum parts other than the spectrum part corresponding to the sub-band largest value in each sub-band. In a harmonic-emphasized normalized low band spectrum resulting from this, many spectrum parts forming the harmonic structure remain, enabling emphasis of the harmonic structure.
FIGS. 11A and 11B illustrate harmonic emphasis processing in harmonic emphasizing section 301 . FIG. 11A indicates the envelope of the input signal spectrum (input signal envelope) illustrated in FIG. 6 and spectrum power of a low band spectrum (core-coding low band spectrum) encoded by core coding section 102 . FIG. 11B indicates a harmonic-emphasized normalized low band spectrum obtained in the present embodiment as spectrum power. In FIGS. 11A and 11B , symbols that are the same as those in FIG. 6, 7 or 8 represent the same in FIG. 6, 7 or 8 .
Also, here, for simplicity, a case where only one pulse is left per sub-band will be described as an example.
Pulses (p2, p5 and p8) indicated by the solid lines in FIGS. 11A and 11B each indicate spectrum power of an encoded spectrum part in the vicinity of a peak of the input signal envelope, and are spectrum parts having a largest amplitude (absolute value) in respective sub-bands (SB1, SB2 and SB4) (spectrum parts corresponding to a sub-band largest value). Pulses (p0, p3, p4, p6 and p9) indicated by the dotted lines in FIGS. 11A and 11B each indicate spectrum power whose amplitude value is not largest in the respective sub-band. Pulses (p1, p7 and p10) indicated by the alternate long and short dash lines in FIGS. 11A and 11B indicate spectrum parts that are not in the vicinity of a peak of the envelope but each have a largest amplitude (absolute value) in the respective sub-bands.
Harmonic emphasizing section 301 leaves spectrum parts each having a sub-band largest value in a normalized low band spectrum and removes spectrum parts other than the spectrum parts each having a sub-band largest value. In other words, in FIGS. 11A and 11 B, harmonic emphasizing section 301 leaves spectrum parts (pulses) p1, p2, p5, p7, p8 and p10 and removes spectrum parts (pulses) p0, p3, p4, p6 and p9.
Consequently, as illustrated in FIG. 11A , all of encoded spectrum parts (solid-line spectrum parts) in the vicinity of peaks of the input signal envelope are left and the spectrum parts other than such spectrum parts are removed, which in turn, enables harmonic structure enhancement.
The above-described configuration and operation of coding apparatus 300 enables a harmonic structure to be expressed in an extension band spectrum. In other words, coding apparatus 300 enables a harmonic structure to be emphasized even in an extension band of an input signal, and thus enables generation of a clearer and higher-quality extension band spectrum compared to Embodiment 1. Consequently, coding apparatus 300 can generate an extension band spectrum of clear and high quality sound.
Also, according to the present embodiment, as in Embodiment 1, even if a low band spectrum obtained by encoding by core coding section 102 is a discrete spectrum, coding apparatus 300 prevents generation of a spectrum part having an extremely-large amplitude, enabling a normalized low band spectrum whose characteristics are flat. Consequently, as in Embodiment 1, generation of a spectrum having an excessively-high peaking property is prevented in the extension band (high band part), enabling generation of a high-quality extension band spectrum.
In the present embodiment, a case where harmonic emphasizing section 301 leaves only a spectrum part having a largest amplitude value in each sub-band (sub-band largest value) has been described. However, it is possible that harmonic emphasizing section 301 sets a predetermined ratio (for example, 0.75) of an amplitude relative to a sub-band largest value as a threshold (hereinafter referred to as “minimal spectrum part removal threshold”) in each sub-band, leave a spectrum part having an amplitude equal to or larger than the minimal spectrum part removal threshold and suppresses or removes spectrum parts each having an amplitude smaller than the minimal spectrum part removal threshold (that is, spectrum parts other than the spectrum part having an amplitude equal to or larger than the minimal spectrum part removal threshold). Also, harmonic emphasizing section 301 may even suppresses or remove a spectrum part having a sub-band largest value if the amplitude of the spectrum part before normalization is small.
Embodiment 3
In Embodiment 3, the degree of emphasis of a harmonic structure in the harmonic emphasis processing in Embodiment 2 is adaptively controlled.
FIG. 12 is a block diagram illustrating a configuration of coding apparatus 500 according to the present embodiment. In coding apparatus 500 illustrated in FIG. 12 , components other than sub-band amplitude normalizing section 501 , threshold controlling section 502 and harmonic emphasizing section 503 are the same as those of coding apparatus 300 ( FIG. 9 ) according to Embodiment 2, and thus are provided with reference numerals that are the same as those of coding apparatus 300 , and a description thereof will be omitted here.
Sub-band amplitude normalizing section 501 outputs a normalized low band spectrum to threshold controlling section 502 and harmonic emphasizing section 503 , and outputs a sub-band largest value in each sub-band, which corresponds to the output of largest value searching section 132 ( FIG. 5 ), to threshold controlling section 502 .
Threshold controlling section 502 controls a minimal spectrum part removal threshold using a normalized low band spectrum and a sub-band largest value received as input from sub-band amplitude normalizing section 501 . Here, the minimal spectrum part removal threshold is a threshold for determining whether or not a normalized low band spectrum part (pulse) is removed (or suppressed) in harmonic emphasis processing in harmonic emphasizing section 503 . For example, threshold controlling section 502 calculates a minimal spectrum part removal threshold based on the degree of importance of each sub-band in the low band spectrum. Threshold controlling section 502 outputs the minimal spectrum part removal thresholds to harmonic emphasizing section 503 .
Harmonic emphasizing section 503 performs harmonic emphasis processing on a normalized low band spectrum received as input from sub-band amplitude normalizing section 501 , using the minimal spectrum part removal thresholds received as input from threshold controlling section 502 . More specifically, harmonic emphasizing section 503 compares each component in each sub-band of the normalized low band spectrum and the minimal spectrum part removal threshold set for the sub-band. For example, harmonic emphasizing section 503 leaves spectrum parts (pulses) having an amplitude equal to or larger than the minimal spectrum part removal threshold and removes (or suppresses) spectrum parts (pulses) having an amplitude smaller than the minimal spectrum part removal threshold.
FIG. 13 is a block diagram illustrating an internal configuration of decoding apparatus 600 according to the present embodiment. In decoding apparatus 600 illustrated in FIG. 13 , components other than sub-band amplitude normalizing section 601 , threshold controlling section 602 and harmonic emphasizing section 603 are the same as those of decoding apparatus 400 ( FIG. 10 ) according to Embodiment 2 and thus are provided with reference numerals that are the same as those of decoding apparatus 400 , and a description thereof will be omitted here. The configuration and operation of sub-band amplitude normalizing section 601 , threshold controlling section 602 and harmonic emphasizing section 603 are the same as those of sub-band amplitude normalizing section 501 , threshold controlling section 502 and harmonic emphasizing section 503 illustrated in FIG. 12 , and thus, a detailed description thereof will be omitted.
Next, details of minimal spectrum part removal threshold setting processing in threshold controlling section 502 and harmonic emphasis processing in harmonic emphasizing section 503 will be described.
In a spectrum in a low band part of an input signal, a sub-band is aurally more important as the largest value (sub-band largest value) in amplitude of the spectrum in the sub-band is larger. Thus, in such sub-band, it is preferable to leave not only a spectrum part corresponding to a sub-band largest value but also spectrum parts which are located around the spectrum part corresponding to the sub-band largest value and each of which has a large amplitude.
On the other hand, it is less likely that spectrum parts in a sub-band of a low band spectrum that has a small sub-band largest value are included in a harmonic structure. Thus, in such sub-band, it is preferable to leave a smallest possible number of spectrum parts only.
An example of setting of minimal spectrum part removal threshold in threshold controlling section 502 will be described taking into account the above described factors.
First, threshold controlling section 502 makes a search to find a largest value from among sub-band largest values in the respective sub-bands and determines the found largest value as an overall sub-band largest value.
Next, threshold controlling section 502 determines a sub-band having a sub-band largest value that is, for example, 0.5 times or more the overall sub-band largest value as a sub-band that is aurally important, and sets the minimal spectrum part removal threshold to be low. For example, threshold controlling section 502 sets the minimal spectrum part removal threshold for such sub-band to 0.25.
On the other hand, threshold controlling section 502 determines a sub-band having a sub-band largest value that is, for example, smaller than 0.5 times the overall sub-band largest value as a sub-band that is not aurally important, and sets the minimal spectrum part removal threshold to be large. For example, threshold controlling section 502 sets the minimal spectrum part removal threshold for such sub-band to 0.95.
In other words, threshold controlling section 502 sets a small minimal spectrum part removal threshold (threshold for harmonic emphasizing section 503 to determine whether or not to leave or remove a normalized low band spectrum part) for a sub-band from among a plurality of sub-bands in a low band part of an input signal if a ratio of the sub-band largest value relative to the overall sub-band largest value (largest value in the sub-band largest values in the respective sub-bands) in the sub-band is equal to or larger than a predetermined value (here, 0.5) and sets a large minimal spectrum part removal threshold for a sub-band from the plurality of sub-bands if the ratio of the sub-band largest value relative to the overall sub-band largest value in the sub-band is smaller than the predetermined value (here 0.5).
Consequently, harmonic emphasizing section 503 , for example, here, leaves spectrum parts having an amplitude that is 0.25 times or more the relevant sub-band largest value in an aurally-important sub-band and removes spectrum parts having an amplitude that is smaller than 0.25 times the sub-band largest value. In other words, it is highly likely that more spectrum parts are left in aurally-important sub-bands.
On the other hand, harmonic emphasizing section 503 , for example, here, leaves spectrum parts having an amplitude that is 0.95 times or more the relevant sub-band largest value in a sub-band that is not aurally important and removes spectrum parts having an amplitude that is smaller than 0.95 times the sub-band largest value. In other words, it is highly likely that only an extremely-small number of spectrum parts are left in a sub-band that is not aurally important.
The above-described configuration and operation of coding apparatus 500 makes a large number of spectrum parts be left in a sub-band that is aurally important and a small number of spectrum parts be left in a sub-band that is not aurally important in a normalized low band spectrum. Consequently, a clear decoded signal resulting from harmonic emphasis can be provided. Furthermore, a large number of spectrum fine structures in aurally-important bands are left, which in turn, enables provision of a more natural decoded signal.
Where the sub-band largest value is an extremely small value and it is determined that a sub-band corresponding to the sub-band largest value is a sub-band that is aurally not indispensable, threshold controlling section 502 may set a minimal spectrum part removal threshold that is larger than 1.0. Consequently, harmonic emphasizing section 503 removes all of spectrum parts (largest value: 1.0) in such sub-band, enabling further emphasis of the harmonic structure.
As described above, according to the present embodiment, when emphasizing a harmonic structure in a normalized low band spectrum, coding apparatus 500 adaptively controls the degree of harmonic emphasis in each sub-band using a sub-band largest value (or sub-band energy) in the sub-band. More specifically, coding apparatus 500 performs control so that a larger number of fine structures in the spectrum are left in sub-bands having a larger sub-band largest value (i.e., aurally-important sub-bands) and only spectrum parts relating to the sub-band largest value (that is, spectrum parts relating to a harmonic structure) are left in sub-bands having a smaller sub-band largest value (sub-bands that are not aurally important).
Consequently, as in Embodiment 2, coding apparatus 500 enables emphasis of a harmonic structure also in an extension band, enabling generation of a clear and high-quality extension band spectrum. Furthermore, according to the present embodiment, spectrum fine structures in aurally-important sub-bands are left more precisely, enabling provision of a more natural decoded signal.
Furthermore, according to the present embodiment, as in Embodiment 1, even if a low band spectrum obtained by encoding in core coding section 102 is a discrete spectrum, coding apparatus 500 limits generation of a spectrum part having an extremely-large amplitude, enabling provision of a normalized low band spectrum whose characteristics are flat. Consequently, as in Embodiment 1, generation of a spectrum having an excessively-high peaking property in an extension band (high band part) is prevented, which in turn, enables generation of a high-quality extension band spectrum.
Embodiment 4
An input signal does not always have only a small energy bias in an extension band spectrum. For example, like a sound of a metallophone, a signal having a large energy bias in an extension band spectrum exists. In the case of such input signal, the sound quality can be enhanced by performing normalization using a spectrum power envelope to generate a normalized extension band spectrum according to the related art, rather than generating a normalized low band spectrum in sub-band amplitude normalizing section 103 . In addition, if a general music signal like in an orchestra and a signal of a sound having a large energy bias like a metallophone are mixed in one input sample, use of a method for determining and selecting a low band spectrum normalization method for each frame enables stable sound quality enhancement.
In Embodiment 4, a description will be given of a configuration in which a normalized extension band spectrum is generated by determining a characteristic of an input signal for each frame and switching between a method for performing normalization using a largest value in a spectrum included in each sub-band and a method for performing normalization using a spectrum power envelope based on a result of the determination.
FIG. 14 is a block diagram illustrating a configuration of coding apparatus 700 according to the present embodiment. In coding apparatus 700 illustrated in FIG. 14 , components other than normalization method determining section 701 , spectrum envelope normalizing section 702 and switches 703 and 704 are the same as those of coding apparatus 100 ( FIG. 1 ) according to Embodiment 1 and thus are provided with reference numerals that are the same as those of coding apparatus 100 , and a description thereof will be omitted here.
Normalization method determining section 701 analyzes a core-coding low band spectrum to determine whether sub-band amplitude normalizing section 103 or spectrum envelope normalizing section 702 is used for normalization of the core-coding low band spectrum, and outputs determination information indicating a result of the determination to switches 703 and 704 . Here, it is assumed that if the determination information indicates “0,” sub-band amplitude normalizing section 103 is selected, and the determination information indicates “1,” spectrum envelope normalizing section 702 is selected.
Normalization method determining section 701 analyzes an intensity of the peaking property of an input core-coding low band spectrum and selects sub-band amplitude normalizing section 103 if the peaking property is smaller than a predetermined threshold, and selects spectrum envelope normalizing section 702 if the peaking property is larger than the predetermined threshold. The magnitude of the peaking property is determined by comparison between a parameter such as, for example, a sub-band energy dispersion value, a spectrum flatness measure expressed by a ratio of an arithmetic average to a geometric average of the spectrum or the number of spectrum parts having a value exceeding a threshold prescribed by an average value and a standard deviation of spectrum part amplitudes, and a threshold.
Spectrum envelope normalizing section 702 normalizes the core-coding low band spectrum input from core coding section 102 to generate a normalized low band spectrum. Details of a configuration and operation of spectrum envelope normalizing section 702 will be described later.
Switch 703 connects core coding section 102 and sub-band amplitude normalizing section 103 if the determination information indicates “0,” and connects core coding section 102 and spectrum envelope normalizing section 702 if the determination information indicates “1.” Switch 704 connects sub-band amplitude normalizing section 103 and band searching section 104 if the determination information indicates “0,” and connects spectrum envelope normalizing section 702 and band searching section 104 if the determination information indicates “1.”
FIG. 15 is a block diagram illustrating a configuration of decoding apparatus 800 according to the present embodiment. In decoding apparatus 800 illustrated in FIG. 15 , components other than normalization method determining section 801 , spectrum envelope normalizing section 802 and switches 803 and 804 are the same as those of decoding apparatus 200 ( FIG. 3 ) according to Embodiment 1 and thus are provided with reference numerals that are the same as those of decoding apparatus 200 , and a description thereof will be omitted here.
The configuration and operation of normalization method determining section 801 are the same as those of normalization method determining section 701 illustrated in FIG. 14 , and a detailed description thereof will be omitted. Normalization method determining section 801 uses a method that is the same as a method selected in normalization method determining section 701 to obtain determination information that is the same as that obtained in normalization method determining section 701 .
Spectrum envelope normalizing section 802 normalizes a core-coding low band spectrum input from core decoding section 202 to generate a normalized low band spectrum. A configuration and operation of spectrum envelope normalizing section 802 are the same as those of spectrum envelope normalizing section 702 illustrated in FIG. 14 (which will be described later) and thus, a detailed description thereof will be omitted. Furthermore, operation of switches 803 and 804 is the same as that of switches 703 and 704 illustrated in FIG. 14 and thus, a detailed description thereof will be omitted.
Switch 803 connects core decoding section 202 and sub-band amplitude normalizing section 203 if the determination information indicates “0,” and connects core decoding section 202 and spectrum envelope normalizing section 802 if the determination information indicates “1.” Switch 804 connects sub-band amplitude normalizing section 203 and extension band decoding section 204 if the determination information indicates “0,” and connects spectrum envelope normalizing section 802 and extension band decoding section 204 if the determination information indicates “1.”
Next, a configuration and operation of spectrum envelope normalizing section 702 will be described in detail with reference to FIG. 16 . Spectrum envelope normalizing section 702 illustrated in FIG. 16 includes sub-band dividing section 731 , sub-band energy calculating section 732 , smoothening section 733 and spectrum correcting section 734 .
Sub-band dividing section 731 divides a core-coding low band spectrum into a plurality of sub-bands and outputs the plurality of sub-bands to sub-band energy calculating section 732 . Sub-band energy calculating section 732 calculates energy of the core-coding low band spectrum in each sub-band (sub-band energy) and outputs the calculated energy to smoothening section 733 . In order to smooth variations of the energy to estimate a spectrum envelope, smoothening section 733 smoothens the sub-band energy on the frequency axis. The smoothening is performed by, e.g., weighted average processing using neighbor sub-band energy or processing for autoregression of sub-band energy from a low-frequency to a high frequency. Smoothening section 733 regards smoothened sub-band energy calculated as described above as an estimated value of the spectrum envelope and outputs the estimated value to spectrum correcting section 734 . Spectrum correcting section 734 multiplies the core-coding low band spectrum by the reciprocal of the smoothened sub-band energy to remove spectrum envelope components from the core-coding low band spectrum to generate and output a normalized low band spectrum.
Although in the present embodiment, the configuration that eliminates the need to transmit determination information to decoding apparatus 800 by analyzing a core-coding low band spectrum to obtain determination information has been described, the present invention is not limited to this configuration and a configuration in which determination information is transmitted to decoding apparatus 800 may be employed. In this case, the determination information is determined based on information that cannot be generated by decoding apparatus 800 . For example, a high band part in an input signal spectrum is analyzed and determination information is determined based on, e.g., bias energy or an intensity of a peaking property of a spectrum included in the high band part.
Also, the present invention may have a configuration resulting from incorporating the harmonic emphasizing section described in Embodiment 2 and the threshold controlling section described in Embodiment 3 into Embodiment 4.
Embodiment 5
In Embodiment 1, a description has been given of the method for generating a candidate spectrum to be used for correlation value calculation so that the candidate spectrum has a starting point at a position shifted by a predetermined sample value expressed by a lag candidate in band searching section 104 .
In Embodiment 5, a description will be given of a method in which a lag candidate does not indicate the amount of shift by a given sample value but indicates what number normalized low band spectrum part included in a low band part. FIG. 17 is a diagram illustrating how band searching section 104 in the present embodiment operates.
As illustrated in FIG. 17 , lag candidates (L0 to L3) each indicate the position of a normalized low band spectrum part whose amplitude value is not zero, as a starting point. In other words, as the lag candidate number is increased by one, positions of normalized low band spectrum parts whose amplitude values are zero are skipped and a position of a following normalized low band spectrum part is set as a starting point. A spectrum to be extracted is one included in a bandwidth that is the same as a bandwidth of an input extension band spectrum (entirety or part of an extension hand) from a frequency at the starting point. The extracted spectrum is output to correlation value calculating section 104 a as a candidate spectrum for correlation value calculation.
Consequently, even if the number of bits assigned to lag information is small, a wide search range can be set, at least one spectrum part certainly exists in a candidate spectrum. Accordingly, the problem of a candidate spectrum with spectrum parts whose amplitude values are all zero can be avoided. Also, at least one spectrum part exists in a low band part of a candidate spectrum, which matches a general characteristic of speech signals and music signals that signal energy is large in a low band relative to a high band, enabling sound quality enhancement.
FIG. 18 is a diagram illustrating how extension band decoding section 204 in the present embodiment operates. In the present embodiment, what number normalized low band spectrum part is to be used as a starting point is determined according to received lag information and a normalized low band spectrum included in a bandwidth of an extension band spectrum from the starting point is generated as an extension band spectrum (before multiplication by a gain). In the example in FIG. 18 , lag information L2 has been obtained, and thus a frequency where normalized low band spectrum part f11 is positioned is used as a starting point.
Embodiment 6
In the above embodiment, an input signal is divided into frames of around 20 milliseconds and a spectrum of each frame is divided into a low band spectrum and an extension band spectrum, and encoding processing is performed using different coding methods for the low band spectrum and the extension band spectrum. In this case, the number of bits allocated to the extension band part is determined based on which coding method is to be used, and if a method using a constant bit rate is used, the bit count is constant. This means that even if energy of the extension band spectrum is very small, a fixed number of bits are constantly consumed, which may result in inefficient bit allocation.
Meanwhile, as in the related art, a case where processing for encoding an entire band of an input signal spectrum using transform coding like in a core coding section will be considered.
FIG. 19 is a diagram illustrating division of an input signal spectrum into a plurality of sub-bands.
As illustrated in FIG. 19 , in transform coding, generally, an input signal spectrum is divided into a plurality of sub-bands, and bits are allocated according to energy in each sub-band (sub-band energy). More specifically, a larger number of bits are allocated to a sub-band as the sub-band has larger sub-band energy, and a smaller number of bits are allocated to a sub-band as the sub-band has smaller sub-band energy. In FIG. 19 , a configuration in which a sub-band in a lower band has a smaller width and a sub-band has a larger width as the sub-band is positioned in a higher band is employed. This configuration is related to a critical band width provided by modeling the human auditory sense characteristics, and since the lower band is considered more important for the sound quality, such configuration is intended to perform high-quality encoding by providing small sub-band widths in the low band to densely allocate bits to the low band.
If transform coding processing is performed on an input signal spectrum in such sub-band configuration, a large number of bits may be allocated to the extension band part depending on the characteristics of the extension band spectrum. In this case, since the sub-bands in the extension band part each have a large sub-band width, even if a large number of bits are allocated to the extension band part, only a small number of pulses can be provided for expressing the extension band spectrum. Also, as a result of a large number of bits being allocated to the extension band part, the number of bits allocated to the low band part is reduced, which causes sound quality deterioration.
Therefore, in the present embodiment, when an input signal spectrum is encoded using transform coding, if a large number of bits are allocated to the extension band part, the extension band spectrum is encoded in an extension band coding section and the low band spectrum is subjected to transform coding processing. On the other hand, when an input signal spectrum is encoded using transform coding, if only a small number of bits are allocated to the extension band part, an entire band of the input signal spectrum is subjected to encoding processing using transform coding. Such switching of coding methods is made on a frame-by-frame basis.
The present embodiment provides the following effects. When an input signal spectrum is encoded using transform coding, if a large number of bits are allocated to the extension band part, switching is made so that the extension band spectrum is encoded by an extension band coding section to efficiently perform the encoding using a small number of bits, whereby encoding for the extension band can be performed using a bit count that is smaller than a bit count that would be consumed for the extension band if transform coding is employed for the entire band, and the resulting extra bits are re-allocated to the low band part. Consequently, noisiness occurred in the low band part are reduced as well as a feeling of an extensive bandwidth is maintained by extension band coding, which in turn, enables sound quality enhancement.
The present embodiment will be described taking, as an example, a configuration in which the total number of bits to be allocated to sub-bands in the extension band when an entire input signal spectrum is encoded by a core layer coding section and the number of bits to be consumed when the extension band spectrum is encoded by the extension band coding section are compared. A detailed description of the embodiment will be described below.
FIG. 20 is a block diagram illustrating a configuration of coding apparatus 900 according to Embodiment 6. In FIG. 20 , components that overlap with those in FIG. 1 are provided with symbols that are the same as those in FIG. 1 , and a description thereof will be omitted.
The present embodiment is configured so that switching is made between a case where an entire input signal spectrum is encoded by transform coding section 904 (hereinafter referred to as “transform coding mode”) and a case where encoding is performed using a combination of core coding section 102 and extension band coding section 106 as in Embodiment 1 (hereinafter referred to as “extension coding mode”). A detailed description of operation of each component will be provided below.
Time-frequency transform section 901 transforms an input time-domain input signal (including a speech signal or/and a music signal) into a frequency-domain signal and outputs the resulting input signal spectrum to mode determining section 902 , bit allocation determining section 903 and transform coding section 904 or outputs the input signal spectrum to mode determining section 902 , bit allocation determining section 905 and core coding section 102 . Here, the below description will be given on the premise that MDCT is employed for time-frequency transform processing in time-frequency transform section 901 . However, the time-frequency changing section may use an orthogonal transform such as FFT (fast Fourier transform) or DCT (discrete cosine transform) for transform from the time domain to the frequency domain.
Mode determining section 902 determines a mode for encoding an input signal spectrum input from time-frequency transform section 901 for each frame, using the input signal spectrum. Mode determining section 902 outputs information on the determination to switch 907 , switch 908 and multiplexing section 906 as mode determination information. Details of the operation will be described later.
Switch 907 switches coding modes using the mode determination information input from mode determining section 902 . Switch 907 connects time-frequency transform section 901 , and transform coding section 904 if the mode determination information indicates “0,” and connects time-frequency transform section 901 and core coding section 102 if the mode determination information indicates “1.”
If the mode determination information indicates “0,” bit allocation determining section 903 outputs information representing the number of bits to be allocated to each sub-band of the input signal spectrum that is received as input from time-frequency transform section 901 (bit allocation information) to transform coding section 904 , using the input signal spectrum. A detailed description of bit allocation determining section 903 will be described later.
Transform coding section 904 performs transform coding processing of the input signal spectrum received as input from time-frequency transform section 901 based on the bit allocation information received as input from bit allocation determining section 903 to generate transform-encoded data. Then, transform coding section 904 outputs the transform-encoded data to multiplexing section 906 .
If the mode determination information indicates “1,” the operation is performed in the extension coding mode. First, bit allocation determining section 905 outputs information representing the number of bits to be allocated to each sub-band of the low band spectrum and extension band coding section 106 (bit allocation information) to core coding section 102 and extension band coding section 106 using the input signal spectrum received as input from time-frequency transform section 901 . A detailed description of bit allocation determining section 905 will be described later. Subsequently, core coding section 102 encodes the low band spectrum using the bit allocation information output from bit allocation determining section 905 and the input signal spectrum received as input from time-frequency transform section 901 , and extension band coding section 106 encodes the extension band spectrum also using the bit allocation information output from bit allocation determining section 905 and the input signal spectrum received as input from time-frequency transform section 901 .
In cooperation with switch 907 , switch 908 connects transform coding section 904 and multiplexing section 906 if the mode determination information received as input from mode determining section 902 indicates “0” and connects core coding section 102 and multiplexing section 906 if the mode determination information indicates “1.”
Multiplexing section 906 multiplexes the transform-encoded data input from transform coding section 904 and the mode determination information received as input from mode determining section 902 or multiplexes core-encoded data received as input from core coding section 102 , extension-band encoded data received as input from extension band coding section 106 and the mode determination information received as input from mode determining section 902 , and outputs the resulting encoded data.
Next, a detailed description of bit allocation determining section 903 and bit allocation determining section 905 will be provided.
Here, bit allocation determining section 903 allocates a large number of bits to sub-bands having large energy in the input signal spectrum and a small number of bits to sub-bands having small energy in the input signal spectrum. For example, the bits are allocated to the sub-bands according to Equation 3.
[
3
]
B
sub
[
j
]
=
B
total
N
+
1
2
log
2
(
E
[
j
]
∏
k
=
1
N
E
[
k
]
N
)
,
1
≤
j
≤
N
(
Equation
3
)
Here, B sub represents the number of bits to be allocated to each sub-band, N represents the total number of sub-bands in an input signal spectrum, B total represents the total number of bits that can be allocated for encoding of the input signal spectrum, E represents energy in each sub-band, and j represents an index indicating a sub-band.
As described above, the number of bits to be allocated to each sub-band is determined according to the magnitude of the energy of the sub-band relative to an average sub-band energy value, and a large number of bits are allocated to sub-bands having large sub-band energy and a small number of bits are allocated to sub-bands having small sub-band energy.
Meanwhile, bit allocation determining section 905 allocates bits to the sub-bands in the low band spectrum of the input signal and extension band coding section 106 .
The allocation of bits to the sub-bands of the low band spectrum is performed as in bit allocation determining section 903 . For example, the bit allocation is performed according to Equation 4.
[
4
]
B
sub
[
j
]
=
B
total
-
B
SWB
S
+
1
2
log
2
(
E
[
j
]
∏
k
=
1
S
E
[
k
]
S
)
,
1
≤
j
≤
S
(
Equation
4
)
Here, S represents the total number of sub-bands in the low band spectrum and B SWB represents the number of bits to be allocated to extension band coding section 106 .
In Equations 3 and 4, if the number of bits to be allocated to a sub-band has a negative value, the number of bits to be allocated to the sub-band is forcibly set to zero.
For bit count B SWB of bits to be allocated to extension band coding section 106 , a value designed in advance is used. For example, if the total number of bits that can be used for encoding is 12 kbps, and 10 kbps in the total number of bits are allocated to core coding section 102 , 2 kbps is allocated to extension band coding section 106 . For example, if the frame length is 20 milliseconds, bit count B SWB of bits to be allocated to extension band coding section 106 for one frame is 2,000×0.02=40 bits.
Next, details of mode determining section 902 will be described with reference to FIG. 21 .
FIG. 21 is a diagram illustrating a configuration of mode determining section 902 .
Mode determining section 902 calculates the number of bits to be required for encoding of an extension band spectrum in each of coding modes for an input signal spectrum and compares counts of bits to be consumed to make a determination.
Bit count 1 calculating section 1001 calculates the total number of bits to be allocated to the extension band part in the transform coding mode. First, bits are allocated to each sub-band of the input signal spectrum. The bit allocation in this case is performed in such a manner as in bit allocation determining section 903 , and a description thereof will be omitted. Bit count 1 calculating section 1001 calculates the total number of bits allocated to the sub-bands in the extension band part from among the bits allocated to the sub-bands and outputs the total number of bits to consumed bit count comparing section 1002 as bit count 1.
Consumed bit count comparing section 1002 compares the total number of bits to be allocated to the sub-bands in the extension band part, which has been calculated by the bit count 1 calculating section 1001 , and consumed bit count B SWB of bits to be consumed in the extension band coding section in the extension coding mode, and outputs a result of the comparison as mode determination information. For example, if bit count 1>B SWB , mode determination information of “1” is output to switch 907 , switch 908 and multiplexing section 906 , and in cases other than the above case, mode determination information of “0” is output to switch 907 , switch 908 and multiplexing section 906 .
Next, a decoding apparatus according to the present embodiment will be described. FIG. 22 is a block diagram illustrating a configuration of decoding apparatus 1010 according to the present embodiment. In FIG. 22 , components that overlap with those in FIG. 3 are provided with symbols that are the same as those in FIG. 3 , and a description thereof will be omitted.
Demultiplexing section 1011 demultiplexes input encoded data into mode determination information and transform-encoded data, or demultiplexing section 1011 demultiplexes input encoded data into mode determination information, core-encoded data and extension-band encoded data. Demultiplexing section 1011 outputs the mode determination information to switch 1012 , switch 1013 and switch 1014 . Also, demultiplexing section 1011 outputs the transform-encoded data to transform coding decoding section 1015 if the mode determination information indicates “0,” and outputs the core-encoded data to core decoding section 202 if the mode determination information indicates “1,” and further outputs the extension-band encoded data to extension band decoding section 204 if the mode determination information indicates “1.”
Switch 1012 connects demultiplexing section 1011 and transform coding decoding section 1015 if the mode determination information received as input from demultiplexing section 1011 indicates “0,” and connects demultiplexing section 1011 and core decoding section 202 if the mode determination information indicates “1.”
In cooperation with switch 1012 , switch 1013 does not connect demultiplexing section 1011 and extension band decoding section 204 if the mode determination information received as input from demultiplexing section 1011 indicates “0,” but connects demultiplexing section 1011 and extension band decoding section 204 if the mode determination information indicates “1.”
Transform coding decoding section 1015 performs processing for decoding the transform-encoded data received as input from demultiplexing section 1011 to generate a transform-coding spectrum, and outputs the transform-coding spectrum to switch 1014 .
Core decoding section 202 performs processing for decoding the core-encoded data input from demultiplexing section 1011 to generate a core-coding low band spectrum and outputs the core-coding low band spectrum to sub-band amplitude normalizing section 203 and combining section 1016 .
Extension band decoding section 204 performs decoding processing using the extension-band encoded data input from demultiplexing section 1011 and a normalized low band spectrum input from sub-band amplitude normalizing section 203 if the mode determination information indicates “1” to generate an extension band spectrum, and outputs the extension band spectrum to combining section 1016 .
Combining section 1016 combines the core-coding low band spectrum input from core decoding section 202 and the extension band spectrum received as input from extension band decoding section 204 to generate a combined spectrum, and outputs the combined spectrum to switch 1014 .
In cooperation with switch 1012 , switch 1014 connects transform coding decoding section 1015 and frequency-time transform section 205 if the mode determination information input from demultiplexing section 1011 indicates “0,” and connects combining section 1016 and frequency-time transform section 205 if the mode determination information indicates “1.”
Frequency-time transform section 205 performs an orthogonal transform of the transform-coding spectrum input from transform coding decoding section 1015 or the combined spectrum input from combining section 1016 into a time-domain signal, and outputs the time-domain signal as an output signal.
By means of the configuration and operation described above, coding apparatus ( FIG. 20 ) switches between coding methods for an input signal spectrum according to the characteristics of the extension band spectrum so that the extension band spectrum is encoded using a smaller number of bits. Consequently, a large number of bits can be allocated to the low band spectrum, enabling sound quality enhancement.
Embodiment 7
In the coding apparatus in FIG. 20 , a coding method in which an extension band spectrum is encoded using a small number of bits is selected to allocate a large number of bits to a low band part, thus providing sound quality enhancement. However, in the case of encoding at a low bit rate, even if a coding method in which an extension band spectrum is encoded using a smaller consumed amount of bits is selected, an increased amount of bits allocated to a low band part is very small. Accordingly, in order to improve the sound quality of the low band part using a small number of bits, it is necessary to efficiently allocate bits to the low band part.
Therefore, in the present embodiment, the configuration in which a method of allocating bits to an input signal spectrum is switched to another along with switching of a coding method to be employed for encoding of the extension band spectrum is employed. More specifically, in the case of the transform coding mode, in order to achieve a sound quality providing a feeling of an extensive bandwidth, bits are allocated so that the bits are arranged in a wide band.
Meanwhile, in the case of the extension coding mode, bits are allocated only to sub-bands having large energy from among sub-bands in a low band part spectrum. As a result of bit allocation is performed only for sub-band having large energy, enabling reduction of noisiness in the low band part in a core coding section.
Here, in the case of the transform coding mode, also, noisiness in the low band part can be reduced by bit allocation being performed only for sub-bands having large energy; however, in this case, a feeling of an extensive bandwidth is lost because the number of bits allocated to sub-bands in an extension band coding section is reduced. However, in the case of the extension coding mode, even if destinations of bit allocation are limited to sub-bands having large energy in a low band spectrum, a high-quality extension band spectrum can be generated by the extension band coding section, enabling prevention of the problem of loss of a feeling of an extensive bandwidth. Also, extra bits generated as a result of employment of the extension band coding section are allocated to the low band part, enabling reduction in noisiness occurring in the low band part.
Therefore, the present embodiment enables provision of a sound quality with noisiness suppressed and providing a feeling of an extensive bandwidth.
A coding apparatus according to the present embodiment employs a configuration that is similar to that of the coding apparatus ( FIG. 20 ) according to Embodiment 6. Therefore, components that overlap with those in FIG. 20 are provided with symbols that are the same as those in FIG. 20 , and a description thereof will be omitted. However, bit allocation determining section 903 and bit allocation determining section 905 each operate in a manner that is different from those in Embodiment 6, and thus, details thereof will be described below.
While bit allocation determining section 903 allocates a large number of bits to sub-bands having large energy in an input signal spectrum and a small number of bits to sub-band having small energy in the input signal spectrum, in order to prevent loss of a feeling of an extensive bandwidth, bit allocation is performed so that bits are widely arranged through the overall input signal spectrum. For example, bit allocation to each sub-band is performed according to Equation 5.
[
5
]
B
sub
[
j
]
=
B
total
N
+
1
2
log
2
(
E
[
j
]
∏
k
=
1
N
E
[
k
]
N
)
,
1
≤
j
≤
N
(
Equation
5
)
Here, B sub represents the number of bits to be allocated to each sub-band, N represents a total number of sub-bands in an input signal spectrum, B total represents the total number of bits that can be allocated to the sub-bands, and j represents an index indicating a sub-band.
In Equation 5, if the number of bits to be allocated to a sub-band has a negative value, the number of bits to be allocated to the sub-band is forcibly set to zero.
Meanwhile, bit allocation determining section 905 arranges bits only in a low band spectrum in an input signal. However, here, in order to reduce noisiness in the low band part, bits are arranged only in sub-bands having large energy in a concentrated manner. For example, bit allocation to each sub-band is performed according to Equation 6.
[
6
]
B
sub
[
j
]
=
{
B
total
-
B
SWB
S
+
1
2
log
2
(
E
[
j
]
∏
k
=
1
S
E
[
k
]
S
)
,
(
if
1
2
log
2
(
E
[
j
]
∏
k
=
1
S
E
[
k
]
S
)
>
0
)
0
(
else
)
,
1
≤
j
≤
S
(
Equation
6
)
Here, S represents the total number of sub-bands in a low band spectrum, and E represents energy of each sub-band. In Equation 6, bit allocation to each sub-band is adaptively adjusted depending on the magnitude of the sub-band energy, and the number of bits to be allocated to sub-bands each having energy that is lower than a geometric average sub-band energy value is forcibly set to zero. In other words, bits are allocated to sub-bands having large energy, i.e., sub-band energy that is equal to or larger than the geometric average value in a concentrated manner.
In Equation 6, extra bits B rest resulting from forcibly setting the number of bits to be allocated to sub-bands having small sub-band energy to zero are further re-allocated according to the magnitude of the sub-band energy. For example, the re-allocation is performed according to Equation 7.
[
7
]
B
sub
′
[
i
]
=
B
rest
M
+
1
2
log
2
(
E
[
i
]
∏
k
=
1
M
E
[
k
]
M
)
,
1
≤
i
≤
M
(
Equation
7
)
Here, B′ sub [i] represents the number of additional bits to be re-allocated to each sub-band, M represents the total number of sub-bands to which bits have been allocated according to Equation 6, and i represents an index indicating a sub-band subject to re-allocation.
The configuration and operation of a decoding apparatus according to the present embodiment are similar to those of the decoding apparatus ( FIG. 22 ) according to Embodiment 6, and thus, a description thereof will be omitted.
By means of the configuration and operation described above, the coding apparatus according to the present embodiment switches between coding modes according to the characteristics of an extension band spectrum of an input signal and changes bit allocation to an input signal spectrum along with the switching, thus enabling provision of a sound quality with noisiness limited and providing a feeling of an extensive bandwidth.
Embodiment 8
In Embodiment 4, a description has been given of a configuration in which switching between a method that determines a characteristic of an input signal for each frame and according to a result of the determination, performs normalization using a largest value in a spectrum included in a sub-band and a method that performs normalization using a spectrum power envelope is made to generate a normalized extension band spectrum. In the present embodiment, a configuration in which when normalization is performed using a spectrum power envelope, in order to avoid generation of abnormal noise attributable to an excessive peak of a spectrum, at least either processing for adding noise generated based on a random number to a core-coding low band spectrum or clipping processing for a generated normalized low band spectrum is used will be described.
A coding apparatus and a decoding apparatus according to the present embodiment share a common basic configuration with coding apparatus 700 and decoding apparatus 800 according to Embodiment 4, and the description will be provided with reference to FIGS. 14 and 15 . However, in the present embodiment, processing in a spectrum envelope normalizing section is partially different from that in spectrum envelope normalizing section 702 in coding apparatus 700 according to Embodiment 4, and in order to indicate the difference, the spectrum envelope normalizing section is indicated by “spectrum envelope normalizing section 702 a ”. Likewise, in the present embodiment, processing in a spectrum envelope normalizing section is partially different from that in spectrum envelope normalizing section 802 in decoding apparatus 800 according to Embodiment 4, and in order to indicate the difference, the spectrum envelope normalizing section is indicated by “spectrum envelope normalizing section 802 a .” Also, a configuration and operation of spectrum envelope normalizing section 802 a are the same as those of spectrum envelope normalizing section 702 a (which will be described later), and thus, a detailed description thereof will be omitted.
The configuration and operation of spectrum envelope normalizing section 702 a according to the present embodiment will be described in detail with reference to FIG. 23 . In FIG. 23 , components that are the same as those in FIG. 16 are provided with reference numerals that are the same as those in FIG. 16 , and a description thereof will be omitted here. More specifically, spectrum envelope normalizing section 702 a illustrated in FIG. 23 includes noise adding section 741 and clipping section 742 in addition to the components of spectrum envelope normalizing section 702 illustrated in FIG. 16 .
A core-coding low band spectrum that has been divided into sub-bands by sub-band dividing section 731 is input to noise adding section 741 . Noise adding section 741 adds noise generated based on a random number to the core-coding low band spectrum. Noise adding section 741 performs the following processing for each sub-band. For example, noise adding section 741 determines whether or not there is any frequency in a sub-band at which an amplitude value of a core-coding low band spectrum part is zero, and if any, noise adding section 741 adds noise generated based on a random number to the frequency.
In this case, noise adding section 741 adds larger noise as the degree of a peak in the spectrum in the sub-band is larger. For an example of a specific noise addition method, noise adding section 741 calculates a range in which amplitude values of spectrum parts are no zero in a sub-band and adds smaller noise as the range is larger. Also, noise adding section 741 adds larger noise as a largest value in absolute value of a spectrum in a sub-band is larger. Noise to be added based on the range in which amplitude values of spectrum parts are not zero and the largest value in absolute value of the spectrum is expressed by, for example, Equation 8.
[
8
]
no
[
i
fzero
]
=
rand_val
*
max_peak
cnt
+
1
(
Equation
8
)
Here, no represents noise to be added, i fzero represents an index indicating a frequency at which an amplitude value of a spectrum part is zero, rand_val represents a random number between −1.0 to 1.0, max_peak represents a largest value in absolute value of the spectrum in a sub-band, and cnt represents a range in which amplitudes of spectrum parts are not zero.
Noise adding section 741 outputs the core-coding low band spectrum subsequent to the noise addition processing to sub-band energy calculating section 732 .
Clipping section 742 performs clipping processing on a spectrum (normalized low band spectrum) output from spectrum correcting section 734 . Clipping processing refers to processing for comparing between a predetermined threshold and the absolute value of the spectrum, and if the absolute value of the spectrum exceeds the threshold, replacing an amplitude value of the spectrum with the threshold. In other words, the amplitude value of the spectrum output from spectrum correcting section 734 is made to be equal to or smaller than the threshold by the clipping processing in clipping section 742 .
The predetermined threshold may adaptively be determined for each frame. Also, a value obtained by calculating an average value in absolute value of a spectrum for an entire band or each sub-band of a core-coding low band spectrum and multiplying the average value by a predetermined value may be used as the threshold. If 1.0 is used for the predetermined value, the average value in absolute value of the spectrum is the threshold. Furthermore; the value by which the average value is multiplied may adaptively be changed. As an example, arrangement may be made so that a ratio of a largest value in the absolute values of the spectrum parts in the entire band or each sub-band of the core-coding low band spectrum relative to a total sum of the absolute values of the amplitudes of the spectrum parts in the entire band or each sub-band is determined, and if the ratio is large, the value by which the average value is multiplied is made to be large and if the ratio is small, the value by which the average value is multiplied is made to be small.
As described above, according to the present embodiment, when normalization is performed using a spectrum power envelope, noise adding section 741 adds noise to a core-coding low band spectrum or clipping section 742 performs clipping processing on the spectrum to reduce an intensity of a peak in a normalized low band spectrum to be generated by spectrum envelope normalizing section 702 a , enabling sound quality deterioration due to an excessive peaking property to be avoided.
The embodiments of the present invention have been described above.
In the above embodiments, it is possible that sub-band amplitude normalizing section ( 103 , 203 , 501 , 601 ) may make all amplitudes of components of a spectrum generated by transform coding the same, instead of normalizing the spectrum using absolute values of the amplitudes. However, in this case, the polarities of the spectrum parts are preserved. This processing enables reduction in processing amount, and causes no spectrum amplitude variations, enabling further reduction of abnormal sounds.
Although the decoding apparatus according to each of the above embodiments performs processing using coding information transmitted from the coding apparatus according to the embodiment, the present invention is not limited to such case, and the coding information does not have to be always coding information from the coding apparatus according to the embodiment, and the processing can be performed using any coding information containing necessary parameters or data.
The present invention is not limited to the embodiments described above, and various modifications are possible. For example, the embodiments described above may be implemented in combination.
In addition, the present invention can be applied in a case where the signal processing program is recorded and written to a machine readable recording medium such as a memory, disk, tape, CD, and DVD, and operated therein. The same effects as those obtained in the embodiments described above can be obtained in this case as well.
Moreover, the present invention is described with a case where the present invention is implemented as hardware. However, the present invention can be achieved through software in concert with hardware.
Moreover, the functional blocks described in the embodiments are achieved by LSI, which is typically an integrated circuit. The functional blocks may be provided as individual chips, or part or all of the functional blocks may be provided as a single chip. Depending on the level of integration, the LSI may be referred to as an IC, a system LSI, a super LSI, or an ultra LSI.
In addition, the circuit integration is not limited to LSI and may be achieved by dedicated circuitry or a general-purpose processor other than an LSI. After fabrication of LSI, a field programmable gate array (FPGA), which is programmable, or a reconfigurable processor which allows reconfiguration of connections and settings of circuit cells in LSI may be used.
Should a circuit integration technology replacing LSI appear as a result of advancements in semiconductor technology or other technologies derived from the technology, the functional blocks could be integrated using such a technology. Another possibility is the application of biotechnology and/or the like.
The disclosures of Japanese Patent Applications No. 2011-197295, filed on Sep. 9, 2011, No. 2011-279623, filed on Dec. 21, 2011, No. 2012-019004, filed on Jan. 31, 2012, and No. 2012-079682, filed on Mar. 30, 2012, including the specifications, drawings and abstracts, are incorporated herein by reference in their entirety.
INDUSTRIAL APPLICABILITY
The present invention enables enhancement in quality of a decoded signal when a spectrum in an extension band is encoded using a spectrum in a low band part, and can be applied to packet communication systems and mobile communication systems, for example.
REFERENCE SIGNS LIST
100 , 300 , 500 , 700 , 900 Coding apparatus
101 , 901 Time-frequency transform section
102 Core coding section
103 , 203 , 501 , 601 Sub-band amplitude normalizing section
104 Band searching section
105 Gain calculating section
106 Extension band coding section
107 , 906 Multiplexing section
131 Sub-band dividing section
132 Largest value searching section
133 Amplitude normalizing section
200 , 400 , 600 , 800 , 1010 Decoding apparatus
201 , 1011 Demultiplexing section
202 Core decoding section
204 Extension band decoding section
205 Frequency-time transform section
301 , 401 , 503 , 603 Harmonic emphasizing section
502 , 602 Threshold controlling section
701 , 801 Normalization method determining section
702 , 702 a , 802 , 802 a Spectrum envelope normalizing section
731 Sub-band dividing section
732 Sub-band energy calculating section
733 Smoothening section
734 Spectrum correcting section
902 Mode determining section
903 , 905 Bit allocation determining section
904 Transform coding section
907 , 908 Switch
1015 Transform coding decoding section
|
By copying to a high-frequency band portion (extension band) a low-frequency band portion in which peaking has been set to a sufficiently low state, this encoding device is capable of preventing generation of a spectrum with overly high peaking in the high-frequency band portion, and of generating a high-quality extension band spectrum. This device comprises: a maximum value search unit which searches, in each of multiple sub-bands obtained by dividing the low-frequency band portion of an audio signal and/or music signal below a prescribed frequency, for the maximum value of the amplitude of a first spectrum obtained by decoding first encoded data, which is encoded data in the low-frequency band portion; and an amplitude normalization unit which obtains a normalized spectrum by normalizing, at the maximum values of the amplitude of each sub-band, the first spectrum contained in each sub-band.
| 6
|
BACKGROUND OF THE INVENTION
The invention relates to an acoustic surface wave filter comprising at least one member which can be stimulated to surface oscillations and is made at least partly of piezoelectric material, the surface on at least one side of the member being provided with disturbance locations (possibly impurity locations) for surface waves, the filter also comprising means for converting electrical into mechanical energy and vice versa, at least some of the disturbance locations being combined into a resonator in the form of a ruled or line grating and the average distance between the disturbance locations in the resonator being equal to half the wave-length of the surface waves or an integral multiple thereof.
The transmission behaviour of acoustic surface wave filters is such that, without weighting the dimensions of the transducer fingers, the attenuation frequency varies approximately in accordance with (sin x/x ) 2 , x being a linear function of the frequency. This transmission behaviour is similar, with regard to flank steepness, to that of a three-circuit band-pass filter. There are known methods of influencing this behaviour, either by weighting the geometry of the transducer fingers or by producing coupled resonance structures in the path travelled by the surface wave, so that the filter slopes are made steeper, like those of a multi-circuit band-pass filter. The disadvantage of this method is that accurate photo-etching is required to prevent diffraction effects.
Coupled resonance structures, which can likewise be used to improve the flank steepness, are described in German Offenlegungsschrift No. 2,133,634 published July 6, 1971. These resonance structures comprise disturbance locations disposed perpendicular to the propagation direction of the surface waves, the distance between adjacent spots being chosen so as to produce a resonator in conjunction with the intermediate portions of surface. As before, however, these structures have to be manufactured very accurately, since the accuracy with which the resonance frequency of a resonator can be tuned depends on the accuracy with which two adjacent disturbance locations satisfy the condition λ/2.
German Offenlegungsschrift No. 2,363,701 published June 26, 1975 describes an acoustic surface wave filter characterised by good flank steepness and adapted for making wide variations in the intensity of the proportion of oscillations transmitted by the filter. To this end, according to the last-mentioned specification, at least some of the disturbance locations are combined into a resonator in the form of a ruled grating and the average distance between disturbance locations is made equal to half the wave-length of the surface waves or to an integral multiple thereof.
As a result of the combined effect of many weak reflections on the grating lines, a standing wave distribution builds up for frequencies at which the distance between adjacent lines of the grating is λ/2 or an integral multiple thereof. In one form of grating of this kind, it is stimulated at its input, for example, at a short interdigital line, with a constant a.c. voltage, and at its output, for example, an interdigital line, it delivers a voltage U which varies in accordance with a resonance curve which exhibits a relatively narrow peak.
A complete ruled or line grating, therefore, has the properties of an individual resonator.
To obtain a filter having a wider pass-band, it is usual to couple a number of resonators together. Some advantageous methods of acoustically coupling resonators are described in detail in German Offenlegungsschrift No. 2,363,701.
SUMMARY OF THE INVENTION
An object of the invention is to provide an acoustic surface wave filter which has the transmission characteristic of a multiple filter and is also very simple to manufacture.
According to a first aspect of the invention, there is provided an acoustic surface wave filter comprising a member stimulable to surface oscillation, first means associated with said member for converting electrical energy into mechanical energy, second means associated with said member for converting mechanical energy into electrical energy and a plurality of disturbance locations on a surface of said member in the form of a line grating with spacings between adjacent lines of said grating of varying size in the longitudinal direction of said lines, at least over part of said grating.
According to a second aspect of the invention, there is provided an acoustic surface wave filter comprising at least one member which can be stimulated to surface oscillations and is made at least partly of piezoelectric material, disturbance locations for surface waves on the surface on at least one side of said member and means for converting electrical energy into mechanical energy and vice versa, at least some of the disturbance locations being combined into a resonator in the form of a ruled grating and the average distance between the disturbance locations in the resonator being equal to half the wave-length of the surface waves or an integral multiple thereof, characterised in that the distance between successive grating lines or between opposite portions of the lines, at least in one part of the resonator, varies in the longitudinal direction of said grating lines.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail, by way of example, with reference to the drawings, in which:
FIG. 1 is a diagrammatic view of a known acoustic surface wave filter;
FIG. 2 is a graphical representation of a typical characteristic of the filter of FIG. 1;
FIG. 3 is a graphical representation similar to FIG. 2 but showing a desired characteristic of an acoustic surface wave filter;
FIG. 4 is a diagrammatic view of one embodiment of acoustic surface wave filter in accordance with the invention;
FIG. 5 is a diagrammatic indication for explaining certain embodiments of the invention;
FIG. 6 is a diagrammatic representation of a form of the lines of the grating in accordance with a filter embodiment, and
FIG. 7 is a diagrammatic view of a still further embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows diagrammatically a known acoustic surface wave filter which can have good flank steepness and is suitable for making wide variations in the intensity of the proportion of oscillations transmitted by the filter. To this end, at least some of the disturbance locations are combined into a resonator in the form of a ruled or line grating and the average distance between disturbance locations is made equal to half the wave-length of the surface waves or to an integral multiple thereof.
As a result of the combined effect of many weak reflections on the grating lines, a standing wave distribution builds up for frequencies at which the distance between adjacent lines of the grating is λ/2 or an integral multiple thereof.
At the filter input, for example, via a short interdigital line, the filter is stimulated with a constant a.c. voltage and at its output, for example via another interdigital line, the filter delivers a voltage U which varies as shown by the resonance curve in FIG. 2. In this curve, f is the frequency and f o = c/ 21 is the resonance frequency, with l being the distance between the centres of any two grating lines and c being the propagation speed of the surface waves.
A complete ruled grating, therefore, has the properties of an individual resonator.
To obtain a filter having a pass-band as shown in FIG. 3, it is usual to couple a number of resonators together.
An object of the invention is to provide an acoustic surface wave filter which has the transmission characteristic of a multiple filter.
Basically, the invention proposes that the distance between successive grating lines or between opposite portions of the lines, at least in one part of the resonator, varies in the longitudinal direction of the grating lines.
Some preferred embodiments of the invention will now be described in detail with reference to FIGS. 4-6.
In a device as shown in FIG. 4, the grating lines of the resonator are formed on a circular strip. Since the straight lines are closer together near the inner boundary circle (radius R i ) than at the outside (radius R a ), the resonance frequency is greater at the inside (f i = c/ 21 i ) than at the outside (f a = c/ 21 a ). It can be proved by geometry that the relative bandwidth μ of a filter of this kind has the following value: ##EQU1## The number of grating lines must be made so large that the reciprocal of the quality Q of a partial resonator bounded by any two successive grating lines, i.e. the attenuation thereof, is small compared with the relative bandwidth ν of the total filter, i.e. ##EQU2##
In most cases this can be done by making ##EQU3##
If the filters do not have an unduly small relative bandwidth, i.e. in the percentage region, the same effect can be obtained by selecting the number of grating lines.
FIG. 4 gives only one, simple, example. In more complicated filters it may happen that the grating lines have to be curved instead of straight. The reason is as follows. If, for example, the transmission characteristic in the transmission region has to be made as flat as possible or the transmission curve (FIG. 3) has to have a Tschebyscheff shape, the contents of the individual partial resonators, i.e. the resonators bounded by successive grating lines or the corresponding parts S of the total strip (FIG. 5) situated between R i + S and R i + S + l, must not be uniformly distributed within the filter bandwidth. Frequently the zero positions of the polynomial describing the transmission are more closely packed at the edges than at the centre of the transmission region. A filter with these properties, therefore, would consist of a series of bent grating lines, as shown in FIG. 6. If this structure is continued with straight parallel lines, parts of the filter can be preferred so as to produce additional humps in the transmission curve.
Advantageously the entire filter system is applied by photolithographic methods on to a substrate of piezoelectric material, preferable crystalline quartz. Advantageously, the required input and output transducers, for example in the form of interdigital coupling-in and coupling-out lines or other resonators, can be formed at the same time. The transducers can also be represented as parts of a ruled-grating resonator, as shown in FIG. 4, in which case the individual resonators must be separated by regions having a different wave impedance from that in the adjacent resonators. Advantageously also, the piezoelectric substrate is used as a support for other components, so as to obtain a compact surface wave filter having small external dimensions. The other components may be for example matching amplifiers at the filter input and/or output, comprising at least one transistor (FIG. 7). If the matching amplifiers are disposed, for example, in chip form, directly on the substrate, the leads to the transducers can be short, thus eliminating interfering capacitances, which restrict the band width.
It will be understood that the aforementioned description of the present invention is susceptible to various modifications, changes and adaptations.
|
An acoustic surface wave filter comprises a member stimulable to surface oscillations with means for converting electrical energy into mechanical energy and vice versa associated therewith and a plurality of disturbance locations on a surface of the member in the form of a line grating with variable spacing between adjacent lines in the longitudinal direction of the lines.
| 7
|
[0001] The present invention relates generally to turbo machines. In particular, one or more aspects of the present invention relate to method and apparatus to apply protective coating to gas turbine wheels.
BACKGROUND OF THE INVENTION
[0002] Turbines generally include a rotor comprised of a plurality of rotor turbine wheels, each of which mounts a plurality of circumferentially-arranged buckets. Each bucket includes an airfoil, a platform, a shank and a dovetail, the dovetail being received in mating dovetail slot in the turbine wheel. The airfoils project into a hot gas path downstream of the turbine combustors and convert kinetic energy into rotational, mechanical energy.
[0003] Often, a protective coating is applied to the turbine wheel for various purposes. For example, the turbine wheel can be instrumented for component and developmental testing (CDT). In CDT, sensors or instruments are attached to the turbine wheel—often by resistance welding the sensors to the turbine wheel. Rather than resistance welding the sensors directly to the turbine wheel itself, a nickel-chromium (NiCr) coating can be applied to the turbine wheel using a plasma spray for example. The sensors then can be welded to the protective coating. In this way, the turbine wheel can be instrumented without inducing or creating stress risers into the base/parent material of the turbine wheel.
[0004] However, it is necessary to prevent the dovetail slots from being coated. The slots, which are critical to the usable life of the turbine wheel, are machined to a precisely shaped profile and surface finish. Complementarily shaped dovetails (also precisely machined) of the buckets are mated with the slots for assembly of the turbine. Due in large part to the precise machining of the dovetails and slots, the usable life of the turbine would be compromised if the slots are coated. The coating can be removed, but the removal process generally requires an abrasive device, which disturbs the surface finish. Any disturbance of the dovetail surface can decrease the usable life of the turbine wheel and negate any applied metal treatments such as shotpeen.
[0005] Prior attempts to prevent the slots from being coated included using high temperature adhesive tapes to mask off the dovetail slots and other critical areas. This is a labor intensive and a time consuming process. Also, the tapes can create sharp edges that can result in coating chipping and flaking which requires extensive detail and blending post processing to remove such defects. In addition, the plasma spray is applied at high pressures, such as at 90 PSI. This can cause the tape to lift allowing overspray to come in contact with the dovetail surface.
[0006] Thus, it is desirable to provide a method and a device to apply protective coating with a greater control of pattern definition, coating surface finish, and to eliminate or vastly reduce incidences of process damage and the necessary re-work that follows such incidences.
BRIEF SUMMARY OF THE INVENTION
[0007] A non-limiting aspect of the present invention relates to a dovetail plug adapted to be inserted into a dovetail slot of a turbine wheel. The plug comprises an insertion part and a protrusion part. The insertion part is shaped to be axially inserted into the dovetail slot from a turbine wheel face to a predetermined insertion depth when the plug is fully inserted into the turbine wheel, and the protrusion part is shaped to axially protrude from the turbine wheel face when the plug is fully inserted into the turbine wheel. The protrusion part comprises a blast portion connected to the insertion part, and a shadow portion on outside of the blast portion. The shadow portion is such that a first contour of the shadow portion is defined at the turbine wheel face and a second contour of the shadow portion is defined at a predetermined protrusion distance from the turbine wheel face. The second contour is outside of the first contour. A shadow surface is a surface of the shadow portion between the first and second contours, and a shadow angle formed between the shadow surface and the turbine wheel face is less than a right angle.
[0008] Another non-limiting aspect of the present invention relates to a method of forming a dovetail plug to be inserted into a dovetail slot of a turbine wheel. The method comprises forming an insertion part in a shape to be axially inserted into the dovetail slot from a turbine wheel face to a predetermined insertion depth when the plug is fully inserted into the turbine wheel. The method also comprises forming a protrusion part in a shape to axially protrude from the turbine wheel face when the plug is fully inserted into the turbine wheel. The step of forming the protrusion part comprises forming a blast portion connected to the insertion part and forming a shadow portion on outside of the blast portion. The shadow portion is formed such that a first contour of the shadow portion is defined at the turbine wheel face and a second contour of the shadow portion is defined at a predetermined protrusion distance from the turbine wheel face. The second contour is outside of the first contour. A shadow surface is a surface of the shadow portion between the first and second contours, and a shadow angle formed between the shadow surface and the turbine wheel face is less than a right angle.
[0009] Another non-limiting aspect of the present invention relates to a method of applying protective coating to a turbine wheel. The method comprises inserting plugs into dovetail slots of a turbine wheel, and subsequently applying the protective coating on the turbine wheel. Each plug inserted into the dovetail slots comprises an insertion part and a protrusion part. The insertion part is shaped to be axially inserted into the dovetail slot from a turbine wheel face to a predetermined insertion depth when the plug is fully inserted into the turbine wheel, and the protrusion part is shaped to axially protrude from the turbine wheel face when the plug is fully inserted into the turbine wheel. The protrusion part comprises a blast portion connected to the insertion part, and a shadow portion on outside of the blast portion. The shadow portion is such that a first contour of the shadow portion is defined at the turbine wheel face and a second contour of the shadow portion is defined at a predetermined protrusion distance from the turbine wheel face. The second contour is outside of the first contour. A shadow surface is a surface of the shadow portion between the first and second contours, and a shadow angle formed between the shadow surface and the turbine wheel face is less than a right angle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features of the present invention will be better understood through the following detailed description of non-limiting example embodiments in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 illustrates an example turbine wheel with a plurality of plugs inserted into corresponding dovetail slots;
[0012] FIG. 2 illustrates a perspective view of a plug inserted into a turbine wheel;
[0013] FIG. 3 illustrates a more detailed perspective view of a plug inserted into a dovetail slot of a turbine wheel;
[0014] FIG. 4 illustrates an axial view of a plug according to a non-limiting embodiment of the present invention;
[0015] FIG. 5 illustrates a circumferential view of a cross-section of the plug illustrated in FIG. 4 along a line ‘j’-‘j’;
[0016] FIG. 6 illustrates a detailed view of a circled portion in FIG. 5 ;
[0017] FIG. 7 illustrates a circumferential view of a cross-section of the plug illustrated in FIG. 4 along a line ‘jj’-‘jj’;
[0018] FIG. 8 illustrates a detailed view of a circled portion in FIG. 7 ;
[0019] FIG. 9 illustrates a radial view of a cross-section of the plug illustrated in FIG. 4 along a line ‘jjj’-‘jjj’;
[0020] FIG. 10 illustrates a detailed view of a circled portion in FIG. 9 ;
[0021] FIG. 11 illustrates perspective views of a plug according to a non-limiting embodiment of the present invention;
[0022] FIG. 12 illustrates a non-limiting example flow chart of a method to form a plug;
[0023] FIG. 13 illustrates a non-limiting example flow chart of a method to form a protrusion part of a plug; and
[0024] FIG. 14 illustrates a non-limiting example flow chart of a method to apply protective coating on a turbine wheel.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Novel plug for use when applying a protective coating on a turbine wheel is described. Methods of forming as well as using the plug are also described.
[0026] FIG. 1 illustrates an example turbine wheel 10 with a plurality of plugs inserted 20 into corresponding dovetail slots. FIG. 1 is an axial view of the wheel 10 towards the turbine wheel face 110 . FIG. 2 illustrates a perspective view of a plug 20 inserted into the turbine wheel 10 , and FIG. 3 illustrates a more detailed view of the inserted plug 20 and corresponds to the circled portion in FIG. 2 . In this particular embodiment, the plug 20 is shaped to match the contour of the dovetail slots 120 . When fully inserted, the plug 20 covers at least a part of the circumferential surface 130 of the turbine wheel 10 .
[0027] As seen in FIG. 5 , when the plug 20 is fully inserted, the plug 20 is shaped such that a part of the plug 20 still protrudes a distance ‘a’ axially from the turbine wheel face 110 , and is referred to as the protrusion part 22 in this document. The part of the plug 20 that is inserted to the predetermined depth ‘d’ is referred to as the insertion part 24 . Thus, the insertion part 24 can be said to be shaped to be axially inserted into the dovetail slot 120 from the turbine wheel face 110 to the predetermined insertion depth ‘d’ when the plug 20 is fully inserted into the turbine wheel 10 .
[0028] FIG. 4 is an axial view of the plug 20 as indicated by reference coordinate direction arrows R (radial), Z (circumferential), and A (axial). In this figure, the axial coordinate reference ‘A’ is circled to indicate that the axial direction is into the page. In particular, FIG. 4 is an axial view of the protrusion part 22 . As seen, the protrusion part 22 includes a central blast portion 210 and a shadow portion 230 on the outside of the blast portion 210 . The shadow portion 230 is bounded by the first contour 232 (long dashed line) and a second contour 234 (solid line). The first contour 232 would not necessarily be visible when viewing the protrusion part 22 . It is drawn in FIG. 4 to demarcate the different portions of the plug 20 for explanatory purposes. As seen, the second contour 234 is outside of the first contour 232 . Distance ‘b’ between the first and second contours 232 , 234 represents a width of the shadow portion 230 .
[0029] Before proceeding further, the following should be noted. For explanatory purposes, the plug 20 is described being comprised of the protrusion and insertion parts 22 , 24 and the protrusion part 22 itself is described as including various portions, the separation of the plug 20 into various parts and portions is for ease of explanation. But it is fully envisioned that the parts and portions of the actual plug 20 , at least in one aspect, are integrally formed as one piece, for example, through a molding process.
[0030] FIG. 5 illustrates a circumferential view of the plug 20 as indicated by reference coordinate direction arrows in which circumferential reference direction Z is circled. In particular, FIG. 5 is a view of a cross-section of the plug 20 taken along a line a line ‘j’-‘j’ in FIG. 4 . FIG. 6 is a detailed view of the circled portion in FIG. 5 . As seen in these figures, the first contour 232 is a contour of the shadow portion 230 at the turbine wheel face 110 , and the second contour 234 is a contour of the shadow portion 230 at a predetermined protrusion distance from the turbine wheel face 110 . As noted above, the second contour 234 is outside of the first contour 232 when viewed axially.
[0031] The surface of the shadow portion 230 between the first and second contours 232 and 234 is referred to as the shadow surface 236 , which forms a shadow angle α with the turbine wheel face 110 as seen in FIG. 6 . In one embodiment, it is preferred that the shadow angle α be less than 90°, i.e., be less than a right angle.
[0032] The shadow angle α being less than the right angle is beneficial for at least the following reason. When the protective coating is sprayed, the shadow portion 230 prevents protective coating with sharp edges, i.e., abrupt changes in coating thickness, from being formed. Instead, coatings with gradual thickness transitions are formed in between the shadow surface 236 and the turbine wheel face 110 . This removes the need for post processing to profile the protective coating. In addition, because the gradual thickness transitions are possible, a single coating of sufficient thickness may be applied rather than the traditional method of applying multiple coats. This saves both time and money.
[0033] It should be noted that the predetermined protrusion distance of the second contour 234 need not be all the way at the thickness ‘a’ of the protrusion part 22 . The second contour 234 need only be defined at some distance away from the turbine wheel face 110 , even if less than ‘a’, so that the shadow surface 236 forms the proper angle α with the turbine wheel face 110 . Any combination of the predetermined distance protrusion distance of the second contour 234 , the thickness ‘b’ of the shadow portion 230 , and the shadow angle α may be adjusted depending on the circumstances. For the remainder of this document, it is assumed that the second contour 234 is the contour of the shadow portion 230 at distance ‘a’ for convenience.
[0034] Preferably, the shape profile of the plug 20 is consistent throughout so that the protection from the coating process can be consistently maintained. This can be achieved by shaping the plug 20 to have various characteristics. As an example, it is preferred that the angle α be substantially constant over an entirety of the shadow surface 236 .
[0035] FIG. 7 illustrates a circumferential view of another cross-section of the plug 20 , this time along a line ‘jj’-‘jj’ in FIG. 4 , and FIG. 8 is a detailed view of the circled portion in FIG. 7 . While FIG. 6 illustrates a cross section of the plug 20 near a center thereof, FIG. 7 illustrates a cross section of the plug 20 near an end thereof. Nonetheless, as seen in FIG. 7 , the shadow portion 230 is formed such that the shadow surface 236 forms a shadow angle that is substantially the same angle α as in FIGS. 5 and 6 . In addition, the width ‘b’ of the shadow portion 230 , the predetermined protrusion distance of the second contour 234 , and a distance ‘c’ from the dovetail slot edge 125 to the first contour 232 are substantially the same as in FIGS. 7 and 8 .
[0036] FIG. 9 illustrates a radial view of a cross-section of the plug illustrated in FIG. 4 along a line ‘jjj’-‘jjj’, and FIG. 10 is a detailed view of the circled portion in FIG. 9 . Again, it is seen that the shadow portion 230 is formed such that the shadow angle α, the width ‘b’, the predetermined protrusion distance of the second contour 234 , and the distance ‘c’ are substantially the same as in FIGS. 5 , 6 , 7 and 8 .
[0037] It suffices to say that when possible, some or all of the predetermined protrusion distance of the second contour 234 , the width ‘b’ of the shadow portion 230 , the distance ‘c’, and the shadow angle α are preferred to be substantially constant throughout. FIG. 11 illustrates perspective views of the plug 20 . Note that throughout the plug 20 , consistent shape profile is maintained.
[0038] It is also preferred that the shape of the dovetail slots 120 be followed so that as much of the surface of the turbine wheel 110 can be protected. Regarding the insertion part 24 , it is indicated above that the insertion part 24 is shaped to be axially inserted into the dovetail slot 120 . Referring back to FIG. 4 , reference numeral 215 represents a contour of the insertion part 24 . It is preferred that the insertion part contour 215 match the contour of the dovetail slot 120 along at least a part of the predetermined insertion depth ‘d’. In FIG. 11 , it is seen that the insertion part contour 215 is shaped to match the contour of the dovetail slot 120 along an entirety of the predetermined insertion depth ‘d’.
[0039] As seen in FIG. 3 , reference numeral 125 represents an edge the contour of the dovetail slot 120 at the turbine wheel face 110 . In an embodiment, the first contour 232 is at or outside the dovetail slot edge 125 . In FIG. 4 , the first contour 232 is shown to be outside the insertion part contour 215 , which in turn coincides with the dovetail slot edge 125 . Thus, FIG. 4 is an example of the first contour 232 being outside of the dovetail slot edge 125 .
[0040] While not shown, it can also be that the first contour 232 and the dovetail slot edge 125 match, i.e., the distance ‘c’ can be zero. But as long as the first contour 232 is at or outside the dovetail slot edge 125 , the dovetail slot 120 will not be coated. It is also preferable that the second contour 234 follow the outline of the dovetail slot edge 125 . That is, an offset from the dovetail slot edge 125 to the second contour 234 (distance ‘b’ plus ‘c’) is preferred to be substantially constant.
[0041] Some engineering requirements dictate that an area of the turbine wheel face 110 near the slot edge 125 , the so-called critical area, not be coated. Typically, these are high stress areas. Any damage or surface finish to such areas causes cracks to develop which in turn can leads to a failure in the dovetail slot allowing the “bucket”, i.e., turbine blade to liberate from the gas turbine causing catastrophic failure.
[0042] The plug 20 in FIG. 4 includes a protection portion 220 in between the blast and shadow portions 210 , 230 . In this instance, it is assumed that the critical area is an area of the turbo turbine wheel face 110 within a critical distance ‘c’ from the dovetail slot edge 125 . The first contour 232 is then outside of the insertion part contour 215 and is at least the critical distance ‘c’ from the dovetail slot edge 125 . The protection portion 220 in this embodiment is shaped to cover the critical area of the turbine wheel face 110 , which is the area from the dovetail slot edge 125 to the first contour 232 when the plug 20 is fully inserted into the turbine wheel 10 . In FIGS. 5-10 , the critical distance ‘c’ is more clearly illustrated.
[0043] Preferably, an offset from the dovetail slot edge 125 to the first contour 232 is substantially constant. That is, the first contour 232 should follow the outline of the dovetail slot edge 125 . This offset should be at least the critical distance ‘c’ and most preferably at ‘c’. This allows the maximum area of the turbine wheel face 110 to be protected while still meeting critical area requirement. This is a vast improvement over the conventional adhesive tape method in which it is difficult, and most certainly impracticable, to shape the tapes to match the shape of the dovetail slots 120 . Also, the offset from the first contour 232 to the second contour 234 should be substantially constant, again to provide nice coating transitions.
[0044] Generally, if critical areas are required, then the first contour 232 is outside the dovetail slot edge 125 , preferably at a constant distance ‘c’. But on the other hand, if there is no critical area requirement, then the protection portion 220 need not be provided. If the protection portion 220 is not provided, then the first contour 232 can coincide with the dovetail slot edge 125 . This again maximizes the area of the turbine wheel 110 being protected while at the same time, preventing the dovetail slot 120 from being coated.
[0045] In FIGS. 4 , 5 and 7 , it is seen that the plug 20 includes a flange part 26 connected to the insertion part 24 and to the protrusion part 22 . The flange part 26 is shaped such that when the plug 20 is fully inserted into the turbine wheel 10 , at least a part of the turbine wheel surface 130 along the predetermined insertion depth. The flange part 26 is at a height ‘h’ above the turbine wheel surface 130 when inserted.
[0046] FIG. 12 illustrates a non-limiting example flow chart of a method 1200 to form the plug 20 . In step 1210 , the insertion part 24 of the plug 20 is formed in a shape to be axially inserted into the dovetail slot from a turbine wheel face to a predetermined insertion depth when the plug is fully inserted into the turbine wheel. In step 1220 , the protrusion part 22 is formed in a shape to axially protrude from the turbine wheel face when the plug is fully inserted into the turbine wheel.
[0047] FIG. 13 illustrates an example method to implement step 1220 . In step 1310 , the blast portion 210 is formed to be connected to the insertion part 24 , the protection portion 220 is formed in step 1320 , and the shadow portion 230 is formed in step 1330 . If the protection portion 220 is not necessary, then only the steps 1310 and 1330 can be performed. As discussed above, the shadow portion 230 is formed such that the shadow angle formed between the shadow surface 236 and the turbine wheel face 110 is less than 90°. Other details of forming the plug 20 is straight forward from the detailed description of the plug 20 provided above with reference to FIGS. 4-10 .
[0048] FIG. 14 illustrates a non-limiting example flow chart of a method 1400 to apply protective coating on the turbine wheel. In step 1410 , the inventive plugs 20 as described above are inserted into the dovetail slots 120 of the turbine wheel 10 . Subsequently, the protective coating is applied on the turbine wheel in step 1420 .
[0049] Recall that due to the advantageous features of the plugs 20 , there is no need to perform post processing to profile the protective coating. Also, in step 1420 , a single coating may be applied. That is, multiple coating is not necessary.
[0050] 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 language of the claims.
|
Prior to instrumenting a turbine wheel for component and developmental testing, a protective coating is applied to the turbine wheel so that sensors can be welded to the coating rather than to the base material of the turbine wheel. But it is important to prevent the dovetail slots, which are critical to the usable life of the turbine wheel, from being coated. Plugs are provided that can be inserted into the dovetail slots prior to applying the coating. Each plug is shaped to match the shape profile of the dovetail slot. The plug prevents critical areas from being coated, removes the need for post processing, and allows a single coating to be applied.
| 5
|
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/949,299, filed Jul. 12, 2007, the entire contents of which are specifically incorporated herein by reference.
TECHNICAL FIELD
The present invention generally relates to vehicle steering systems of, for example, automobiles, boats, etc. More particularly, the present invention relates to parking assist features of vehicle steering systems.
BACKGROUND OF THE INVENTION
Parking a vehicle properly can be difficult at times. Parallel parking especially poses challenges to many drivers when, for example, the parking space is small or other conditions such has curb variations, adverse weather, moving obstacles, grade variations, etc. exist. Other parking maneuvers, such as 90 degree back up parking, often present similar challenges to drivers.
Recently, parking assist systems have been developed to assist drivers in these tasks. The developed systems have focused on either (a) controlling the motion of the steering wheel while control of braking and acceleration is left to the driver, (b) providing audial/visual guidance to the driver regarding motion of the steering wheel, or (c) controlling the motion of the steering wheel as well as controlling braking and acceleration of the vehicle. Options (a) and (c), by removing some or all control from the drivers during parking maneuvers, require very robust systems that can compensate for all of the potential variations in the parking situation such as those listed above. Current systems of this type have a narrow range of operability and/or only function within large parking areas. Furthermore, acceptance of systems that entirely remove control of the vehicle from the driver, as in option (c), may be difficult because of potential liability issues.
Option (b) leaves control of the vehicle with the driver, but the driver must process the audial/visual cues and convert those cues into motion of the steering wheel. Further, visual cues displayed forward of the driver, for example, on the dashboard, seem contradictory to the premise of the driver remaining in control while driving the vehicle backward.
SUMMARY OF THE INVENTION
A method for assisting the parking of a vehicle includes determining a vehicle position relative to an obstacle. When the relative position meets a first set of criteria, a first torque pulse is delivered to the steering wheel in the first direction to cue an operator of the vehicle to turn the steering wheel in the first direction. When the relative position meets a second set of criteria, a second torque pulse is delivered to the steering wheel in the second direction, opposite to the first direction to cue the operator to turn the steering wheel in the second direction.
A system for assisting the parking of a vehicle includes at least one sensor for determining a position of a vehicle relative to an obstacle and a torque generator in operable communication with a steering wheel. When the position of the vehicle relative to the obstacle meets a first set of criteria, the torque generator is capable of delivering a first torque pulse to the steering wheel in the first direction to cue an operator of the vehicle to turn the steering wheel in the first direction. When the position of the vehicle relative to the obstacle meets a second set of criteria, the torque generator is capable of delivering a second torque pulse to the steering wheel in the second direction, opposite to the first direction to cue the operator to turn the steering wheel in the second direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a plan view of a typical parallel parking situation;
FIG. 2 is a graph of torque cues provided over time by an embodiment of a steering assist system of the present invention;
FIG. 3 is an alternative torque cue configuration including bias torques for the system of FIG. 2 ;
FIG. 4 is an alternative torque cue configuration for the system of FIG. 2 ;
FIG. 5 is an alternative torque cue configuration including multiple torque pulses for the system of FIG. 2 ;
FIG. 6 is an alternative torque cue configuration including multiple torque pulses of varying magnitude for the system of FIG. 2 ;
FIG. 7 is an example of a visual cue;
FIG. 8 is another plan view of a typical parking situation and staging;
FIG. 9 is a schematic of an algorithm utilized in the system of FIG. 2 ; and
FIG. 10 is an illustration of variation in vehicle location profiles relative to an ideal vehicle location profile.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A parking assist system is disclosed that provides cues to the driver through torque pulses delivered through the steering wheel. This can be achieved with, for example, an electric or hydraulic actuator or the like. FIG. 1 illustrates a typical parallel parking situation. Vehicle 10 is attempting to park between parked vehicles 12 and 14 . Profile 16 is a desired path of a center of gravity 18 of the vehicle 10 . Further in FIG. 1 , steering wheel angle (θ) versus vehicle station (S) along the profile 16 is plotted, and illustrates the angles θ 1 and θ 2 that a driver may turn the steering wheel at stations S 1 and S 2 , respectively, in order to successfully maneuver the vehicle 10 between parked vehicles 12 and 14 .
A determination is made preliminarily and/or during the parking maneuver as to whether the vehicle 10 can possibly be parked in an available space between parked vehicles 12 and 14 . This determination can be made by the driver alone or, in some embodiments, by the parking assist system which may then communicate the determination to driver through visual and/or audial cues.
The system of the present invention assists the driver in determining when they have reached station S 1 and the steering wheel is to be turned to angle θ 1 . As shown in FIG. 2 , the system provides a pulse of torque, T 1 , through the steering wheel in the direction the steering wheel is to be turned. In reaction to T 1 , the driver then turns the steering wheel to angle θ 1 , which is normally the end of the travel of the steering wheel.
As the vehicle 10 continues to S 2 , another pulse of torque, T 2 , is delivered to the steering wheel indicating to the driver that it is time to turn the steering wheel to θ 2 . T 2 is delivered in the opposite direction of T 1 since the direction of turn of the steering wheel is opposite at S 2 compared with S 1 . Further, the magnitude of the torque pulse T 2 is greater than the magnitude of the torque pulse T 1 . As the vehicle 10 moves from a staging station, S 0 , to S 1 , the vehicle 10 is moving substantially directly rearward thus a driver applied torque to the steering wheel during this portion of the parking is minimal. As a result, a small magnitude of torque T 1 can be applied by the parking assist system and it will be perceived by the driver. When T 2 is applied, however, the driver is inputting significant torque into the system in turning the steering wheel to θ 1 . Therefore, for the driver to perceive T 2 , the magnitude of T 2 must be greater than that of T 1 . In the case of a pulse with a larger magnitude such as T 2 , instead of being a pulse having an abrupt end, the pulse may have a gradual end since an abrupt end may cause an oversteer-like sensation for the driver. Further, an additional impulse, T 3 , may be provided at station S 3 as a signal to the driver to straighten the vehicle and complete the parallel parking maneuver in a forward motion.
In some parallel parking situations, an initial lateral offset, D 0 , between vehicle 10 and parked vehicle 12 is large enough or, there may be an adjacent vehicle in traffic so that a θ 1 of the complete travel of the steering wheel is not necessary or is determined to be inappropriate by the system. After T 1 is delivered and the driver responds by turning the steering wheel in the suggested direction, if the driver turns the steering wheel to an actual angle 20 that is less than θ 1 , the system will not provide additional T 1 in the form of pulses or constantly varying torque. If, however, the driver attempts to turn the steering wheel to an actual angle greater than θ 1 , the system will respond with a torque T 4 to give the driver a perception that the end of steering wheel travel has been reached. System intervention in this case is continuous of a magnitude in proportion to an amount of overturning and one sided. T 4 is only provided when attempting to go beyond θ 1 , not when failing to reach θ 1 , so that the driver does not have the perception that the system is taking control from him/her. Similarly, if the driver attempts to turn the steering wheel to an actual angle 20 greater than θ 2 or attempts to turn the steering wheel to θ 2 prior to reaching S 2 , the system will respond with a continuous torque T 5 to resist the driver's input. Again, it should be noted that T 1 , T 2 , and T 3 are, in some embodiments, singular events while T 4 and T 5 may be transient or repetitive in nature.
An alternative for providing additional assistance to the driver is to provide a first bias torque, T 6 , subsequent to T 1 , and a second bias torque, T 7 , subsequent to T 2 . T 6 is in the same direction as T 1 , but is longer in duration and of lesser magnitude than T 1 . Likewise, T 7 is in the same direction as T 2 , but is longer in duration and of lesser magnitude than T 2 . In some embodiments, T 7 is of greater magnitude than T 6 because, as described above, the driver may be inputting significant torque in an opposite direction of T 7 during the first turn, so a greater magnitude T 7 is necessary to have a desired effect. Because of their longer durations and lesser magnitudes, the effect of the bias torques, T 6 and T 7 , is different from the effect of T 1 and T 2 . T 1 and T 2 are meant to alert the driver to turn the steering wheel in the desired direction, while T 6 and T 7 provide a level of assistance in parking that may not be readily perceived, thus may be acceptable, to most drivers.
In some embodiments, the torque pulses T 1 , T 2 and T 3 may be single pulses as shown in FIG. 2 , or the pulses may vary in duration, magnitude, and/or quantity. FIG. 4 illustrates pulses T 1 , T 2 and T 3 as single pulses with increasing magnitude over time. FIG. 5 illustrates each of pulses T 1 , T 2 and T 3 as multiple pulses, each of equal magnitude, while the pulses of FIG. 6 are multiple pulses with each subsequent pulse increasing in magnitude over the previous pulse.
In some embodiments, visual cues 22 such as shown in FIG. 7 , for example, may be included to complement the torque pulses, T 1 , T 2 , and T 3 , and/or continuous torques T 4 and T 5 . The first indicator 24 illustrates a current position of the steering wheel, while the second indicator 26 illustrates a desired position of the steering wheel and the arrow 28 indicates a necessary direction of rotation of the steering wheel to reach the desired position of the steering wheel indicated by the second indicator 26 . The visual cue 22 must be visible to the driver while the driver is looking rearward during the parking maneuver. Possible locations for the visual cue 22 include, for example, displaying it on a rear windshield of the vehicle, or displaying it on a device that could be pulled down from ceiling of the vehicle near the rear windshield. An additional display in the front of the vehicle would be complementary to one in the rear of the vehicle.
An important consideration in providing steering cues is an initial position of the vehicle 10 . Shown in FIG. 8 is a typical parking situation. The staging zone 30 illustrates where the center of gravity 18 must be located with respect to a left rear corner 32 of the parked vehicle 12 for the parking maneuver to be successful. When the vehicle 10 is driven rearward, for instance with no heading angle offset and with straight steering wheel angle, as the vehicle starts going straight backward from its stationary position, the steering wheel must begin to be turned when the center of gravity 18 crosses staging zone border 34 . The greater the distance y 0 the center of gravity 18 is from the parked vehicle 12 , the sooner along axis x steering wheel turning must be initiated. The particular shape of the staging zone 30 may vary based on the shape of the vehicle 10 , whether a large heading angle offset is permitted at staging, or whether a motion other than directly rearward is allowed while the center of gravity 18 is inside the staging zone 30 and other factors. Because the steering cues are to correspond to a successful steering profile and the staging zone 30 , the location of the first steering cue along the x axis is a substantially linear function of the initial lateral distance y 0 as depicted by the boundary line 34 of the staging zone 30 .This holds for the case where the vehicle's initial heading angle is close to zero and it is driven directly rearward within the staging zone 30 . Alternative steering profiles and staging zones are possible and would result in similar methodology for determining the steering cues.
An algorithm for determining the location along the x-axis to begin providing steering cues is illustrated in FIG. 9 . A first input 36 is an enable that starts a Parking Assist with Steering Cues mode. This is typically activated by the driver through an interface (audio, click, etc.). A second input 38 and a third input 40 are measurements of x and y of the center of gravity 18 relative to the parked car 12 (see FIG. 8 ). The x and y measurements can be provided by a variety of sensors such as ultrasonic, GPS, radar, etc. Furthermore, it is not necessary to directly measure the x and y of the center of gravity 18 . Other points in the vehicle 10 could be utilized as well, and the x and y of the center of gravity 18 could be derived therefrom.
To determine the initial lateral position y 0 , a trig_stage_zone subsystem 42 is used. It takes in the real time y value and since the trig stage zone subsystem 42 is triggered by the first input 36 , an output will be the lateral distance y 0 at a time the driver provides the first input 36 . An X_tresh_RT block 44 receives y 0 from the trig_stage_zone subsystem 42 and outputs the longitudinal location of the first cue or X 1 , based on: X 1 =m Y 0 +b, where m and b are constants representing the boundary 34 of the staging zone 30 . A decision 46 is made whether the calculated X 1 or a fixed X 1a is to be used, followed by a continual comparison 48 between X and X 1 as the vehicle 10 is driven directly rearward. Once X is less than X 1 , the first steering pulse, T 1 , is generated by a trig_pulse block 50 .
A staging check system 52 evaluates whether the vehicle 10 is within the staging zone 30 or not. The staging check system 52 may output a stage_zone_ok signal 54 to the driver, if desired.
A second torque system 56 triggers a second torque pulse T 2 . T 2 is triggered by continually comparing X with a constant value for X 2 (such as −1.8). Note that it has been experimentally verified that unlike X 1 , X 2 is not sensitive to initial staging variation. Also note that triggering of the second torque pulse T 2 may be achieved by comparing Y to a second constant. Alternatively, the triggering of T 2 may be achieved by comparing a distance D 1 between a front right corner 58 of vehicle 10 and the rear left corner 32 of the parked vehicle 12 to a third constant (see FIG. 8 ). Further, the triggering of T 2 can be achieved by generating and comparing a heading angle of the vehicle 10 against a fourth constant. Once the vehicle 10 is at the appropriate location, X equaling X 2 , the second torque pulse, T 2 , is generated by trig_pulse 1 block 60 .
If the vehicle 10 is to be driven directly rearward while the center of gravity 18 is in the staging zone 30 , variation in X 1 is due to variations in the initial location X 0 , y 0 of the center of gravity 18 of the vehicle 10 . The driver's driving style is, by definition, irrelevant. On the other hand, the location of X 2 for application of T 2 is influenced by the driver's driving style. For example, a speed at which the vehicle 10 is moving, the magnitude the driver turns the steering wheel, and speed at which the driver turns the steering wheel are factors in determining the optimal location to apply T 2 .
FIG. 1 illustrates an initial ideal steering wheel profile as a function of station. The ideal profile is perhaps better achievable with an actuator of some kind with driver's hands off the wheel. Since station is defined as an arc length along the path of the center of gravity 18 , it will be conveniently determinable as an integral of the vehicle speed. Thus if the driver decides to bring the vehicle 10 to a halt, the ideal steering wheel location will not change as long as the vehicle is stationary. The steering cues which follow the lead of the ideal steering wheel rotation will also need to be position based as opposed to time based, if the vehicle speed variations are to be taken into account. Furthermore, an exact shape of the ideal profile is a function of the vehicle speed. Generally speaking, the faster the vehicle 10 is moving, the faster the steering wheel must be turned for the vehicle 10 to traverse through the same path. Therefore, one can imagine that the profile shown in FIG. 1 corresponds to a vehicle 10 traveling at an average, or ideal, speed.
As shown in FIG. 10 , one approach to modifying the location X 2 of T 2 is to determine a real time steering wheel profile 62 while the driver is turning the steering wheel. An ideal steering wheel profile 64 corresponding to an ideal center of gravity profile is compared to the real time steering wheel profile 62 and an error signal, e, is found that can be integrated for a desired duration past X 1 . The integrals may be expressed as:
I=∫e ( t ) dt or I=∫e ( s ) dS
If I is positive, it indicates that the driver has been aggressive in turning the steering wheel ahead of the steering wheel ideal profile 64 . If for that interval, an average vehicle speed has been greater than the ideal, the location X 2 is not altered. However, if the average vehicle speed has been close to or less than the ideal vehicle speed, T 2 is provided at a location X 2+ which is past the original location of X 2 . This allows the vehicle path to become closer to the ideal profile 64 . The amount of change in the location of steering cue, ΔX 2+ , is proportional to I.
On the other hand if I is negative, it indicates that the driver has been passive in turning the steering wheel. In particular, if that has occurred while the vehicle 10 has been moving at a higher speed, on the average, compared to the ideal speed, T 2 is provided at location X 2− which is before the original location of X 2 . This allows the vehicle path to again move closer to the ideal profile 64 . If the average vehicle speed has been lower than the ideal speed while I was negative, no change in X 2 is made. The amount of change in the location of steering cue, ΔX 2− , is proportional to I.
Alternatively, a process comparing an actual average steering wheel speed when the vehicle 10 is past X 1 to an ideal steering wheel speed for the same interval may be used. The driver would be considered passive if the actual average steering wheel speed is less than the ideal steering wheel speed, and active when the actual steering wheel speed exceeds the ideal steering wheel speed. With the same considerations for vehicle speed as described above, the same consequences would apply in terms of moving the application of T 2 relative to X 2 . This approach does not require real time computation of the ideal profile.
In addition to the location of T 2 , its amplitude, duration, and/or its number of occurrences may be changed. For example, when the driver is passive after the application of T 1 , T 2 could occur before the vehicle 10 reaches X 2 , with more amplitude, with more duration, and/or it may even be a double pulse or the like.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention.
|
Disclosed is a method for assisting the parking of a vehicle. The method includes determining a vehicle position relative to an obstacle. When the relative position meets a first set of criteria, a first torque pulse is delivered to the steering wheel in the first direction to cue an operator of the vehicle to turn the steering wheel in the first direction. When the relative position meets a second set of criteria, a second torque pulse is delivered to the steering wheel in the second direction, opposite to the first direction to cue the operator to turn the steering wheel in the second direction. A system for assisting the parking of a vehicle is also disclosed.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Phase Entry of International Application No. PCT/FR2008/001052, filed on Jul. 17, 2008, which claims priority to French Application 07 05 367, filed on Jul. 24, 2007, both of which are incorporated by reference herein.
TECHNICAL FIELD
The present invention belongs to the field of bitumens/polymers. More specifically, it relates to thermoreversibly crosslinked bitumen/polymer compositions. The invention also relates to the use of these bitumen/polymer compositions in the fields of highway applications, in particular in the production of road binders, and in the fields of industrial applications. The invention also relates to the process for the preparation of these thermoreversibly crosslinked bitumen/polymer compositions.
TECHNICAL BACKGROUND
The use of bitumen in the production of materials for highway and industrial applications has been known for a long time: bitumen is the main hydrocarbon binder used in the field of road construction or civil engineering. To be able to be used as a binder in these different applications, the bitumen must have certain mechanical properties, in particular elastic or cohesive properties. Since bitumen on its own is generally not sufficiently elastic or cohesive, polymers are added which can optionally be crosslinked. These polymers, crosslinked or not, provide improved elastic and cohesive properties to the bitumen/polymer compositions. Generally, the crosslinking is irreversible; once the crosslinking has been carried out, it is not possible to return to the initial state existing before the crosslinking reaction. Crosslinked bitumen/polymer compositions thus have good mechanical properties, but their viscosity is very high. In fact, the two characteristics “mechanical properties” on the one hand, and “fluidity” on the other hand, are contradictory. The mechanical properties (elasticity and cohesion), are promoted by long chain lengths, therefore by crosslinking of the polymer chains. Fluidity is promoted by a short chain length, therefore by an absence of crosslinking or a weak crosslinking of the polymer chains. According to the applications envisaged, it is necessary to find a good compromise between mechanical properties and fluidity by adjusting the rate or the nature of the crosslinking.
PRIOR ART
Crosslinking according to the prior art is usually irreversible crosslinking based on the formation of covalent bonds between the polymer chains. Thus, one of the crosslinkings most used in the field of bitumens is sulphur crosslinking or vulcanization. In sulphur crosslinking, more or less short sulphur chains (in general having 8 to 2 atoms of sulphur) covalently bond the polymer chains. By altering the chemical nature of the donor of the sulphur and/or the polymer, the temperature, the concentration of the polymer and/or of the sulphur donors, the Applicant has thus developed and patented a large number of crosslinked bitumen/polymer compositions having clearly improved properties with respect to bitumen without polymers and with respect to the non-crosslinked bitumen/polymer physical mixture. Among the Applicant's patents, there can be mentioned the following references in particular: FR2376188, FR7818534, EP0799280, EP0690892.
Novel thermoreversibly crosslinked polymers have recently been developed. Most of the thermoreversible crosslinking is carried out using thermoreversible covalent bonds. There are also thermoreversible crosslinkings which are carried out via coordination bonds or ionic bonds.
Thus, JP 11106578 describes the modification of a polyolefin by an acid anhydride which reacts in the presence of alcohols to form thermoreversible ester bonds. EP 870793 describes a mixture of a first polymer having at least two acid functions and a second polymer having at least two amine functions so as to form stable amide groups at low temperature which can be dissociated at high temperature. FR2558845 describes the reaction between a divinyl ether and a copolymer bearing acid functions. The acyl obtained is stable at low temperature and decomposes when the temperature is increased. Other thermoreversibly crosslinked polymers involve polymers comprising carboxylic acid units which bond reversibly to metals (JP 50139135, JP 51019035, JP 56014573). Others still involve labile ionic bonds between acid groups and amine groups (JP 52065549, JP57158275).
OBJECTIVES OF THE INVENTION
In these circumstances, the present invention relates to obtaining thermoreversibly crosslinked bitumen/polymer compositions. Another objective of the invention is to propose bitumen/polymer compositions having the properties of reversibly crosslinked bitumen/polymer compositions at operating temperatures, in particular with respect to elasticity and/or cohesion, and having a reduced viscosity at processing temperatures. Another objective of the invention is to propose a simple process for the preparation of thermoreversibly crosslinked bitumen/polymer compositions.
BRIEF DESCRIPTION
The Applicant company has developed novel thermoreversible crosslinked bitumen/polymer compositions. The bitumen/polymer compositions obtained have the properties of conventional crosslinked bitumen/polymer compositions at operating temperatures, and the properties of non-crosslinked bitumen/polymer compositions at processing temperatures.
Firstly, the invention relates to a bitumen/polymer composition comprising at least one bitumen and at least one graft polymer GP comprising a polymer main chain P and at least one side graft G bonded to the polymer main chain, the graft comprising a branched, linear or saturated hydrocarbon chain, having at least 18 carbon atoms. Preferably, the branched, linear or saturated hydrocarbon chain with at least 18 carbon atoms of the graft has the general formula C n H 2n+1 , where n represents an integer greater than or equal to 18, preferably varying from 18 to 110. The graft polymer GP results from the reaction between at least one reactive function of a polymer P and a reactive function of a graft G, the reactive functions of the polymer P and the graft G being chosen from double bonds, epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines.
The polymer P results from the polymerization of units comprising reactive functions chosen from double bonds, epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines, in particular double bonds. The polymer P results in particular from the copolymerization of diene units, preferably conjugated diene. Preferably, the polymer P results from the copolymerisation of conjugated diene units and aromatic monovinyl hydrocarbon units.
The conjugated diene units are chosen from those comprising 4 to 8 carbon atoms per monomer, for example butadiene, 2-methyl-l, 3-butadiene(isoprene), 2,3-dimethyl-l,3-butadiene, 1,3-pentadiene and 1,3-hexadiene, chloroprene and mixtures thereof, in particular butadiene. The aromatic monovinyl hydrocarbon units are chosen from styrene, o-methyl styrene, p-methyl styrene, p-tert-butyl styrene, 2,3 dimethyl styrene, α-methyl styrene, vinyl naphthalene, vinyl toluene, vinyl xylene, and similar or mixtures thereof, in particular styrene. Preferably, the polymer main chain of the polymer P comprises double bonds, in particular pendant vinyl double bonds originating from the 1-2 addition of conjugated diene units, in particular butadiene units.
Preferably, the polymer P has a styrene content by weight of 5% to 50%. Preferably, the polymer P has a butadiene content by weight of 50% to 95%. Preferably, the polymer P has a content by weight of pendant vinyl double-bond units originating from the 1-2 addition of butadiene from 5% to 50%.
According to a variant of the invention, the graft G has the general formula C n H 2n+1 —XH where X represents a sulphur atom, an oxygen atom or the NH group and n represents an integer varying from 18 to 110. In another embodiment, the graft G has the general formula C n H 2n+1 —(OCH 2 CH 2 ) m —XH where X represents a sulphur atom, an oxygen atom or the NH group, n represents an integer varying from 18 to 110 and m represents an integer varying from 1 to 20.
Preferably, the graft polymer GP is obtained by reaction between at least one double bond of polymer P, in particular a pendant vinyl double bond originating from the 1-2 addition of a conjugated diene unit of polymer P and a reactive function of a graft G chosen from the thiol, alcohol or amine functions. Preferably, the graft polymer GP is obtained by reaction between at least one double bond of polymer P, in particular a pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P and a thiol function, preferably terminal, of a graft G. Preferably, the graft polymer GP is obtained by reaction between at least one double bond of polymer P, in particular a pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P and a graft G of general formula C n H 2n+l —XH where X represents a sulphur atom, an oxygen atom or an NH group and n represents an integer varying from 18 to 110.
Preferably, the graft polymer GP comprises at least two grafts per main polymer chain. Preferably, the content of graft polymer GP by weight with respect to the bitumen is from 0.1 to 30%, preferably 1 to 10%. The bitumen/polymer composition comprises moreover at least one flux (fluxing agent). The bitumen is chosen from atmospheric distillation residues, vacuum distillation residues, visbroken residues, blown residues, de-asphalting residues, mixtures and combinations thereof.
The invention relates moreover to a process for the preparation of thermoreversibly crosslinked bitumen/polymer compositions. Two preparation processes are envisaged. In the so-called “ex situ” process the graft polymer GP is introduced into the bitumen. In the so-called “in-situ” process, the polymer P and the graft G are introduced into the bitumen, the grafting reaction taking place in the bitumen.
Preferably, the ex situ preparation process is such that:
a) a bitumen is introduced into a receiving vessel equipped with mixing means, and the bitumen is taken to a temperature comprised between 90 and 220° C., preferably between 140 and 180° C., b) from 0.1 to 30%, preferably 0.1 to 10% by mass of a graft polymer GP with respect to the mass of bitumen is introduced, c) the composition is heated at a temperature comprised between 90 and 220° C., preferably between 140 and 180° C., under stirring, until a homogeneous final bitumen/polymer composition is obtained.
Preferably, the in situ preparation process is such that:
a) a bitumen is introduced into a receiving vessel equipped with mixing means, and the bitumen is taken to a temperature between 90 and 220° C., preferably between 140 and 180° C., b) from 0.1 to 30%, preferably 0.1 to 10% by mass of a polymer P and 0.1 to 30%, preferably 0.1 to 10% by mass of a graft G with respect to the mass of bitumen are introduced, c) the composition is heated at a temperature comprised between 90 and 220° C., preferably between 140 and 180° C., under stirring, until a homogeneous final bitumen/polymer composition is obtained.
Finally, the invention relates to the use of bitumen/polymer compositions according to the invention in order to produce a bituminous binder, capable of being implemented as it is, in anhydrous form, in emulsion form or in fluxed bitumen form. These bituminous binders can then be combined in a mixture with aggregates in order to produce a surface dressing, a hot mix, a cold mix, a cold-cast mix, a gravel emulsion. Applications of the bitumem/polymer according to the invention are capable of use in highway applications or industrial applications in order to produce a wearing course, a sealing membrane, a membrane or an impregnation layer.
DETAILED DESCRIPTION
The bitumen/polymer compositions comprise a graft polymer GP. By graft polymer is meant a polymer which comprises a polymer main chain and side grafts bonded to this chain. The grafts are bonded directly to the main chain of the polymer. The polymer main chain is obtained by polymerisation of several monomers. The grafts are then grafted to the polymer main chain, after polymerisation of the latter, by chemical reaction. The result is a covalent bond between the grafts and the polymer main chain. The graft polymers according to the invention are thus obtained by polymerization, then grafting of the grafts, and not by polymerization of monomers already comprising grafts.
The graft polymer GP according to the invention results from the reaction between at least one reactive function of a polymer P and a reactive function of a graft G. The reactive functions present on the polymer P and/or on the graft G are chosen from double bonds, epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines. In particular, the reactive functions present on the polymer are chosen from double bonds. Preferably, the reactive functions present on the graft G are chosen from epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines, preferably thiols, alcohols and amines, preferably thiols.
The reactive function(s) present on the polymer P is/are situated along the polymer P chain while the reactive function(s) of the graft G is/are preferably terminal i.e. situated at the ends of the molecule. Preferably the graft G has only one terminal reactive function while the polymer P has several reactive functions. The grafts are bonded directly to the polymer main chain by reaction between their reactive functions, via a covalent bond.
The polymers according to the invention result from polymerization (homopolymerization, copolymerization, terpolymerization, etc) of units (or monomers) comprising reactive functions chosen from double bonds, epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines, in particular double bonds. Among the polymers which can be used according to the invention, there can be mentioned for example polybutadienes, polyisoprenes, butyl rubbers, polyacrylates, polymethacrylates, polychloroprenes, polynorbornenes, ethylene and vinyl acetate copolymers, ethylene and methyl acrylate copolymers, ethylene and butyl acrylate copolymers, ethylene and maleic anhydride copolymers, ethylene and glycidyl methacrylate copolymers, ethylene and glycidyl acrylate copolymers, ethylene/propene/diene (EPDM) terpolymers, acrylonitrile/butadiene/styrene (ABS) terpolymers, ethylene/acrylate or alkyl methacrylate/acrylate or glycidyl methacrylate terpolymers and in particular ethylene/methyl acrylate/glycidyl methacrylate terpolymers and ethylene/alkyl acrylate or methacrylate/maleic anhydride terpolymers and in particular ethyl/butyl acrylate/maleic anhydride terpolymers. The polymers P can also be those described in the Applicant's patents EP1572807, EP0837909, and EP1576058.
The preferred polymers P can also be those resulting in particular from the polymerization of diene units, preferably conjugated diene. These polymers are thus obtained from at least one diene unit (or monomer), preferably conjugated diene. In a variant of the invention, the polymers can result from homopolymerization of diene units only, preferably conjugated diene. In these polymers, along the polymer chain a number of double bonds resulting from the homopolymerization of diene units, preferably conjugated diene are present. Such polymers are for example polybutadienes, polyisoprenes, polyisobutenes, polychloroprenes, but also butyl rubbers which are obtained by the concatenation of isobutene and isoprene copolymers. Copolymers or terpolymers obtained from diene units are also present such as butadiene, isoprene, isobutene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, chloroprene units.
In another variant of the invention, the polymers can also result from copolymerisation or terpolymerization of diene units, preferably conjugated diene, and other units containing other reactive functions. These reactive functions will be chosen for example from double bonds, epoxides, acid anhydrides, carboxylic acids, esters, amides, thiols, alcohols and amines, in particular double bonds.
Thus, the polymers can be obtained from diene units, preferably conjugated diene and units such as vinyl acetate, methyl acrylate, butyl acrylate, maleic anhydride, glycidyl methacrylate, glycidyl acrylate, norbornene units. The polymers can also be obtained from diene units, preferably conjugated diene and units comprising double bonds. Polymers such as ethylene/propene/diene (EPDM) terpolymers, acrylonitrile/butadiene/styrene (ABS) terpolymers can be used. The polymers according to the invention obtained from at least one diene unit (or monomer), preferably conjugated diene, can also be hydrogenated, or partially hydrogenated, after polymerization.
The preferred polymers P are the polymers which have double bonds along their main chain. There can be mentioned for example homopolymers such as polybutadienes or polyisoprenes. Preferred polymers are also the polymers resulting exclusively from the copolymerization of conjugated diene units and aromatic monovinyl hydrocarbon units.
Among the conjugated diene units, there can be mentioned for example, those comprising 4 to 8 carbon atoms per monomer, such as butadiene, 2-methyl-l,3-butadiene (isoprene), 2,3-dimethyl-l,3-butadiene, 1,3-pentadiene and 1,2-hexadiene, chloroprene. The preferred conjugated diene units are butadiene units. Among the aromatic monovinyl hydrocarbon units, there can be mentioned for example, styrene, o-methyl styrene, p-methyl styrene, p-tert-butylstyrene, 2,3 dimethyl-styrene, alpha-methyl styrene, vinyl naphthalene, vinyl toluene, vinyl xylene. The preferred aromatic monovinyl hydrocarbon units are styrene units. The preferred polymers are the polymers resulting from the copolymerization of butadiene units and styrene units.
The reactive functions present on the polymer P after the polymerization reaction are preferably double bonds. According to the type of polymerization of the conjugated diene units via a 1-2 addition or via a 1-4 addition, the reactive double bonds of polymer P are of two types. The first results from the 1-4 addition of the conjugated dienes and the second from the 1-2 addition of the conjugated dienes.
The double bonds originating from the 1-2 addition of the conjugated dienes are pendant vinyl double bonds. The reactive functions present on the polymer P after the polymerization reaction are preferably pendant vinyl double bonds originating from the 1-2 addition of conjugated diene units. In particular, the reactive functions present on the polymer P after the polymerization reaction are pendant vinyl double bonds originating from the 1-2 addition of butadiene units.
The preferred polymers P are styrene- and butadiene-based block copolymers. Advantageously, they have a styrene content by weight ranging from 5% to 50% and a butadiene content by weight ranging from 50% to 95%. Advantageously, the polymer P has a pendant vinyl double-bond units originating from the 1-2 addition of butadiene content by weight ranging from 5% to 50%. The average molecular mass by weight of the polymer P can be comprised, for example, between 10,000 and 600,000 daltons and is situated preferably between 30,000 and 400,000 daltons.
The graft G comprises a branched, linear or saturated hydrocarbon chain, of at least 18 carbon atoms, preferably at least 22 carbon atoms, preferably at least 30 carbon atoms. Preferably the saturated hydrocarbon chain of the graft is linear. The saturated hydrocarbon chain of the graft has a general formula C n H 2n+l , where n represents an integer greater than or equal to 18, preferably varying from 18 to 110, preferably varying from 18 to 90, preferably varying from 18 to 50, preferably varying from 20 to 40, preferably 25 to 30. Preferably, the graft G has the general formula C n H 2n+l —XH where X represents a sulphur atom, an oxygen atom or an NH group and n represents an integer varying from 18 to 110, preferably varying from 18 to 90, preferably varying from 18 to 50, preferably varying from 20 to 40, preferably 25 to 30.
When X is a sulphur atom, the graft G has the general formula CnH2n+l—SH, and n varies from 18 to 110, preferably 18 to 90, preferably 18 to 50, preferably 20 to 40, preferably 25 to 30. When X is an oxygen atom, the graft G has the general formula C n H 2n+1 —OH, and n varies from 18 to 110, preferably 18 to 90, preferably 18 to 50, preferably 20 to 40, preferably 25 to 30. When X represents the NH group, the graft G has the general formula C n H 2n+1 —NH 2 , and n varies from 18 to 110, preferably 18 to 90, preferably 18 to 50, preferably 20 to 40, preferably 25 to 30.
Preferably, the graft G of general formula C n H 2n+1 —XH is chosen for example from the following thiols: C 18 H 37 —SH, C 40 H 81 —SH, C 70 H 141 —SH and/or C 90 H 181 —SH. The graft G can also have, as general formula, the following general formula: C n H 2n+1 —(OCH 2 CH 2 ) m —XH where X represents a sulphur atom, an oxygen atom or an NH group, n represents an integer varying from 18 to 110 and m represents an integer varying from 1 to 20, preferably n represents an integer varying from 18 to 90, preferably varying from 18 to 50, preferably varying from 20 to 40, preferably 25 to 30.
Preferably, the graft G of general formula C n H 2n+1 —(OCH 2 CH 2 ) m —XH is an alcohol (X═O), chosen for example from the following alcohols:
—CH 3 —(CH 2 ) 32 —(OCH 2 CH 2 ) 3 —OH,
—CH 3 —(CH 2 ) 49 —(OCH 2 CH 2 ) 4 —OH,
—CH 3 —(CH 2 ) 32 —(OCH 2 CH 2 ) 11 —OH,
—CH 3 —(CH 2 ) 49 —(OCH 2 CH 2 ) 16 —OH.
According to a preferred embodiment of the invention the graft polymer GP is obtained by reaction between at least one double bond of polymer P, in particular a pendant vinyl double bond originating from the 1-2 addition of a conjugated diene of polymer P and a function chosen from the thiol, alcohol or amine functions of the graft G. In particular, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a conjugated diene unit of polymer P, and a thiol function, preferably terminal, of a graft G. In particular, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P, and a thiol function, preferably terminal, of a graft G.
More preferably, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P, and a graft G of general formula C n H 2n+1 —XH where X represents a sulphur atom, an oxygen atom or an NH group and n represents an integer varying from 18 to 110, preferably varying from 18 to 90, preferably varying from 18 to 50, preferably varying from 20 to 40, preferably 25 to 30. More preferably, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P, and a graft G chosen from the following thiols: C 18 H 37 —SH, C 40 H 81 —SH1 C 70 H 141 —SH and/or C 90 H 181 —SH.
According to another preferred embodiment of the invention the graft polymer GP is obtained by reaction between at least one double bond of polymer P, in particular a pendant vinyl double bond originating from the 1-2 addition of a conjugated diene of the polymer P and an alcohol function, preferably terminal, of a graft G. More preferably, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P, and a graft G of general formula C n H 2n+1 —(OCH 2 CH 2 ) m —OH where n represents an integer varying from 18 to 110 and m represents an integer varying from 1 to 20, preferably n represents an integer varying from 18 to 90, preferably varying from 18 to 50, preferably varying from 20 to 40, preferably 25 to 30.
More preferably, the graft polymer GP is obtained by reaction between at least one pendant vinyl double bond originating from the 1-2 addition of a butadiene unit of polymer P, and a graft G chosen from the following alcohols:
—CH 3 —(CH 2 ) 32 —(OCH 2 CH 2 ) 3 —OH,
—CH 3 —(CH 2 ) 49 —(OCH 2 CH 2 ) 4 —OH,
—CH 3 —(CH 2 ) 32 —(OCH 2 CH 2 ) 11 —OH,
—CH 3 —(CH 2 ) 49 —(OCH 2 CH 2 ) 16 —OH.
The scope of the invention is not exceeded when the polymer
P reacts firstly with a reactive species comprising a function chosen from the following functions: alkenes, dienes, epoxides, acid anhydrides, carboxylic acids, esters, carboxylic acids, thiol, alcohol and/or primary amine and only subsequently with a graft G as defined in the invention. According to the invention, the polymer GP comprises at least one side graft. Preferably the average number of grafts per main polymer chain is greater than 2.
Preferably, the polymer GP comprises from 3 to 55% in moles of grafts G, preferably 5 to 35% in moles, more preferably 10 to 20% in moles. Preferably, the polymer GP comprises from 10 to 55% by mass of grafts G, preferably 15 to 35% by mass, more preferably 10 to 20% by mass. When the polymer GP is a polymer having a high content by weight of pendant vinyl double-bond units originating from the 1-2 addition of the butadiene (for example of the order of 30% by mass, instead of 10% by mass for a polymer GP is a polymer having a high content by weight of pendant vinyl double-bond units originating from the 1-2 addition of the butadiene), the grafting rate is greater and the polymer GP comprises more grafts G.
These grafts can all have the same chemical structure or have different chemical structures within the graft polymer GP. Grafts having a different chain length can therefore coexist within a single main polymer chain. Thus, for example, the graft polymer GP can comprise at least one graft comprising a C 18 H 37 — side chain and at least one graft comprising a C 70 H 141 — side chain.
Without being bound by the following theory, these are the grafts G allowing thermoreversible crosslinking. The crosslinking results from assembling the graft polymers GP via the grafts G (more precisely via the hydrocarbon chains of the grafts G). This assembly allows crystalline areas to be defined between the grafts G of the graft polymer GP. These crystalline areas are stables at low temperature. When the temperature increases, these crystalline areas melt, recrystallizing when the temperature reduces. At low temperature the interactions of the crystalline areas of the grafts G bring together the chains of the graft polymer GP which are then crosslinked. When the crystalline areas of the grafts melt, the chains of the graft polymer GP move apart, they are no longer crosslinked.
Thus, when a bitumen with the graft polymers GP according to the invention is used as an additive, bitumen/polymer compositions are obtained which are reversibly, and more particularly thermoreversibly crosslinked. By thermoreversible crosslinking of the bitumen/polymer compositions according to the invention, is meant a crosslinking demonstrated by the following phenomena:
at low temperature, for example at working temperatures, the grafts G of the cograft polymers GP are combined and form crosslinking points. The polymer network formed confers good mechanical properties on the bitumen/polymer composition, in particular with regard to flexibility and cohesion. when hot, a temperature increase causes the rupture of the crosslinking points and as a result the disassociation of the polymer chains. The polymer network disappears and the bitumen/polymer composition returns to a low viscosity and therefore a good fluidity. a reduction in temperature allows the crosslinking points to reform. The phenomenon is thermoreversible.
The bitumen/polymer compositions according to the invention are constituted by at least one bitumen and at least one graft polymer GP. The graft polymers GP introduced into the bitumen have been described previously. The graft polymers GP represent 0.1 to 30% by weight with respect to the bitumen. According to a preferred implementation, the graft polymers GP represent from 1 to 10% by weight with respect to the bitumen, preferably, from 1 to 5% by weight with respect to the bitumen.
The bitumen/polymer compositions according to the invention can contain bitumens of different origins. There can be mentioned firstly the bitumens of natural origin, those contained in deposits of natural bitumen, natural asphalt or bituminous sands. The bitumens according to the invention are also the bitumens originating from the refining of crude oil. The bitumens originate from the atmospheric and/or vacuum distillation of oil. These bitumens being able to be optionally blown, visbroken and/or de-asphalted. The bitumens can be bitumens of hard or soft grade. The different bitumens obtained by the refining processes can be combined with each other in order to obtain the best technical compromise.
The bitumens used can also be bitumens fluxed by the addition of volatile solvents, fluxes originating from oil, carbochemical fluxes and/or fluxes of vegetable origin. The fluxes used can comprise C 6 to C 24 fatty acids in acid, ester or amide form in combination with a hydrocarbon cut.
The invention relates to a process for the preparation of thermoreversibly crosslinked bitumen/polymer compositions. Two processes can be envisaged: a so-called ex-situ and a so-called in-situ process. By ex situ process is meant a process in which the grafting of the grafts G onto the polymer P is carried out apart from the bitumen, the polymer GP being obtained apart from the bitumen.
Obtaining a bitumen modified according to the so-called ex situ process comprises the following essential steps:
a) a bitumen is introduced into a receiving vessel equipped with mixing means, and the bitumen is taken to a temperature between 90 and 220° C., preferably between 140° C. and 180° C., b) from 0.1 to 30% by mass of a graft polymer GP according to the invention with respect to the mass of bitumen, preferably 0.1 to 10% is introduced. c) throughout the process, the composition is heated at a temperature between 90 and 220° C., preferably between 140 and 180° C., under stirring, until a homogeneous final bitumen/polymer composition is obtained.
It can also be envisaged to obtain a modified bitumen according to the so-called in-situ process where the formation of the graft copolymer GP according to the invention is carried out in the bitumen. The so-called in-situ process comprises the following essential steps:
a) a bitumen is introduced into a receiving vessel equipped with mixing means, and the bitumen is taken to a temperature between 90 and 220° C., preferably between 140° C. and 180° C., b) from 0.1 to 30%, preferably 0.1 to 10% by mass of a polymer P is introduced, then from 0.1 to 30%, preferably 0.1 to 10% by mass of a graft G is introduced.
Throughout the process, the composition is heated at a temperature between 90 and 220° C., preferably between 140 and 180° C., under stirring, until a homogeneous final bitumen/polymer composition is obtained.
Various uses of the bitumen/polymer compositions obtained according to the invention are envisaged, in particular for the preparation of a bituminous binder, which can in turn be used for preparing a combination with aggregates, in particular road aggregates. Another aspect of the invention is the use of a bituminous composition in various industrial applications, in particular for preparing a sealing membrane, membrane or impregnation layer. With regard to highway applications, the invention relates in particular to bituminous mixes as materials for the construction and maintenance of road foundations and their surfacing, as well as for carrying out all road works. Thus, the invention relates for example to surface dressings, hot mixes, cold mixes, cold-cast mixes, gravel emulsions, base, binder, bonding and wearing courses, and other combinations of a bituminous binder and highway aggregate having particular properties such as anti-rutting courses, draining mixes, or cast asphalts (mixture of a bituminous binder and sand-type aggregates). With regard to the industrial applications of the bituminous compositions, there can be mentioned the production of sealing membranes, anti-noise membranes, insulating membranes, surface coatings, carpet tiles, impregnation layers, etc.
EXAMPLES
Preparation of the polymer GP
Three polymers GP according to the invention are prepared from a polymer P which is a styrene/butadiene block copolymer, having 25% by weight of styrene and 75% by weight of butadiene. This copolymer has a molecular mass by weight Mw of 128,000 Dalton, a polymolecularity index Mw/Mn of 1.11 and a content of pendant vinyl double-bond unit originating from the 1-2 addition of butadiene of 10% by mass with respect to the assembly of butadiene units. 50 ml of toluene, 2 g of polymer P described above are introduced into a reactor kept under a nitrogen atmosphere. Then 1.5 g of graft G and 10 mg of AIBN (azobisisobutyronitrile) are introduced into the reactor; the mixture is heated progressively to approximately 90° C. under stirring.
Three grafts are used: C 18 H 37 —SH (G 1 ), C 40 H 81 —SH (G 2 ), C 70 H 141 —SH (G 3 ). After 3 to 4 hours, the solution is cooled down to ambient temperature and the copolymer GP is precipitated using methanol and acetone. The graft polymers PG 1 , PG 2 and PG 3 are obtained from grafts G 1 , G 2 and G 3 respectively.
Bitumen
The bitumen is a bitumen of penetration grade 50 1/10 mm the characteristics of which correspond to the standard NF EN 12591.
Bitumen/Polymer Compositions C 1 , C 2 and C 3 According to the Invention
Three bitumen/polymer compositions according to the invention are prepared from the graft polymers PG 1 , PG 2 and PG 3 and the bitumen described above (ex-situ process). 35 g of bitumen is introduced into a reactor kept at 180° C. and equipped with a mechanical stirring system. The bitumen is heated at 185° C. and stirred for approximately 60 minutes. Then 1.8 g of the graft polymer PG 1 , PG 2 or PG 3 obtained above is added. The mixture forms during a period of 4 hours under stirring. The bitumen/polymer compositions C 1 , C 2 and C 3 are obtained from the graft polymers PG 1 , PG 2 and PG 3 respectively.
Preparation of the Polymer GP in-situ and Bitumen/Polymer Compositions C 4 , C 5 , and C 6 According to the Invention
Three further bitumen/polymer compositions according to the invention are prepared, starting from the in-situ preparation process. 35 g of bitumen described above it introduced into a reactor heated at 185° C. and stirred. The bitumen is heated and stirred for approximately 60 minutes. Then, 1.8 g of the polymer P (styrene-butadiene bi-block copolymer, having 25% by weight of styrene and 75% by weight of butadiene described above) and 1.8 g of graft G are added.
Three grafts are used: C 18 H 37 —SH (G 1 ), C 40 H 81 —SH (G 2 ), C 70 H 141 —SH (G 3 ). The mixtures are stirred for approximately 4 hours. The compositions C 4 , C 5 and C 6 are obtained from the grafts G 1 , G 2 and G 3 respectively.
A Control Bitumen/Polymer Composition T 1
An irreversibly-crosslinked bitumen/polymer composition is also prepared as follows:
35 g of the above bitumen is introduced into a reactor. The bitumen is heated at 185° C. and stirred for approximately 60 minutes. Then 1.8 g of the styrene-butadiene bi-block copolymer, having 25% by weight of styrene and 75% by weight of butadiene described above is added. The mixture is stirred and heated at 185° C. for approximately 4 hours. Then 50 mg of sulphur is added. The mixture is stirred and heated at 185° C. for I hour 30 minutes.
The Table below shows the physical characteristics of the compositions according to the invention and of the control composition.
Results
C 1
C 2
C 3
T 1
Penetrability (0.1 mm) (1)
52
37
32
43
RBT (° C.) (2)
51.8
74.2
83.8
61.6
Viscosity at 80° C.
35.0
38.2
58.10
59.00
Viscosity at 100° C.
6.10
5.50
11.40
14.94
Viscosity at 120° C.
1.60
1.10
2.82
4.27
Viscosity at 140° C.
0.59
0.41
0.97
1.48
Viscosity at 160° C.
0.26
0.18
0.42
0.63
Viscosity at 180° C.
0.14
0.10
0.22
0.37
Viscosity at 200° C.
0.08
0.05
0.12
0.18
Max. elongation at 5° C. (%) (3)
701
520
150
697
Stress (daN/cm 2 ) (3)
1.0
1.3
1.3
1.3
(1) According to standard EN 1426
(2) Ring and Ball temperature, according to standard EN 1427
(3) Traction test at 5° C., according to standard NF T 66-038, with a stretching rate of 500 mm/min.
The results of this table show that the viscosities at 80° C. to 200° C. of the bitumen/polymer compositions according to the invention are always less than those of the control composition T 1 . The bitumen/polymer compositions according to the invention from 80° C. are therefore less viscous than a sulphur-crosslinked bitumen/polymer composition. Low viscosities at processing temperatures are thus reached using the bitumen/polymer compositions according to the invention.
Moreover, it is noted that the elastic properties of the bitumen/polymer compositions according to the invention depend on the chain length of the graft grafted on the polymer. The best elasticity/viscosity compromise is obtained for the compositions C 1 and C 2 in which the elastic properties are of the same order of magnitude as those of a sulphur-crosslinked bitumen/polymer composition (maximum elongation under traction and stress equivalent for C 1 , C 2 and T 1 ). At operating temperatures, the bitumen/polymer compositions according to the invention, in particular C 1 and C 2 , are therefore elastic while having a reduced viscosity at processing temperatures. Similarly, it is noted that the Ring and Ball temperatures of the bitumen/polymer compositions according to the invention depend on the chain length of the graft grafted on the polymer. In the case of the compositions C 2 and C 3 , these values are even greater than that of the sulphur-crosslinked control T 1 .
|
The disclosure relates to a bitumen/polymer composition comprising at least one bitumen and at least one graft polymer, the grafts enabling the bitumen/polymer compositions to be thermoreversibly cross-linked. The disclosure also relates to the use of said bitumen/polymer compositions in fields of application relating to roads, especially in the production of asphalt binders, and in industrial fields of application. The disclosure further relates to the method for producing said thermoreversibly cross-linked bitumen/polymer compositions.
| 2
|
RELATED APPLICATIONS
The present application is a continuation-in-part of applicant's application Ser. No. 601,924 filed June 15, 1984 now abandoned entitled Cuff Device.
BACKGROUND OF THE INVENTION
The present invention relates to therapeutic and prophylactic devices, particularly to a cuff device that dynamically tightens and loosens on a wearer's body part as another body part is moved.
Various compressive cuff devices are known such as the straps that hold braces on a patient's limb and trunk to protect ligaments, tendons and bones as they heal following injury or surgery. Various strapping devices are also used to help prevent injury or provide support for the chronic instability of a body part. Elastic stockings and inflatable cuffs are used to reduce edema and blood stasis in the extremities that result from disease, injury, prolonged confinement or surgery.
Unfortunately, at the present time, ideal conditions for the efficient application of these braces, cuffs and stockings cannot be achieved with conventional means. These supporting structures tend to be either too loose on the body part, in which case the support members cannot adequately stabilize the body part against undesirable or abnormal movement or fluid stasis or, more frequently, these supporting structures are held too tightly, intensifying discomfort. prolonging immobility and aggravating the problem of stasis or atrophy.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide a cuff device that overcomes the drawbacks of previously known devices of the above known type.
Another object of the present invention is to provide a dynamic cuff assembly that momentarily tightens on a body part in response to movement of another body part.
It is still another object of the present invention to provide a dynamic cuff assembly that momentarily tightens and loosens from a close fit position on a body part in response to movement of another body part in desirable directions but not in other directions.
It is still another object of the present invention to provide a dynamic cuff assembly that can be adjusted to control the rate and amount of tightening and loosening of the cuff assembly on a body part in response to a predetermined movement in a predetermined direction from a predetermined position of another body part.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a cuff assembly of the present invention in extension showing the various parts.
FIG. 2 is an enlarged fragmentary side elevation view of the cuff assembly showing the pivot, lever and cam assembly.
FIG. 3 is a vertical sectional view taken along line A--A of FIG. 2.
FIG. 4 is an enlarged fragmentary side elevation view of the cuff assembly of an alternative embodiment of the present invention showing the pivot and gear assembly.
FIG. 5 is an enlarged fragmentary side elevation view of the cuff assembly of another alternative embodiment of the present invention showing the pivot and plate assembly in the normal position.
FIG. 6 is an enlarged fragmentary side elevation view of the cuff assembly of FIG. 5 pivoted from the normal position.
FIG. 7 is a vertical sectional view taken along line B--B of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3, a cuff device for the lower extremity is shown, but it is understood that the principals of the invention are also applicable to other articulated body parts. There is shown in FIG. 1 a cuff assembly 1 which includes an upper limb engaging cuff component 2 and a lower limb engaging cuff component 3. These cuff components comprise a fitting means and are respectively adapted to engage the body parts above and below the articulation. A pair of arms 4 and 5 are respectively attached to and extend toward each other from the limb engaging components 2 and 3. These arms 4 and 5 terminate in movable overlaping end regions 6 and 7 remote from the fitting means and formed with aligned openings through which a single pivot pin 8 extends. A more complex slidable and pivotable orthotic joint can be used and additional arms can be located on the limbs. The pivot pin 8 has a head 9 and a section 10 secured in the opening in the end region 6 by a hexigonal shaped configuration complimentary to a hexigonal shaped opening in end region 6. End region 7 pivots freely about pivot pin 8. Thus, pivot pin 8 forms a pivot axis which is substantially perpendicular to the arms 4 and 5 and which coincides with the predominent axis to which swinging of the upper and lower limbs are limited. The arms 4 and 5 may be of a slightly flexible material construction such as metal or plastic. The cuff components 2 and 3 are fixed at one end to the arms 4 and 5 by rivets 11 or the like. The cuff components are constructed of relatively soft yieldable material such as plastic or cloth to conform to the limb configuration. The opposite ends of the cuff components 2 and 3 are fixed to relatively stiff bars 12 and 13 by rivets 11 or the like.
A cable 14 is releasably and adjustably secured with a cable clamp bolt 15 head on arm 4, passes through a guide 16 on bar 12, passes through guide 17 on arm 4 and is directed in a groove around cam 18 of lever mechanism 20. The cable is then secured to the lower end of the cam 18 by a cable clamp bolt head to provide a close fit of the upper limb engaging cuff component and to prevent loosening of the cuff component from the close fit position. The cam 18 is attached by bolts 20 or the like to lever 19 which is attached to end region 7 by bolts 20 or the like. The cam and lever can be constructed in various shapes and lengths to adjust the amount and rate of tightening of the cuff components.
A cable 21 is secured under cable clamp bolt 22 head on bar 13, passes through guide 23 on arm 5 and is directed through guide 24 on lever 25 attached to end region 6 by bolt 20a or the like. The cable is then releasably and adjustably secured under a cable clamp bolt 26 head on arm 4 to provide a close fit of the lower cuff component. A lever 28 is adjustably attached to end region 7 by a bolt 28a or the like and engages the cable 21 by a guide 29. The levers 25 and 28 can be adjusted such that the cuff component 3 is tightened from the close fit when the body part is moved away from a predetermined position relative to the other body part. In this instance in both flexion and extension of the thigh relative to the leg from the normal resting position.
In use, the cuff device is placed on the wearer's limb by situating the upper and lower arms 4 and 5 in the region of the knee or other articulation. The cuff components 2 and 3 are wrapped around the limbs and the cables 14 and 21 adjustably secured under the appropriate cable clamp bolt heads 15 and 26. The cuffs should have a close fit in the resting position for the articulation. The cable, lever and cam mechanisms are arranged and adjusted to tighten the cuff components when the body parts move in the direction of flexion and extension. However, numerous prophylactic and therapeutic conditions can be accomodated by various combinations and arrangements of the cables, levers and cams. One or both cuff components can be appropriately connected to the end regions to tighten in flexion or extension only or each in both directions from a predetermined position. One cuff device may serve to immobilize one arm and a tibia to prevent or restrain anterior and posterior movement of the tibia relative to the femur by arranging the mechanism to dynamically tighten on the limbs in both flexion and extension. As another example, the cuff can serve to protect the knee from lateral bending and rotation by tightening both cuffs in extension of the extremity. Further, the device can be arranged to first tighten the lower cuff component then the upper cuff component during the toe off and swing through phases of the wearer's gait to compress the limb to minimize stasis and improve venous return.
Referring to FIG. 4, there is provided in accordance with another embodiment of the present invention, a cuff assembly designated generally as 30. Except as hereinafter described, the cuff assembly 30 is substantially identical to the cuff assembly 1 and operates in the same manner for dynamically and momentarily tightening the cuff components on the body parts. For convenience, those features of the cuff assembly which are identical to those of the cuff assembly of FIGS. 1-3 are identified using the same numbers used in FIGS. 1-3. A pivot pin 8 is fixed in an opening in end region 6 and pivots freely in the opening in end region 7 as in the embodiment of FIGS. 1-3. A gear 31 is removably attached to the shaft of pivot pin 8 and rotates with pivot pin 8 relative to end region 7. A gear 32 is rotatably and removably attached to end region 7 by a bolt 33 or the like and has teeth that mesh with cooperating teeth on gear 31. Cable 14 passes from an upper limb engaging cuff component (not shown) and is secured in a groove in gear 32. Thus, hinging end regions 6 and 7 cause the cable 14 to wind and unwind on gear 32 tightening and loosening the cuff component. Using interchangeable gears of various sizes, the rate and amount of tightening and loosening can be adjusted for the individual requirement. A lower limb engaging cuff component (not shown) may be held tightly in a static manner using a conventional strap and a Velcro® strip or additional cables, gears, cams and levers may be utilized to provide a dynamic fitting cuff assembly for the lower limb.
Referring to FIGS. 5-7 there is provided in accordance with still another embodiment of the present invention, a cuff assembly designated generally as 40. Except as hereinafter described, the cuff assembly 40 is substantially identical to the cuff assembly 1 and operates in the same manner for dynamically and momentarily tightening the cuff components on the body parts. Those features of the cuff assembly which are identical to those of the cuff assembly of FIGS. 1-3 are identified using the same numbers used in FIGS. 1-3. Arms 4 and 5 and end regions 6 and 7 operate in the same manner as the arms and end regions in FIGS. 1-3. A cuff component 42 is fixed at one end to the arm 4 by rivets 43 or the like. The cuff component 42 passes around the limb (not showm) passes through a loop 44 and is adjustably and releasably fixed to itself by a Velcro® strip 45 or the like. The loop 44 is attached to a cable 46 which passes through guides 47 and 48 on arm 4 and is then directed around guide members 49 press fit in two of a series of holes 50 forming a cam plate in end region 7 and is releasably secured by a press fit hook 51 in one of the holes in end region 7 or a hole in pivot pin 8. Thus, hinging end regions 6 and 7 causes the cable 46 to tighten cuff component 42 in a direction generally transverse to the long axis of the body part when the arms are pivoted from the normal position. By guiding the cable around guide members selectively placed in holes in the end region, the normal position and rate and amount of tightening and loosening can be adjusted for the individual requirement. End region 7 includes a slot 52 to slidably engage a screw 53 attached in one of a series of threaded holes 54 in end region 6 to provide a stop to limit the extent of movement of hinging end regions 6 and 7. A cuff component complementary to cuff component 42 may be fixed to end region 5 or to an arm located on the opposite side of the body part and connected by an arm to cuff assembly 40.
Details have been disclosed to illustrate the invention in a preferred embodiment of which adaption and modification within the spirit and scope of the invention will occur to those skilled in the art. The scope of the invention is limited only by the following claims.
|
A support including cuff components for engaging body parts articulated to each other about a joint, arms attached to and extending from the cuff components and pivotably attached to each other remote from the cuff components and in substantial alignment with the joint, and tightening cables attached to the cuff components and arms for temporarily increasing the tightness with which the cuff components engage the body parts in response to movement of one body part relative to the other body part.
| 0
|
FIELD OF THE INVENTION
The present invention relates generally to a device for inserting and removing electronic components such as memory modules from a printed circuit board.
BACKGROUND OF THE INVENTION
Computer memory is frequently mounted onto modular circuit boards or modules which can be inserted into a computer so as to expand the aggregate memory of the computer. Memory modules are connected to a main circuit board of a computer system through multi-pin edge connectors which reside on the main circuit board. Typically, an edge of the memory module is inserted into an edge connector so that the module is positioned perpendicular to the main circuit board. A number of memory modules can be closely positioned parallel to each other and perpendicular to the main circuit board. Such an arrangement conserves space on the main circuit board but results in a dense coupling of memory modules on the main circuit board.
Memory modules, particularly dual in-line memory modules (DIMM), can be quite large. Some DIMM's may be six inches long and have approximately 200 contacts. Normal insertion of a module into a connector is accomplished by forcing the edge of the memory module between opposing rows of metal contacts in the connector. Upwards of 20 pounds of force is sometimes required to properly seat a module in a connector. Further, the surface area on the module where force can be applied is very small. In some instances, the edge of the module where force may be applied is only 0.050 inches wide. Applying insertion pressure to hundreds of modules per day, such as is required in a computer assembly line, can become very uncomfortable for the person charged with such a task. Thus, there is a need in the art for a device which provides assistance in inserting memory modules into a connector.
It is known in the art to provide a memory module extraction device. For example, U.S. Pat. Nos. 5,203,074, 5,367,761, 5,106,315, and 3,952,232 disclose various purported memory module extraction devices. Each of these devices is specialized to work with a particular type of memory module and connector.
An alternative module and connector type for which an extraction device has not been designed employs a lever applied to an exterior edge of the module and connector. For such module and connector configurations, applying downward pressure to the lever causes the module to be unseated from the connector. However, it can sometimes be difficult to access the lever due to the relative little clearance that is often available between components connected to a circuit board. Thus, there is a need in the art for a memory extraction device for use with memory modules and connector pairs which employ a lever mechanism for extraction of the module.
Accordingly, a goal of the present invention is to provide an electronic component insertion and extraction device for assistance in inserting and removing electronic components from a printed circuit board connector.
SUMMARY OF THE INVENTION
An electronic component insertion and extraction device in accordance with the present invention addresses these and other shortcomings in the art. According to one aspect of the invention there is provided an insertion device for inserting a memory module into a circuit board connector. Typically, the memory module has a pressure area along at least one edge where pressure can be applied for seating the module in the connector. The connector may also have a base portion with leverage points positioned on its exterior. The insertion device comprises the following elements: an elongated handle having a first end and a second end; a first leverage arm extending from the first end of the handle, which first leverage arm has a first distal end positioned opposite the handle; a second leverage arm extending from the first end of the handle, the second leverage arm having a second distal end positioned opposite the handle and being displaced from the first leverage arm so as to form a channel between the first leverage arm and the second leverage arm; and a pressure applicator disposed in the channel between the first leverage arm and the second leverage arm. The pressure applicator is positioned away from the distal end of the first leverage arm and the distal end of the second leverage arm so that upon the first distal end and the second distal end being positioned against the leverage pressure points of the connector, the pressure applicator is positioned along the pressure area of the memory module. Movement of the second end of the device in a direction having both a horizontal and vertical components relative to the leverage points exerts downward pressure on the memory module and thereby causes the module to be seated in the connector. According to a preferred embodiment, the distal ends of the leverage arms have a hooked configuration. Further, the handle has grooves inserted therein for improved gripping of the device. Also the pressure applicator has a substantially curved surface for facilitating horizontal movement of the pressure applicator along the memory module. Where the connector has leverage points that are circular shaped trunnions, the hooked distal ends of the insertion device fit partially around the trunnions and provide a leverage point for application of an insertion force to the second end of the device.
According to another embodiment, the insertion device comprises the following items: a handle; at least one leverage arm extending from the handle, which leverage arm has a distal end remote from the handle; a pressure applicator disposed between the distal end and the handle for applying downward force on a memory module.
According to another aspect of the invention, there is disclosed an extraction device for removing a memory module from a connector. Typically, the connector has a lever disposed on at least one of the terminal ends of the connector so that application of a substantially downward force on the lever causes the memory module to be unseated from the connector. The connector might also have leverage points positioned on its exterior. The extraction device comprises the following items: an elongated handle having a first end and a second end; a first clearance arm extending from the second end of the handle; a second clearance arm extending from the second end of the elongated handle, which second clearance arm is displaced from the first clearance arm so as to form a channel between the first clearance arm and the second clearance arm; and a pressure applicator positioned substantially in the channel between the first clearance arm and the second clearance. When the pressure applicator is positioned upon the lever, the first and second clearance arms are positioned against the leverage points. Thereafter, if the first end of the handle is rotated downward relative to the leverage points, pressure is applied by the pressure applicator to the lever. The pressure displaces the lever and causes the memory module to be unseated from the connector. In a preferred embodiment, the first clearance arm and the second clearance arm have recesses formed therein. When the pressure applicator contacts the lever, the recesses are positioned substantially around the leverage points of the connector. In one embodiment, the recesses are formed at the distal ends of the clearance arms.
Other features of the present invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following description of preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1A provides a perspective view of an insertion/extraction device in accordance with the present invention;
FIG. 1B provides a side view of the insertion/extraction device shown in FIG. 1A;
FIG. 1C provides a top view of the insertion/extraction device shown in FIG. 1A;
FIG. 1D provides a sectional view of the insertion/extraction device shown in FIG. 1A;
FIG. 2A is a perspective view of the insertion end of an insertion/extraction device in accordance with the present invention applied to a memory module and circuit board connector;
FIG. 2B is a detailed view of the insertion end of an insertion/extraction device in accordance with the present invention applied to a memory module and circuit board connector;
FIGS. 3A and 3B provide a perspective view of an insertion/extraction device in accordance with the present invention at various stages of the insertion process;
FIG. 4A provides a view of the extraction end of an insertion/extraction device in accordance with the present invention applied to a memory module and circuit board connector;
FIG. 4B provides a detailed view of the extraction end of an insertion/extraction device in accordance with the present invention applied to a memory module and circuit board connector; and
FIGS. 5A and 5B provide perspective views of the extraction end of an insertion/extraction device in accordance with the present invention at various stages of the extraction process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A memory module insertion device with the above-mentioned beneficial features in accordance with a presently preferred exemplary embodiment of the invention will be described below with reference to FIGS. 1 through 5. The description given herein with respect to those figures is for illustrative purposes only and is not intended in any way to limit the scope of the invention. Questions regarding the scope of the invention may be resolved by referring to the appended claims.
FIGS. 1A through 1D provide various views of inventive insertion/extraction device 10. As shown, insertion/extraction device 10 comprises an elongated handle 12 with a first end or insertion end 14 and a second end or extraction end 16. In a preferred embodiment, a first leverage arm 18a and a second leverage arm 18b extend from opposite sides of insertion end 14. A single leverage arm 18a may be employed in alternative embodiments. Pressure applicator 20 is disposed in channel 22 that is formed between leverage arms 18a, 18b. In a preferred embodiment, distal ends 24 of leverage arms 18a, 18b have a hook-like configuration.
A first pivot arm 26 and a second pivot arm 26 extend from opposite sides of extraction end 16 of device 10. In an alternative embodiment, a single pivot arm 26 may be employed. Notch 28 or extraction application surface is disposed in channel 30 that is formed between pivot arms 26. A pivot recess or notch 32 is formed at or near distal ends 34 of each pivot arm 26.
FIG. 2A provides a perspective view of insertion end 14 of inventive insertion/extraction device 10 applied to module 36 and module connector 38. FIG. 2B provides a detailed view of the interaction between device 10, electronic component 36 which may be a memory module and connector 38. As shown, module 36 has been situated above connector 38. Connector 38 comprises base 39 and leverage points 40. Leverage points or trunnions 40 are disposed along the exterior sides of connector 38 and provide leverage during the insertion and extraction process. Leverage arms 18a, 18b extend around memory module 36 with pressure applicator 20 coming to rest on pressure area or surface 42 of module 36. Hook distal ends 24 of leverage arms 18a, 18b are positioned against leverage points 40 and thereby provide leverage during the insertion process. In a preferred embodiment, pressure applicator 20 has a substantially rounded exterior which facilitates horizontal movement of pressure applicator 20 as module 36 is gradually inserted into connector 38. Handle 12 has grooves located therein to facilitate gripping device 10. Leverage recess 52 in module 36 is shaped to accept a lever and is used during the extraction of module 36. The extraction process is described below with reference to FIGS. 4A through 5B.
FIGS. 3A and 3B provide a perspective view of insertion/extraction device 10 and module 36 at various stages of the insertion process. With distal ends 24 positioned against leverage points 40, second end 16 of device 10 is rotated in a clockwise fashion relative to leverage points 40. As a result of this rotation, pressure applicator 20 exerts a downward force on surface 42 of module 36. The downward force causes module 36 to be gradually seated in connector 38. As module 36 is displaced into connector 38, pressure applicator 20 is free to move horizontally along the surface of module 36 away from leverage point 40. As pressure applicator 20 moves along surface 42, it exerts downward force on successive portions of module 36 and thereby gradually seats module 36 into connector 38.
It should be noted that in FIGS. 3A and 3B, a corner section only of connector 38 is shown, i.e. a portion of base 39 is not shown. In this way FIGS. 3A and 3B illustrate the movement of bottom edge 44 relative to base 39.
As shown in FIG. 3A, at the beginning of the insertion process, bottom edge 44 of module 36 is not seated in connector 38 and pressure applicator 20 is located near the terminal end of module 36. Gradually, second end 16 of insertion/extraction device 10 is displaced clockwise relative to said leverage point 40 to arrive in a position shown in FIG. 3B. As shown in FIG. 3B, bottom edge 44 of module 36 has been displaced downward relative to base 39 so as to become seated in connector 38 and pressure applicator 20 has been displaced sideways away from the terminal end of the module 36.
Generally, due to the large size of some modules, the process of seating a module using an insertion device in accordance with the present invention requires applying device 10 to the opposite end of module 36 and connector 38 opposite that shown in FIGS. 3A and 3B. When insertion/extraction device is applied to this opposite end, second end 16 of device 10 is rotated in a counterclockwise (i.e. opposite the direction illustrated in FIGS. 3A and 3B) fashion to seat the remaining portion of module 36 into connector 38.
FIG. 4A provides a view of extraction end 16 of device 10 prior to application to connector 38 and module 36. A lever 46 is positioned or situated substantially on connector 38. A first lever arm 48 of lever 46 is positioned away from module 36. A second lever arm 50 of lever 46 is located substantially within recess 52 of module 36 which was previously described above with reference to FIG. 2B. Notch 28 disposed between first and second pivot arms 26 is designed to engage first lever arm 48 of lever 46. Pivot recesses or notches 32 at distal ends 34 of pivot arms 26 are formed to engage leverage points 40 on the exterior of connector 38. FIG. 4B provides a view of extraction end 16 of device 10 seated on lever 46 and connector 38. As shown, recesses 32 are situated around leverage points 40 while notch 28 is positioned over first lever arm 48 of lever 46.
FIGS. 5A and 5B provide a perspective view of the extraction end 16 and module 36 at various stages of the extraction process. It should be noted that in FIGS. 5A and 5B, a corner section only of connector 38 is shown, i.e. a portion of base 39 is not shown. In this way FIGS. 5A and 5B illustrate the movement of bottom edge 44 relative to base 39. As shown in FIG. 5A, at the start of the extraction process, module 36 is seated in connector 38. Handle 12 of insertion/extraction device is substantially perpendicular to module 36 and connector 38. In order to unseat module 36 from connector 38, insertion end 14 of device 10 is rotated clockwise relative to leverage points 40. As insertion end 14 rotates, notch 28 applies a force in a clockwise direction to first lever arm 48 of lever 46. The clockwise motion of first lever arm 48 of lever 46 causes second lever arm 50 to exert an upward force on module 36 at lever recess 52. The upward force is sufficient to unseat a portion of module 36 from connector 38. FIG. 5B provides a view of the insertion/extraction device 10 rotated clockwise from the position shown in FIG. 5A. As shown, bottom edge 44 of module 36 has been lifted relative to connector 38. Thus, the rotation of device 10 has caused a first end of module 36 to be unseated from connector 38. Extraction end 16 of device 10 can be positioned at the end of module 36 and connector 38 opposite that shown in FIGS. 5A and 5B so as to similarly unseat the opposite end of module 36.
The present invention may be employed in other specific forms without departing from the spirit or essential attributes thereof. For example, either the insertion end or extraction end of the device described above can be manufactured as a separate device from the other. Also, according to one embodiment, a single leverage arm may extend from the insertion end of the device. Likewise, a single pivot arm may extend from the extraction end of the device. Of course, in still other embodiments, more than two leverage arms or pivot arms may extend from ends of the device. Accordingly, the scope of protection of the following claims is not limited to the presently preferred embodiment disclosed above.
|
Disclosed is a memory insertion and extraction device for inserting a memory module into and removing a memory module from a circuit board connector. An insertion end of the device comprises two leverage arms with a pressure applicator disposed there between. An extraction end of the device comprises two pivot arms with a leverage applicator disposed there between. The insertion and extraction device is preferably manufactured from or coated with a non-conductive material.
| 7
|
BACKGROUND
[0001] The invention relates to image printing apparatuses, and in particular to diverters and image printing apparatuses utilizing the same.
[0002] FIG. 1 is a schematic view of a conventional diverter used in multi-function devices such as printers, facsimile machines, copy machines, and the like, as disclosed in U.S. Pat. No. 6,572,105. The diverter 10 ′ includes a pair of shafts (not shown), an inlet 12 ′, an upper gate 13 ′, a lower gate 14 ′, and a plurality of outlets 17 ′, 18 ′, and 19 ′. The upper gate 13 ′ and the lower gate 14 ′ comprise an upper cam 15 ′ and a lower cam 16 ′, respectively. The upper cam 15 ′ of the upper gate 13 ′ is disposed on a side of the diverter 10 ′. The lower cam 16 ′ of the lower gate 14 ′ is disposed on a side opposite to the upper cam 15 ′.
[0003] A media sheet X enters the inlet 12 ′ of the diverter 10 ′ in a direction P. The diverter 10 ′ provides three outlets 17 ′, 18 ′, 19 ′ for processed media sheet X, as shown by arrows A, B, C. Thus, the diverter 10 ′ can direct the media sheet X in directions A, B, or C.
[0004] The multi-function device allows media sheets to move through first, second and third media paths A, B, and C. The first media path A is a default direction. The media sheet X passes over the upper gate 13 ′ along the first media path A to a paper cassette (not shown) The second media path B is a path to a finisher (not shown). After processing, each media sheet is delivered to a different tray for further processing such as binding, punching, or distribution, and categorization into groups. The third media path C is a path to a duplexer (not shown) to print an image on the second side of the media sheet X. The media sheet X delivered to the third media path C is flipped over and returned to the multi-function device for printing or copying the other side.
[0005] As shown in FIG. 2 , the conventional diverter 10 ′ comprises, a pair of shafts 11 ′ located at two sides thereof. The shafts 11 ′ move the upper gate 13 ′ or lower gates 14 ′ between the up and down positions. The direction of the force exerted by the shafts 11 ′ is shown by arrows F. One force is exerted downward, and another force is exerted upward. The direction of movement of the shafts 11 ′ depends on printing commands. Each shaft 11 ′ comprises an ejector pin 21 ′ and a cam (not shown). The shafts 11 ′ are symmetrically arranged, and thus, only one shaft 11 ′ is shown in FIG. 2 .
[0006] As shown in FIG. 3A , in a default printing mode, both shafts 11 ′ remain stationary and the upper and lower gates 13 ′ and 14 ′ are in the down position without moving. The media sheet X can pass above the upper gate 13 ′ along the first media path A.
[0007] As shown in FIG. 3B , the shafts 11 ′ move both the upper and lower gates 13 ′ and 14 ′ to the up position by rotating the cam 22 ′ to divert the media sheets to the second media path B. Thus, the media sheet X can pass under the lower gate 14 ′ along the second media path B.
[0008] When the shaft 11 ′ at the right-side is moved to contact another cam (not shown) thereon, the upper gate 13 ′ is elevated such that the upper gate 13 ′ and the lower gate 14 ′ are separated, and the media sheet X can pass therebetween, as shown by the arrow C in FIG. 3C . Thus, the diverter 10 ′ requires one shaft at each side thereof to provide different media paths.
[0009] Since the conventional diverter 10 ′ requires a shaft 11 ′ at each side thereof, the image printing apparatus requires two moving devices (not shown) to drive shafts 11 ′, respectively. Thus, a moving device is connected to a cam of one shaft to move upward, and the other moving device is connected to a cam of the other shaft to move downward, providing opposing pushing forces. The structure of conventional diverters is complicated and difficult to assemble, thus, manufacturing costs cannot be reduced.
SUMMARY
[0010] Diverters and image printing apparatuses are provided. An exemplary embodiment of an image printing apparatus for diverting media comprises a first separating unit, and a second separating unit. A shaft is further disposed on one side of the first separating unit and on the same side of the second separating unit. The shaft abuts the first and second separating units simultaneously to control directions of movement thereof.
[0011] The first separating unit comprises a first arm. The second separating unit comprises a second arm, disposed on the same side as the first arm and the shaft, and the shaft abuts at the first arm.
[0012] The shaft further comprises a hole, and the second arm is partially disposed in the hole with the first arm contacting a top portion of the shaft.
[0013] The image printing apparatus further comprises a cam, contacting a bottom portion of the shaft. The shaft is movable between a first position, a second position, and a third position by rotating the cam. The second position is between the first position and the third position, and when the shaft is at the first position, the shaft is at a lowest position.
[0014] The first separating unit is movable between a first up position and a first down position. The second separating unit is movable between a second up position and a second down position. When the shaft is at the first position, the first separating unit is at the first down position and the second separating unit is at the second down position such that the media passes by an upper surface of the first separating unit. When the shaft is at the second position, the first separating unit is at the first up position and the second separating unit is at the second up position such that the media passes under the second separating unit. When the shaft is at the third position, the first separating unit is at the first up position and the second separating unit is at the second down position such that the media passes between the first separating unit and the second separating unit.
[0015] The first arm comprises a first protrusion, contacting a top portion of the shaft. The second arm comprises a second protrusion, penetrating the hole, and the cam is abutted at the first protrusion and the second protrusion by the shaft. When the shaft is at the first position, the first protrusion is abutted at the top portion of the shaft. When the cam rotates to move the shaft upward to the second position, the second protrusion remains horizontal in the hole. When the cam rotates to move the shaft upward to the third position, the second protrusion is located at a lower end of the hole.
[0016] The image printing apparatus further comprises a cover, and the shaft further comprises a slot and a positioning element. The cover comprises an extended portion, extending to the cover. The positioning element penetrates the slot to connect the shaft and the extended portion such that movement of the shaft is restricted by the slot.
[0017] The image printing apparatus further comprises a moving device, connected to the cam.
[0018] The image printing apparatus is an ink-jet printer or a laser-printer.
[0019] Diverters for directing media are provided. An exemplary embodiment of a diverter comprises a first separating unit, a second separating unit, and a shaft, disposed on one side of the first separating unit and on the same side of the second separating unit and contacting the first and second separating units simultaneously to control moving directions thereof.
DESCRIPTION OF THE DRAWINGS
[0020] Image printing apparatuses and diverters thereof can be more fully understood by reading the subsequent detailed description in conjunction with the examples and references made to the accompanying drawings, wherein:
[0021] FIG. 1 is a schematic side view of a conventional diverter;
[0022] FIG. 2 is a perspective view of a conventional diverter;
[0023] FIG. 3A is a schematic side view illustrating the upper and lower gates of a conventional diverter in a down position for directing media to a first path A;
[0024] FIG. 3B is a schematic side view illustrating the upper and lower gates in an up position for directing media to a second path B;
[0025] FIG. 3C is a schematic side view illustrating the upper gate in the up position and the lower gate in a down position for directing media to a third path C;
[0026] FIG. 4 is a schematic view of an embodiment of an image printing apparatus;
[0027] FIG. 5A is a perspective view of an embodiment of a diverter after assembly;
[0028] FIG. 5B is an exploded view of an embodiment of the diverter;
[0029] FIG. 6A-1 is a schematic view of an embodiment of the diverter in a first position;
[0030] FIG. 6A-2 is a side view of an embodiment of the diverter in a first position;
[0031] FIG. 6B-1 is a schematic view of an embodiment of the diverter in a second position;
[0032] FIG. 6B-2 is a schematic view of an embodiment of the diverter in a second position;
[0033] FIG. 6C-1 is a schematic view of an embodiment of the diverter in a third position;
[0034] FIG. 6C-2 is a schematic view of an embodiment of the diverter in a third position;
[0035] FIG. 7 is a local enlarged view of an embodiment of the image printing apparatus.
DETAILED DESCRIPTION
[0036] An image printing apparatus is provided. The image printing apparatus can be an ink-jet printer or a laser-printer. An exemplary embodiment of an image printing apparatus comprises a diverter applicable in copy-machines, fax machines, and other multi-function devices. Here, a printer is given as an example.
[0037] FIG. 4 is a schematic view of an embodiment of an image printing apparatus or a printer 100 . The printer 100 comprises a cover 30 , a diverter 1 b , and a moving device (not shown). The diverter 10 and the moving device are disposed under the cover 30 . The diverter 10 is used to divert media in different directions. Note that other elements are omitted to clearly show the details of the diverter 10 .
[0038] FIG. 5A is a perspective view of the diverter 10 after assembly. FIG. 5B is an exploded view of the diverter 10 .
[0039] As shown in FIGS. 5A and 5B , the diverter 10 comprises a frame 25 , a shaft 11 , a first separating unit 13 , and a second separating unit 14 .
[0040] The first and second separating units 13 and 14 comprise a first arm 15 and a second arm 16 , respectively. The frame 25 comprises at least two openings 251 and 252 , corresponding to the first and second arms 15 and 16 , respectively.
[0041] During assembly, the first and second arms 15 and 16 are rotatably disposed in the openings 251 and 252 such that the first and second separating units 13 and 14 are disposed on the frame 25 . The shaft 11 comprises a lever 21 and a cam 22 . The first and second arms 15 and 16 are positioned on the same side 255 of the frame 25 .
[0042] Furthermore, as shown in FIG. 5A , the first arm 15 is abutted at a top portion 214 of the lever 21 of the shaft 11 . The lever 21 comprises a hole 211 and at least a slot 212 . The second arm 16 of the second separating unit 14 is disposed in the hole 211 . The first and second separating units 13 and 14 are movably disposed on the frame 25 by the first and second arms 15 and 16 and the shaft 11 . Thus, the image printing apparatus 100 comprises an inlet 12 and three outlets 17 , 18 , and 19 in three directions.
[0043] As mentioned, the media enter the diverter 10 through the inlet 12 . After printing, the media are directed to the outlets 17 , 18 , and 19 , as shown in FIGS. 6 A- 1 to 6 C- 2 . The cam 22 is connected to a bottom portion 215 of the shaft 11 . The cam 22 comprises a connecting portion 221 , connected to the moving device (no shown). The lever 21 of the shaft 11 can be positioned at three different levels by rotating the cam 22 by the moving device.
[0044] The lever 21 of the shaft 11 can move between a first position, as shown in FIGS. 6A-1 and 6 A- 2 , a second position, as shown in FIGS. 6B-1 and 6 B- 2 , and a third position, as shown in FIGS. 6C-1 and 6 C- 2 . The second position is between the first and third positions. The first position is the lowest position with respect to the second and the third positions. Namely, the cam 22 and the lever 21 are at the lowest position when the shaft 11 is at the first location. Note that the first position may not be the beginning position. The second position can be changed to the first position or the third position. Thus, the sequence of the first, second, and third positions is not restricted.
[0045] As shown in FIGS. 6A-1 and 6 A- 2 , when the lever 21 is at the first position, the second arm 16 comprises a second protrusion 161 disposed in the upper portion of the hole 211 . The first arm 16 comprises first protrusion 151 contacting the top portion 214 of the lever 21 such that the first and the second separating units 13 and 14 are at a first and second down position, respectively. Thus, the media can pass by an upper surface of the first separating unit 13 , in the direction A as shown by the arrow.
[0046] As shown in FIGS. 6B-1 and 6 B- 2 , when the cam 22 rotates to move the lever 21 upward to the second position, the lever 21 pushes the first protrusion 151 of the first arm 15 . The first arm 15 is moved such that the first separating unit 13 is at the first up portion such that the second protrusion 161 of the second arm 16 remains horizontal in the hole 211 . The second separating unit 14 is at the second up position, contacting the first separating unit 13 such that the media passes under the second separating unit 14 in the direction B.
[0047] As shown in FIGS. 6C-1 and 6 C- 2 , the cam 22 is rotated again to move the lever 21 upward to the third position. The second protrusion 161 of the second arm 16 is located at the lowest portion of the hole 211 . The first separating unit 13 is at the first up position and the second separating unit 14 is at the second down position such that the media passes between the first separating unit 13 and the second separating unit 14 in the direction C.
[0048] Moreover, as shown in FIG. 7 , the cover 30 comprises an extended portion 31 , extending to an interior of the cover 30 , and the shaft 11 further comprises a positioning element 40 such as screws. The positioning element 40 penetrates the slot 212 to connect the lever 21 of the shaft 11 and the extended portion 31 of the cover 30 such that movement of the shaft 11 is restricted by the slot 212 . Thus, the movement of the lever 21 is restricted in a direction perpendicular to the axes of the cams 15 and 16 , preventing deviation of the lever 21 .
[0049] In conclusion, the cam 22 is moved by the moving device in the image printing apparatus such that the lever 21 connected to the cam 22 can push and rotate the first and second separating units 13 and 14 at a predetermined angle by the protrusions 151 and 161 of the cams 15 and 16 . The first and second separating units 13 and 14 remain at up or down positions, providing three output directions.
[0050] The image printing apparatus only requires one shaft to have three output directions. The structure is simplified offering lower manufacturing costs and easier assembly.
[0051] Moreover, the elevation distance of the lever 21 depends on the size of the hole and the angle and length of the cams, and thus, the invention does not limit the size thereof.
[0052] 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.
|
A diverter and an image printing apparatus utilizing the same. The diverter directs media within an image printing apparatus along one of media paths. The image printing apparatus includes a first separating unit, a second separating unit, and a shaft. The shaft is disposed at one side of the first separating unit and on the same side of the second separating unit. The shaft abuts the first and second separating units simultaneously to control directions of movement thereof.
| 1
|
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of contract number FO9604-98-C-0011 awarded by United States Air Force.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to voltage multiplier circuits and more particularly to DC to DC converters.
2. Prior Art
Voltage multipliers typically require a pre-regulated input voltage and multiple stacked transformer windings. Most high voltage designs (above 10 kv) use a combination of single-phase transformers and multipliers which generally require heavy magnetic elements with labor intensive windings and potting. Also, voltage multipliers generating high voltages typically require coatings to prevent arcing between components. In addition, high voltage power supply designs generally use hermetically sealed semiconductors and polarized capacitor components; where in practice the capacitors and diodes in a high voltage power supply dissipate large amounts of heat leading to hot spots within the sealing coat causing component failure. Consequently, many high voltage power supply designs are designed on the basis of short mean time to repair (MTTR) versus low mean between failures (MTBF) and are only about 90% efficient. The other 10% is lost as heat lastly, because most packaging sub-assemblies of high voltage power supplies are cubic in shape, i.e., non-planar, they require expensive mechanical assembly techniques.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, a voltage multiplying circuit, comprising a multiphase power stage and at least one phased voltage multiplier stage connected to the multiphase power stage.
In accordance with one method of the present invention a method for providing a high voltage power supply. The method comprising the steps of providing a multi-phased power stage and providing at least one multi-phased voltage multiplier stage connected to the multi-phase power stage.
In accordance with a second method of the present invention a method for generating high voltage. The method comprising steps of providing a plurality of multi-phased voltages and providing at least one multi-phase multiplier stage. Then connecting the plurality of multi-phased voltages to at least one multi-phase multiplier stage.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 illustrates a high altitude platform such as a satellite employing a laser based system requiring a high voltage multiplier;
FIG. 2 illustrates a low altitude platform such as a military reconnaissance aircraft employing a cathode ray tube requiring a high voltage multiplier;
FIG. 3 is a schematic diagram of two segments of the multi-phase power stage of the preferred embodiment of the invention and two stages of the multi-phase voltage multipliers, each stage having two segments;
FIG. 4 is a schematic diagram of a preferred embodiment of the invention; and
FIG. 5 is a waveform diagram showing the relative on/off states of V 1 , and V 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is first made to FIG. 1 for illustrating a high altitude platform 10 , such as but not limited to a high altitude satellite, and FIG. 2 for illustrating a low altitude platform 18 , such as a military reconnaissance aircraft. Features of the present invention can be used in these types of platforms. Alternatively, features of the present invention could be used in any suitable type of electrical device where high DC voltages are required. For example, the present invention relates to high voltage DC power supplies generally used in television cathode ray tubes (CRTs), lasers, x-ray systems, travelling wave tubes (TWTs), ion pumps, electrostatic systems, copy machines, medical systems, and portable devices such as, but not Limited to, stun guns, and crowd control devices. More particularly, the present invention relates to light weight, miniaturized, high voltage multipliers used in applications where light weight, and high reliability high voltage DC power supplies are required, such as commercial and military aircraft and satellites. Referring now to FIG. 1 showing a high altitude satellite 10 in orbit around the planet 1 . The high altitude satellite 10 generally includes a laser sub-system 12 which is assumed to include a high voltage DC power supply 14 . The low altitude aircraft 18 shown in FIG. 2 can comprise a display 16 such as a cathode ray tube which is also assumed to include a high voltage DC power supply 20 .
Referring to FIG. 3, there is shown a high voltage DC power supply circuit diagram incorporating features of the present invention. Components V 1 ,V 2 ,V q ,R 1 ,R 2 , Q 1 ,Q 2 ,L 1 ,and L 2 form two segments of the multiphase power stage providing current and ground isolation for the phased voltage multiplier stages. Components D 11 -D 14 ,R 11 -R 13 , R c11 ,R c12 ,C 11 , and C 12 form two segments of the first phased voltage multiplier stage. Similarly, components D 21 -D 24 ,R 21 -R 23 , R c21 ,R c22 ,C 21 , and C 22 form two segments of the second phased voltage multiplier stage. Resistor R 3 provides a charging current path and inductor L 9 provides signal dampening. R load provides a load to the invention and is shown for illustration. Similarly, voltages V 1 ,V 2 , and V q may be external to the circuit and are shown for illustration.
Voltage source V q provides a regulated DC voltage. Voltage sources V 1 and V 2 provide alternately phased transistor bias voltages. Stated differently, when V 1 , is on, V 2 is off as shown in FIG. 5 . As seen with reference to FIG. 5, at time T 1 , V 1 is on, turning transistor Q 1 on. With Q 1 on current will conduct along the circuit path V q -L 1 -Q 1 -R 1 to ground. Inductor L 1 , by the inherent action of an inductor, will attempt to oppose the change in the current path by generating a counter electromagnetic force (CEMF) equal to the voltage applied by V q . However, the CEMF will begin to decay at a rate determined by the resistor/inductor (RL) time constant for the current path. Concurrently the current through the inductor will begin to increase to a value ultimately limited by the DC resistance of Q 1 and resistor R 1 . When V 1 reverses polarity at time T 2 , Q 1 is biased to the off or non-conducting state. Inductor L 1 again attempts to oppose the change in current by reversal of the CEMF polarity. Capacitor C 11 inherently opposes the change in voltage but begins to charge to the applied voltage through diode D 12 and resistors R c11 and R 3 . Capacitor C 21 also begins to charge to the applied voltage through diode D 22 and resistors R 3 ,R 13 , and R c21 .
At time T 2 , transistor Q 1 is off and transistor Q 2 is on. Similar to the earlier description, inductor L 2 attempts to oppose the change in current by a CEMF equal and opposite to the applied voltage. The current through L 2 , Q 2 , and R 2 , to ground builds as the CEMF force decays. At time T 3 , Q 2 turns off. Inductor L 2 attempts to oppose the change in current by reversing the polarity of the CEMF. Capacitor C 12 opposes the change in voltage but begins to charge to the voltage through diode D 14 and resistors R c12 and R 3 . Capacitor C 22 also begins to charge to the applied voltage through diode D 24 and resistors R 3 ,R 13 , and R c22 .
At subsequent times T N , where N=5,7,9, the circuit operation is as described above for time T 1 . Transistor Q 1 is turned on and current flows through L 1 , Q 1 , and R 1 to ground. However, after several iterations, C 11 and C 21 have been charged to the applied voltage V q . Thus, when transistor Q 1 is turned on capacitors C 11 and C 21 begin to discharge current through the diode resistor pairs D 11 /R 11 and D 21 /R 21 and the respective stage resistors R 23 and R 13 . Using Ohm's law, the output voltage for a stage is the discharging current times the stage resistance. The sum of the voltages across the stage resistors R 23 and R 13 is the output voltage seen by a load R load . Note that while capacitors C 11 and C 21 are discharging, diodes D 12 and D 22 are reversed bias thus preventing current .flow through the diodes.
At a subsequent time T M , where M=4,6,8, . . . the circuit description is similar. Capacitors C 12 and C 22 begin to discharge current through diode resistor pairs D 23 /R 22 and D 13 /R 12 to the stage resistors R 23 and R 13 , respectively. Similarly diodes D 14 and D 24 are reversed bias to prevent current flow through the diodes.
In summary, after several iterations the capacitors in each segment will have charged to the applied voltage V q . During a multi-phase power stage segments on time, i.e., the transistor is biased on, the capacitors associated with that segment will begin to discharge current through the associated stage resistance as described above. The capacitors associated with the off segments recharge the current that was discharged during their discharge cycle.
A preferred embodiment of the invention provides low output ripple voltages. In general, undesirable ripple voltage on the output are caused by a capacitor's current discharge and is, in general, a function of the Resistance Capacitance (RC) time constant for the particular discharging capacitor (or capacitors) and its current discharge path. A low RC time constant indicates a faster discharge of the capacitor and a higher ripple voltage. Thus, a low resistance load R load in parallel with the stage resistors would result in a lower output resistance R seen by the discharging capacitor and would permit the capacitor to discharge at a faster rate during the capacitor's discharge cycle. By adding more parallel segments as required, the capacitance C is increased, thereby increasing the RC time constant and decreasing the undesirable ripple voltage.
A preferred embodiment of the present invention provides an efficient and reliable high voltage DC power supply. Since each capacitor in the multiplier stages carries an equal amount of voltage, i.e., the input voltage and provide an equal amount of the output current, the need for special high current, high voltage capacitors is eliminated for most applications. By comparison, in a typical eight stage voltage multiplier the eighth stage capacitor would have eight times the input voltage, the seventh stage capacitor seven times the input voltage, and so on. The capacitor current drain is similarly multiplied thus requiring expensive and hermetically sealed high current capacitors as well as high current diodes. In addition, high current devices generally have inherent deficiencies due to the high current and resulting heat radiation. In a preferred embodiment of the present invention shown in FIG. 4, thirty two of the capacitors share the current load during the discharge cycle, eliminating the need for special high current capacitors and diodes. Thus, the preferred embodiment of this invention provides about a 97% efficiency since the current through the segments is not wasted as heat.
A preferred embodiment of the present invention provides a reliable high voltage DC power supply capable of extended mean times before failure of the supply. For example, assume for purposes of illustration that the bias voltage supplies V 1 -V 8 are phased 45 degrees apart resulting in half of the transistors in the multi-phase power stage being on while the other half are off. As described above, the capacitors associated with the off voltage supplies are charging while the capacitors associated with on supplies are discharging and providing the output current. In this example of the preferred embodiment of the present invention there are thirty-two capacitors providing output current while the other thirty-two are charging. Thus, the failure of any one capacitor or segment will not result in the failure of the voltage multiplier circuit as a whole. By comparison, the failure of a stage in a typical DC voltage multiplier will result in the total failure of the typical DC voltage multiplier. Thus, an advantage of the preferred embodiment of the present invention is to provide a reliable high voltage DC power supply with a long mean time before failure of the supply
It is also an advantage of this invention to provide a high voltage multiplier comprised of low cost and physically smaller components as compared to the higher cost and larger size of hermetically sealed and high voltage components. The smaller components permit the manufacture of the invention based on multi-layer circuit board assembly techniques requiring minimal mechanical design, lower material costs, shorter procurement lead times, and fewer errors in the build process.
It is also an advantage of this invention to provide a high voltage multiplier comprised of light weight components as compared to high voltage multipliers requiring heavy transformers with labor intensive windings and potting requirements. The comparatively light weight components permit the generation of high DC voltages while conserving payload space and weight.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. For example, referring again to FIG. 3 . In an alternate embodiment, or embodiments, the field effect transistors shown in FIG. 3 could be replaced by bipolar junction transistors or other devices performing a switching function. Similarly, the constant current source inductors and the voltage supply source could be replaced by a constant current source comprised of an operational amplifier and power supply. Likewise, the bias supply voltages could be replaced by suitable digital logic circuitry or programmable power supplies to finely control the duty cycle of a power stage segment to compensate for variances in component values or to turn segments on or off as required. Similarly, the charging and discharging diodes can be any suitable non-linear device such as a diode connected transistor.
|
A voltage multiplying circuit including a multiphase power stage and at least one phased voltage multiplier stage connected to the multiphase power stage.
| 7
|
This Application Claims Benefit of Provisional Application Ser. No. 60/612,994, Filed Sep. 25, 2004.
TECHNICAL FIELD
The present invention is directed towards systems and method of reinforcing poles, and more particularly a reinforcement system comprising steel members (e.g., steel reinforcing rods, steel plates, threaded rods or functionally equivalent members), closely positioned with respect to, or positioned in contact with, the exterior of:
straight, tapered and/or pipe/stepped poles,
such as wireless telecommunication poles. The method of use results in providing additional strength to said poles to enhance resistance against deflection caused by, for instance, wind forces and/or added weight resulting from mounting antennas thereto, thereby enabling the placement of, for instance, more antenna arrays and other communication antennas thereon than would otherwise be possible.
BACKGROUND
It is known to use free-standing monopoles to, for instance, support power transmission lines and to support antennas, (e.g., cell sites), such as required for cellular telephone. Particularly as regards the latter, even though demand for improved cellular telephone service continues to grow, local zoning laws are becoming increasingly prohibitive as regards new construction. As a result, wireless companies are placing additional antennas on existing towers. While this approach avoids zoning problems, it creates-leads to loading existing monopoles beyond their design capacity.
Various inventors have noted the problem and proposed systems to increase the loading capacity of existing monopoles. For instance, published applications of Harrison, Nos. 2002/0140621 and 2002/20140623 A1, describe the addition of strengthening elements to the exterior surface of a monopole, and suggests that base plate and/or foundation strengthening might also provide benefit.
Another Published Application, No. 2003/0010426, of Lockwood, describes upgrading existing steel monopoles by bonding fiber reinforced polymer materials to existing steel member or component surfaces.
Another Published Application, No. 2003/0205021 of Ryan, describes applying an exo-skeleton of tubular steel rods and adjustable clamps directly in contact with the exterior of previously erected tapered wireless communication monopoles.
Another Published Application, No. 2003/0026923 of Al-Zoubi et al. describes a sleeve system for reinforcing self-standing monopoles at select, predetermined locations. At least one pair of complimentary non-slip Filler is inserted between the monopole and the sleeve.
Another Published Application, by Cash, No. US 2004/0148903 describes applying sleeves to a tower. There are two foundations, one for the tower and one for the sleeves.
Another Published Application, by Brunozzi et al., No. US 2002/0170261 describes use of sectional elongated tubes affixed to a tower by clamping collars.
Another Published Application, by Kopshever, Sr., No. US 2004/0020158 describes the use of collars to sandwich vertical bars to a tower.
Another Published Application, by Hill et al., No. US 2002/0194794 describes the use of sleeves which are secured to a pole to provide enhanced strength.
Another Published Application, by Lockwood et al., No. US 2004/0134161 describes affixing supports to towers by structural adhesive.
A patent to Damiano, U.S. Pat. No. 6,513,299 describes a sleeve secured to a pole by braces.
A patent to Ritz, U.S. Pat. No. 6,453,636 describes the use of sleeves, wherein a second load is attached to the sleeve.
A patent by Ryan, U.S. Pat. No. 6,694,698 describes use of adjustable mounting clamps to secure a plurality of exo-skeleton tubular steel rods to an existing tower.
A patent to Payne, U.S. Pat. No. 6,915,618 describes another reinforcing apparatus for tower monopoles.
Even in view of the known prior art, need remains for additional system and methodology for reinforcing existing monopoles.
DISCLOSURE OF THE INVENTION
The disclosed invention is a system for reinforcing a pole comprising a plurality of reinforcing rods or steel members ( 1 ) and a number of mounting brackets ( 2 ) located at predetermined locations along the length of the pole. At the ends there can be an elongated bracket, or the spacing between a plurality of mounting brackets can be shorter than is the spacing between centrally located mounting brackets. The purpose is to effect transfer of the total force in the reinforcing rod or members to said pole, rather than just the unit force per length that the typical intermediate mounting brackets would support, such that the composite structure functions as a single member. Said mounting brackets are preferably affixed to said pole using off-the-shelf steel bolts (Lindapter Hollo-Bolt) ( 3 ) designed to connect to hollow steel structures not accessible from the inside, or can be welded thereto. Said reinforcing rods or steel members ( 1 ) are preferably affixed to said mounting brackets ( 2 ) by “U” bolts.
The disclosed invention can be applied to poles which comprise:
a substantially constant diameter over their entire length; a tapering diameter over their length, said diameter being smaller at the top; and a plurality of sections which are of a sequentially stepwise decreasing diameter as the length of said pole is transversed from the bottom thereof to the top, and in which there is present at the juncture between at least two of said sections a transition ring designed to allow the continuous force transfer in the reinforcement rods or members.
In the latter case, said transition ring is preferably of a substantially donut shape having holes present at different distances along each of at least two radial loci which are projected from a common center point, such that reinforcing rods or steel members ( 1 ) from one section project through holes at one distance along said radial loci, and reinforcing rods or steel members ( 1 ) from the section adjacent thereto project through holes at another distance along said radial loci.
The present invention can be considered as a method of increasing the strength of poles, (such as those which carry a number of communications antennas), by reinforcing the outside thereof using several reinforcing rods or steel members and a number of mounting brackets located at predetermined locations along the length of the pole. And at the ends of the reinforcing rods or members, the mounting brackets provide the means for transferring excess forces and stresses in the pole shaft to the reinforcing rods or steel members, thus providing additional reinforcement to offset any increase in the bending force of the monopole structure resisting the weight and wind resistance from one or more additional communications antennas.
Each mounting bracket comprises a standard steel member in the form of a standard steel angle or standard steel I-beam or wide flange or the like, cut to the required length and connected to the outside of pole structure. The reinforcing mounting brackets are connected to the outside surface of the pole shaft with the means of a patented off-the-shelf steel bolt (Lindapter Hollo-Bolt) which is designed to connect to hollow steel structures not accessible from the inside. As mentioned, the mounting brackets can also be welded to the pole shaft.
The plurality of reinforcement steel rods or the like are connected to mounting brackets with standard steel bolts.
Typical practice involves use of several reinforcing rods or steel members and a number of mounting brackets located at predetermined locations along the length of the pole, and at the ends of the reinforcing rods or members. The ends of the reinforcement rods or members are attached to the face of the pole shaft in a manner which transfers the total force in the reinforcing rod or members to the pole, and not just the unit force per length that the typical intermediate mounting brackets would support. It is the combination of said mounting brackets with the considerably stronger and longer mounting bracket used at the respective ends that make the pole and the reinforcing rods or members act and behave as one 100% composite manner, thus providing the means for transferring the excess forces and stresses in the pole shaft to the reinforcing rods or steel members thus providing the needed additional reinforcement to offset any increase in the bending force of the monopole structure resisting the weight and wind resistance from one or more additional communications antennas.
One end of the reinforcing rods or the like terminate at the base of the pole at the foundation and said reinforcing rods or the like are anchored to, and extended into the foundation by drilling a hole into the concrete and grouting using cement grout or epoxy.
Where one end of the reinforcing rods or the like terminates at the base of the pole, the pole base plate might have to be notched and reinforced with welded stiffeners to allow the reinforcement members to pass therethrough and anchor into the foundation.
The system of several reinforcing rods or steel members and a number of mounting brackets located at predetermined locations along the length of the pole can also be applied to poles that are made of tapered or non-tapered circular pipe sections attached together and referred to in the industry as pipe poles or stepped poles. The system can also be applied to the outside of a pipe pole or stepped pole structure where a transition ring is used to allow the continuous force transfer in the reinforcement rods or members. The number of transition rings used per pole is dependent on the number of joints or sections that make up a pipe pole or stepped pole structure.
A present invention method of reinforcing poles comprises the steps of:
a) providing a system for reinforcing towers as described above;
b) positioning a transition ring of a donut shape and having holes present at different distances, along each of at least two radial loci which are projected from a common center point, at the location of said juncture between at least two of said sections;
c) causing reinforcing rods or steel members ( 1 ) from one section project through holes at one distance along said radial loci, and reinforcing rods or steel members ( 1 ) from one the section adjacent thereto project through holes at another distance along said radial loci.
The disclosed invention will be beter understood by reference to the Detailed Disclosure Section in combination with the Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 3 show several reinforcing rods or steel members ( 1 ) and a number of mounting brackets ( 2 ) located at predetermined locations along the length of the pole and at the respective ends of the reinforcing rods or members.
FIG. 2 demonstrates preferred means for affixing said mounting brackets ( 2 ) to said pole, and preferred “U” bracket means for affixing said reinforcing rods or steel members ( 1 ) to said mounting brackets ( 2 ).
FIG. 3 is a cross-sectional taken at through FIG. 1 at “a—a”.
FIG. 4 shows a plurality of transition rings in place in a pole which comprises a plurality of sections which are of a sequentially stepwise decreasing diameter as the length of said pole is transversed from the bottom thereof to the top.
FIG. 5 provides more detail at the juncture between at least two of said sections and shows a transition ring designed to allow the continuous force transfer in the reinforcement rods or members.
FIG. 6 . shows a transition ring of a donut shape and having holes present at different distances, along each of at least two (eg. four shown), radial loci which are projected from a common center point, such that reinforcing rods or steel members ( 1 ) from one section project through holes at one distance along said radial loci, and reinforcing rods or steel members ( 1 ) from one the section adjacent thereto project through holes at another distance along said radial loci.
DETAILED DESCRIPTION
Turning now to the Drawings, there is demonstrated a system for reinforcement of poles on the outside thereof, said pole structure being of the sort suitable for carrying a number of communications antennas. FIG. 1 shows a reinforcing rod or steel member ( 1 ) and a number of mounting brackets ( 2 ) located at predetermined locations along the length of the pole ( 10 ), with the brackets at the ends of reinforcing rod or member being longer, or the spacing being a plurality of brackets being shorter at the respective ends of said reinforcing rod or member. Said shorter spacing between laterally located mounting brackets is determined to effect transfer of the total force in the reinforcing rod or members to said pole, rather than just the unit force per length that the typical intermediate mounting brackets supports. The result is that the composite structure functions as a single member. Each of said mounting brackets provides means for transferring excess forces and stresses in the pole shaft to the reinforcing rods or steel members thus providing the needed additional reinforcement to offset any increase in the bending force of the monopole structure to resist weight and wind effected forces resulting from communications antennas mounted on said pole.
The reinforcement preferably provides that each mounting bracket ( 2 ) comprise a standard steel member in the form of a standard steel angle or standard steel I-beam or wide flange or the like, which is cut to the required length and connected to the outside of pole structure. Said reinforcement mounting brackets ( 2 ) are preferably connected to the outside surface of the pole shaft by being welded thereto, or by means of a off-the-shelf steel bolts ( 3 ), (eg. Lindapter Hollo-Bolts), which are designed to connect to hollow steel structures which not accessible from the inside. FIG. 2 demonstrates preferred means for affixing said mounting brackets ( 2 ) to said pole, and preferred “U” bolt ( 4 ) means for affixing said reinforcing rods or steel members ( 1 ) to said mounting brackets ( 2 ).
The disclosed invention provides that reinforcement, comprising a plurality of reinforcing rods or steel members ( 1 ) be applied via a number of mounting brackets ( 2 ) which are located at predetermined locations along the length of a pole, and that at the ends of the reinforcing rods or members, each of the reinforcement rods or members be attached to the face of the pole shaft in a way to transfer the total force in the reinforcing rod or members, and not just the unit force per length that the typical intermediate mounting brackets would support. It is the application of stronger and effectively longer mounting brackets at the respective ends ( 5 ) of rods ( 1 ) that make the pole and the reinforcing rods or members act and behave as one 100% composite manner, and thus provide the means for transferring the excess forces and stresses in the pole shaft to the reinforcing rods or steel members. Use of the present invention provides additional reinforcement which offsets increase in the bending force of the monopole structure resisting the weight of added communication antennas, and wind resistance presented by additional communications antennas.
It is noted that said several reinforcing rods or steel members ( 1 ) can terminate at the base of the pole and in the foundation ( 8 ). Said reinforcing rods or members are then anchored to, and/or extended into the foundation via a hole drilling into present concrete and grouting using cement grout and/or epoxy ( 6 ). It is noted that for the reinforcing rods or members to be anchored to and extended into the foundation, the pole base plate ( 12 ) has to be notched and reinforced with welded stiffeners ( 7 ) in order to allow the reinforcement members to pass through and anchor into the foundation.
FIG. 4 shows a plurality of transition rings ( 26 ) in place in a pole which comprises a plurality of sections ( 20 , 22 , 24 ) which are of a sequentially stepwise decreasing diameter as the length of said pole is transversed from the bottom thereof to the top.
FIG. 5 provides more detail at the juncture between at least two of said sections and shows a transition ring designed to allow the continuous force transfer in the reinforcement rods or members.
FIG. 6 shows a transition ring ( 26 ) of a donut shape and having holes ( 30 , 32 ) present at different distances, along each of at least two (e.g., four shown), radial loci which are projected from a common center point, such that reinforcing rods or steel members ( 1 ) from one section project through holes at one distance along said radial loci, and reinforcing rods or steel members ( 1 ) from the section adjacent thereto project through holes at another distance along said radial loci.
It is to be appreciated that the reinforcement system and method described above can be applied to poles that are straight, tapered, made of a plurality of tapered (not typical) and/or non-tapered circular pipe sections attached together and referred to in the industry as pipe poles or stepped poles. Where a plurality of tapered and/or non-tapered circular pipe sections are present, the use of a transition ring (see FIGS. 5 & 6 ) which is designed to allow the continuous force transfer in the reinforcement rods or members ( 1 ) is utilized. The number of transition rings (see FIGS. 5 & 6 ) used per pole is, of course, dependent on the number of joints or sections that make up a pipe pole or stepped pole structure.
Having hereby disclosed the subject matter of the present invention, it should be obvious that many modifications, substitutions, and variations of the present invention are possible in view of the teachings. It is therefore to be understood that the invention may be practiced other than as specifically described, and should be limited in its breadth and scope only by the Claims.
|
A reinforcement system made of steel members, (e.g., steel reinforcing rods, threaded rods or functionally equivalent steel members), closely positioned with respect to, or positioned in contact with, the exterior of straight, tapered, and/or pipe/stepped poles, such as wireless telecommunication poles. The method of use results in providing additional strength to the poles to enhance resistance against deflection caused by, for instance, wind forces and/or added weight resulting from mounting antennas thereto, enabling the placement of, for instance, more antenna arrays and other communication antennas thereon than is otherwise possible.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to a timing recovery circuit for a receiver for pulse amplitude-modulated (PAM) signals.
Reception of a PAM signal of L discrete amplitude levels (where L is an integer equal to or greater than 2) is generally performed through the sampling of the incoming PAM signal at a proper time (point) and the subsequent determination of the amplitude level of the sampled signal. In this case, the timing signal for the determinaion of the proper sampling time is usually obtained by a self-timing method for extracting the timing signal from a reception signal in some way or other. One of such self-timing methods already known is the nonlinear extraction technique. This technique performs the extraction of a timing signal by utilizing a line spectrum appearing at the clock frequency position when a reception PAM signal is subjected to a nonlinear operation, such as a squaring operation. For this purpose, a nonlinear circuit is needed together with a bandpass filter for passing the clock frequency and an amplitude limiting circuit for eliminating the level fluctuation of said spectrum. As a result, the timing recovery circuit resorting to this technique becomes complicated. Moreover, those circuits used tend to malfunction in the high frequency region, leading to the disadvantage that the extracted timing signal is liable to contain undesirable phase noise. For example, the timing recovery circuit outlined above is shown in FIG. 18 of a paper entitled "An Experimental 560 Mbits/s Repeater with Integrated Circuits" by Engel Roza and Peter W. Millenaar, published in the IEEE TRANSACTIONS ON COMMUNICATIONS, Vol. COM-25, No. 9, pages 995 to 1004, September 1977 (Reference 1).
Another known self-timing method is the maximum likelihood detection technique. With this technique, a reception PAM signal is differentiated to control a timing signal generator so that timing positions may be adjusted to coincide with the zero crossings of the differentiated waveforms. This technique, employing a voltage-controlled oscillator (VCO) in place of such a nonlinear circuit as mentioned above, enables the generation of timing signals of a constant amplitude free from undesirable phase noise. However, since a differentiating circuit and a sample hold circuit for holding each sampled value of the differentiated waveforms (or the polarity signal of the sampled value) are indispensable to the second technique, the whole circuit structure eventually becomes bulky and complicated (see FIG. 4 of a paper entitled "Carrier and Bit Synchronization in Data Communication-A Tutorial Review" by L. E. Franks, published in the IEEE TRANSACTIONS ON COMMUNICATIONS, Vol. COM-28, No. 8, Pages 1107 to 1121, August 1980 (Reference 2)). Furthermore, because the fluctuation of a reception signal adversely affects the differentiated waveforms by the use of this technique, waveform deterioration on the transmission line must be minimized. This consequently makes the transmission system expensive.
One object of the present invention, therefore, is to provide a significantly small-scale timing recovery circuit capable of withstanding the deteriorated reception waveforms and free from the above-mentioned disadvantages unavoidable with the prior art timing recovery circuits.
SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided a timing recovery circuit for a receiver for PAM signals, which is so structured as to control the frequency of a timing signal by the value of correlation between the one-clock delayed differential signal of a reception signal and an NRZ (non-return-to-zero) data sequence obtained as a result of the decision procedure as such by the use of said timing signal. By so controlling the phase of the timing signal as to make zero the integrated value of the delayed difference waveform taken out by a rectangular wave having duty cycle ratio of 100 percent, the influence of local deterioration of the reception waveform is smoothed and the timing signal can thereby be subjected to stable phase control.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be made more apparent by the detailed description hereunder taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of a first embodiment of the invention;
FIGS. 2(a) through (h) are diagrams of waveforms in various parts of the embodiment;
FIG. 3 is a circuit diagram of a part of the embodiment; and
FIG. 4 is a block diagram of a second embodiment.
In the drawings, the same reference numerals represent the same structural elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, referring to FIG. 1, a first embodiment is shown for use with PAM signals given in the form of binary sequences of ("+1" or "-1") or ("1" or "0").
This embodiment has an input terminal 10 to which a reception signal r(t) subjected to waveform equalization is fed; a delayed difference circuit 11 for subtracting from the signal r(t) a one-clock delayed signal r(t-T), which is T (T is the period of reference clock pulses) seconds behind r(t); a decision circuit 12; a multiplier 13 for analog-multiplying an NRZ data sequence, provided as the output of the circuit 12, by the output of the circuit 11; a low-pass filter 14; and a VCO 15. The output of the VCO 15 is a timing signal taking the form of clock pulses to provide the synchronization with the input signal r(t).
A reception PAM signal r(t), or a binary sequence having levels of "±1", received through the input terminal 10, is fed to the circuit 11 and the decision circuit 12. The circuit 11 produces as a difference signal the difference between the input signal r(t) and another input signal r(t-T) received one clock T prior to r(t). The circuit 12 determines the polarity of the difference between the input signal r(t) and a prescribed threshold level at each sampling time determined by each timing pulse received from the VCO 15. Thus, if the signal r(t) is greater than the threshold level at the sampling time, the circuit 12 will provide a logical "1" or, if the former is smaller than the latter, it will provide a logical "0". Through the analog multiplying operation, the multiplier 13 supplies the low-pass filter 14 with the difference signal provided by said circuit 11, passing the signal unchanged if the output of the circuit 12 is a "1" or with the polarity of said difference signal inverted if the output of the decision circuit 12 is a logical "0". The output of the multiplier 13 is smoothed by the low-pass filter 14, and supplied as control voltage to control the oscillation frequency of the VCO 15 for determination of the decision timing of the decision circuit 12.
Next will be described the operation of this embodiment with reference to FIGS. 2(a ) through (h) illustrating waveforms in different parts thereof. These waveforms correspond to those parts shown in FIG. 1 marked respectively with the same letters as the reference letters of the waveforms.
FIG. 2(a) shows the reception signal having levels of ±1, and FIG. 2(b), the output of the circuit 11. Now supposing that a timing pulse supplied from the VCO 15 is Δt behind a reference clock pulse (not shown) as shown in FIG. 2(c), and assuming that the threshold level of the decision circuit 12 is zero, the output of the circuit 12 will be like FIG. 2(e). Consequently the output of the circuit 11 multiplied by the output of the circuit 12 in the multiplier 13 becomes a waveform such as shown in FIG. 2(g). The mean value of this waveform takes a negative value. The VCO 15 is controlled by a waveform resulting from the averaging of the waveform of FIG. 2(g) by the low-pass filter and, if the averaged waveform is negative, will act to recover the phase delay by raising the frequency of oscillation. Conversely, if the timing pulse supplied from the VCO 15 is Δt'0 ahead of said reference clock pulse shown in FIG. 2(d), the output of the circuit 12 will have a waveform such as shown in FIG. 2(f) and, the output of the circuit 11 provided through the multiplier 13 becomes a waveform such as shown in FIG. 2(h). The mean value of this waveform takes a positive value. At this time, the VCO 15 will act to recover the phase advance, with its oscillating frequency lowered for control.
FIG. 3 shows the phase detecting circuit 16 formed by the integration of the circuit 11 and the multiplier 13.
Referring to FIG. 3, a reception PAM signal r(t) from the terminal 10 is provided to the base electrodes of transistors 37 and 39 through resistors 44 and 48. On the other hand, another signal r(t-T) delayed by one clock T by a delay circuit 43 formed of a one-clock delay line is provided by way of resistors 45 and 49 to the base electrodes of transistors 38 and 40. The emitter electrodes of the transistors 37 and 38 are connected through resistors 46 and 47 for gain adjustment, respectively, to the collector electrode of a transistor 41. The collector electrodes of the transistors 37 and 38 are connected via resistors 52 and 53, respectively, to a positive power supply terminal 35 connected to a positive-voltage power source +V R . In this example, a first differential amplifier is composed of the transistors 37 and 38 and the resistors 44 to 47. Similarly, a second differential amplifier is made up primarily of the transistors 39 and 40 and resistors 48 to 51. The positive-polarity output terminal of said fist differential amplifier, i.e., the collector electrode of the transistor 38, and the negative-polarity output terminal of said second differential amplifier, i.e., the collector electrode of the transistor 39, are connected to each other, and so are the negative-polarity output terminal of said first differential amplifier (the collector electrode of the transistor 37) and the positive-polarity output terminal of said second differential amplifier (the collector electrode of the transistor 40). The emitter electrodes of the transistors 39 and 40 are connected by way of the resistors 50 and 51, respectively, to the collector electrode of a transistor 42. The emitter electrode of said transistor 41 and that of said transistor 42 are commonly connected by way of a resistor 54 to a negative-voltage power source terminal 36 connected to a negative-voltage power source -V R .
As shown in FIG. 3, the part surrounded by the one-dot-dash line in FIG. 1 is integrated, and the output of the decision circuit 12 is supplied by way of the terminal 32 to the base electrode of the transistor 41. At this time, the base electrode of the transistor 42, i.e., a terminal 33, is fixed at zero volt.
In operation, with a logical "1" output received from the circuit 12 to provide Va volts (V a being greater than zero and equal to or smaller than V R ) at the terminal 32, the transistors 41 and 42 are turned on and off, respectively, because the base electrode of the transistor 42 is at zero volts. As a result, the amplifier (37, 38, 46, 47) produces a delayed differential signal {r(t)-r(t-T)} from the collector electrode of the transistor 38, whereas said amplifier (39, 40, 50, 51) does not operate at this time.
On the other hand, a logical "0" output from the circuit 12 causes the terminal 32 to be held at -Va volts. As a result, the transistors 42 and 41 are turned on and off, respectively, so that only the amplifier (39, 40, 50, 51) operates to produce an inverted version of said delayed differential signal at the collector electrode of the transistor 39. Therefore, from the output terminal 34 is supplied the result of analog multiplication of a delayed difference signal by a decision sequence, and it is supplied to the low-pass filter 14 referred to in FIG. 1.
The structure shown in FIG. 1 can also be applied to a binary sequence having levels of "0" and "1". In this case, the multiplier 13 and the circuit 12 function differently from those shown in FIG. 1. More specifically, the multiiplier 13 functions as a gate for passing a delayed difference signal from the circuit 11 only while the output of the decision circuit 12 is logical "1". The signal passed by said gate controls the oscillating frequency of the VCO 15 through the low-pass filter 14. Also, the decision circuit 12 decides whether a given input signal is larger than a threshold level 0.5. More clearly, in response to a logical "1" output from the circuit 12 to provide the terminal 32 with V a volts, the amplifier (37, 38, 46, 47) operates to produce a a delayed differential signal from the collector electrode of the transistor 38, because the base electrode of the transistor 42 is at zero volts. On the contrary, with a logical "0" output fed from the circuit 12 to provide zero volts for the terminal 32, both the amplifiers (37, 38, 46, 47) and (39, 40, 50, 51) operate to produce a zero volt output at the terminal 34.
Referring now to FIG. 4, a second embodiment suited for a ternary sequence having levels of "0" and "±1" includes the decision circuit 12 consisting of a first decision circuit 20 for discriminating a reception signal with a threshold level ±0.5 and a second decision circuit 21 for discriminating the reception signal with a threshold level -0.5, and the multiplier 13.
In this embodiment, the reception signal is determined to be greater or smaller than the threshold levels ±0.5 and -0.5 by the first decision circuit 20 and the second decision circuit 21, respectively. These determinations are accomplished at the identical time prescribed by each timing pulse supplied from the VCO 15. Each of the circuits 20 and 21 will provide a logical "1" if the reception signal is found to be greater than its threshold level, or a logical "0" if it is found smaller. Supposing that the logical outputs of the circuits 20 and 21 are represented here by a 1 and a 2 , respectively, the circuit 13 will supply a delayed difference signal received from the circuit 11 to the low-pass filter 14 if the two-bit input (a 1 , a 2 ) thereby obtained is (1, 1), or supply said delayed difference signal inverted to the filter 14 if (a 1 , a 2 ) is (0, 0), and its output will be 0 in all other cases. In this embodiment, modifications should be made to the circuit 16 shown in FIG. 3 so that the output of the circuit 20 is supplied to the terminal 32 and an inverted version of the output of the circuit 21 is supplied to the terminal 33. More specifically, logical "1" outputs from the circuits 20 and 21 cause the terminals 32 and 33 to be held at V a and -V a volts, respectively. As a result, only the amplifier (37, 38, 46, 47) operates to produce a delayed differential signal 55 r(t)-r(t-T)} at the terminal 34, since -V a volts, or an inverted version of the output of the circuit 21, is given to the terminal 33. In contrast, logical "0" outputs fed from the circuits 20 and 21 cause the terminals 32 and 33 to be held at -V a and V a volts, respectively, so that the other amplifier (39, 40, 50, 51) produces an inverted version of {r(t)-(r(t-T)} at the terminal 34. Further, where either logical outputs "1" and "0" or "0" and "1" are supplied from the circuits 20 and 21, a zero volt output is produced at the terminal 34.
As described above, the present timing recovery circuit, which is so structured as to detect the global positive-negative balance of a one-clock delayed difference signal and to control the frequency of the timing signal therewith, is not affected by the deterioration of reception waveforms. Thus, the present circuit can be useful even when the transmission performance is poor.
Each of the decision circuits 12, 20, and 21 used in the first and second embodiments may be composed of the type shown in FIG. 13 on page 999 of Reference 1.
As has been discussed above, the invention can dispense with the use of differential wave sample values, which are sensitive to phase distortion, for obtaining information on phase differences. This consequently enables the simplification of the entire structure as well as the suppression of performance deterioration owing to phase distortion of the system.
It will be readily understood that the above-mentioned embodiments suited for the reception PAM signals given by binary and ternary sequences may also be applied to those signals of multi-level sequences of more than three levels by regarding these sequences as being formed by superimposing noises on binary or ternary sequences.
The invention is suitable for use, for instance, with coaxial and optical PCM reception systems, which are required not to consume much electric power, and therefore will prove highly useful for practical purposes.
|
A timing signal is generated from a received pulse-amplitude-modulated (PAM) signal by generating a delayed difference signal, multiplying the delayed difference signal by ±1 in accordance with a decision signal, averaging the multiplication output to control a voltage-controlled oscillator, and using the oscillator output to clock a sampler/comparator which compares the input signal to a predetermined threshold at time instants determined by the VCO output to generate the decision signal.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a securing eye or lug to form a releasable attachment point and to a securing system which comprises a securing eye of this kind.
[0003] 2. Description of Related Art
[0004] Detachable attachment points are used where persons need to work under secure conditions at a considerable height, e.g., when cleaning the outsides of windows on large buildings. A securing system which is referred to as a detachable attachment point may, in this case, comprise a plurality of anchoring elements which are solidly anchored into the outside wall of the building in various positions and which serve to receive, in such a way that it can be released, a securing eye which the person to be secured inserts, as required, in the particular anchoring element involved. The person is then able to secure himself to this securing eye by means of a carabiner for example. The principal advantage of an attachment point which, rather than being installed in a fixed position where the securing eye is fixed permanently into the wall of the building, is detachable lies in the fact that it does not draw attention to itself visually.
[0005] A securing system to form a releasable attachment point is known for example from EP 0 379 282 B1. This securing system comprises a bush, to be solidly anchored into the wall of a building for example, and a securing eye which has a spigot which is intended to be inserted in the bush. Following on from the spigot there is a securing ring which serves to receive a carabiner. The spigot and securing ring are connected solidly together in this case or in other words are integral with one another. The disadvantage which this design involves is that the securing eye has to be inserted in the bush in a defined orientation and should not twist around while in use because it is not permissible for the securing ring to be loaded in every direction.
[0006] To overcome this disadvantage, similar securing systems have been developed where the securing ring is connected to the spigot to be pivotable on an axis which lies perpendicular to the longitudinal axis of the spigot. The additional degree of freedom which the securing ring has ensures that it is almost always loaded in the permitted direction. In constructional terms, the securing ring is given the ability to pivot by connecting it to a mounting shaft which is mounted to be rotatable in a transverse hole through the spigot. This produces an ability to pivot through an angular range of pivot which is more than 180° and which in particular is limited only by the abutment of the securing ring against the spigot itself or against the adjacent wall.
[0007] However, something which has proved to be a problem in this case is that, due to the ability of the securing ring to pivot, a carbiner which is attached thereto regularly comes into contact with the wall of the building, as a result of which the latter may be damaged or dirtied.
BRIEF SUMMARY OF THE INVENTION
[0008] Taking the above prior art as a point of departure, the object underlying the invention was to specify a securing system of the generic kind which had been improved. The intention was in particular that damage to or dirtying of a wall of a building due to a carabiner attached to a securing eye of the securing system would be largely avoided by the improved securing system.
[0009] This object is achieved by a securing eye according to the claims. Advantageous embodiments of the securing eye according to the invention form the subject matter of the dependent claims and can be seen from the following description of the invention.
[0010] The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention which is directed to a securing eye comprising: a spigot; a securing ring pivotably connected to the spigot; and one or two abutments limiting the angular range of pivot of the securing ring to a range extending between 90°, such that the range is between +45° and −45° from an alignment where the longitudinal axis of the spigot is within a plane defined by the securing ring, and 120°, such that the range is between +60° and −60° from an alignment where the longitudinal axis of the spigot is within a plane defined by the securing ring.
[0011] The one or two abutments are designed in such a way that they free the limitation on the angular range of pivot if there is an increased load on the securing ring.
[0012] The spigot and the securing ring are preferably formed from metal and the one or two abutments are formed from plastics material.
[0013] The one or two abutments have an intended point of fracture and/or may be replaceable.
[0014] In a second aspect, the present invention is directed to a securing system having a securing eye comprising: a spigot; a securing ring pivotably connected to the spigot; one or two abutments limiting the angular range of pivot of the securing ring to a range extending between 90°, such that the range is between +45° and −45° from an alignment where the longitudinal axis of the spigot is within a plane defined by the securing ring, and 120°, such that the range is between +60° and −60° from an alignment where the longitudinal axis of the spigot is within a plane defined by the securing ring; and a securing bush in which the spigot of the securing eye is removeably insertable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be explained in more detail herein below with reference to the drawings, in which:
[0016] FIG. 1 is an isometric view of a securing eye according to the invention;
[0017] FIG. 2 is a view from the side of the securing eye shown in FIG. 1 ;
[0018] FIG. 3 is a view from the front of the securing eye shown in FIG. 1 ;
[0019] FIG. 4 shows a securing bush for use with the securing eye shown in FIGS. 1 to 3 ; and
[0020] FIG. 5 is an isometric view, partly in section, of a securing system comprising the securing eye shown in FIGS. 1 to 3 and the securing bush shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] The idea on which the invention is based is that, in the case of a securing system whose securing eye is designed to have a spigot and a securing ring which is mounted to be pivotable relative thereto, the risk of damage to or dirtying of a wall of a building caused by contact with a carabiner fastened to the securing ring can be effectively and easily avoided by limiting the angular range of pivot of the securing ring to less than 180° (and in particular to less than ±90° from the co-axial alignment of the securing ring relative to the spigot). In this way, the advantages of a securing ring of a securing eye where the securing ring is mounted to be pivotable on the spigot, namely the assurance that the securing ring will always be correctly loaded, can be combined with the advantage of a design where the securing eye is not movable, namely that there is less risk of damage to or dirtying of a wall of a building.
[0022] Provision is preferably made for the angular range of pivot of the ring to be limited to a range from 120° to 90° (and in particular to between ±60° and ±45° from the co-axial alignment of the securing ring relative to the spigot).
[0023] The angular range of pivot of the securing eye according to the invention may, in accordance with the invention, be limited by one abutment or two abutments (which limit it in both the directions of movement). Provision is preferably made in this case for the abutments to be so designed that they free the limitation on the angular range of pivot if there is an increased load on the securing ring. Hence, provision may be made for the abutments to limit the angular range of pivot only when the tractive load which is exerted on the securing ring and of which a component of force acts on one of the abutments is comparatively low (e.g., is a maximum of 100 N, 200 N, 300 N, 400 N, or 500 N) and for it to free (i.e., no longer limit) the angular range of pivot if the tractive load, and hence the load applied by the securing ring to the relevant abutment as well, exceeds this limiting value. In the event of the securing eye going into action, e.g., in the event of a person secured to it falling, as a result of which the securing eye is loaded at least by the bodyweight of the person secured, the given abutment thus frees the angular range of pivot, as a result of which the entire angular range of pivot (limited only by, for example, abutment of the securing ring against the wall of the building) is freed.
[0024] In a preferred embodiment of the securing eye according to the invention, the spigot and the securing ring may be formed (largely) from metal and in particular from steel, while the abutments limiting the angular range of pivot may be formed from plastics material. In this way, the components which perform the actual securing function may be produced from high-strength steel whereas the abutments which serve merely to protect the wall of the building may be inexpensively produced from plastics material.
[0025] Where the abutments are formed from plastics material, an intended point of fracture may also be incorporated in them, and provision may be made for this in a preferred embodiment of the securing eye according to the invention. The given abutment may break off in a defined way at this intended point of fracture when loaded by the securing ring in the event of its going into action.
[0026] To enable the securing eye according to the invention to continue in fully functional use even after it has gone into action and an abutment has broken off, provision is preferably made for the abutments to be connected to the spigot or the securing ring in such a way as to be replaceable.
[0027] The invention also relates to a securing system having a securing eye according to the invention and a securing bush which is intended for anchoring in a wall and in which the securing eye can be inserted (in particular lockably).
[0028] FIGS. 1 to 5 show an embodiment of securing system according to the invention (see FIG. 5 ) which comprises a securing eye 1 (see FIGS. 1 to 3 ) and a securing bush (see FIG. 4 ).
[0029] The securing eye 1 comprises a main body of steel which forms a spigot 3 , having a smooth-faced circumferential surface, which is intended for insertion in the securing bush 2 shown in FIG. 4 . At that end of the main body which is not intended for insertion in the securing bush 2 , the said main body is provided with a rotatable securing ring 4 . The securing ring 4 is pivotable in this case on an axis which lies perpendicular to the longitudinal axis of the spigot 3 . The angular range of pivot of the securing ring 4 is limited by an abutment ring 5 of plastics material which is fastened to the main body in such a way as to be replaceable and which comprises four projecting abutment members 6 which limit the range of pivot to approximately ±45° from a co-axial alignment of the securing ring 4 , i.e. an alignment where the longitudinal axis of the spigot 3 is within a plane defined by the securing ring 4 .
[0030] At its end for insertion, the spigot 3 of the securing eye 1 is provided with a total of four spherical locking members 7 . These are mounted to be moveable within openings in the circumferential surface of the spigot 3 and are held in the locking position shown in FIGS. 1 , 2 and 5 by a locking rod (not shown) which is guided to be movable within the spigot (in the direction defined by the longitudinal axis thereof). In the locking position, the locking members 7 project from the circumferential surface of the spigot 3 and, when a securing eye 1 is inserted in the securing bush 2 , engage in appropriate depressions on the inside of the securing bush 2 . The securing eye 1 is thus secured against coming free from the securing bush 2 when this is not wanted. Pressure is applied to the locking rod by a spring member (not shown) which is also arranged inside the main body of the securing eye, as a result of which the locking rod is held in a position which produces the locking position of the locking members 7 .
[0031] To insert the spigot 3 of the securing eye 1 in the securing bush 2 and to release it from its hold therein, it is necessary for the locking members 7 to be displaced sufficiently far into the interior of the spigot 3 for them no longer to project substantially from the circumferential surface thereof. This is done by pressing in an actuating member 8 connected to the locking rod, as a result of which the locking rod is displaced a defined distance (in the direction defined by the longitudinal axis) within the spigot. When this is done, a portion of the locking rod where the latter is of a reduced outside diameter is brought into contact with the locking members 7 and the latter are thus able to move back into the interior of the spigot 3 . Because the locking rod is spring-loaded into the locking position, it moves back into the locking position shown in FIGS. 1 , 2 and 5 automatically once the actuating member 8 is released.
[0032] The securing bush 2 is intended to be fixed permanently in a wall (not shown) such for example as a wall of a building. It comprises a threaded sleeve 9 having an outside thread and, fastened to one end of its main body 9 , a ring for contact 10 which limits the depth of insertion of the threaded sleeve 9 in a hole in the wall and also acts as a pivot bearing for the securing eye 1 inserted in the securing bush 2 . The securing bush 2 also comprises a closing-off or sealing-off cap 11 in sleeve form by means of which the interior of the main body 9 is closed off from the surroundings even when there is no securing eye 1 inserted. The sealing-off cap 11 is loaded into the position shown in FIG. 4 , in which it closes off the receiving opening formed by the ring for contact 10 , by means of a (cylindrical coil) spring 12 . For this purpose, the spring 12 extends into the closing-off cap 11 in sleeve form at one end and by the other end is supported against a closing-off member 13 which closes off the opposite end of the threaded sleeve 9 from the ring for contact 10 . When the spigot 3 of the securing eye 1 is inserted, the closing-off cap 11 is displaced by the spigot 3 in the direction of the closing-off member 13 in opposition to the force exerted by the spring 12 .
[0033] The purpose of the spring 12 is not only to displace the closing-off cap 11 towards the closing-off position shown in FIG. 4 when there is not a securing eye 1 inserted but also to assist the release of the securing eye 1 from the securing bush 2 , as soon as the locking members 7 are released by actuating the actuating member 8 .
[0034] The purpose of the outside thread on the threaded sleeve 9 is to fix the securing bush 2 securely in the wall. Provision is made in this case either for the securing bush to be fixed in a hole in the wall over the entire length of the threaded sleeve 9 or, where the thickness of the wall is less than the length of the threaded sleeve 9 , for the securing bush 2 to be secured by screwing a securing nut (not shown) onto the opposite end of the threaded sleeve 9 from the ring for contact.
[0035] While the present invention has been particularly described, in conjunction with the specific preferred embodiment(s), it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art, in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications, and variations as falling within the true scope and spirit of the present invention.
|
A securing lug having a bolt and a securing ring which is connected pivotably to the bolt, as a result of which the pivoting-angle range of the securing ring is limited to less than 180°.
| 5
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an inflatable pillow and, more particularly, to a multi-airbag inflatable pillow having both functions of comfort and supporting.
[0003] 2. Description of Related Art
[0004] An inflatable pillow can be either inflated or deflated by filling or discharging air from the pillow when used as a supporting cushion. It has the advantages of portability and ease of storage, and serves various functional effects depending on how it is used. An inflatable pillow can be used as a backrest to prevent problems of sore waist, humpback, and any discomfort caused by sitting in an extended time period. When an inflatable pillow is supporting under the calf, it not only relieves the pressure that the leg is putting on the calf but also prevents the fatigue that the leg may experience. An inflatable pillow, as it is well known, can certainly be used as a headrest for supporting the head or neck.
[0005] The level of the inflation of an inflatable pillow can be adjusted by an user in order to determine the pillow's softness or stiffness. When the pillow is inflated, its stiffness is increased. On the other hand, when the pillow is deflated, its softness is increased. The degree of softness of an inflatable pillow has a large influence to the resting or sleeping quality of the pillow user. An ideal supporting cushion requires a certain degree of softness in order to provide the expected comfort to the user and to bear any pressure that an user may otherwise needs to experience. The structure of a conventional inflatable pillow does not provide the objectives as described above.
[0006] As shown in FIG. 1 , a prior art inflatable pillow 10 is composed of a single airbag 11 . When the inflatable pillow 10 is inflated, air is filled in the airbag 11 and its air pressure cannot be locally adjusted. Consequently, the inflatable pillow 10 is either over inflated, resulting in less softness and discomfort, or less inflated causing insufficient supporting capability. Therefore, the prior art inflatable pillow may as well cause more fatigues and aches.
SUMMARY OF THE INVENTION
[0007] A primary objective of the present invention is to provide a multi-airbag inflatable pillow, in which multiple airbags are used to provide better comfort and support in order to achieve the purpose of relieving users stress and providing improved resting.
[0008] Another objective of the present invention is to provide a multi-airbag inflatable pillow, which can be used as a supporting cushion to be used as a neck pillow, mattress, cushion, holding pillow and head pillows. Users can adjust the inflation levels of each airbag according to personal requirement in order to obtain the expected comfort and resting.
[0009] Yet another embodiment of the present invention is to provide a multi-airbag inflatable pillow, in which liquid is filled into one of these airbags for the purpose of heat absorption and radiation by the liquid.
[0010] In order to achieve the above objectives, the present invention provides a multi-airbag inflatable pillow which comprises a plurality of airbags and each airbag comprises at least a valve. Each airbag is either inflated or deflated with air or any liquid of choice via the valve. The inflation level of a first airbag can be adjusted by the user to attain the most comfortable softness. A second airbag, other than the first airbag among the plurality of airbags, is used to supplement the insufficient support from the first airbag due to its less than enough inflation. The second airbag can be inflated enough to sustain where the user resting on it so that any pressure caused by the resting can be relieved.
[0011] The multi-airbag inflatable pillow of the present invention can be used as a neck pillow, mattress, cushion, holding pillow and sleeping pillow. In practical use, the inflation levels of the first and second airbags can be freely adjusted to reach the most comfortable and relaxation state for a user. A valve for filling liquid into or discharging from the second airbag can be added on the second airbag. Taking advantage of the heat dissipation by the liquid, the excessive heat of an user can be absorbed by the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various objectives and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawings, in which:
[0013] FIG. 1 is a diagram of an inflatable pillow of a prior art;
[0014] FIG. 2A is a plan view of a multi-airbag inflatable pillow of the present invention;
[0015] FIG. 2B is a cross-sectional view along section line A-A of FIG. 2A ;
[0016] FIGS. 3A to 3D are diagrams showing various usages of a multi-airbag inflatable pillow of the present invention;
[0017] FIG. 4 is a diagram of a multi-airbag inflatable pillow having a valve of the present invention;
[0018] FIG. 5 is a diagram of a multi-airbag inflatable pillow having a pillow case of the present invention; and
[0019] FIGS. 6 to 8 are side views of a multi-airbag inflatable pillow having three airbags of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The multi-airbag inflatable pillow of the present invention can be used as a neck pillow, holding pillow, backrest cushion, sleeping pillow, cushion and mattress. As shown in FIGS. 2A and 2B , this embodiment is exemplified with a U-shaped neck pillow. In practice, the multi-airbag inflatable pillow can be of a cylindrical shape, an animal shape or a polygonal shape. All of these variations and modifications of shapes are embraced within the scope of the current invention.
[0021] As shown in FIGS. 2A and 2B , a multi-airbag inflatable pillow 20 comprises a first airbag 30 and a second airbag 40 . In this embodiment, the multi-airbag inflatable pillow is a U-shaped neck pillow. The first airbag 30 is located at the outer portion of the pillow while the second airbag 40 is located at the inner portion of the pillow. Each airbag contains a valve 31 and 41 respectively.
[0022] The first airbag 30 and the second airbag 40 can be either inflated or deflated by filling or discharging air via the valve 31 and 41 respectively. The inflation level of the first airbag 30 can be adjusted by the user to attain the most comfortable softness. The second airbag 40 is used to remedy the height due to insufficient inflation level of the first airbag 30 . The second airbag 40 can be inflated to sustain the user's neck and obtain the most comfortable height, in supporting the user's cheeks, for a better resting and sleeping quality.
[0023] FIGS. 3A to 3D are diagrams showing various usages of a multi-airbag inflatable pillow of the present invention. As shown in FIG. 3A , the second airbag 40 is first inflated via the valve 41 to a desired height for supporting the user's shoulder and neck. As shown in FIG. 3B , the first airbag 30 is then inflated via the valve 31 to support the user's neck so that the neck does not move around as shown in FIG. 3C . The inflation level of the first airbag 30 can be adjusted for a desired softness by the user in order to obtain the expected comfortable level as shown in FIG. 3D .
[0024] In practical use, a user can adjust the inflation level of the first airbag 30 or the second airbag 40 , and determine how the multi-airbag inflatable pillow 20 is used in order to achieve the most comfortable and relaxing level. The above described embodiments illustrate only some objectives of the present invention. It should be understood that the present invention is not limited to the described embodiments only.
[0025] The material of the first airbag 30 and the second airbag 40 of the multi-airbag inflatable pillow 20 can be selected among plastic, flocked plastic, and plastic laminated fabrics. When the second airbag 40 is made of waterproof plastic material, a valve 42 can be added thereon so that liquid can be filled into the second airbag 40 as shown in FIG. 4 . The temperature range of the liquid is between 5° C. and room temperature for the purpose of heat absorption in order to provide a comfortable feeling to the user.
[0026] As shown in FIG. 5 , in order to make the multi-airbag inflatable pillow 30 to be more comfortable when it is used, a pillow case 60 can be used to sleeve onto the current invention including first airbag 30 and the second airbag 40 . The shape of the pillow case 60 varies in order to accommodate the design of the current invention. A zipper 61 is provided on a side of the pillow case 60 . The pillow case 60 can be made of materials such as breathable material, hyper-elastic composite foamed material, polyester fiber, silicone, rubber, plastic, wool, cotton, hemp, or the combination of any two or more of the above materials.
[0027] It should be noted that although the above described embodiment demonstrates only a second airbag 40 to remedy the height of the first airbag, more airbags (e.g., a third airbag or a fourth airbag) can also be added on the side of the first airbag or the side of the second airbag to enhance the supporting effect.
[0028] FIGS. 6 to 8 are side views of a multi-airbag inflatable pillow having three airbags of the present invention. As shown in FIGS. 6 to 8 , a multi-airbag inflatable pillow 70 comprises a first airbag 30 , a second airbag 40 and a third airbag 80 . The FIG. 6 shows only the first airbag 30 is inflated. In FIG. 7 , the first airbag 30 and the second airbag 40 are inflated. The FIG. 8 shows all three airbags 30 , 40 , 80 are inflated. The first airbag 30 can be adjusted for a desired softness and comfort level. The second airbag 40 and the third airbag 80 can be used to remedy the height of the first airbag 30 . In practical use, an user can adjust the inflation level of the first airbag 30 according to a preferred feeling of softness. One or multiple airbags to be used together is a choice of the user. When the first airbag 30 is used alone, the inflation level is generally preferred to be 60%˜80%. When three airbags are used together, the inflation level of the first airbag 30 is determined by the desired softness level of the user, and is generally preferred to be 30%˜60%. When the second airbag 40 and the third airbag 80 are used, their inflation level is generally preferred to be 80%˜90%.
[0029] Although the present invention has been described with reference to the preferred embodiments thereof, it will be understood that the invention is not limited to the details thereof. Various substitutions and modifications have been suggested in the foregoing description, and other will occur to those of ordinary skill in the art. Therefore, all of such substitutions and modifications are intended to be embraced within the scope of the current invention as defined in the appended claims.
|
A multi-airbag inflatable pillow is formed by adding at least one second airbags on one side of a first airbag so that a user can freely adjust the inflation of the first airbag according to personal requirement to obtain the most comfortable air pressure. Moreover, the second airbag can solve the problem of insufficient height of the inflated first airbag to achieve the objective of fully support so that the user can get effective relaxation and rest.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to a temperature measuring apparatus for detecting temperature of an object and, more particularly, a temperature measuring apparatus suitable for a microwave oven.
In a microwave oven, magnetron energizing control for generating microwave energy to heat food is carried out in response to food temperature. A conventional temperature measuring apparatus for a microwave oven comprises an infrared sensor, a chopper, a chopper temperature sensor, and a signal processing circuit. More particularly, the food temperature is usually detected indirectly with the infrared sensor, which consists of an infrared-sensitive material LiTaO 3 , for instance, and is provided on the ceiling of a heating chamber with its detecting surface directed toward the food. Infrared radiation emitted from the food is intermittently blocked by the chopper which is provided between the infrared sensor and food. While the radiation from the food is blocked, it does not reach the infrared sensor. During this time, however, a certain amount of infrared radiation is emitted from the chopper. The infrared sensor thus detects infrared radiation from the food and that from the chopper alternately, so that it produces an AC output signal varying between alternate high and low levels according to the amount of the incident infrared radiation. The chopper temperature sensor comprising a thermistor, for instance, is provided separately to obtain a signal representing the chopper temperature or ambient temperature of the chopper. The signal processing circuit carries out arithmetic operations (subtraction/addition) in an analogue manner so as to derive a food temperature signal for the magnetron energizing control from output signals of the infrared sensor and the chopper temperature sensor. However, the infrared sensor output y does not vary with a linear function y=x f of the food temperature x f (°C.) as shown by a dashed line in FIG. 1 but varies with a function y=f(x f ) shown by a solid curve.
The infrared sensor output voltage is also subject to the chopper temperature. If the chopper temperature x cp (°C.) is taken into account and the temperature measuring apparatus operates on condition that the infrared emissivity of the chopper is considered to be substantially identical to that of the food while the chopping duty cycle is 50 percent, then the infrared sensor output y is given as
y=|f(x.sub.f)-f(x.sub.cp)| (1)
where the absolute value expression in equation (1) represents an output of a full wave rectifier in the signal processing circuit. A dot-dash curve shown in FIG. 1 indicates the equation (1). The solid curve for y=f(x f ) is obtained when f(x cp )=0, i.e., when the chopper temperature is 0° C.
The infrared sensor output y given by the equation (1) greatly differs from the linearized plot for y=x f . In addition, the sensitivity characteristics of the infrared sensor are basically different from those of the chopper temperature sensor. Accordingly, the conventional temperature measuring apparatus above-mentioned can not always provide an accurate food temperature signal over a wide temperature range.
SUMMARY OF THE INVENTION
An object of the invention is to provide a highly reliable temperature measuring apparatus, which can accurately measure the temperature of an object without being influenced by chopper temperature changes.
To attain the above object, according to the invention there is provided a temperature measuring apparatus, comprising:
a chopper for intermittently blocking infrared radiation emitted from an object in accordance with a predetermined chopping duty cycle;
a chopper temperature sensor for measuring temperature of the chopper;
an infrared sensor including a receiving surface for receiving infrared radiation from the object and the chopper alternately;
said infrared sensor producing an electric output signal consisting of object temperature components and chopper temperature components; and
a control circuit for deriving a signal corresponding to temperature of the object from output signals of the chopper temperature sensor and the infrared sensor,
the control circuit including
a device for correcting the output signal of said chopper temperature sensor to be substantially in accord with the chopper temperature components in the output signal of the infrared sensor, and
a device for substantially removing the chopper temperature components from the output signal of the infrared sensor by applying an output signal of the correcting device to the output signal of the infrared sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows output characteristics of an infrared sensor;
FIG. 2 is a schematic diagram of an embodiment of the invention;
FIG. 3 is a block diagram of a control circuit shown in FIG. 2;
FIG. 4 is a time chart for explaining the operation of the circuit of FIG. 3; and
FIG. 5 shows a function diagram of a microcomputer shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will now be described in conjunction with an embodiment thereof with reference to the drawings.
FIG. 2 schematically shows an embodiment of the invention applied to a microwave oven in which food temperature is measured to properly heat food to be cooked. Food 2 is placed on a food table 2a in a heating chamber 1 of a microwave oven. A magnetron 3 for generating microwave energy is provided on a ceiling of the heating chamber 1, and an antenna 3a projects into the heating chamber 1.
The heating chamber 1 has an infrared permeable window, which is impermeable to microwave energy, provided substantially at the center of its ceiling. An infrared sensor 4 made of an infrared sensitive material LiTaO 3 , for instance, is disposed outside the heating chamber 1 with its receiving surface directed toward the food 2 to detect infrared radiation passing through the infrared permeable window. A chopper 5 is interposed between the infrared permeable window and the infrared sensor 4. It is alternatively movable between two positions by a solenoid 6. In one of the two positions, it blocks infrared radiation from the food 2 so that the radiation from the chopper 5 is only incident on the infrared sensor 4. In the other position, it allows the infrared radiation from the food 2 to be incident on the infrared sensor 4. The solenoid 6 is driven in response to a drive signal A supplied from a control circuit 7. Accordingly, the infrared sensor 4 produces an electric output signal B corresponding in level to resultant infrared intensity of the chopper 5 and the food 2.
A chopper temperature sensor 8 consisting of a thermistor is provided in the vicinity of the chopper 5. It produces an electric output signal C corresponding to the temperature of the chopper 5. The output signals B and C are respectively fed to the control circuit 7. The control circuit 7 determines the temperature of the food 2 from the output signals B and C, and provides an on-off control signal S to a relay switch 9 according to a programmed temperature so that the food 2 may be heated satisfactorily. The relay switch 9 and a high voltage transformer 10 are connected to a power source circuit of the magnetron 3. The microwave output level of the magnetron 3 is controlled through the control of conduction period of the relay switch 9 in response to the signal S.
In this embodiment, the control circuit 7 processes the output signal of the chopper temperature sensor 8 to derive therefrom data substantially identical to those in accordance with the output (sensitivity) characteristics of the infrared sensor 4. The control circuit 7 further operates to provide a linearlized temperature signal with respect to the food in response to output signals of the chopper temperature sensor 8 and the infrared sensor 4 which, in turn, is used for the on-off control signal S.
The construction and operation of the control circuit 7 will now be described in detail with reference to FIGS. 3 through 5.
Referring to FIG. 3, the output signal of the infrared sensor 4, which is an electric output signal, is fed to a filter 21 in a sensor circuit 20 of the control circuit 7. The filter 21 removes a DC component from the sensor output signal B. Its AC output signal B' is amplified by an amplifier 22 and then fed through a switch 23 to an integrating circuit 24. The output of the amplifier 22 is also full-wave rectified by a full-wave rectifier 25 and then integrated by an integrating circuit 26.
The output E of the integrating circuit 24 in the sensor circuit 20 is supplied to a microcomputer 31 in an arithmetic operation circuit 30. The output y i of the integrating circuit 26 is fed together with the output signal C of the chopper temperature sensor 8 to a switch circuit 32. The switch circuit 32 selects the output signals y i and C in response to a switch command signal J from the microcomputer 31. The output signals y i and C from the switch circuit 32 are respectively converted by an A/D converter 33 into digital signals which are provided to the microcomputer 31. The microcomputer 31 supplies drive signals to a relay driving circuit 34 and a chopper driving circuit 36, which, in turn, respectively produce the on-off control signal S for on-off operation of the relay switch 9 and the drive signal A for the solenoid 6.
An operation panel having various operating keys is provided on the front surface of a cabinet of the microwave oven. The operating keys are connected to a key matrix circuit 41, which is scanned in accordance with a key scanning signal from the microcomputer 31. The operating panel also has a display unit 42 for displaying alpha-numerical data which the microcomputer 31 receives from the key matrix circuit 41. The display unit 42 may include a liquid crystal display device driven by a segment drive signal F and a digit drive signal G which are fed from the microcomputer 31.
Now, the operation of the circuit of FIG. 3 will be described with reference to the time chart of FIG. 4. After the food 2 is placed on the table 2a in the heating chamber 1, a door (not shown) is closed. Then, a timer (not shown) is set to be a desired cooking period of time and, a cooking button is depressed. As a result, cooking is started with power supplied to the magnetron 3. At the same time, the drive signal is supplied from the microcomputer 31 to the chopper driving circuit 36, so that the chopper driving circuit 36 feeds the drive signal A with a duty cycle of 50 percent, as shown in FIG. 4(a), to the solenoid 6. When the solenoid 6 is energized periodically in response to the drive signal A, the chopper 5 is brought to an "open" position, allowing the infrared radiation emitted from the food 2 to be detected by the infrared sensor 4. The solenoid 6 is de-energized during an alternative period of the signal A, and the chopper 5 is brought to a "block" position. In this position of the chopper 5, the infrared radiation emitted therefrom is detected by the infrared sensor 4.
In an initial stage of the cooking, the chopper 5 is substantially at room temperature. If the food 2 to be cooked is a frozen foodstuff, for example, its temperature is below the freezing point in the initial stage. In this stage, since the chopper temperature x cp is higher than the food temperature x f , the output signal B of the infrared sensor 4 decreases in level while the chopper 5 is in the "open" position and increases while the chopper 5 is in the "block" position.
With the progress of the cooking, the temperature of the food 2 eventually exceeds the temperature of the chopper 5. Thereafter, the output level B of the infrared sensor 4 increases while the chopper 5 is in the "open" position. In either case, an AC signal B that varies in level according to the temperature x f of the food 2 and the temperature x cp of the chopper 5 is obtained from the infrared sensor 4.
The AC signal B has a DC component which is removed by the filter 21, and the output signal B' thereof is amplified by the amplifier 22 to a predetermined level. The amplified output signal is gated by the switch 23 under the control of a gating signal D as shown in FIG. 4(d). The gating signal D supplied from the microcomputer 31 has the same frequency as the drive signal A but shifts in phase therebehind by a predetermined period of time. With the gating operation of the switch 23, a positive going output signal shown in FIG. 4(e) is derived from the output signal B' shown in FIG. 4(b) when the temperature of the food 2 is equal to or higher than the temperature of the chopper 5, i.e., x f ≧x cp , or otherwise a negative going output signal shown in FIG. 4(f) is derived from the output signal B' shown in FIG. 4(c).
The output signal from the switch 23 is smoothed by the integrating circuit 24 so that there is provided a DC signal E which is higher or lower in level than a reference level as shown in FIG. 4(g). This DC signal E is fed to the microcomputer 31 as a discrimination signal for discriminating between x f ≧x cp and x f <x cp .
The output signal of the amplifier 22 is also supplied to the full-wave rectifier 25, which, in turn, produces an output signal corresponding to the absolute value expressed by the equation (1). The output signal of the full-wave rectifier 25 is smoothed by the integrating circuit 26, whereby a DC output signal y i as shown in FIG. 4(h) is obtained.
Meanwhile, infrared radiation intensity y 0 of an object is generally given as
Y.sub.0 =aX.sup.4 +b (2)
where X is temperature (in Kelvin) of an infrared radiation source, and a and b are constants.
Denoting components with respect to food temperature X f and chopper temperature X cp in the infrared radiation intensity y 0 of an object respectively by y 1 and y 2 , from the equation (2) we may state
Y.sub.1 =a.sub.1 X.sub.f.sup.4 +b.sub.1 (3) and
y.sub.2 =a.sub.2 X.sub.cp.sup.4 +b.sub.2 (4)
where X f (°K.) and X cp (°K.) are respectively the absolute temperature equivalents of x f (°C.) and x cp (°C.)
If the infrared emissivities of the food 2 and the chopper 5 are substantially identical, then from equations (3) and (4) the DC output signal y i is given by ##EQU1## where β is a constant,
X.sub.f 273 +x.sub.f.
and
X.sub.cp =273 +x.sub.cp.
The DC output signal y i is further given by ##EQU2## where β'=β×(273) 4 . As is seen from the equation (6), there is no need of carrying out calculations by using absolute temperature values.
As discussed above, the output signal y i of the integrating circuit 26, as shown in FIG. 4(h), also represents the absolute value of a function with respect to the food temperature x f and the chopper temperature x cp , defined by
y.sub.i =M=|f(x.sub.f)-f(x.sub.cp)| (7)
This analogue signal is converted by the A/D converter 33 into a digital signal, which is stored in a memory (not shown) of the microcomputer 31.
The chopper temperature sensor output signal C is also converted in the A/D converter 33 into a digital signal to be applied to the microcomputer 31. The memory of the microcomputer 31 has an area to store a function conversion table for converting the digital signal with respect to the chopper temperature x cp from the A/D converter 33 into a digital signal corresponding to a function f(x cp ).
Therefore, even if the output (sensitivity) characteristics of the chopper temperature sensor 8 are different from those of the infrared sensor 4, with reference to the conversion table the microcomputer 31 carries out arithmetic operations so as to provide the following digital output signal
N=f(x.sub.cp) (8)
which, in turn, is stored in the memory.
If the level of the discrimination signal E from the integrating circuit 24 is higher than or equal to the reference one, i.e., x f ≧x cp , then the microcomputer 31 executes an adding operation to obtain ##EQU3## where f(x f )≧f(x cp )>0.
If the signal level is lower than the reference one, i.e., x f <x cp , then a subtracting operation is executed to obtain ##EQU4## where f(x cp )>f(x f )>0.
With respect to data T the microcomputer 31 further executes the following arithmetic operation;
x.sub.f =f.sup.-1 (T) (11)
The equation (11) represents that accurate data with respect to the temperature of the food 2 can be derived from the microcomputer 31. Detected temperature data are compared with a programmed temperature preset in the microcomputer 31. According to the result of the comparison, a driving signal is supplied to the relay driving circuit 34 to on-off control the relay switch 9.
As has been described in the foregoing, according to the invention the output signal of the chopper temperature sensor 8 is converted into a signal corresponding to the output characteristics of the infrared sensor 4 so that the converted signal can be used for a correction signal for the infrared sensor output signal. Thus, accurate and reliable food temperature can be obtained irrespective of a temperature change of the chopper 5 due to an ambient temperature rise from room temperature or a temperature rise of the magnetron 3.
The microcomputer 31 described above may be replaced with an arithmetic circuit comprising as operational amplifier or the like.
In the above-mentioned embodiment, the infrared sensor 4 made of an infrared sensitive material LiTaO 3 , for instance, and the chopper temperature sensor 8 consisting of a thermistor are used. The infrared sensor 4 and the chopper temperature sensor 8 may also be made of an identical material such as LiTaO 3 . In case, however, that these sensors 4 and 8 have different characteristics, it is possible to correct the output signal of the sensor 4 or 8.
Further, while the previous embodiment has concerned with the determination of the temperature of the food in the microwave oven, the invention is applicable to the measurement of the temperature of any other object as well.
|
An infrared sensor made of LiTaO 3 is provided on a ceiling of a heating chamber of a microwave oven, and a chopper is provided so as to intermittently block infrared radiation emitted from food in the heating chamber. The infrared sensor is brought to face the food and the chopper alternately and provides a corresponding AC output signal. The temperature of the chopper is detected from the output signal of a separately provided chopper temperature sensor consisting of a thermister. The detected chopper temperature output signal is corrected in a microcomputer to be substantially in accord with chopper temperature components in the output signal of the infrared sensor. The corrected chopper temperature data is applied to the infrared sensor output data for removing the chopper temperature components from the output signal of the infrared sensor to obtain a food temperature signal corresponding to the sole temperature of the food.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/650,340, filed on 8 Jun. 2015, now U.S. Pat. No. 9,351,377, issued on May 24, 2016, which is the National Stage Application of International Application No. PCT/KR2012/010930, having an International Filing Date of 14 Dec. 2012, which designated the United States of America, and which International Application was published under PCT Article 21 (s) as WO Publication 2014/092221 A1, the disclosures of which are incorporated herein by reference in their entireties.
BACKGROUND
[0002] The presently disclosed embodiment relates to a dimming control apparatus and a dimming control method thereof.
[0003] Recently, in a lighting, a dimming function, that is, a photochromic function, to control an amount of light of a lamp has been used for various lamps including an incandescent lamp, a fluorescent lamp, and a light-emitting diode (LED).
[0004] In addition, various control methods thereof have been provided. In particular, many dimming stabilizers have been supplied since a dimming function for power saving has begun to be used for a fluorescent lamp which is one of lamps that are used the most in the country.
[0005] However, since most dimming stabilizers are operated through a manual method using a controller, it is inconvenient and cumbersome for a user to operate it and an effective control due to changes in an amount of natural lighting or ambient light is not possible. Additionally, since a dimming function is controlled using illuminance of a lamp that is uniformly set, there is a problem in that a user cannot control brightness by stages and cannot conveniently manipulate levels of brightness.
SUMMARY
[0006] The presently disclosed embodiment provides a dimming control apparatus in which a user may control brightness by stages and may conveniently manipulate levels of brightness, and a dimming control method thereof.
[0007] According to an aspect of the presently disclosed embodiment, there is provided a dimming control apparatus that controls illuminance of a lamp, the dimming control apparatus including a power pad that is configured as a touch panel for turning on/off power supply of the lamp; dimming pads that are configured as at least two touch panels for controlling illuminance of the lamp; a sensing unit that senses touch operations from the power pad and the dimming pads; and a control unit that controls turning on/off of power supply to the lamp according to whether or not the power pad is touched and controls illuminance of the lamp according to whether or not the dimming pads are touched.
[0008] The control unit controls the illuminance of the lamp using a dimming value according to touch locations of the dimming pads configured as at least two touch panels.
[0009] The control unit controls the illuminance of the lamp according to touch directions of the dimming pads configured as at least two touch panels.
[0010] The dimming pads configured as at least two touch panels are arranged by stages to correspond to the illuminance of the lamp.
[0011] The dimming control apparatus further includes at least two display lamps that are turned on/off according to whether the dimming pads configured as at least two touch panels are touched and display operational states of the respective dimming pads.
[0012] The dimming control apparatus further includes a storage unit that stores a dimming value at the time when the lamp is turned on/off, wherein the control unit controls the illuminance of the lamp to correspond to the stored dimming value when the lamp is turned on.
[0013] According to another aspect of the presently disclosed embodiment, there is provided a dimming control method of controlling illuminance of a lamp, the dimming control method including turning on/off power supply to the lamp when a power pad that is configured as a touch panel for turning on/off the power supply to the lamp; and controlling the illuminance of the lamp according to whether dimming pads configured as at least two touch panels for controlling the illuminance of the lamp are touched.
[0014] In the controlling of the illuminance of the lamp, the illuminance of the lamp is controlled using a dimming value according to touch locations of the dimming pads configured as at least two touch panels.
[0015] In the controlling of the illuminance of the lamp, the illuminance of the lamp is controlled according to touch directions of the dimming pads configured as at least two touch panels.
[0016] The dimming control method further includes storing the dimming value of the lamp when the power pad is touched; and turning off power supply to the lamp.
[0017] In a dimming control apparatus according to one or more aspects of the presently disclosed embodiment, power on/off of a lamp is controlled according to whether or not a power pad is touched and illuminance of the lamp is controlled according to whether or not dimming pads are touched so that a user may control brightness step by step and may conveniently manipulate levels of brightness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a diagram showing the appearance of a dimming control apparatus, according to an aspect of the presently disclosed embodiment.
[0019] FIG. 2 is a block diagram schematically showing the dimming control apparatus shown in FIG. 1 .
[0020] FIG. 3 is a flowchart for describing a dimming control method, according to another aspect of the presently disclosed embodiment.
[0021] FIG. 4 is a flowchart for describing a dimming control method, according to another aspect of the presently disclosed embodiment.
DETAILED DESCRIPTION
[0022] Various changes in form and details may be made to the presently disclosed embodiment and thus should not be construed as being limited to the aspects set forth herein. The presently disclosed embodiment is not limited to the aspects described in the present description, and thus it should be understood that the presently disclosed embodiment does not include every kind of variation example or alternative equivalent included in the spirit and scope of the presently disclosed embodiment. Also, while describing the aspects, detailed descriptions about related well-known functions or configurations that may diminish the clarity of the points of the aspects of the presently disclosed embodiment will be omitted.
[0023] Also, though terms like a first and a second are used to describe various elements, components, regions, layers, and/or portions in various aspects of the presently disclosed embodiment, the elements, components, regions, layers, and/or portions should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or portion from another.
[0024] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of exemplary aspects. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.
[0025] Hereinafter, the presently disclosed embodiment will be described in detail by explaining exemplary aspects of the disclosed embodiment with reference to the attached drawings. Like reference numerals in the drawings denote like elements, and thus their description will be omitted.
[0026] FIG. 1 is a diagram showing the appearance of a dimming control apparatus, according to an aspect of the presently disclosed embodiment.
[0027] Referring to FIG. 1 , the dimming control apparatus 100 is an apparatus that controls illuminance of a lamp (not shown). The dimming control apparatus 100 according to an aspect of the presently disclosed embodiment may be used for various types of lightings, for example, a desk lamp or a general lighting, and the lamp may be any of various types of lamps, for example, a light-emitting diode (LED) or a fluorescent lamp.
[0028] The dimming control apparatus 100 may include a power pad 110 , dimming pads 120 - 1 to 120 - 11 , and display lamps 130 - 1 to 130 - 11 that display operational states of the respective dimming pads 120 - 1 to 120 - 11 . The power pad 110 is disposed in a center portion of a user interface unit of the dimming control apparatus 100 and is configured as a touch panel. Here, the touch panel may be an optical sensor-type, resistive-type, capacitive overlay-type, or hybrid-type touch panel, and the presently disclosed embodiment is not limited thereto. The display lamps 130 - 1 to 130 - 11 may be turned on/off according to whether or not the power pad 110 is touched.
[0029] In FIG. 1 , the dimming pads 120 - 1 to 120 - 11 form a circle centering around the power pad 10 . The dimming pads 120 - 1 to 120 - 11 show the degree of illuminance of the respective display lamps 130 - 1 to 130 - 11 , and the dimming pads 120 - 1 to 120 - 11 are configured as touch panels similar to the power pad 110 . The dimming pads 120 - 1 to 120 - 11 are disposed in a direction in which illuminance of the display lamps 130 - 1 to 130 - 11 increases by stages. For example, the dimming pad 120 - 1 may show a minimum dimming value, and the dimming pad 120 - 11 may show a maximum dimming value. Thus, when a user touches the dimming pad 120 - 1 , the luminance of the lamp is controlled using minimum brightness of the lamp, and when a user touches the dimming pad 120 - 11 , the luminance of the lamp is controlled using maximum brightness of the lamp. In an aspect of the presently disclosed embodiment, dimming control is performed using a predetermined dimming value according to arrangement of the dimming pads 120 - 1 to 120 - 11 . In another aspect of the presently disclosed embodiment, when a user drags the dimming pads 120 - 1 to 120 - 11 in a dragging direction or a touch direction, for example, clockwise, the user may perform dimming control for increasing illuminance of the lamp by a length between the dimming pad that is initially touched by the user and the dimming pad that is finally touched by the user. On the other hand, when the user drags counterclockwise, the user may perform dimming control for decreasing illuminance of the lamp. Here, although eleven dimming pads are shown in FIG. 1 , the presently disclosed embodiment is not limited thereto. In addition, although FIG. 1 shows the power pad 110 and the dimming pads 120 - 1 to 120 - 11 that are separated from each other, the presently disclosed embodiment is not limited thereto, and the power pad 110 and the dimming pads 120 - 1 to 120 - 11 may be configured in an integrated fashion.
[0030] Referring back to FIG. 1 , the display lamps 130 - 1 to 130 - 11 are shown that display the operational states of the respective dimming pads 120 - 1 to 120 - 11 and are disposed adjacent to the respective dimming pads 120 - 1 to 120 - 11 . The display lamps 130 - 1 to 130 - 11 are turned on or turned off according to whether or not the dimming pads 120 - 1 to 120 - 11 are touched.
[0031] FIG. 2 is a block diagram schematically showing the dimming control apparatus 100 shown in FIG. 1 .
[0032] Referring to FIG. 2 , the dimming control apparatus 200 includes the dimming pads 120 - 1 to 120 - 11 , a sensing unit 220 that senses a touch operation to the power pad 110 , a control unit 210 that performs turning on/off of the lamp and dimming control according to a touch signal corresponding to the touch operation to the power pad 110 which is sensed by the sensing unit 220 , and a storage unit 230 .
[0033] The sensing unit 220 senses touch operations to the power pad 110 and the dimming pads 120 - 1 to 120 - 11 . Here, in order to prevent malfunction of the power pad 110 , a sensing period of the sensing unit 220 may be set to be longer than sensing periods of the dimming pads 120 - 1 to 120 - 11 so as to sense the touch operation.
[0034] The control unit 210 controls power on/off of the lamp according to whether or not the power pad 110 is touched, and controls illuminance of the lamp according to whether or not the dimming pads 120 - 1 to 120 - 11 are touched. In addition, the control unit 210 controls turning on/off of the display lamps 130 - 1 to 130 - 11 shown in FIG. 1 . Specifically, the control unit 210 may be a micro computer unit (MCU). The control unit 210 may control power on/off and dimming control of the lamp and controls turning on/off of the display lamps 130 - 1 to 130 - 11 using a power control unit 240 , a dimming control unit 250 , and a display control unit 260 .
[0035] The storage unit 230 stores a dimming value and a dimming control value that are currently set when the lamp is turned off due to the power pad 110 that has been touched. The control unit 210 may perform dimming control using the stored dimming value when the lamp is turned on due to the power pad 110 that has been touched. In addition, the control unit 210 may perform dimming control on the basis of an intermediate dimming value when there is no set or stored dimming value.
[0036] FIG. 3 is a flowchart for describing a dimming control method, according to another aspect of the presently disclosed embodiment.
[0037] Referring to FIG. 3 , when a power pad is touched in operations 300 and 302 , power is supplied to a lamp to turn on the lamp. When a dimming pad is touched in operation 304 , it is sensed, for example, which one of the eleven dimming pads shown in FIG. 1 has been touched in operation 306 . Dimming control is performed using a dimming value corresponding to the touched dimming pad in operation 308 . Although not shown in FIG. 3 , controlling turning on of the display lamp of the touched dimming pad shown in FIG. 1 may be performed at the same time when the dimming control is performed.
[0038] FIG. 4 is a flowchart for describing a dimming control method, according to another aspect of the presently disclosed embodiment.
[0039] Referring to FIG. 4 , when a power pad is touched in operations 400 and 402 , power is supplied to a lamp to turn on the lamp. Dimming control is performed to correspond to a predetermined dimming value in operation 404 . Here, the predetermined dimming value may be an intermediate dimming value that is set by default or a dimming value that is set before the previous power off.
[0040] It is determined whether or not a dimming pad has been touched in operation 406 . A touch direction or a drag direction of the dimming pad are sensed in operations 408 and 410 , and dimming control is performed according to the sensed direction. For example, when five dimming pads are dragged clockwise, the dimming control may be performed on the lamp using illuminance level 5 , while when three dimming pads are dragged counterclockwise, the dimming control may be performed using a dimming value that is reduced by three levels from the current dimming value.
[0041] When the power pad is touched in operation 412 , a dimming value that is currently set is stored in operation 414 , and then power supply to the lamp is stopped to turn off the lamp in operation 416 .
[0042] The device described herein may comprise a processor, a memory for storing program data and executing it, a permanent storage such as a disk drive, a communications port for handling communications with external devices, and user interface devices, such as a touch panel, keys, buttons, etc. When software modules or algorithms are involved, these software modules may be stored as program instructions or computer readable codes executable by the processor on a computer-readable medium. Examples of the computer readable recording medium are magnetic storage media (e.g., ROM, floppy disks, and hard disks), and optical recording media (e.g., CD-ROMs and DVDs). The computer readable recording medium can also be distributed over network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. These media can be read by a computer, stored in the memory, and executed by the processor.
[0043] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0044] For the purposes of promoting an understanding of the principles of the disclosed embodiment, reference has been made to the preferred aspects illustrated in the drawings, and specific terminology has been used to describe these aspects. However, no limitation of the scope of the disclosed embodiment is intended by this specific terminology, and the disclosed embodiment should be construed to encompass all aspects that would normally occur to one of ordinary skill in the art.
[0045] The presently disclosed embodiment may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the presently disclosed embodiment may employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. Similarly, where the elements of the presently disclosed embodiment are implemented using software programming or software elements the disclosed embodiment may be implemented with any programming or scripting language such as C, C++, Java, assembler, or the like, with the various algorithms being implemented with any combination of data structures, objects, processes, routines or other programming elements. Functional aspects may be implemented in algorithms that execute on one or more processors. Furthermore, the presently disclosed embodiment could employ any number of conventional techniques for electronics configuration, signal processing and/or control, data processing and the like. The words “mechanism”, “element”, “means”, and “configuration” are used broadly and are not limited to mechanical or physical embodiments, but can include software routines in conjunction with processors, etc.
[0046] The particular implementations shown and described herein are illustrative examples of the disclosed embodiment and are not intended to otherwise limit the scope of the disclosed embodiment in any way. For the sake of brevity, conventional electronics, control systems, software development and other functional aspects of the systems may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the disclosed embodiment unless the element is specifically described as “essential” or “critical”.
[0047] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosed embodiment (especially in the context of the following claims) are to be construed to cover both the singular and the plural. Furthermore, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Finally, the steps of all methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The presently disclosed embodiment is not limited to the described order of the steps. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosed embodiment and does not pose a limitation on the scope of the disclosed embodiment unless otherwise claimed. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the presently disclosed embodiment.
[0048] While the presently disclosed embodiment has been particularly shown and described with reference to exemplary aspects thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the presently disclosed embodiment as defined by the following claims.
|
The present invention relates to a dimming control device and method, and a dimming control device according to an embodiment of the present invention may control the ON/OFF of a lamp depending on whether a power pad is touched, and control the brightness of the lamp depending on whether dimming pads are touched. Thus, a user may control brightness step by step and may conveniently manipulate each step of brightness.
| 7
|
CLAIM OF PRIORITY
This application claims the benefit of an earlier application filed in the Korean Intellectual Property Office on Feb. 4, 2009 and assigned Serial No. 10-2009-0008847, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an FM radio, and in particular, to an apparatus for improving the sound quality of an FM radio in a portable terminal.
2. Description of the Related Art
The portable terminal becomes extensively used due to convenience of its portability. Accordingly, portable terminal manufacturers have been currently developing portable terminals for supporting additional services (such as wireless internet, a camera, an MP3 player, and an FM radio) to attract even more consumers.
If the portable terminal supports an FM radio function, it typically includes an FM radio module for receiving an FM radio signal. In this case, the portable terminal amplifies the received FM radio signal through the FM radio module, and outputs the amplified signal through a speaker or an earphone.
As mentioned above, the portable terminal including an FM radio function may tune the volume of an FM radio signal through a gain adjustment of an amplifier. However, the FM radio signal is vulnerable to noise in current portable terminals.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an apparatus and a method of improving the sound quality of an FM radio signal in a portable terminal.
Another object of the present invention is to provide an apparatus and a method of improving the sound quality of an FM radio signal by a post-processing an FM radio signal in a portable terminal.
According to an aspect of the present invention, an apparatus for receiving an FM radio signal in a portable terminal includes: an FM radio module receiving an FM radio signal; an application processor processing an application program for playing an audio signal; a switch switching to transmit an audio signal processed in the application processor or the FM radio signal received through the FM radio module into an audio sub system; the audio sub system decoding and post-processing the audio signal or the FM signal, which is provided through the switch; and an amplifier amplifying the signal decoded and post-processed in the audio sub system and output the amplified signal to an external.
According to another aspect of the present invention, a method of receiving an FM radio signal in a portable terminal includes: switching to transmit an FM radio signal received through the FM radio module into an audio sub system for decoding and post-processing a signal when an FM radio service is provided; switching to transmit an audio signal played in an application processor into the audio sub system when an audio signal is played; decoding and post-processing an FM radio signal or an audio signal, which is transmitted into the audio sub system through the switching; and amplifying the decoded and post-processed signal to output it to an external.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will become more apparent to those skilled in the art from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a view illustrating a configuration of a portable terminal for performing a post-processing on an FM radio signal according to the present invention; and
FIG. 2 is a view of a procedure for performing a post-processing on an FM radio signal in a portable terminal according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described herein below with reference to the accompanying drawings. For the purposes of clarity and simplicity, detailed descriptions of well-known functions or constructions will be omitted as they would obscure the invention in unnecessary detail. Also, the terms used herein are defined according to the functions of the present invention. Thus, the terms may vary depending on user's or operator's intentions or practices. Therefore, the terms used herein must be understood based on the descriptions made herein.
Hereinafter, the present invention describes a technique for improving the sound quality of an FM radio signal in a portable terminal with an FM radio function.
According to the teachings of the present invention, the portable terminal performs a post-processing on an FM radio signal, which is received through an FM radio module, in order to improve the sound quality of the FM radio signal. For example, the portable terminal is configured as shown in FIG. 1 to perform the post-processing on an FM radio signal. It should be noted that the configuration of an audio system of a portable terminal shown in FIG. 1 with a communication function is for illustrative purposes, but may be identically applied to a portable terminal without having the communication function or may be applied to process signals other than FM radio signals.
FIG. 1 is a view illustrating a configuration of a portable terminal for performing a post-processing on an FM radio signal according to the present invention.
As shown in FIG. 1 , the portable terminal is configured to include an audio system 100 , an analog codec 140 , an amplifier (AMP) 150 , an FM radio module 160 , a switch 170 , an application processor 180 , and a modem processor 190 .
The audio system 100 further includes a voice sub system 110 for processing a voice signal, an audio sub system 120 for processing an audio signal, and an analog front end (AFE) 130 .
The voice sub system 110 is configured to include a pre-processing unit 111 , an encoding unit 113 , a decoding unit 115 , and a post-processing unit 117 .
The pre-processing unit 111 performs pre-processing on a voice signal provided from the AFE 130 according to a predetermined pre-processing method. For example, the pre-processing unit 111 is configured to include a first pre-processing unit for removing echo, a second pre-processing unit for automatic gain control (AGC), a third pre-processing unit for automatic volume control (AVC), and a fourth pre-processing unit for noise suppressor (NS). The pre-processing unit 111 activates only a corresponding pre-processing unit according to a predetermined pre-processing method among the first to fourth pre-processing units in the pre-processing unit 111 , and then performs pre-processing on a voice signal provided from the AFE 130 .
The encoding unit 113 encodes a voice signal provided from the pre-processing unit 111 and outputs the encoded signal to the modem processor 190 .
The decoding unit 115 decodes a voice signal provided from the modem processor 190 and then outputs the decoded signal to the post-processing unit 117 .
The post-processing unit 117 performs the post-processing on a voice signal provided from the decoding unit 115 according to a predetermined post-processing method. For example, the post-processing unit 117 includes a first post-processing unit for performing filtering according to a pulse code modulation, a second post-processing unit for AGC, and a third post-processing unit for AVC. The post-processing unit 117 activates only a corresponding post-processing unit according to a predetermined post-processing method among the first to third post-processing units in the post-processing unit 117 , then performs the post-processing on a voice signal provided from the decoding unit 115 .
The audio sub system 120 is configured to include a pre-processing unit 121 , an encoding unit 123 , a decoding unit 125 , and a post-processing unit 127 in order to process an audio signal.
The pre-processing unit 121 performs pre-processing on an audio signal provided from the AFE 130 according to a predetermined pre-processing method. For example, the pre-processing unit 121 includes a first pre-processing unit for AGC and a second pre-processing unit for NS. The pre-processing unit 121 activates only a corresponding pre-processing unit according to a predetermined pre-processing method among the first and second pre-processing units in the pre-processing unit 111 , then performs the pre-processing on an audio signal provided from the AFE 130 .
The encoding unit 123 encodes an audio signal provided from the pre-processing unit 121 and outputs the encoded signal to the application processor 180 .
The decoding unit 125 decodes an audio signal or an FM radio signal, provided from the switch 170 , and then outputs the decoded signal to the post-processing unit 127 .
The post-processing unit 127 performs post-processing on an audio signal or an FM radios signal, provided from the decoding unit 125 , according to a predetermined post-processing method. For example, the post-processing unit 127 performs post-processing on an audio signal or an FM radios signal, provided from the decoding unit 125 , in order to perform an equalizer function. At this point, the post-processing unit 127 may include a plurality of post-processing units, each of which performs a post-processing function.
The AFE 130 converts a digital signal, provided from the voice sub system 110 and the audio sub system 120 , into an analog signal and outputs the converted signal into the analog codec 140 . At this point, the AFE 130 combines signals from the voice sub system 110 and the audio sub system 120 into one signal and then outputs it.
Additionally, the AFE 130 converts a digital signal, provided from the analog codec 140 , into an analog signal, and outputs the converted signal into the voice sub system 110 or the audio sub system 120 .
The analog codec 140 controls a gain of an analog signal. That is, the analog codec 140 controls a gain of a signal, provided from the AFE 130 , and then outputs it to the AMP 150 . In addition, the analog codec 140 controls a gain of an analog signal received through an input device, then outputs it to the voice sub system 110 or the audio sub system 120 . Here, an input device includes a microphone, a headset, or the like.
The AMP 150 amplifies an analog signal, provided from the analog codec 140 , and outputs it to a speaker or a headset.
The FM radio module 160 receives an FM radio signal. For example, the FM radio module 160 includes a pin grid array (PGA) module, an analog/digital converter (ADC), and a digital signal processor (DSP).
The switch 170 selectively switches an audio signal provided from the application processor 180 and an FM radio signal provided from the FM radio module 160 into the audio sub system 120 in response to a control of the application processor 180 . For example, while listening to MP3 music, the switch 170 switches to connect the application processor 180 with the audio sub system 120 in response to a control of the application processor 180 . Moreover, while providing an FM radio service, the switch 170 switches to connect the FM radio module 160 with the audio sub system 120 in response to a control of the application processor 160 .
The application processor 180 processes an application program for playing an audio signal that is encoded with an MP3 or advanced audio coding (AAC) format.
In addition, the application processor 180 controls the switch 170 to selectively switch an audio signal provided from the application processor 180 and an FM radio signal provided from the FM radio module 160 into the audio sub system 120 in response to a control of the application processor 180 . At this point, the application processor 180 switches to connect the application processor 180 with the audio sub system 120 when an audio signal is transmitted.
The modem processor 190 processes a voice signal that is received and transmitted for voice communication.
Hereinafter, a method of performing post-processing on an FM radio signal in a portable terminal will be described.
FIG. 2 is a view of a procedure for performing post-processing on an FM radio signal in a portable terminal according to an embodiment of the present invention.
Referring to FIG. 2 , the portable terminal confirms whether an FM radio service is provided or not according to input information of a user in operation 201 .
If an FM radio service is provided, the portable terminal proceeds to operation 203 and activates an FM radio module to provide the FM radio service.
At this point, the portable terminal proceeds to operation 205 and then connects the FM radio module with an audio system. For example, the portable terminal controls the switch 170 to connect the audio sub system 120 with the FM radio module 160 shown in FIG. 1 .
After the FM radio module is connected to an audio system, the portable terminal proceeds to operation 207 and confirms whether an FM radio signal is received or not through the FM radio module.
If the FM radio signal is received, the portable terminal proceeds to operation 209 and decodes the FM radio signal received through the FM radio module. For example, the portable terminal decodes the FM radio signal, received through the FM radio module, using the decoding unit 125 of the audio sub system 120 of FIG. 1 .
Next, the portable terminal proceeds to operation 211 , and performs post-processing on the FM radio signal decoded in the operation 209 according to a predetermined post-processing method. For example, the portable terminal performs post-processing on the FM radio signal decoded in the operation 209 , using the post-processing unit 127 of the audio sub system 120 shown in FIG. 1 . At this point, the portable terminal performs post-processing on the FM radio signal by selecting at least one of post-processing methods including equalizing, base enhancement, automatic volume limiting, high frequency band improvement, noise reduction, volume setting, and three-dimensional sound.
After the post-processing of the FM radio signal, the portable terminal proceeds to operation 213 and outputs the FM radio signal, which is post-processed in the operation 211 , through a speaker.
Next, the portable terminal terminates this algorithm.
As mentioned above, the portable terminal performs post-processing on an FM radio signal received through the FM radio module such that sound quality of the FM radio signal can be improved.
The above-described methods according to the present invention can be realized in hardware or as software or computer code that can be stored in a recording medium such as a CD ROM, an RAM, a floppy disk, a hard disk, or a magneto-optical disk or downloaded over a network, so that the methods described herein can be executed by such software using a general purpose computer, or a special processor or in programmable or dedicated hardware, such as an ASIC or FPGA. As would be understood in the art, the computer, the processor or the programmable hardware include memory components, e.g., RAM, ROM, Flash, etc. that may store or receive software or computer code that when accessed and executed by the computer, processor or hardware implement the processing methods described herein.
While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention.
|
Provided are an apparatus and a method of improving the sound quality of an FM radio signal in a portable terminal. The apparatus includes: an FM radio module receiving an FM radio signal; an application processor processing an application program for playing an audio signal; a switch selectively switching to transmit an audio signal processed in the application processor or the FM radio signal received through the FM radio module into an audio sub system; the audio sub system decoding and post-processing the audio signal or the FM signal, which is provided through the switch; and an amplifier amplifying the signal decoded and post-processed in the audio sub system and output the amplified signal to an external.
| 7
|
CROSS REFERENCE TO OTHER PATENT APPLICATIONS
[0001] This application is a divisional of pending prior U.S. patent application Ser. No. 12/683,503 filed on 7 Jan. 2010 and claims the benefit under 35 U.S.C. §121 of the prior application's filing date.
[0002] This patent application is co-pending with the following related U.S. patent application, Ser. No. 12/683,503 by the same inventor, Derke R. Hughes.
STATEMENT OF GOVERNMENT INTEREST
[0003] The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefore.
BACKGROUND OF THE INVENTION
[0004] (1) Field of the Invention
[0005] The present invention is directed to underwater based electric energy production systems. In particular, the present invention is directed to a system for generating power from a lead zirconate titanate sonar transducer.
[0006] (2) Description of the Prior Art
[0007] The main mission for a long sonar transducer is the generation of certain acoustic tones in the ocean. One feature of lead zirconate titanate material is the voltage generation produced when this material is stressed. By taking advantage of this material property, the prospect exists for a long lead zirconate titanate transducer to become a power harvesting unit in an extended life capacity. By creating a trickle charging device, the mission life of dipping sonar or an airdropped transceiver could be extended. What is needed is a long transducer between ten and three hundred meters long, for environmental energy transfer that acquires energy from the ocean waves by bobbing on the water surface with a buoy and anchor system that vibrates at the strumming frequency generated by underwater currents thereby generating power, wherein the power can then be regulated by an alternating current to direct current converter and voltage regulator and captured by charging a battery such as a nickel cadmium battery.
SUMMARY OF THE INVENTION
[0008] It is a general purpose and object of the present invention to generate power from a sonar transducer that has a long lead zirconate titanate core within a cable such as an armored cable used in towed array systems.
[0009] The above object is accomplished with the present invention through the use of a long lead zirconate titanate cable for underwater environmental energy transfer, which acquires energy from the underwater currents by surrounding the long lead zirconate titanate cable with an armored cable and attaching it to a buoy and anchor system. As the buoy bobs on the water the lead zirconate titanate core experiences vibrations from underwater currents. These vibrations cause the lead zirconate titanate core to generate electrical power that is captured and regulated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A more complete understanding of the invention and many of the attendant advantages thereto will be more readily appreciated by referring to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:
[0011] FIG. 1 illustrates a buoy, anchor and cable system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Referring to FIG. 1 there is illustrated a buoy 10 floating on the surface of the ocean or a large body of water, and an anchor 12 resting on the floor of the ocean or large body of water and used to keep the tension on a long (from 10 to 300 meters) lead zirconate titanate core 14 within a cable 16 , such as a reinforced armored tow cable used in towed arrays, such that a fixed string configuration embodies a mathematical representation for the transducer cable system 18 . The vertical configuration is adjustable to generate a variety of levels of energy because the draft on the anchor 12 and buoy 10 are regulated to produce different amounts of tension on the cable 16 based on the predetermined environmental conditions of the associated currents and sea states. In one embodiment, regulation of the tension can be accomplished through the use of a reservoir tank 34 within the anchor 12 and a valve 32 such that the process of opening and closing the valve regulates the amount of water in the reservoir thereby increasing the weight contained in the anchor 12 and thus controlling the amount of tension load on the cable 16 . Regulating the tension on the cable 16 to adjust to the wave speed and natural frequencies in the water will alter the amount of mechanical energy created by the transducer cable system 18 . A strain sensor 36 is mounted on the cable 16 and joined to a computer mother board 26 to measure the tension on the cable 16 . Therefore, the transducer cable system 18 serves as an electromechanical generator that is tunable to produce enough power for a basic low power (i.e. 1 watt or less) sensor system.
[0013] A vibrating string contains both kinetic and potential energies. The total amount of energy for a string vibrating at frequency ω n is expressed in equations (1a) and (1b) below:
[0000]
E
n
=
1
4
ρ
L
L
ω
n
2
(
A
n
2
+
B
n
2
)
(
1
a
)
E
T
=
∑
n
=
1
N
E
n
(
1
b
)
[0000] Equation (1a) is a simplification of the kinetic and potential energy per unit length of the string. The amplitude A n is the integration of the cosine terms associated with the solution at the nth frequency. The amplitude B n is associated with the nth solution of the sine term. The mass per unit length is ρ L where L is the length of the string. In equation (1b), the modal energies, E n , of equation (1a) are summed for all modes N to obtain the total energy, E T , associated with the string's vibration. The derivation assumes small strains for each element of the string. Therefore, an elastic material with large deflections like a rubber band could not utilize equations (1a) and (1b).
[0014] While equations (1a) and (1b) characterize the approximate mechanical energy for a string, the following equations calculate the energy translated into electrical energy. To calculate the estimated energy transfer the constitutive equations for material strain and its dielectric properties are computed from the following equations.
[0000] S=s·T (2a)
[0000] D=ε·E (2b)
[0000] The strains constitutive equation, (2a), is derived from Hooke's Law, but expressed in the inverse form where S is strain, s is compliance and T is stress. In the dielectric equivalent form equation, (2b), D is charge density, ε is permittivity, and ·E is electric field. The constitutive equations are combined to from new equations, which represent the coupled constitutive equations for linear piezoelectric materials:
[0000] S=S E T+dE (3a)
[0000] D=dT+ε T E (3b)
[0000] One of the coupling terms is the compliance (s E ) of the material, which is the inverse of the modulus of elasticity. The piezoelectric constant (d) corresponds to the sensitivity of the material. The permittivity of the material is represented by ε T . These coupling terms establish the relationships to compute the mechanical to electrical energy conversion for a piezoelectric system. To obtain the coupling efficiency of a mechanical to electrical energy conversion for a vibrating structure the following equation is used:
[0000]
k
=
d
2
s
E
ɛ
T
(
4
)
[0000] Where k is the coupling factor for the stored mechanical energy over the input electrical energy.
[0015] This invention is a system that keeps a long lead zirconate titanate core 14 within an armored cable 16 in such tension that the fixed string equation and boundary conditions described above are sufficient to describe the modes and energy generation within the cable. The total energy computation considers the tension, cross-sectional area, current speed, and wave periodicity to describe the amount of power potentially available from the system. In general, the total energy increases with frequency, although, very high modes in the kilohertz (kHz) range are associated with decreasing energy. Environmental conditions producing such high frequencies are unlikely within typical sea states. The combination of more tension, relatively higher modes, and complicated mixed modes generates power that can then be regulated by an alternating current to direct current converter 20 and voltage regulator 22 and captured by charging a battery 24 such as a nickel cadmium battery that can power a low powered sensor suite 38 .
[0016] In one embodiment, the present invention only needs to produce one watt of power or less to function. Microprocessor and data acquisition board combinations 26 often operate at 200 mW. Since the present invention is not a stand alone device, it may also function for several days in the same general location performing its mission as a long transducer array. For example, approximately 0.5 W of power are consumed in a two second interval. After frictional losses and unforeseen conditions the power could drop to 5 mW, which is two orders of magnitude. An hour mission in environmental conditions with the same physical loads would generate 9 W despite these additional losses. In one embodiment, the microprocessor and data acquisition board combinations 26 are a GUMSTIX® computer, which operates with approximately 1.0 W load with a standard electronics configuration. Therefore, data acquisition can be performed by the GUMSTIX® until the cyclical loading damages the rechargeable battery 24 or during a long duration of stagnant ocean. In addition, with the remaining wattage available, less than 1.0 W of power could be used for radio frequency transmission from a radio 28 , such as a 900 MHz radio, so that information gathered by the GUMSTIX® computer can be transmitted off of the system 18 .
[0017] After deploying the apparatus in the configuration illustrated in FIG. 1 , the intention is to maintain a sufficient amount of power generation as represented by E T to accomplish a predetermined specific task, such as powering a sensor suite. This can involve monitoring and adjusting the tension on cable 16 in response to wave speed and current to optimize the total energy, E T , associated with the string's vibration. The value of optimum tension P T is predetermined prior to deploying the apparatus of system 18 and is based on specifications of the cable and the current, wave speed, and sea states of the body of water where the apparatus of system 18 is deployed. The predetermined tension P T for the cable 16 is designed to allow the cable 16 to operate in common sea states 0 - 3 , and is largely determined by the static tension of the cable 16 . Higher sea states cause more horizontal forces to act on the buoy and anchor, which in turn does not yield as consistent a strumming motion on the cable 16 . The dynamic tension of cable 16 is also crucial in creating the piezoelectric strain required to generate the desired power.
[0018] The method of operation of the apparatus of the present invention based on the above stated intention to maintain a sufficient amount of power generation comprises the following steps. The first step of the method is to take a periodic measurement the speed U of the water current flowing over the diameter D of cable 16 . This measurement can be taken by the velocity sensor 30 and relayed to the processor 26 . If the velocity is within the range of the predetermined sea state, then no further action needs to be taken. After a specified period of time another periodic measurement is taken. If the velocity is determined by processor 26 to be outside of the range of a predetermined sea state, then the next step is for the processor 26 to associate a strum frequency f s with the current flowing over the diameter of cable 16 according to the following equation:
[0000] f s =StrU/D (5)
[0000] where the Str variable refers to Strouhal's number, which is derived from the Reynold's number Re. The Reynold's number is shown by Equation (6):
[0000] Re=UD/v (6)
[0000] The variable U stands for velocity current or flow across a diameter D of the cable 16 , and v is the kinematic viscosity. These fluid dynamic constants are common terms used to describe flow over a surface.
[0019] The next step is for the processor to substitute f s as ω n in equations (1a) and (1b) above to get determinative energy associated with the strum that is the main overall frequency mode that cable 16 is in. The next step is for processor 26 to solve for E T , which indicates the energy being produced by the system 18 at the time of the water current measurement. Based on the value of E T processor 26 determines if a sufficient amount of power is being generated to accomplish a specified task, for example the operation of a GUMSTIX® computer, which operates with approximately 1.0 W load as mentioned above. If the determination indicates that there is an insufficient amount of power then the tension in the cable 16 is incrementally adjusted by adding water into the reservoir 34 in the anchor 12 . In one embodiment, the water can be added by having valve 32 electro-mechanically actuated by a control signal from processor 26 . These method steps are repeated periodically to keep the system 18 tuned to the surrounding underwater environment.
[0020] The advantage of the present invention is that the lead zirconate titanate core material for a cable could operate as a sensor, transducer, and an energy generation source. By combining the appropriate electronics, this invention allows for the possibility of a sonar array, which makes it a multi-functional self powered sensor. Additionally, the present invention offers the possibility to support a distributed network system infrastructure by extending the operation life of a multi-functional sensor suite.
[0021] While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives of the present invention, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Additionally, feature(s) and/or element(s) from any embodiment may be used singly or in combination with other embodiment(s). Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the present invention.
|
The invention as disclosed is an underwater based electric energy production method. A cable having a piezoelectric core is attached on one end thereof to a floating buoy and on the other end thereof to an anchor. The system is deployed in the water such that the cable extends vertically through a water column. Movement of the cable due to water current generates electric power that can be harvested and stored. The floating buoy can be at or near the water's surface and the anchor can but need not rest on the sea floor.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/686,084 filed Oct. 14, 2003, the entire content of which is expressly incorporated herein by reference.
BACKGROUND ART
[0002] This invention generally relates to a method of concurrently producing at least two structures, each having at least one useful layer on a substrate, for applications in the fields of electronics, optoelectronics or optics. In particular, the method includes providing an initial structure that includes a useful layer having a front face on a support substrate, implanting atomic species to form a zone of weakness within the useful layer, bonding a stiffening substrate is bonded to a front face of the initial structure, and detaching a first useful layer from a second useful layer along the zone of weakness to obtain a pair of semiconductor structures. The first structure includes the stiffening substrate and the first useful layer and the second structure includes the support substrate and the second useful layer.
[0003] Several layer transfer methods are known. One concerns implanting atomic species under the surface of a source substrate to create a zone of weakness which delimits a thin layer. The next step is to contact the free face of this thin layer with a support substrate, then to detach the thin layer from the remainder of the source substrate and to transfer it to the support substrate. A description of this type of method can be found in the art with reference to the method known under the registered trademark “SMART-CUT®”. Use of this method results in generating a source substrate remainder that can be recycled and reused during a future layer transfer. However, this process involves polishing and finishing operations that can be long and costly, due to both the cost of the materials used and the time spent on them. In addition, for some extremely hard materials such as silicon carbide, the aforementioned recycling steps can prove to be very long and difficult.
[0004] Another known layer transfer method is called “Bond and Etch Back Silicon on Insulator” (“BESOI”). This technique involves a burning-in method and/or chemical etching treatment via chemical attack used after molecular bonding a source substrate to a support substrate. The free surface (or rear face) of this source substrate is then polished until a thin layer of desire thickness is obtained on the support. It is to be noted that such a method destroys the majority of the source substrate as each structure is made, so this technique is not economically viable, especially when the thin layer material is expensive.
[0005] Lastly, Silicon on Insulator (“SOI”) type materials include a layer of thick silicon covering a buried layer of silicon dioxide (SiO 2 ) and a transferred superficial layer of silicon, and the same problems concerning recycling exist for the silicon material used to form the transferred layer. In addition to the aforementioned recycling problems, it is difficult to transfer very thin layers, meaning layers that are less than 100 nanometers (100 nm) thick when using the SMART-CUT® type method. Indeed, thin layers transferred in such manner have numerous defects, such as blisters. The defects may be due to, for example, treatments used to strengthen the bonding interface between the thin layer and the support substrate.
[0006] The problems concerning transferring very thin good quality layers also exist for SOI substrates. In particular, is noted that the transferred layer of silicon if an SOI structure has defects when less than a certain thickness, for example 20 nm. The defects can increase if a high temperature thermal treatment is also used. In this regard, reference can be made to the article by Q.-Y. Tong, G. Cha, R. Gafiteau and U. Gösele, “Low temperature wafer direct bonding”, J. Microelectomech Syst., 3, 29, (1994).
[0007] During thermal treatments, for example to strengthen the bonding interface (which is known as “stabilizing”) after detachment occurs, a gas is created in the bonding interface. In the case of a thick SOI substrate, the transferred layer is thick and fills the role of a stiffener. In the case of a thin SOI substrate in which the transferred layer and/or the oxide layer are thin, the aforementioned absorption and stiffening phenomena do not take place and use of a gas leads to poor bonding.
[0008] In addition, as described in published International Application No. WO 01/115218, implantation of atomic species and detachment of the wafer create defects that are principally concentrated on the inside of the layer to be transferred. It has been observed that the thinner the layer the poorer the quality that results.
SUMMARY OF THE INVENTION
[0009] A method for concurrently producing at least a pair of semiconductor structures that each include at least one useful layer on a substrate. The method includes providing an initial structure that includes a useful layer having a front face on a support substrate. Atomic species are implanted into the useful layer to a controlled mean implantation depth to form a zone of weakness within the useful layer that defines first and second useful layers. Next, a stiffening substrate is bonded to the front face of the initial structure. The first useful layer is then detached from the second useful layer along the zone of weakness to obtain a pair of semiconductor structures with a first structure including the stiffening substrate and the first useful layer and a second structure including the support substrate and the second useful layer.
[0010] Advantageously, the method includes implanting by introducing atomic species through the front face of the useful layer to form the zone of weakness. In addition, the useful layer is provided at a sufficient thickness to provide multiple first and second useful layers during further processing. In a preferred embodiment, the technique includes repeating the implanting, bonding and detaching steps on the useful layers of the first and second structures to provide a third and fourth semiconductor structures, with the third structure including a second stiffening substrate and a third useful layer, and the fourth structure including a third stiffening substrate and a fourth useful layer. In a variation, the first and second useful layers are provided at sufficient thicknesses to provide multiple third and fourth useful layers during further processing. Such structures are suitable for use in electronic, optoelectronic or optic applications.
[0011] An alternative embodiment relates to a method for producing a semiconductor structure that includes at least one useful layer on a substrate. This method includes providing a source substrate with a zone of weakness therein that defines a relatively thick useful layer between the zone of weakness and a front face of the source substrate; bonding the front face of the source substrate to a support substrate and detaching the useful layer from the source substrate at the zone of weakness to transfer the useful layer to the support substrate, wherein the transferred useful layer has a free face provided by the detachment at the zone of weakness; implanting atomic species into the free face of the useful layer to a controlled mean implantation depth therein to form a zone of weakness within the useful layer that defines front and rear useful layers, with the rear useful layer contacting the support substrate and the front useful layer containing a greater concentration of defects; bonding a stiffening substrate to the free face of the front useful layer after implantation of the atomic species; and detaching the front useful layer from the rear useful layer along the zone of weakness to form a semiconductor structure comprising the support substrate and the rear useful layer thereon. The latter embodiment enables the production of a semiconductor structure that has a relatively useful layer having a thickness of 50 nanometers or less and which is relatively free of defects.
[0012] In an advantageous implementation, included is at least one intermediate layer in the initial structure between the useful layer and the support substrate. In another variation, an intermediate layer is provided in the second structure between the stiffening substrate and the first useful layer. Such intermediate layers are preferably made of at least one of silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), a high permitivity insulating material, or diamond.
[0013] In another advantageous implementation, bonding is achieved by molecular adhesion. In addition, at least one of the support substrate, the stiffening substrate, or the useful layer is made of a semiconductor material. The support substrate and/or the stiffening substrate may include at least one layer made of at least one of silicon, silicon carbide, sapphire, diamond, germanium, quartz, yttrium-stabilized zirconia or an alloy of silicon carbide. In addition, the useful layer may be made of at least one of silicon, silicon carbide, sapphire, diamond, germanium, silicon-germanium, a group III-V compound or a group II-VI compound, and the support substrate may be made of a single-crystal or poly-crystal silicon, the useful layer is made of a single-crystal silicon, and the stiffening substrate is made of a single-crystal or poly-crystal silicon.
[0014] The methods according to the invention allow at least one pair of structures to be formed at the end of each cycle using a single source substrate which can then be recycled. The present invention is thus more economical to use and commercially feasible than known methods that recycle the source substrate. Moreover, as the cycles are repeated, an operator can choose to use the same or different types of stiffener substrates, and can also choose to include one or more intermediate or interposed layers. The technique according to the invention is thus flexible, allowing for different possible combinations of concomitantly formed structures that include stacks of different layers.
[0015] Furthermore, depending on the parameters used to implant atomic species, it is also possible to create a zone of weakness such that the rear or second useful layers are very thin. For example, such thin layers may be less than 50 nanometers (50 nm) thick, whereas the neighboring front useful layers are much thicker. The thickness of the front useful layer associated with that of the stiffener which is pressed against it allows for a later thermal annealing treatment that will not deform the rear useful layer, and that will not cause blisters to form on the rear useful layer. The result is that a much thinner rear useful layer can be transferred than presently possible using conventional methods. Yet further, it has been found that the implantation of atomic species steps carried out on the substrates of the first rank or higher structures concentrate the defects in the front useful layers. Consequently, the rear useful layers were not directly subjected to the implantation, and thus have defects linked to the implantation and to detachment that extend over a lesser thickness in the detachment zone than that of the front layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Other aspects, purposes and advantages of the invention will become clear after reading the following detailed description with reference to the attached drawings, in which:
[0017] FIGS. 1A to 1 C illustrate the different steps of a method of producing a structure comprising a useful layer transferred to a support substrate;
[0018] FIGS. 2A to 2 C are diagrams illustrating an alternative embodiment of the method represented in FIGS. 1A to 1 C according to which a structure is obtained that includes a useful layer transferred to a substrate via an intermediate layer;
[0019] FIGS. 3A to 3 F are diagrams illustrating the different steps of a first embodiment of the method of concurrently producing at least a pair of structures according to the invention;
[0020] FIGS. 4A to 4 F are diagrams illustrating an alternative embodiment according to the invention of the method represented in FIGS. 3A to 3 F; and
[0021] FIGS. 5A to 5 F are diagrams illustrating the different steps of a second embodiment of the method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The present method includes forming a first structure 5 or 5 ′ obtained by, for example, using one of the methods whose successive steps are illustrated in FIGS. 1A to 1 C or 2 A to 2 C. These first structures are called rank 1 structures. In particular, FIG. 1A shows a source substrate 1 having a zone of weakness 4 that includes two parts: a useful layer 11 and a remainder layer 12 or rear part of the source substrate. This zone of weakness 4 is the “initial zone of weakness”.
[0023] The source substrate 1 has a “front face” 13 which will come into contact with a support substrate 2 which will be described later. Advantageously, the source substrate 1 is made of a semiconductor material, in particular those commonly used for applications in the field of electronics, optoelectronics or optics. For example, it could be made of silicon, silicon carbide, sapphire, diamond, germanium, silicon-germanium, III-V compounds or II-VI compounds. III-V compounds are compounds wherein one of the elements appears in column III of the periodic table and the other appears in column V, such as gallium nitride (GaN), gallium arsenide (AsGa) or indium phosphide (InP). II-VI compounds are compounds wherein one of the elements appears in column II of the periodic table and the other appears in column VI, such as cadmium telluride (CdTe). The source substrate 1 can also be a compound substrate, which is a substrate composed of a solid part, for example silicon, having an overlying a buffer layer, for example, of silicon germanium (SiGe).
[0024] According to a first alternative embodiment, atomic species could be implanted to obtain the initial zone of weakness 4 . The phrase “implantation of atomic species” means any bombardment of atomic, molecular or ionic species, which introduces these species into a material, with a maximum concentration of the species located at a predetermined depth below the bombarded surface 13 . Atomic species can be implanted in the source substrate 1 by using, for example, an ion beam implanter or a plasma immersion implanter. Preferably, implantation is carried out by ion bombardment. In addition, the ionic species that is implanted is hydrogen. Other ionic species can be advantageously used alone or in combination with hydrogen, such as rare gases (for example helium). Other variations of implantation techniques could also be used.
[0025] The implantation results in creating the initial zone of weakness 4 in the volume of the source substrate 1 at an average depth of penetration of the ions. The zone of weakness 4 extends substantially parallel to the plane of the front face 13 . The useful layer 11 extends between the front face 13 and this zone of weakness 4 . This step can be carried out by utilizing the method known under the registered trademark “Smart Cut”.
[0026] The initial zone of weakness 4 can also be comprised of a porous layer that is formed, for example, as described U.S. Pat. No. 6,100,166. In this case, the useful layer 11 may be obtained via epitaxy.
[0027] The support substrate 2 acts as a mechanical support and thus generally has a thickness of at least about 300 micrometres. It is preferably made of any single-crystal or poly-crystal semiconductor material often used in the aforementioned applications. The support substrate 2 can be a single-layer solid substrate chosen for example from among silicon, silicon carbide, sapphire, diamond, germanium, quartz, yttrium-stabilized zirconia (ZrO 2 (YO 3 )) and an alloy of silicon carbide.
[0028] Referring to FIG. 1A , the support substrate 2 has one face 20 , termed the “front face” which receives the front face 13 of the source substrate 1 . Then, as represented in FIG. 11B , the front face 13 of the useful layer 11 is directly bonded onto the support substrate 2 without an intermediate layer. Advantageously, this bonding is carried out via molecular adhesion. After a possible thermal annealing step, the remainder 12 is detached along the initial zone of weakness 4 by applying stresses (see FIG. 1C ). One of the following techniques may be used to detach the remainder: the application of mechanical or electric stresses, chemical etching or the application of energy, for example the use of a laser, of microwaves, of an inductive heater, or a thermal treatment in an oven. These detachment techniques are known to those skilled in the art and will not be described in any further detail, and can be used alone or combined. A first rank structure (rank 1 ) 5 is thus obtained which includes the useful layer 11 transferred to a support substrate 2 .
[0029] FIGS. 2A to 2 C illustrate an alternative embodiment of the method which has been described with regard to FIGS. 1A to 1 C. This alternative technique differs in that at least one intermediate layer 3 is inserted between the useful layer 11 and the support substrate 2 . For reasons of clarity and simplicity, in FIGS. 2A to 2 C and in FIGS. 5A to 5 F only one intermediate layer 3 has been represented, but additional intermediate layers could be used. Advantageously, each of these intermediate layers 3 are made of a material chosen from among silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), high permitivity insulating materials, and diamond. It is also possible to have an intermediate layer made of strained silicon on a useful layer of relaxed silicon-germanium (SiGe). In the case where there are several intermediate layers 3 , the latter layer or layers can be either of the same nature or of a different nature.
[0030] The intermediate layer 3 can be formed via chemical plating techniques in vapor phase or any other technique known to those skilled in the art. Such techniques could be conducted on either the front face 20 of the support substrate 2 , on the front face 13 of the source substrate 1 , or on the two front faces. Such a technique is conducted prior to applying or bonding these two substrates against one other. When the intermediate layer 3 is an oxide layer, it can also be formed via thermal oxidation of one or the other of the two substrates 1 or 2 . Irrespective of how the intermediate layers 3 were formed, the free surface of the upper intermediate layer is bonded to the free surface of the substrate 1 or 2 facing it, preferably via molecular adhesion.
[0031] The result of the alternative embodiment of the method is a first rank structure 5 ′ that includes the source substrate 2 , the useful layer 11 , and the intermediate layer 3 inserted between them. The word “transferred” herein with regard to a first rank structure signifies that a useful layer is transferred to a support substrate via a method comprising at least one bonding step, with or without an intermediate layer 3 . According to another embodiment not shown in the figures, the useful layer 11 can be transferred to the support substrate 2 via the BESOI technique, with or without an intermediate layer 3 .
[0032] FIGS. 3A to 3 C illustrate a complete cycle of steps of a first embodiment of the present method, which results in a pair of structures each comprising a useful layer transferred to a substrate. As shown in FIG. 3A , a zone of weakness 6 is formed on the inside of the useful layer 11 of the previously obtained first rank structure 5 , via the implantation of atomic species according to the previously described technique for obtaining a zone of weakness. Two layers are thus defined, namely a first or front useful layer 110 and a second or rear useful layer 120 located between the front useful layer 110 and the support substrate 2 .
[0033] As shown in FIG. 3B , a stiffening substrate 71 is adhered to the free surface 130 of the front useful layer 110 , via bonding, preferably by direct bonding via molecular adhesion. The last step illustrated in FIG. 3C consists of detaching the stacks of layers obtained during the previous step, along said zone of weakness 6 . The layers are detached by applying stresses according to techniques known to those skilled in the art, and previously described above with regard to FIGS. 1C and 2C .
[0034] Two structures 51 and 52 of a second rank are thus obtained. The first structure 51 comprises the support substrate 2 and the rear useful layer 120 and the second structure 52 comprises the stiffening substrate 71 and the front useful layer 110 . It is to be noted that the useful layer 11 must have a sufficient thickness so that, after detachment, the two useful layers 110 and 120 do not have any defects or blisters. The thickness of the two useful layers 110 and 120 can be identical or different according to the depth of implantation of the atomic species and therefore of the localization of the zone of weakness 6 . It should also be noted that the useful layer may be of sufficient thickness to permit multiple structures to be formed, which will be explained below.
[0035] It is possible to repeat the cycle of operations that has just been described (that is, the creation of a zone of weakness, adhesion of a stiffening substrate, and detachment along the zone of weakness) with at least one of the structures 51 , 52 of the second rank, or to both of them. Consequently, one or two pairs of third rank structures 511 , 512 , 521 , 522 (see FIG. 3F ) are obtained.
[0036] As illustrated in FIG. 3D , the front face 140 of the useful layer 110 is subjected to implantation of atomic species to create a zone of weakness 6 , to define a rear useful layer 111 and a front useful layer 112 . A similar method is used to continue processing with the second rank structure 51 , to obtain a front useful layer 122 and a rear useful layer 121 . The next step is to adhere or bond, via molecular adhesion, a stiffening substrate 72 to the front face 140 of the front useful layer 112 and a stiffening substrate 73 to the front face 150 of the rear useful layer 122 . As shown in FIG. 3F , the next step is to detach the two stacks of layers along the zone of weakness 6 so as to obtain four third rank structures.
[0037] The two third rank structures 521 and 522 issue from the second rank structure 52 through use of a stiffener 71 and the rear useful layer 111 for the first one, and the use of stiffener 72 and the front useful layer 122 for the second one. The two third rank structures 511 and 512 issue from the second rank structure 51 and include the stiffener 73 and the front useful layer 122 for the first one, and the support substrate 2 and the rear useful layer 121 for the second one.
[0038] It is then possible to repeat, if desired, the cycle of the three operations that has just been described. The starting structure could be at least one of the rank three structures or of following ranks. The cycle should end when the useful layers transferred onto a substrate reach a thickness above which an extra cycle would result in the transfer of a poor quality useful layer, meaning one having defects or blisters.
[0039] FIGS. 4A to 4 F illustrate an alternative embodiment of the present method. This method is different from that described with reference to FIGS. 3A to 3 F in that at least one interposed layer 8 and/or 8 ″, is inserted between the stiffening substrates 71 and 73 , respectively and the useful layer that faces it. It should be noted that the figures show only a single interposed layer 8 , 8 ″ for the purposes of simplification, but more such layers could be used.
[0040] The interposed layer 8 or 8 ″ can be made, for example, via chemical plating in a vapor phase or by any other layer plating technique known to those skilled in the art. The interposed layers 8 or 8 ″, respectively, can also be obtained via oxidation of the stiffening substrate 71 or 73 , respectively. This plating can be carried out either on the stiffener prior to its application onto the useful layer, or onto the latter, preferably prior to implanting atomic species to create the zone of weakness 6 . The interposed layer 8 or 8 ″ is then bonded to the layer facing it, preferably by molecular adhesion. For example, the interposed layers 8 , 8 ″ are made in a chosen material from among silicon dioxide (SiO 2 ), silicon nitride (Si 3 N 4 ), high permitivity insulating materials, and diamond. In the case where there are several interposed layers 8 , 8 ″, these can be of the same nature or of different natures.
[0041] FIG. 4E shows that the stiffener 72 is directly bonded onto the front useful layer 112 , meaning that it is bonded without an interposed layer. Four third rank structures are thus obtained, of which only two, reference numbers 521 ′ and 511 ′, comprise a stiffener, a useful layer and an interposed layer.
[0042] FIGS. 5A to 5 F show a second embodiment of the present method. This method is different from the first embodiment of FIGS. 4A to 4 F in that the starting structure used is the first rank structure 5 ′, comprising an intermediate layer 3 inserted between the useful layer 11 and the support substrate 2 . In addition, an interposed layer 8 ′ is used between the stiffener 72 and the front useful layer 112 . This interposed layer 8 ′ is of the same nature and is obtained in the same way as the previously described interposed layers 8 or 8 ″.
[0043] Two second rank structures 51 ′ and 52 ′, and then four third rank structures 521 ′, 522 ′, 511 ′ and 512 ′ are obtained. Each of the third rank structures 521 ′ m 52 ′ and 51 ′ include a stiffener, an interposed layer 8 , 8 ′ or 8 ″ and a useful layer. The fourth structure 512 ′ includes the support substrate 2 , the intermediate layer 3 and the useful layer 121 .
[0044] The expression “adhere a stiffening substrate onto a useful layer” herein encompasses the case where there is close contact between the stiffener and the useful layer, and the case where at least one interposed layer 8 , 8 ′ or 8 ″ is present between them. In the different methods which have just been described, the expression “stiffening substrate” refers to any type of substrate that acts as a mechanical support and allows for the detachment of the useful layer from the substrate from which it issues.
[0045] The choice of the type and/or material (nature) of the stiffener 71 , 72 , 73 depends on the final targeted application for the structure. The stiffening substrates 71 , 72 , 73 can be chosen from among the examples given for the support substrate 2 .
[0046] The different alternative methods which have just been described allow at least one pair of structures to be formed at the end of each cycle for a single source substrate 1 which can then be recycled. The present methods are thus more economical and commercially feasible than the known methods which require recycling of the source substrate after each structure is created.
[0047] Moreover, upon each cycle repetition, an operator can choose to apply the same type or different stiffeners and can leave out all or include at least one of interposed layer 8 , 8 ′ or 8 ″. The methods are thus flexible, because there is the possibility of concomitantly forming the structures comprising stacks of different layers.
[0048] Finally, depending on the parameters used to implant atomic species, it is also possible to create a zone of weakness 6 so that the rear useful layers 120 , 111 or 121 are very thin. For example, such thin layers may be less than 50 nanometers (50 nm) thick, whereas the neighboring front useful layers 110 , 112 or 122 may be much thicker. The thickness of the front useful layer associated with that of the stiffener which is pressed against it allows for a later thermal annealing treatment that will not deform the rear useful layer, and that will not cause blisters to form on the rear useful layer. The result is that a much thinner rear useful layer can be transferred than presently possible using conventional methods such as the SMART-CUT® method.
[0049] Additionally, the implantation of atomic species steps carried out on the substrates of the first rank or higher structures concentrate the defects in the front useful layers 110 or 122 . The rear useful layers 120 or 121 were not directly subjected to the implantation and thus have a zone with defects linked to the implantation and to the detachment extending over a lesser thickness in the detachment zone than that of the front layer.
[0050] The following is a description of an example of the present method with reference to FIGS. 5A to 5 F.
EXAMPLE 1
[0051] The first rank structure used here is a SOI substrate type structure 5 ′ that includes a support substrate 2 of single-crystal silicon, an intermediate layer 3 of silicon dioxide SiO 2 having a thickness of 20 nm, and a useful layer 11 of single-crystal silicon having a thickness of 1.5 μm. A zone of weakness 6 is created by implanting hydrogen ions based on an implantation energy of about 150 keV and an implantation dose of about 6.10 16 H + /cm 2 . A rear useful layer 120 is thus created having a thickness of 20 nm. A single-crystal silicon stiffener 71 having an interposed layer 8 of silicon dioxide SiO 2 of a thickness of 20 nm is then applied. The two structures are then detached along the zone of weakness 6 to simultaneously obtain a pair of SOI substrates 51 ′ and 52 ′. The cycle of the operations is then repeated using the second rank SOI substrate 52 ′ as a starting structure.
[0052] Once the surfaces have been prepared, the front useful layer 112 has a thickness of about 0.6 microns and the rear useful layer 111 has a thickness of about 0.6 microns. When a single-crystal silicon stiffener 72 covered in a layer of silicon dioxide 8 ′ of a thickness of 20 nm (20 nanometers) is used, two third rank SOI substrates 521 ′ and 522 ′ are obtained after detachment that have respective useful layers 111 and 112 that are about 0.6 microns thick.
|
A method for producing a semiconductor structure that includes at least one useful layer on a substrate. This method includes providing a source substrate with a zone of weakness therein that defines a relatively thick useful layer between the zone of weakness and a front face of the source substrate; bonding the front face of the source substrate to a support substrate and detaching the useful layer from the source substrate at the zone of weakness to transfer the useful layer to the support substrate; implanting atomic species into a free face of the useful layer to a controlled mean implantation depth therein to form a zone of weakness within the useful layer that defines front and rear useful layers, with the rear useful layer contacting the source substrate and the front useful layer containing a greater concentration of defects; bonding a stiffening substrate to the free face of the front useful layer after implantation of the atomic species; and detaching the front useful layer from the rear useful layer along the zone of weakness to form a semiconductor structure comprising the support substrate and the rear useful layer thereon. The structures obtained can be used in the fields of electronics, optoelectronics or optics.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor device and a method for manufacturing the same and, more particularly, to a semiconductor device having a bipolar integrated circuit with I 2 L elements and a method for manufacturing the same.
An I 2 L (Integrated Injection Logic) is a logic element which has a composite structure involving a vertical transistor (e.g., an npn transistor) of inverted structure and a lateral transistor (e.g., a pnp transistor) of complementary structure to that of the vertical transistor. In an I 2 L element of the structure as described above, the lateral transistor serves as an injector for injecting charge into the base of the vertical transistor which, in turn, serves as an inverter. For this reason, I 2 L elements have a small logic amplitude and are capable of operating at high speed with low power consumption. Since element isolation between the vertical and lateral transistors is unnecessary, I 2 L elements can achieve a high integration and are suitable for large scale integration. Furthermore, since an I 2 L involves the bipolar process technique, other bipolar circuits such as linear and ECL (Emitter Coupled Logic) circuits may be easily formed on the same chip, thus realizing a multi-functional integrated circuit.
Various studies have been made to achieve higher operation speed of the I 2 L. It has been recently pointed out that it is important to achieve a short storing time, that is, the time required for a switching transistor to sink the minority carriers stored at an emitter or base region of a switching transistor of the next stage. This is described, for example, in IEEE Journal of Solid-State Circuits, Vol. SC-14. No. 2, April 1979, pp. 327 to 336. In order to eliminate storage of minority carriers, it is effective to optimize the concentration profile of the epitaxial semiconductor layer and the emitter region as well as to minimize the size of the region at which the minority carriers are stored. In view of this, it has been conventionally proposed to manufacture I 2 L elements by the method to be described below. According to this conventional method, referring to FIGS. 1A to 1C, an n + -type buried layer 2 is selectively formed in a p-type silicon substrate 1. After growing an n-type epitaxial layer 3 on the substrate 1, a thick field oxide film 4 for element isolation is formed by selective oxidation. After selectively forming a silicon oxide film 5 on the prospective element forming region by the CVD process or photolithography, boron is thermally diffused through the silicon oxide film 5 as a mask to form a p-type base region 6 and a p-type injector 7 (FIG. 1A). In the next step, an arsenic-doped polycrystalline silicon film (arsenic is an n-type impurity) is deposited over the entire surface of the structure. The arsenic-doped polycrystalline silicon film is selectively etched to form n + -type polycrystalline silicon patterns 8a and 8b on collector forming regions (FIG. 1B). Thermal oxidation under heating is performed to grow a thick thermal oxide film 9 around the polycrystalline patterns 8a and 8b and to grow a thin thermal oxide film 10 on the p-type injector 7. Arsenic doped in the polycrystalline silicon patterns 8a and 8b is diffused into the p-type base region 6 to form n + -type collector regions 11a and 11b. The thin thermal oxide film 10 is etched to provide the polycrystalline silicon patterns 8a and 8b as collector electrodes 12a and 12b. After an aluminum film is deposited over the entire surface of the structure, the aluminum film on the field oxide film 4 and the silicon oxide film 5 is patterned to form a base electrode 13 and an injector electrode 14. An integrated circuit including an I 2 L element is thus completed (FIG. 1C). Referring to FIGS. 1A to 1C, reference numerals 15a to 15c denote base contact holes, and reference numeral 16 denotes an injector contact hole.
In the conventional method for manufacturing an integrated circuit with an I 2 L described above, the entire surface of the substrate is oxidized utilizing differences between etching rates of the n + -type polycrystalline silicon patterns 8a and 8b and of the p-type base region 6 at a low temperature. Thereafter, only a thin portion above the p-type base region 6 can be etched. The base contact holes can be formed in self-alignment with the collector electrodes 12a and 12b, so that the base electrode 13 may be able to contact the base region 6 with a wider area. Moreover, the area of the base region 6 may be made smaller than the total area of the collector regions 11a and 11b. An I 2 L element manufactured is capable of high speed operation, and the ratio of the collector area to the base area (S C /S B ) is increased. Therefore, the current amplification factor (h FE ) can be improved and higher integration can also be achieved. However, in the above I 2 L arrangement, the collector regions 11a and 11b and the base contact holes 15a and 15b come close to each other when the oxide film is etched too much, resulting in flow of a leakage current therebetween.
The following problems are presented in the elaborate patterning of the I 2 L structure. The n + -type polycrystalline silicon layer which is patterned as the n + -type polycrystalline silicon layers 8a and 8b and the p-type base region 6 contact each other. In order to selectively etch the n + -type polycrystalline silicon layer, the etching rates of the n + -type polycrystalline silicon layer and the p-type base region 6 are controlled so that the p-type base region 6 may not be etched when it is exposed after the n + -type polycrystalline silicon layer is selectively etched. In order to achieve selective etching of this type, an etchant of HF:HNO 3 :CH 3 COOH=1:3:8 is known. The etching rate of the n + -type polycrystalline silicon layer is at least ten times that of the p-type base region 6. However, the etchant of this type is not suitable for elaborate etching. If a pattern width of the n + -type polycrystalline silicon layer is 1 to 2 μm and if the etchant described above is used, the side surfaces of the n + -type polycrystalline silicon layer are etched by isotropic etching. Therefore, it is difficult to control precision of the n + -type polycrystalline silicon pattern. It is also difficult to maintain the etching rate constant on the entire surface of the wafer. Thus, elaborate patterning is limited. Meanwhile, a reactive ion etching (RIE) method is known in which patterning of 1 to 2 μm is effectively performed by anisotropic etching. However, at present, there is no RIE method which allows selective etching of the n + -type polycrystalline silicon layer and the p-type region. If the conventional RIE method is used to etch the n + -type polycrystalline silicon layer, the p-type base region is also etched. This method is not suitable for achieving the I 2 L arrangement shown in FIG. 1C.
SUMMARY OF THE INVENTION
The present invention has been developed in light of the above problems. Its object is to provide a bipolar semiconductor device with I 2 L elements and a method for manufacturing the same wherein base contact holes are formed in a self-aligned manner in a n + -type polycrystalline silicon layer which is used as a diffusion source of an I 2 L collector region or as a collector connecting wiring to minimize an outer base region of the I 2 L gate whereby elaborate patterning is performed and flow of a leakage current between the base and the collector of the I 2 L element is avoided, so that the packaging density and switching speed of the I 2 L element are improved.
According to one aspect of the present invention, there is provided a semiconductor device comprising:
a semiconductor substrate above which a semiconductor layer of a first conductivity type n + is formed;
a projecting region which projects above the semiconductor layer and which has a conductive layer of the first conductivity type and a first insulating film formed on the conductive layer of the first conductivity type;
a second insulating film which is formed on side surfaces of the projecting region;
an impurity region of a second conductivity type p + which is formed in a recessed region around the projecting region; and
a wiring layer electrically connected to the impurity region of the second conductivity type;
wherein the impurity region of the second conductivity type is separated from the conductive layer of the first conductivity type layer through the side surfaces of said projecting region.
According to another aspect of the present invention, there is also provided a method for manufacturing a semiconductor device, comprising the steps of:
forming a first impurity region of a second conductivity type in a semiconductor layer of a first conductivity type which is formed above a semiconductor substrate;
selectively forming a conductive layer of the first conductivity type on the first impurity region of the second conductivity type, and a first insulating layer above the conductive layer of the first conductivity type;
forming a projecting region which has the conductive layer of the first conductivity type and the first insulating layer by anisotropic etching, using the first insulating layer as a mask, thereby defining a groove reaching at least the first impurity region of the second conductivity type;
forming a second insulating film to cover the entire surface and simultaneously forming a second impurity region of the second conductivity type on a bottom of the groove;
selectively etching the second insulating film to leave the second insulating film only on the side surfaces of the projecting region; and
depositing a wiring layer electrically connected to the second impurity region of the second conductivity type on the bottom of the groove.
First, according to the present invention, in order to pattern a conductive layer such as the n + -type polycrystalline silicon layer which is used for the collector connecting wiring, anisotropic etching, such as the RIE method, is used to selectively etch the conductive layer. Furthermore, the groove which is formed in the semiconductor substrate extends beyond the conductive layer. As a result, a collector layer is formed on a non-etched projection, while the base contact hole is formed in the lower portion of the groove. Therefore, the base contact hole can not contact the collector layer, thus preventing the flow of a leakage current and short-circuiting therebetween. An I 2 L element manufactured according to the method of the present invention may have elaborate patterning which is a necessary factor for high packaging density.
Secondly, according to the present invention, a metal or metal silicide is used for a Schottky collector and a collector electrode wiring. The I 2 L element according to the present invention has a small logical amplitude compared to that of the conventional I 2 L. Thus, the collector electrode wiring has a low resistance, resulting in a high-speed I 2 L structure having low power consumption.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1C are sectional views showing the steps of manufacturing an I 2 L element according to a conventional method;
FIGS. 2A to 2F are sectional views showing the steps of an I 2 L manufacturing method according to one embodiment of the present invention;
FIG. 3 is a circuit diagram of a Schottky collector I 2 L gate circuit;
FIGS. 4A to 4F are sectional views showing the steps of an I 2 L manufacturing method according to a second embodiment of the present invention; and
FIGS. 5A to 5E are sectional views showing the steps of an I 2 L manufacturing method according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An I 2 L element and a method of manufacturing the element according to one embodiment of the present invention will be described.
Referring to FIG. 2A, antimony is selectively diffused into a p-type silicon substrate 101 to form an n + -type buried layer 102 therein. After growing an n-type silicon epitaxial layer 103 (semiconductor layer of a first conductivity type), a field oxide film 104 is formed around a prospective region in which an I 2 L gate should be formed. A p --type base region 105 (first impurity region of a second conductivity type) for intrinsic npn transistors is formed in part of the silicon epitaxial layer 103 by the ion-implantation or thermal diffusion method. A silicon oxide film 106 is formed to cover the base region of the pnp transistor by thermal oxidation, CVD film formation, or selective etching. Thereafter, an As-doped n +-type polycrystalline silicon film 108, a CVD-SiO 2 film 109, and a silicon nitride film 110 are sequentially formed.
A resist pattern (not shown) is formed by photoetching on the silicon nitride film 110. The silicon nitride film 110 is then etched using the resist pattern as a mask to form silicon nitride film patterns 110a and 110b. The CVD-SiO 2 film 109 is etched using the silicon nitride film patterns 110a and 110b as a mask to form CVD-SiO 2 film patterns 109a and 109b. Exposed parts of the n + -type polycrystalline silicon film 108 are then etched using an etchant of HF:HNO 3 :CH 3 COOH=1:3:8, or etched by reactive ion etching (FIG. 2B). The n + -type polycrystalline silicon film 108 may comprise a bi-layered structure in which a layer of a metal such as tungsten or molybdenum, having a high melting point, or a layer of a metal silicide such as molybdenum silicide having a high melting point, is formed on the n + -type polycrystalline silicon layer.
Exposed portions of the silicon substrate in FIG. 2B are then etched by anisotropic etching such as the RIE method to form grooves 107 (FIG. 2C). The grooves 107 may be formed to reach the p - -type base region 105 or beyond the p - -type base region 105. The bottom surfaces of these grooves 107 are generally formed deeper than the lower surface of the semiconductor layer 103 of the first conductivity type (collector regions 113a and 113b which are formed in the p - -type base region 105 by diffusion using the n + -type polycrystalline silicon layer 108 as the diffusion source will be described later). More particularly, the depth of the grooves 107 relative to the silicon substrate is often preferably within a range of 0.15 to 0.7 μm. If the grooves 107 are formed to a depth shallower than the above range, the n-type impurity in the n + -type polycrystalline silicon layer is diffused transversely, resulting in the flow of a leakage current between the base and the collector. However, if the grooves 107 are formed deeper than the above range, a p +-type base layer 112 is far separated from a p - -type base layer 105, degrading the high speed operation of the I 2 L, as is apparent from FIG. 2E. This also applies to the bi-layered structure in which molybdenum silicide is deposited on the n + -type polycrystalline silicon patterns 108a and 108b. With this arrangement, the wiring resistance is advantageously reduced.
The wafer thus obtained is annealed in an atmosphere of low-temperature steam or in a wet atmosphere of 700° to 900° C. Since the oxidation rate of the n + -type polycrystalline silicon patterns 108a and 108b is 4 to 10 times higher than that of the n-type silicon epitaxial layer 103 or the p - -type base region 105, a thick thermal oxide film 111a is formed on the exposed side surfaces of the n + -type polycrystalline silicon patterns 108a and 108b, and a thin thermal oxide film 111b is formed on the exposed surfaces of the n-type silicon epitaxial layer 103 and on the exposed side surfaces of the p - -type base region 105, as shown in FIG. 2D. Also, the sides of the CVD SiO 2 film patterns 109a and 109b, are, like the film patterns 108a and 108b, changed to thermal oxide films 111a, whereupon the films are narrowed as shown in FIGS. 2(c) and 2(d). After this annealing process, silicon nitride films 110 are selectively dry-etched by a conventional etchant such as Freon gas, O 2 and N 2 .
As shown in FIG. 2E, a p-type impurity such as boron is ion-implanted through the thin thermal oxide film 111b. Thereafter, the wafer is annealed to form an external p + -type base layer 112. Simultaneously, arsenic in the n + -type polycrystalline silicon patterns 108a and 108b is diffused into the n + -type polycrystalline silicon layers 103 to form the n + -type collector regions 113a and 113b.
As shown in FIG. 2F, part of the thin thermal oxide film 111b which is formed on the bottom surface of the grooves 107 is etched by anisotropic etching in a self-aligned manner to form contact holes. An Al-Si alloy metal layer is deposited to cover the entire surface and is patterned to form an injector electrode 114 and a base electrode 115 which connects the base contact holes. Thus, the final I 2 L element is prepared as shown in FIG. 2F.
As is apparent from the above embodiment, the n + -type collector layers or n + -type polycrystalline silicon patterns 108a and 108b of the vertical transistors is formed in projections separated by the grooves 107. Therefore, the n + -type collector layers may not extend transversely. Furthermore, these layers may not be exposed to the self-aligned base contact holes at the bottom of the grooves 107. Flow of a leakage current and short-circuiting between the base and the collector of the I 2 L are thus prevented. Further, anisotropic etching such as the RIE method is used to control the patterning size of the n + -type collector layers. Thus, a bipolar integrated circuit having high-speed I 2 L elements with a high packing density is obtained.
In the above embodiment, arsenic-doped n + -type polycrystalline silicon is used. However, polycrystalline silicon doped with phosphorus or other impurities may also be used.
An I 2 L gate structure according to another embodiment of the present invention will be described. FIG. 3 shows an I 2 L gate circuit having a Schottky collector. Reference numeral 141 denotes a vertical npn transistor of an inverted structure; 142, a lateral pnp transistor of a complementary type to that of the vertical npn transistor 141; and 143 1 , 143 2 and 143 3 , Schottky barrier diodes connected to the collector of the lateral pnp transistor 142, respectively.
The detailed arrangement of the I 2 L gate circuit and its manufacturing method according to a second embodiment of the present invention will be described with reference to FIGS. 4A to 4F.
Referring to FIG. 4A, an n + -type impurity layer 152 and an n-type epitaxial layer 153 are formed on a p-type silicon substrate 151 and selective oxidation is performed to form a field oxide film 154. After a relatively thin SiO 2 film 155 is formed to cover the entire surface, a p - -type region 156 of an impurity concentration defined as an internal base layer of the I 2 L is formed in the n-type epitaxial layer 153. The p - -type region 156 can be formed utilizing accelerated ion implantation of boron. As shown in FIG. 4B, after part of the thin SiO 2 film 155 is etched, a Schottky metal layer 157 and a CVD-SiO 2 film 158 (formed at a low temperature so as not to alloy the metals by the CVD method) are sequentially formed. As shown in FIG. 4C, the Schottky metal layer 157 and the CVD-SiO 2 film 158 are selectively etched using a photoresist film as a mask so that grooves reach part of the epitaxial layer 153. Thus, projecting regions are formed. The RIE method is preferably used to etch the Schottky metal layer 157 and the CVD-SiO 2 film 158 in a substantially vertical direction. As shown in FIG. 4D, a CVD-SiN film 159 formed at a low temperature so as not to alloy the metal by the CVD method is formed to cover the entire surface. Thereafter, a relatively high p-type impurity such as boron is ion-implanted using the CVD-SiO 2 film as a mask. The p-type impurity is then activated upon radiation of laser beams. At this time, the metal has a high reflection coefficient, so the Schottky metal layer 157 is not heated to a high temperature, while the silicon is heated to a high temperature. As shown in FIG. 4E, only p + -type external base regins 160 are activated. Thereafter, as shown in FIG. 4F, part of the CVD-SiN film 159 is etched by the RIE method such that the CVD-Sin film 159 remains only on the side surfaces of projections comprising the epitaxial layer 153, the Schottky metal layer 157 and the CVD-SiO 2 film 158. Then, a metal is deposited to form metal wiring 161. The metal wiring 161 is then sintered to prepare the I 2 L.
The I 2 L prepared by a method described above has the following effects.
(1) Since the collector of the npn transistor 141 forms a Schottky clamp, the logical amplitude is smaller than that in the conventional arrangement in which the n + -type polycrystalline silicon wiring is deposited on the n + -type collector layer. The I 2 L element according to the present invention has a small parasitic capacitance. Therefore, a high-speed I 2 L with a high packaging density is obtained. Furthermore, since the collector wiring comprises a metal, the wiring resistance is substantially negligible.
(2) Since the p + -type external base region 160 is sufficiently vertically spaced apart from the Schottky metal layer 157, the dielectric strength between the external base and the collector is degraded.
(3) Since the metal for collector wiring can be used with another low-resistant wiring material in the manufacturing process, a bi-layered wiring can be formed in practice.
With the I 2 L of this type, a high performance device can be readily manufactured. Note that the Schottky metal may comprise tungsten (W), silver (Ag), aluminum (AL), gold (Au), Pt plutinum), or the like. The silicide film may comprise a silicide of the metals described above.
An I 2 L according to a third embodiment of the present invention will be described with reference to FIGS. 5A to 5E. Referring to FIG. 5A, an n + -type impurity region 172 and an n-type epitaxial layer 173 are formed on a p-type silicon substrate 171 in the same manner as in FIGS. 4A to 4F. Field oxide films 174 are then formed by selective oxidation. After a relatively thin SiO 2 film 175 is formed, a p - -type region 176 is formed in the n-type epitaxial layer 173. A Schottky metal layer 177 and a CVD-SiO 2 film 178 formed by the CVD method at a low temperature are sequentially formed to cover the entire surface. As shown in FIG. 5B, The Schottky metal layer 177 and the CVD-SiO 2 film 178 are selectively etched using a photoresist film as a mask. If the Schottky metal layer 177 of aluminum, for example, is etched by an etchant of a phosphoric acid type, the CVD-SiO 2 film 178 overhangs the patterned Schottky metal layer.
As shown in FIG. 5C, a p-type impurity such as boron is ion-implanted to a relatively high concentration to form external base regions 180, using the oxide films 174, 175 and as a mask. After a CVD-SiN film 179 formed at a low temperature is deposited, laser beams are radiated on the doped layer which is then activated to convert base regions of 180 into extended p + -type regions. Thereafter, as shown in FIG. 5D, the CVD-SiN film 179 is selectively etched by the RIE method to the extent that the CVD-SiN film 179 remains only on the side surfaces of the projections comprising the Schottky metal layer 177 and the CVD-SiO 2 film 178. A metal is deposited to form metal wiring 181 and to electrically connect the p + -type base regions 180, as shown in FIG. 5E. Finally, the metal wiring 181 is sintered to prepare the I 2 L.
This I 2 L has the same effects as in the I 2 L shown in FIGS. 4A to 4F.
According to the present invention, a high-speed I 2 L with low power consumption can be manufactured.
In the above embodiments, a bipolar I 2 L element is described. However, the present invention is not limited to this, but may be extended to field effect transistors.
|
A semiconductor device wherein collector connecting wiring made of for example n + -type polycrystalline silicon layer is formed by an anisotropic etching which simultaneously engrave a groove in a semiconductor substrate. A collector layer is formed on a non-etched projection, while base contact hole is formed in the lower portion of the groove. Therefore, the base contact hole is not contacted with collector layer, thus preventing the flow of a leakage current and short-circuiting therebetween.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 383,889 filed July 30, 1973 which was a continuation of application Ser. No. 177,313 filed Sept. 2, 1971, said application Ser. No. 177,313 having been abandoned.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates to thin film magnetic recording and storage devices having high abrasion and wear resistance and a method of producing such devices. Since only slight damage to a magnetic film will likely result in improper recording of the information desired to be stored, abrasion and wear resistance is a desired quality of magnetic recording and storage devices. For example, in recording apparatus, using magnetic recording and storage disks as the storage device, even though the read and write head of such apparatus does not normally contact the disk during actual operation, the head does impact with the disk and bounce several times when the disk first begins to spin up to its operating speed, which is normally between 2400 rpm and 3600 rpm. These impacts can be highly damaging to the brittle solid magnetic material now being used on certain types of magnetic disks.
II. Prior Art
In conventional magnetic recording and storage devices the magnetic layer or film is comprised or particles such as, for example, particles of magnetite (Fe 3 O 4 ) or gammic ferric oxide (γ-Fe 2 O 3 ) which are bonded to each other and to the substrate by such bonding and filler materials as vinyl, urethane, epoxy or the like. Such a combination layer of binder and magnetic particles is somewhat flexible and is not significantly affected by abrasion or impacts received from the read and write head. However, improved magnetic recording and storage devices having higher coercivity, lighter weight and thinner magnetic layers or films are now being economically produced. These devices have a thin solid magnetic film which is chemically bonded to the substrate such that no bonding or filler material is required. Experiments indicate that the magnetic recording properties of these solid film devices are superior to conventional devices. However, the solid magnetic film chemically bonded to the substrate is somewhat brittle and cannot readily withstand repeated impact and abrasion. Therefore, it has become desirable to find some means of increasing the abrasion and wear resistance of these films.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention to provide a magnetic recording and storage device having a solid magnetic film which is highly resistant to abrasion and wear, and a simple and economical method of producing such a device.
Briefly, according to this invention, a magnetic recording and storage device having a solid magnetic film chemically bonded to a substrate is provided. A film of lubricating compound is applied to the exposed surface of the magnetic film.
Additional features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an oblique view of a solid film magnetic recording and storage disk produced in accordance with the teachings of the invention.
FIG. 2 shows a broken cross-sectional view taken along lines 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 there is shown a magnetic recording and storage device 10. In the cross-sectional view of FIG. 2 the magnetic recording and storage device is shown having a suitable substrate 12, on a broad surface of which has been chemically bonded a magnetic film 14 which consists substantially of a material especially suitable for use with this invention, such as magnetite (Fe 3 O 4 ), gamma ferric oxide (γ-Fe 2 O 3 ), cobalt in combination with magnetite or cobalt in combination with gamma ferric oxide. Other suitable magnetic film materials include but are not limited to magnetite, or gamma ferric oxide in combination with one or more of the following metals: nickel, copper, zinc or manganese. A lubricating film 16 covers the exposed surface of the magnetic film 14. The thickness of the magnetic film and lubricating film as shown in FIG. 2 have been greatly enlarged with respect to the substrate thickness to better illustrate the invention. In addition, portions of the device shown in FIG. 2 have been broken away so that the drawings can be accomodated on a single sheet.
Magnetic recording and storage devices particularly benefited by this invention are those having solid, that is, non-particulate chemically bonded magnetic films. Such films are different from the conventional magnetic films presently used on most magnetic recording and storage devices. For example, conventional magnetic films are comprised of particles of magnetic material such as magnetite or gamma ferric oxide bonded to each other and to the substrate by a bonding and filler material such as vinyl, urethane, epoxy or the like. Magnetic recording and storage devices having a solid magnetic film chemically bonded to a substrate, may be produced by methods including but not limited to those described in the two U.S. Pat. Nos. 3,795,542 and 3,892,888 each entitled "Method of Making a Magnetic Recording and Storage Device" by James A. Murphy, Sami A. Halaby and Neal S. Kenny.
The lubricating film is preferably an organic compound including but not limited to a silicone based chlorosilane, polyethylene, or a stearate such as polyoxyethylene monostearate, morpholino stearate, triethanolamine stearate and mixtures of such materials. Silicone based chlorosilane compound contains a hydrocarbon radical having between 4 and 18 carbon atoms and an amino group to make the compound soluble in water, and such compound is herein referred to as a silicone based chlorosilane. The polyethylene is preferably an emulsified polyethylene having a molecular weight less than about 4000 and preferably between about 2000 and 3000. The stearates are preferably waxy solids which are soluble in water.
A particularly suitable lubricating compound is an emulsion of polyethylene and polyoxyethylene monostearate. Preferably the ratio of the constituents in the emulsion is between about 1 and 2.5 parts by weight of polyethylene for each part of polyoxyethylene monostearate.
In addition to the principal constituents of the lubricating compounds as set forth above, other constituents may be included therein provided they do not deleteriously affect the lubricating properties and characteristics of the compound. For example, a coloring agent may be included, or a dispersing and emulsifying agent may be employed to facilitate mixing of the lubricating compound. In addition, it may be desirable to incorporate stabilizers, bactericides, mold inhibitors or other similar materials into the compound.
The lubricating compound may be applied to the magnetic film by any convenient method including but not limited to painting, swabbing, silk screening, dipping or spraying. If the lubricant is applied by such methods as dipping or spraying, it is preferably to dilute the compound to the proper consistency with water. For such methods of application, the lubricating composition is preferably an aqueous composition containing less than about 2%, and still more preferably containing between about 0.01% and 1%, by weight of the organic material. The lubricant may be used without dilution if applied by painting, swabbing or silk screening.
The film of lubricating compound may be applied to the magnetic film in almost any desired thickness so long as the magnetic properties are not adversely affected. However, for most applications, a thickness of less than about 5000 A is preferable. If the lubricating compound is applied in excess of 5000 A, the excess may be removed by polishing, scraping or the like.
It should also be noted that the thickness of the lubricating film on a device may vary widely without adverse effect. For example, the lubricating film on a single device might vary from a few hundred angstroms to several thousand angstroms without adverse effect.
The lubricant may satisfactorily be applied to the magnetic film at any temperature up to the decomposition point of the lubricating compound, the temperature at which deterioration of the magnetic properties of the magnetic film occur, or the temperature at which deterioration of the physical properties of the substrate occurs, whichever is less. Experimental results indicate, however, that although excellent results are obtained when the lubricant is applied at any temperature not destructive to the lubricant or magnetic film, somewhat better results may be obtained if the lubricant is applied to the magnetic film at a temperature of about 80° C.
A commercially available polyethylene base lubricating compound satisfactory for use with this invention is AP-4 made by Ball Brothers Company, Inc. A commercially available silicone based chlorosilane compound satisfactory for use with the method of the invention is Z-4141 made by Dow Corning Corp.
EXAMPLE I
A magnetic recording and storage disk produced by the method described in Example IV of the aforementioned U.S. Pat. No. 3,892,888 is provided. The magnetic disk is heated to approximately 80° C., and a coating of full strength Ball Brothers AP-4 polyethylene based lubricant is painted onto the surface of the magnetic film. The disk and lubricant combination is then allowed to cool. After cooling, any excess lubricant is removed from the surface of the magnetic film by polishing said surface with a soft cloth such that a film of less than 5000 A remains on the surface of said magnetic film.
EXAMPLE II
A magnetic recording and storage disk of the type described in Example I is provided. The disk is heated to a temperature of approximately 80° C. and a coating of full strength Dow Corning Z-4141 silicone based chlorosilane lubricant is silk-screened onto the surface of the magnetic film. The disk and lubricant combination is then allowed to cool. After cooling, any excess lubricant is removed from the surface of the magnetic film by polishing said surface with a soft cloth such that a film of less than 5000 A remains.
EXAMPLE III
A magnetic recording and storage disk of the type described in Example I is provided. The disk is heated to a temperature of approximately 80° C. after which it is sprayed with a 0.1% aqueous solution of polyoxyethylene monostearate. The magnetic disk and polyoxyethylene monostearate combination is then allowed to cool. After cooling any excess lubricating solution is removed by polishing the surface of said magnetic disk with a soft cloth such that a film of less than 5000 A remains on the surface of said magnetic film.
EXAMPLE IV
The magnetic disk of the type described in Example I is provided. The disk is heated to a temperature of approximately 80° C. and is then sprayed with an aqueous emulsion of about 0.05% polyethylene having a molecular weight of about 2500, and 0.025% polyoxyethylene monostearate containing about 40 moles of polyoxyethylene per mole stearate.
The magnetic disk and lubricant combination is then allowed to cool to room temperature. After cooling, any excess lubricant is removed by polishing with a soft cloth such that a film of less than 5000 A remains on the surface of said magnetic film.
Although the present invention has been discussed with respect to specific examples, it is not intended that such specific examples be limitations upon the scope of the invention except insofar as is set forth in the following claims.
|
A magnetic recording and storage device having high wear resistance is produced by providing a magnetic recording and storage device having a film of solid magnetic material which has been bonded to a surface of a rigid substrate. A thin film of a lubricating compound is then applied to the film of magnetic material.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/530,181 filed on Apr. 4, 2005, now U.S. Pat. No. 7,467,522. The entire disclosure of U.S. patent application Ser. No. 10/530,181 is hereby incorporated herein by reference. U.S. patent application Ser. No. 10/530,181 is the U.S. National Stage application of PCT/JP2004/006021, filed Apr. 26, 2004 and claims priority to Japanese Patent Application No. 2003-123493, filed on Apr. 28, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a refrigerator unit for a container.
2. Background Information
For some time, refrigerator units for container have been used to cool the inside of containers used for freight transport and the like. Some of these refrigerator units for container are equipped with ventilation units for ventilating the interior of the container. For example, in the case of a container used for transporting fruits and vegetables, it is necessary to provide an appropriate degree of ventilation of the air inside the container in order to keep the fruits and vegetables fresh. A ventilation unit is therefore used to accomplish the ventilation of the interior of the container (see Japanese Laid-Open Patent Publication No. 9-280720).
Meanwhile, there is a need to know the quantity of air that is exchanged by the ventilation units used in container refrigeration units. In the example presented above, since the ventilation affects the freshness of the fruits and vegetables, knowing the quantity of air that has been ventilated is useful for maintaining the freshness of the fruits and vegetables. Also, if the quantity of ventilation is known, a transport company transporting fruits and vegetables can provide a fruit and vegetable owner with a guarantee that an appropriate degree of ventilation is being conducted.
However, it is difficult to know the quantity of air that is ventilated to and from conventional container refrigeration units like that just described.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a refrigerator unit for container for which it is possible to know the quantity of air that is ventilated.
A refrigerator unit for container in accordance with the first invention is equipped with a ventilation unit, an acquisition unit, and a recording unit. The ventilation unit ventilates the air inside the container. The acquisition unit acquires ventilation data related to the quantity of air ventilated by the ventilation unit. The recording unit records the ventilation data acquired by the acquisition unit. The ventilation data is not limited to data that indicates the quantity of ventilated air directly; it is also acceptable for the ventilation data to be data that indicates the quantity of ventilated air indirectly.
With this refrigerator unit for container, the interior of the container is ventilated and ventilation data related to the quantity of ventilated air is recorded. Consequently, it is possible to review the recorded ventilation data. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air.
A refrigerator unit for container in accordance with the second invention is a refrigerator unit for container according to the first invention, further equipped with a first output unit. The first output unit is configured to output the quantity of air ventilated by the ventilation unit based on the ventilation data recorded by the recording unit.
With this refrigerator unit for container, the quantity of air ventilated by the ventilation unit is outputted by the first output unit. Thus, with this refrigerator unit for container, it is possible to easily know the quantity of ventilated air.
A refrigerator unit for container in accordance with the third invention is a refrigerator unit for container according to the first invention, further equipped with a second output unit. The second output unit is configured to output the ventilation data recorded by the recording unit.
With this refrigerator unit for container, the ventilation data is outputted by the second output unit. Consequently, if the ventilation data is data that directly indicates the quantity of ventilated air, the quantity of ventilated air can be known directly. Meanwhile, if the ventilation data is data that indirectly indicates the quantity of ventilated air, the quantity of ventilated air can be known indirectly. Thus, with this refrigerator unit for container, it is possible to easily know the quantity of ventilated air.
A refrigerator unit for container in accordance with the fourth invention is a refrigerator unit for container according to any one of the first to third inventions, wherein the ventilation unit has a ventilation passage and an opening/closing member. The ventilation passage serves as a passage through which the ventilated air passes. The opening/closing member opens and closes the ventilation passage. The ventilation data includes opening degree data indicating the degree to which the opening/closing member has opened the ventilation passage.
With this refrigerator unit for container, the interior of the container is ventilated by opening and closing the ventilation passage with the opening/closing member. Consequently, the quantity of ventilated air is affected by the degree to which the opening/closing member opens the ventilation passage. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air based on the opening degree data.
A refrigerator unit for container in accordance with the fifth invention is a refrigerator unit for container according to the fourth invention, wherein the opening/closing member is configured to open and close the ventilation passage by being moved in a manual fashion.
With this refrigerator unit for container, the opening/closing member is configured to open and close the ventilation passage by being moved in a manual fashion. Conventionally, it is difficult to know the quantity of ventilated air when the opening degree of the ventilation passage is changed manually. For example, if the opening/closing member is manually moved more than once during a transport, at the end of the transport it is difficult to know the history of how the opening degree of the ventilation passage has changed. However, with this refrigerator unit for container, the opening degree data is recorded by the recording unit. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air.
A refrigerator unit for container in accordance with the sixth invention is a refrigerator unit for container according to the fourth or fifth inventions, wherein the acquisition unit has an opening degree detecting means. The opening degree detecting means detects the opening degree based on the amount of movement of the opening/closing member.
With this refrigerator unit for container, the opening degree detecting means detects the opening degree based on the amount of movement of the opening/closing member. As a result, the opening degree data can be acquired easily based on the movement amount of the opening/closing member.
A refrigerator unit for container in accordance with the seventh invention is a refrigerator unit for container according to the sixth invention, wherein the acquisition unit has a transmitting means configured to transmit the movement amount of the opening/closing member to the opening degree detecting means.
With this refrigerator unit for container, the transmitting means transmits the movement amount of the opening/closing member to the opening degree detecting means. As a result, the movement amount of the opening/closing member can be transmitted to the opening degree detecting means even if the opening/closing member and the opening degree detecting means are in separated positions.
A refrigerator unit for container in accordance with the eighth invention is a refrigerator unit for container according to the seventh invention, further equipped with a thermally insulated wall. The thermally insulated wall is made of a thermal insulation material and is arranged and configured to separate the interior and exterior of the container. The transmitting means is a member imbedded in the thermally insulated wall.
Refrigerator units for container are generally provided with a thermally insulated wall in order to maintain the temperature of the container interior. If the transmitting means is installed on the outside of the thermally insulated wall in a position facing the exterior of the container, it will affect the exterior appearance of the container. Conversely, if the transmitting means is installed on the inside of the thermally insulated wall in a position facing the interior of the container, it is possible that the ability of the transmitting means to transmit will be disturbed when the temperature of the container interior is extremely low.
However, with this refrigerator unit for container, the transmitting means is embedded in the thermally insulated wall. As a result, the transmitting means is prevented from affecting the external appearance of the container. Also, the transmitting means can transmit in a trouble-free manner without being affected by the temperature of the container interior.
A refrigerator unit for container in accordance with the ninth invention is a refrigerator unit for container according to the seventh or eighth inventions, further provided with a temperature detecting means and a correction unit. The temperature detecting means detects the ambient temperature surrounding the transmitting means. The correction unit corrects the opening/closing member movement amount transmitted by the transmitting means based on the ambient temperature.
With this refrigerator unit for container, the opening/closing member movement amount transmitted by the transmitting means is corrected based on the ambient temperature. As a result, even if the transmitting means elongates or shortens due to the temperature, the movement amount of the opening/closing means can be detected accurately.
A refrigerator unit for container in accordance with the tenth invention is a refrigerator unit for container according to any one of the fourth to ninth inventions, wherein the recording unit is configured to record ventilation data when the opening degree of the opening/closing member is changed.
With this refrigerator unit for container, ventilation data is recorded when the opening degree of the opening/closing member is changed. As a result, it is possible to know with good precision how the quantity of ventilated air has changed due to changes in the opening degree of the opening/closing member.
A refrigerator unit for container in accordance with the eleventh invention is a refrigerator unit for container according to any one of the first to tenth inventions, wherein the recording unit is configured to record ventilation data when the refrigerator unit for container starts running.
With this refrigerator unit for container, ventilation data is recorded when the refrigerator unit for container starts running. As a result, ventilation data can be obtained from the time when the refrigerator unit for container starts running.
A refrigerator unit for container in accordance with the twelfth invention is a refrigerator unit for container according to any one of the first to eleventh inventions, wherein the recording unit is configured to record ventilation data each time a specific amount of time elapses or at a specific time of day.
With this refrigerator unit for container, the ventilation data is recorded each time a specific amount of time elapses or at a specific time of day. As a result, it is possible to know how the quantity of ventilated air changes with respect to a specific repeated time interval or a specific time of day.
A refrigerator unit for container in accordance with the thirteenth invention is a refrigerator unit for container according to any one of the first to third inventions, wherein the ventilation unit has a ventilation passage and an air speed detecting means. The ventilation passage serves as a passage through which the ventilated air passes. The air speed detecting means detects the speed of the air passing through the ventilation passage. The ventilation data includes the air speed data detected by the air speed detecting means.
With this refrigerator unit for container, the air speed data detected by the air speed detecting means is recorded. The speed of the air passing through the ventilation passage indicates the quantity of ventilated air indirectly. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air because the air speed data is recorded.
A refrigerator unit for container in accordance with the fourteenth invention is a refrigerator unit for container according to any one of the first to third inventions, wherein the ventilation unit has a ventilation passage and a blower device. The ventilation passage serves as a passage through which the ventilated air passes. The blower device generates a flow of air that is ventilated through the ventilation passage. The ventilation data includes output data from the blower device.
With this refrigerator unit for container, the output data of the blower device is recorded. The output of the blower device indicates the quantity of ventilated air indirectly. For example, the larger the output of the blower device, the larger the quantity of ventilated air; the smaller the output of the blower device, the smaller the quantity of ventilated air. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air because the output data is recorded.
A refrigerator unit for container in accordance with the fifteenth invention is a refrigerator unit for container according to any one of the first to third inventions, wherein the ventilation unit has a ventilation passage and a pressure detecting means. The ventilation passage serves as a passage through which the ventilated air passes. The pressure detecting means detects the pressure difference between the inlet and outlet of the ventilation passage. The ventilation data includes the pressure difference data detected by the pressure detecting means.
With this refrigerator unit for container, the pressure difference data detected by the pressure detecting means is recorded. The pressure difference between the inlet and outlet of the ventilation passage indicates the quantity of ventilated air indirectly. For example, the larger the pressure difference between the inlet and outlet of the ventilation passage, the larger the quantity of ventilated air; the smaller the pressure difference between the inlet and outlet of the ventilation passage, the smaller the quantity of ventilated air. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air because the pressure difference data is recorded.
A refrigerator unit for container in accordance with the sixteenth invention is a refrigerator unit for container according to any one of the first to third inventions, wherein the ventilation data includes freight quantity data related to the quantity of freight loaded in the container.
With this refrigerator unit for container, freight quantity data related to the quantity of freight loaded in the container is recorded. The quantity of freight loaded in the container affects the pressure difference between the interior and exterior of the container. The pressure difference between the interior and exterior of the container affects the quantity of air that is ventilated. Thus, with this refrigerator unit for container, it is possible to know the quantity of ventilated air because the freight quantity data is recorded.
A refrigerator unit for container in accordance with the seventeenth invention is a refrigerator unit for container according to any one of the first to sixteenth inventions, wherein the ventilation data is data that indirectly indicates the quantity of air ventilated by the ventilation unit. Also, this refrigerator unit for container is further provided with a conversion unit configured to convert the ventilation data into a quantity of air.
With this refrigerator unit for container, the ventilation data is converted into a quantity of air by the conversion unit. Thus, even if the ventilation data is data that indirectly indicates the quantity of ventilated air, the quantity of ventilated air can be known directly by converting the ventilation data into the quantity of ventilated air.
A refrigerator unit for container in accordance with the eighteenth invention is a refrigerator unit for container according to the seventeenth invention, wherein the conversion unit has a plurality of different converting means adapted to different ventilation unit configurations.
The relationship between the ventilation data and the quantity of air often differs depending on the constituent features of the ventilation unit. Consequently, it is difficult to convert the ventilation data accurately when the same conversion formula is used irregardless of the constituent features of the ventilation unit.
With this refrigerator unit for container, however, the ventilation data is converted into a quantity of air using a plurality of different converting means adapted to different ventilation unit configurations. Thus, with this refrigerator unit for container, the ventilation data can be converted more accurately into the quantity of ventilated air.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the external appearance of the refrigerator unit for container 1 .
FIG. 2 is a side cross sectional view showing of the refrigerator unit for container 1 .
FIG. 3( a ) shows the ventilation mechanism 4 in a completely closed state.
FIG. 3( b ) shows the ventilation mechanism 4 in an opened state.
FIG. 3( c ) shows the ventilation mechanism 4 in a completely opened state.
FIG. 4 is a schematic view of the opening degree detecting mechanism 5 .
FIG. 5 illustrates how the opening degree detecting mechanism 5 detects the opening degree.
FIG. 6 is a side cross sectional view in the vicinity of the thermally insulated wall 26 .
FIG. 7 is a control block diagram.
FIG. 8 is a graph plotting the first conversion formula F 1 and the second conversion formula F 2 .
FIG. 9 is a front view of the control panel 72 .
FIG. 10 illustrates an example of the output indicating the ventilation quantity and other information.
FIG. 11 is a flowchart indicating the procedure for logging and outputting the ventilation quantity.
FIG. 12( a ) is a schematic view illustrating a case in which air speed data is detected.
FIG. 12( b ) is a schematic view illustrating a case in which output data is detected.
FIG. 12( c ) is a schematic view illustrating a case in which pressure difference data is detected.
FIG. 13( a ) is a schematic view illustrating a case in which the opening degree of the ventilation passage 40 is detected using a photoelectric sensor 66 .
FIG. 13( b ) is a schematic view illustrating a case in which the opening degree of the ventilation passage 40 is detected using a reed switch 67 .
FIG. 13( c ) is a schematic view illustrating a case in which the movement of the opening/closing member 41 is transmitted by means of a gear.
FIG. 14( a ) shows an opening/closing member 41 configured to open and close the ventilation passage 40 by rotating.
FIG. 14( b ) is a schematic view illustrating a case in which the movement of the opening/closing member 41 is transmitted by means of a wire 51 .
FIG. 14( c ) is a schematic view illustrating a case in which the movement of the opening/closing member 41 is transmitted by means of a gear.
FIG. 15 is a schematic view illustrating a case in which the ventilation passage 40 is provided in a position that is separated from the first chamber R 1 or the second chamber R 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Constituent Features of Refrigerator Unit for Container
A refrigerator unit for container 1 that employs an embodiment of the present invention is shown in FIGS. 1 and 2 . FIG. 1 is a perspective view of the external appearance of the refrigerator unit for container 1 and FIG. 2 is a side cross sectional view of the refrigerator unit for container 1 when it is mounted to a container C. The refrigerator unit for container 1 is a device for maintaining a prescribed temperature in the interior IS of the freight container C and is mounted to an opening of the container C in such a manner as to separate the interior IS of the container C from the exterior OS of the same. The refrigerator unit for container 1 is provided with a frame 2 , refrigerant circuit component parts 3 , a ventilation mechanism 4 (ventilation unit), an opening degree sensing mechanism 5 (acquisition unit), various sensors 6 (see FIG. 7 ), and a control unit 7 .
Frame
The frame 2 has a generally sheet-like shape and is mounted in such a fashion as to block one side of the container C. As shown in FIG. 2 , the frame 2 is provided with an exterior storage space SP 1 and an interior storage space SP 2 .
The exterior storage space SP 1 has a recessed shape and is formed in a lower portion of a front face 21 on the side of the frame 2 that faces the exterior OS of the container C. The exterior storage space SP 1 is isolated from the interior IS of the container C and communicates with the exterior OS of the container C. The upper portion of the front face 21 has a flat shape that is generally parallel to the vertical direction.
The interior storage space SP 2 is arranged between the front face 21 and a rear panel 22 . The rear panel 22 faces the interior IS of the container C and is separated from the front face 21 by a prescribed distance. The interior storage space SP 2 spans from the rear (rear panel side) of the external storage space SP 1 to space above the exterior storage space SP 1 and communicates with the interior IS of the container C through air vents 23 , 24 provided near the top and bottom ends of the rear panel 22 . A plate-shaped fan guide 25 is provided in a generally horizontal state in the interior storage space SP 2 . The an evaporator fan 36 (described later) is mounted to the fan guide 25 . The interior storage space SP 2 is divided by the fan guide 25 and evaporator fan 36 into a first chamber R 1 located above the fan guide 25 and a second chamber R 2 located below the fan guide 25 .
A thermally insulated wall 26 is provided on the rear side of an upper portion of the front face 21 between the interior storage space SP 2 and the exterior OS and on the rear side of a lower portion of the front face 21 between the interior storage space SP 2 and the exterior storage space SP 1 . The thermally insulating wall 26 is made of a thermal insulation material and is arranged and configured to separate the interior IS and exterior OS of the container C. The thermally insulated wall 26 serves to suppress the movement of heat between the interior IS and exterior OS of the container C.
Refrigerant Circuit Component Parts
The refrigerant circuit component parts 3 include such parts as a condenser 30 , a compressor 31 , an expansion valve 32 (see FIG. 7 ), and an evaporator 33 and these parts constitute a refrigerant circuit.
The condenser 30 , the compressor 31 , and the expansion valve 32 are housed in the external storage space SP 1 . The external storage space SP 1 also houses a condenser fan 34 and a condenser fan motor 35 . The condenser fan 34 is rotated by the condenser fan motor 35 and serves to produce a flow of air that is drawn into the exterior storage space SP 1 from the exterior OS, passes through the condenser 30 , and is discharged to the exterior OS (see unshaded arrow A 1 ).
The evaporator 33 is housed in the second chamber R 2 of the interior storage space SP 2 on the rear side of the upper portion of the front face 21 . The internal storage space SP 2 also houses an evaporator fan 36 and an evaporator fan motor 37 . The evaporator fan 36 and evaporator fan motor 37 are arranged above the evaporator 33 . The evaporator fan 36 is provided in the opening of the fan guide 25 and is positioned between the first chamber R 1 and the second chamber R 2 . The first chamber R 1 is positioned on the inlet side of the evaporator fan 36 and the second chamber R 2 is positioned on the outlet side of the evaporator fan 36 . The evaporator fan 36 is rotated by the evaporator fan motor 37 and produces an interior air flow. The interior air flow flows from the interior IS of the container C through the air vent 23 at the upper end of the rear panel 22 and into the first chamber R 1 of the interior storage space SP 2 (see unshaded arrow A 2 ). The interior air flow then flows from the first chamber R 1 through the opening of the fan guide 25 and into the second chamber R 2 , where it passes through the evaporator 33 arranged in the second chamber R 2 . Then, the interior air flow flows through the vent 24 at the lower end of the rear panel 22 to the interior IS (see unshaded arrow A 3 ).
Ventilation Mechanism
The ventilation mechanism 4 serves to ventilate the interior IS of the container C and is provided with a ventilation passage 40 and an opening/closing member 41 .
The ventilation passage 40 is a passage through which the ventilated air passes and has an intake passage 42 and an exhaust passage 43 . The intake passage 42 and exhaust passage 43 are provided so as to be aligned above and below each other in an upper portion of the front surface 21 ; the inlet passage 42 is positioned above the exhaust passage 43 . The exhaust passage 42 is the passage through which air is drawn into the first chamber R 1 from the exterior OS of the container C and is arranged and configured to communicate from an intake port 44 to the first chamber R 1 through the thermally insulated wall 26 . The exhaust passage 43 is the passage through which air is discharged to the exterior OS of the container C from the second chamber R 2 and is arranged and configured to communicate to an exhaust port 45 and the exterior OS through the thermally insulated wall 26 . The intake port 44 and the exhaust port 45 are provided in an upper portion of the front face 21 and arranged so as to face the exterior OS with a prescribed vertical spacing there-between. As shown in FIG. 3 , the intake port 44 and the exhaust port 45 have the shapes of trapezoids arranged such that the upper and lower bases are parallel to the vertical direction. The upper edges of the intake port 44 and the exhaust port 45 are horizontal and the bottom edges are slanted.
The opening/closing member 41 serves to open and close the ventilation passage 40 . The opening/closing member 41 is provided such that it slides freely up and down over the front face 21 . The opening/closing member 41 serves to adjust the quantity of ventilated air by adjusting the opening degree of the intake port 44 and the exhaust port 45 in accordance with its slide position. As shown in FIG. 3( a ), the opening/closing member 41 has the shape of a rectangle that is long in the vertical direction in a frontal view and is provided with a square opening 46 in the center thereof.
When the ventilation passage 40 is closed, the opening 46 of the opening/closing member 41 is positioned between the intake port 44 and the exhaust port 45 such that the intake port 44 and the exhaust port 45 are closed by the opening/closing member 41 . As shown in FIG. 3( b ), the opening cross sectional areas of the intake port 44 and exhaust port 45 increase in accordance with the amount of movement of the opening/closing member 41 when the opening/closing member 41 is slid in the vertical direction. When the opening/closing member is moved in this way and the exhaust passage 40 is opened, pressure differences causes the interior IS of the container C to be ventilated. The pressure differences mentioned here are the pressure difference between the interior IS and the interior storage space SP 2 and the pressure difference between the exterior OS and the interior storage space SP 2 . Since the first chamber R 1 is positioned on the inlet side of the evaporator fan 36 , its pressure is lower than the pressures of both the interior IS and the exterior OS. Consequently, air is drawn from the interior IS to the first chamber R 1 through the air vent 23 . Likewise, air is drawn from the exterior OS to the first chamber R 1 through the intake port 44 and intake passage 42 . The air drawn into the first chamber R 1 is pulled through the opening of the fan guide 25 by the evaporator fan 36 and delivered to the second chamber R 2 . Since the second chamber R 2 is positioned on the outlet side of the evaporator fan 36 , its pressure is higher than the pressures of both the interior IS and the exterior OS. Consequently, a portion of the air delivered to the second chamber R 2 is discharged to the exterior OS through the exhaust passage 43 and the exhaust port 45 . Meanwhile, the remainder of the air delivered to the second chamber R 2 is sent to the interior IS through the evaporator 33 and the air vent 24 . In this way, with this refrigerator unit for container 1 , the pressure difference generated by the evaporator fan 36 is utilized to ventilate the container C. By moving the opening/closing member 41 , the opening degree of the ventilation passage 40 is adjusted and thus the ventilation quantity is adjusted. As shown in FIG. 3( c ), the ventilation passage 40 is completely open when the positions of the opening 46 of the opening/closing member 41 and the intake port 44 are aligned.
When the opening/closing member 41 is slid in the opposite direction as just described, the opening cross sectional areas of the intake port 44 and exhaust port 45 decrease in accordance with the amount of movement of the opening/closing member 41 . The ventilation passage 40 is fully closed when the opening 46 of the opening/closing member 41 is positioned between the intake port 44 and the exhaust port 45 (see FIG. 3( a )). A graduated scale is provided in near the opening/closing member 41 and the opening/closing member 41 is moved manually using this scale as an indicator of the ventilation quantity.
Opening Degree Detecting Mechanism
The opening degree detecting mechanism 5 is configured to acquire opening degree data (ventilation data) indicating the opening degree of the ventilation passage 40 . The opening degree data indicates the quantity of air ventilated by the ventilating mechanism 4 (hereinafter called “ventilation quantity”) indirectly. As shown in FIG. 4 , the opening degree detecting mechanism 5 is provided with an opening degree detecting device 50 (opening degree detecting means) and a wire 51 (transmitting means) configured and arranged to transmit the amount of movement of the opening/closing member 41 to the opening degree detecting device 50 .
The opening degree detecting device 50 is arranged in the exterior storage space SP 1 and serves to detect the opening degree of the ventilation passage 40 based on the movement amount of the opening/closing member 41 . The opening degree detecting device 50 has a wire winding drum 52 and a position meter 53 . The wire winding drum 52 has a circular shape for winding the wire 51 and is configured to rotate in accordance with the movement of the wire 51 (see unshaded arrow A 6 ). The position meter 53 serves to detect the rotational angle of the wire winding drum 52 and send the detected rotational angle to a controller 7 . In short, the position meter 53 can detect the opening degree of the ventilation passage 40 by detecting the movement amount and position of the opening/closing member 41 based on the rotational angle of the wire winding drum 52 .
The wire 51 is a metal wire member configured and arranged to transmit the movement amount of the opening/closing member 41 to the opening degree detecting device 50 . The wire 51 is arranged to span from the upper portion of the front face 21 where the opening/closing member 41 is provided to the exterior storage space SP 1 where the opening degree detecting device 50 is arranged and, as shown in FIG. 5 , the wire 51 links the opening/closing member 41 and the wire winding drum 52 together. FIG. 5 illustrates the linkage of the opening/closing member 41 and the wire winding drum 52 in a simplified schematic manner. As shown in FIG. 6 , the wire 51 is inserted through a lead-through pipe 54 embedded in the thermally insulated wall 26 . The lead-through pipe 54 passes from the upper portion of the front face 21 where the opening/closing member 41 is provided, through the interior of the thermally insulated wall 26 , and down into the exterior storage space SP 1 and serves to guide the wire 51 from the upper portion of the front face 21 to the external storage space SP 1 . The wire 51 moves through the lead-through pipe 54 (see unshaded arrow A 5 ) in accordance with the movement of the opening/closing member 41 (see unshaded arrow A 4 ) and thereby transmits the movement of the opening/closing member 41 to the opening degree detecting device 50 .
Thus, with this opening degree detecting mechanism 5 , the opening/closing member 41 and the opening degree detecting device 50 can be arranged in separated positions because the movement amount of the opening/closing member 41 is transmitted to the opening degree detecting device 50 by the wire 51 .
Sensors
The sensors 6 include an exterior temperature sensor 61 (temperature detecting means) for detecting the temperature of the exterior OS of the container C and an interior temperature sensor 62 for detecting the temperature of the interior IS of the container C (see FIG. 7 ). The exterior temperature, interior temperature, and other information detected by the sensors are sent to the controller 7 .
Controller
The controller 7 is a device for controlling the refrigerator unit for container 1 and is arranged in the external storage space SP 1 . As shown in FIG. 7 , the controller 7 has a control unit 70 comprising a CPU or the like, a memory 71 , a control panel 72 for displaying information and making entries to control, an output unit 78 , etc.
The control unit 70 is connected to the compressor 31 , the condenser fan motor 35 , the expansion valve 32 , the evaporator fan motor 37 , and the sensors 6 and serves to control the operation of the refrigerator unit for container 1 . The control unit 70 is also connected to the position meter 53 of the opening degree detecting device 50 and is configured to log (record) the ventilation quantity in the memory 71 based on the information detected by the opening degree detecting device 50 . The control unit 70 has a conversion unit 73 , a correction unit 74 , and a recording unit 75 .
The conversion unit 73 converts the opening degree data, which indicates the ventilation quantity indirectly, into the ventilation quantity. More specifically, the conversion unit 73 is configured to convert the movement amount of the opening/closing member 41 detected by the opening degree detecting device 50 into a quantity of ventilated air. Since the opening cross sectional areas of the intake port 44 and exhaust port 45 are adjusted when the opening/closing member 41 moves, the movement amount of the opening/closing member 41 corresponds to the quantity of ventilated air. Thus, the quantity of ventilated air can be calculated using a conversion formula that indicates the correspondence between the movement amount of the opening/closing member 41 and the quantity of ventilated air. The conversion unit 73 is provided with a first conversion formula F 1 (conversion means) and a second conversion formula F 2 as shown in FIG. 8 and is configured to use either conversion formula, whichever is selected. The first conversion formula F 1 indicates the correspondence between the movement amount of the opening/closing member 41 and the quantity of ventilated air in a case where a protective screen is not mounted to the intake port 44 and exhaust port 45 . The second conversion formula F 2 indicates the correspondence between the movement amount of the opening/closing member 41 and the quantity of ventilated air in a case where a protective screen is mounted to the intake port 44 and exhaust port 45 and is different from the first conversion formula F 1 . The protective screen serves to prevent contaminants from entering the interior IS of the container C from the exterior OS and is mounted to the intake port 44 and exhaust port 45 . Since the pressure difference between the first chamber R 1 and the exterior OS is different in a case where a protective screen is mounted to the intake port 44 and exhaust port 45 than in a case where a protective screen is not provided, the first conversion formula F 1 and the second conversion formula F 2 are different. Thus, a more accurate conversion can be accomplished by using the conversion formulas F 1 , F 2 selectively depending on the constituent features of the ventilation mechanism 4 .
The correction unit 74 corrects the movement amount of the opening/closing member 41 transmitted by the wire 51 based on the exterior temperature. More specifically, since the wire 51 expands and contracts as the temperature changes, error occurs in the movement amount of the opening/closing member 41 depending on the change in the temperature. The correction unit 74 is configured to compensate for the error that results from changes in the exterior temperature. The correction unit 74 corrects the detected movement amount using, for example, the formula shown below.
l c =l t ×{1+α( t−t 0 )}
In the formula, l c is the corrected movement amount, l t is the actual measured value of the movement amount, α is the coefficient of linear thermal expansion of the wire 51 , t is the exterior temperature at the time when the movement amount is detected, and t 0 is the exterior temperature when setting the zero-point.
Since the error resulting from expansion and contraction of the wire 51 is corrected in this way, the ventilation quantity can be calculated more accurately.
Although in this embodiment the correction is performed using the exterior temperature as the ambient temperature of the wire 51 , it is also acceptable to detect the temperature near the wire 51 and use the detected temperature for the correction.
In addition to logging the history of the ventilation quantity in the memory 71 , the recording unit 75 displays the ventilation quantity on a display panel 76 (first output unit and second output unit) of the control panel 72 (see FIG. 9 ). The recording unit 75 records the history of the ventilation quantity, which comprises the ventilation quantities obtained by converting the opening degree of the ventilation passage 40 and the dates (year/month/day) and times of day when the ventilation quantities were recorded, in the memory 71 . The recording unit 75 logs the ventilation quantity history at the following three timings. The first timing is when the refrigerator unit for container 1 starts running. That is, the recording unit 75 logs the ventilation quantity and other data when the compressor 31 , evaporator fan motor 37 , and condenser fan motor 35 are driven and the refrigerator unit for container 1 starts cooling the interior IS of the container C. The second timing is each time a specific amount of time elapses or at a specific time of day. For example, the recording unit 75 might log the ventilation quantity and other data once per day at a specific time (e.g., 00:00 AM). The third timing is when the opening degree of the ventilation passage 40 is changed. That is, the recording unit 75 logs the ventilation quantity and other data when the opening/closing member 41 is moved and the opening degree of the ventilation passage 40 is changed. By logging the ventilation quantity and other data at these three timings, the ventilation quantity can be logged in a more detailed fashion. Thus, the ventilation quantity can be known in more detail. Additionally, the value of the ventilation quantity is logged according to a prescribed incremental value. For example, in consideration of the conversion error between the opening degree and the ventilation quantity, the ventilation quantity might be logged in increments of 5 m 3 /h.
The control panel 72 is arranged in the external storage space SP 1 of the front face 21 and faces the exterior OS. As shown in FIG. 9 , the control panel 72 is provided with a display panel 76 and input keys 77 . The display panel 76 displays such information as the interior temperature of the container C and the ventilation quantity obtained by converting the opening degree data. The input keys 77 are used to turn the refrigerator unit for container 1 on and off and to enter operation details.
The ventilation quantity is not only displayed on the display panel 76 but also outputted by the output unit 78 (first output unit and second output unit). The output unit 78 outputs the logged history of the ventilation quantity. The output unit 78 is, for example, a printer serving to print the ventilation quantities, dates (year/month/day), and times that have been logged, a write device configured to write the ventilation quantities and other data to a recording medium as electronic data, or an output port for transmitting the ventilation quantities and other data to another information terminal through a communication cable or wireless connection as electronic data. An example of the ventilation quantity history list outputted by the output unit 78 is shown in FIG. 10 . In this history list, the ventilation quantity D 1 is a ventilation quantity logged when the opening degree of the ventilation passage 40 is changed. The ventilation quantity D 2 is a ventilation quantity logged at a specific time of day. The ventilation quantity D 3 is a ventilation quantity logged when the refrigerator unit for container 1 started operating. The ventilation quantities D 1 , D 2 , D 3 are outputted together with the temperatures T 1 and the date (year/month/day) and time T 2 when the ventilation quantities D 1 , D 2 , D 3 , and the interior temperature T were detected. The temperatures T 1 are the temperature setting, the interior temperature of the container C detected during transport, etc. The temperatures T 1 and the ventilation quantities D 1 , D 2 , D 3 are detected and recorded at a plurality of times T 2 during transport.
Logging and Output of Ventilation Quantities
The procedure for logging the ventilation quantity will now be described based on the flowchart shown in FIG. 11 .
In step S 1 , the ventilation passage 40 is closed or opened. In this embodiment, the opening degree of the ventilation passage 40 is changed manually by sliding the opening/closing member 41 . When the opening/closing member 41 is moved, the wire 51 is either pulled or pushed in accordance with the movement of the opening/closing member 41 . The movement of the wire 51 is transmitted to the wire winding drum 52 and the wire winding drum 52 rotates.
In step S 2 , the opening degree is detected. In this embodiment, the position meter 53 detects the rotational angle of the wire winding drum 52 . The opening degree of the ventilation passage 40 is outputted from the opening degree detecting device 50 . That is, the opening degree of the ventilation passage 40 is outputted in the form of the rotational angle of the wire winding drum 52 . The outputted opening degree is sent to the control unit 70 of the controller 7 .
In step S 3 , a conversion calculation is executed to obtain the ventilation quantity. In this embodiment, the opening degree of the opening/closing member 41 is converted to a ventilation quantity using either the first conversion formula F 1 or the second conversion formula F 2 .
In step S 4 , the ventilation quantity and other data is logged and displayed. In this embodiment, the conversion-calculated ventilation quantity and the date (year/month/day) and time it was logged are recorded in the memory 71 and the ventilation quantity is displayed on the display panel 76 . The logging and display of the ventilation quantity and other data are performed at the aforementioned three timings. The output unit 78 outputs the history of the ventilation quantity and other data.
Characteristic Features
(1) With this refrigerator unit for container 1 , the interior IS of the container C is ventilated and the ventilation quantity is logged. As a result, the fact that the opening/closing member 41 was moved and ventilation was conducted during transport of a container C can be confirmed afterwards by checking the ventilation quantity history.
In particular, it is difficult to check the history of the opening degree of the opening/closing member 41 and the ventilation quantity when the opening/closing member 41 is moved a plurality of times. However, with this refrigerator unit for container 1 , the history of the ventilation quantity can be known easily by outputting the logged ventilation quantities.
For example, in the case of a container C used to transport fruit, it is necessary to exhaust the ethylene gas generated by the fruit and draw in fresh outside air. Therefore, it is important to manage the ventilation quantity in order to maintain the freshness of the fruit. With this refrigerator unit for container 1 , by logging the ventilation quantity, a transport company transporting the container C can provide the fruit owner with a guarantee that a certain amount of ventilation is conducted.
(2) With this refrigerator unit for container 1 , the opening degree of the ventilation passage 40 is detected based on the amount of movement of the opening/closing member 41 and the ventilation quantity is calculated based on the opening degree. As a result, ventilation quantity can be obtained with a system having a simple configuration.
Other Embodiments
(1) In the embodiment described above, the ventilation quantity is found using the movement amount of the opening/closing member 41 and a conversion formula. It is also acceptable to find the ventilation quantity based on the speed of the ventilated air and the opening cross sectional area. For example, as shown in FIG. 12( a ), an air speed sensor 63 (air speed detecting means) can be provided in the ventilation passage 40 . In such a refrigerator unit for container as this, an air speed sensor 63 that detects the speed of the air passing through the exhaust passage 43 is provided in the exhaust passage 43 . The control unit 70 logs data (ventilation data) that includes the air speed data detected by the air speed sensor 63 and the opening cross sectional area. The control unit 70 converts the air speed data into a ventilation quantity by finding the product of the detected air speed and the opening cross sectional area of the exhaust port 45 and logs the resulting ventilation quantity. In view of improving the detection accuracy, it is preferred that the air speed sensor 63 be mounted on the side where the opening/closing member 41 begins to open.
(2) Although in the embodiment described above, the ventilation quantity is found using the movement amount of the opening/closing member 41 and a conversion formula, when the refrigerator unit for container 1 is provided with a blower device 47 for ventilation as shown in FIG. 12( b ), it is also acceptable to detect the output of the blower device 47 and log the detected output data (ventilation data). It is also acceptable to convert the output data into a ventilation quantity and log the ventilation quantity. The blower device 47 conducts ventilation by creating a flow of air that flows from the second chamber R 2 to the exterior OS and a flow of air that flows from the exterior OS to the first chamber R 1 . Since the ventilation quantity is affected by the output of the blower device 47 , the controller 70 can find the ventilation quantity based on the output of the blower device.
(3) In the embodiment described above, the ventilation quantity is found using the movement amount of the opening/closing member 41 and a conversion formula. It is also acceptable to find the ventilation quantity by detecting the pressure difference between the exterior OS and the interior IS. For example, as shown in FIG. 12( c ), there may be a refrigerator unit for container 1 provided with an exterior pressure sensor 64 (pressure detecting means) that detects the pressure of the exterior OS and an interior pressure sensor 65 (pressure detecting means) that detects the pressure of the first chamber R 1 or the second chamber R 2 . In such a refrigerator unit for container 1 as this, pressure difference data (ventilation data) indicating the difference between the exterior pressure detected by the exterior pressure sensor 64 and the interior pressure detected by the interior pressure sensor 65 are logged. The output data can then be converted into a ventilation quantity and logged.
The ventilation of the air in the interior IS of the container C takes place due to the pressure difference between the exterior OS and the interior IS. In other words, the existence of a pressure difference between the exterior OS and the interior IS causes a flow of air that flows from the exterior OS to the interior IS or a flow of air that flows from the interior IS to the exterior OS to be generated. As a result, ventilation occurs. Thus, the ventilation quantity can be found by detecting the pressure difference between the exterior OS and the interior IS.
It is also acceptable to log freight quantity data related to the quantity of freight in the interior IS of the container C and find the ventilation quantity using the freight quantity data. The quantity of freight in the interior IS of the container C affects the pressure difference between the exterior OS and the interior IS. In other words, the pressure inside the container C is different when the quantity of freight in the interior IS of the container C is large than when the quantity of freight is small. Thus, the ventilation quantity can be found by taking the freight quantity data into consideration.
(4) Although in the embodiment described above, the opening degree of the ventilation passage 40 is detected by using a wire 51 to transmit the movement of the opening/closing member 41 to an opening degree detecting device 50 , it is also acceptable to detect the opening degree of the ventilation passage 40 with a photoelectric sensor 66 (opening degree detecting means) as shown in FIG. 13( a ). The photoelectric sensor 66 is arranged to face the opening/closing member 41 in the direction in which the opening/closing member 41 moves so that it can detect the distance between itself and the opening/closing member 41 . With this arrangement, the movement amount of the opening/closing member 41 and thus the opening degree of the ventilation passage 40 imposed by the opening/closing member 41 can be detected. It is also acceptable to detect the amount of movement of the opening/closing member 41 using radio waves instead of light.
(5) Although in the embodiment described above, the opening degree of the ventilation passage 40 is detected by using a wire 51 to transmit the movement of the opening/closing member 41 to an opening degree detecting device 50 , it is also acceptable to detect the opening degree of the ventilation passage 40 with a plurality of reed switches 67 (opening degree detecting means) as shown in FIG. 13( b ). The reed switches 67 are arranged parallel to the slide direction of the opening/closing member 41 and are configured to enter an on state when exposed to a magnetic force. A magnet 68 is provided on the opening/closing member 41 and the magnet 68 moves over the reed switches 67 when the opening/closing member 41 moves. Thus, the movement amount and position of the opening/closing member 41 can be detected based on the on/off status of the reed switches 67 .
It is also acceptable to detect the opening degree of the ventilation passage 40 using a plurality of limit switches. In such a case, the limit switches are arranged parallel to the slide direction of the opening/closing member 41 and are configured to enter an on state when subjected to mechanical contact. A lever configured and arranged to contact the limit switches is provided on the opening/closing member 41 so that when the opening/closing member 41 moves, the limit switches in positions through which the opening/closing member 41 has passed are turned on. Thus, the movement amount of the opening/closing member 41 can be detected based on the on/off status of the limit switches.
(6) Although in the embodiment described above, the movement of the opening/closing member 41 is transmitted to the opening detecting device 50 by means of a wire 51 , it is also acceptable to transmit the movement of the opening/closing member 41 to the opening degree detecting device 50 with a gear 55 (transmitting means) as shown in FIG. 13( c ). The gear 55 has a circular shape and is arranged to the side of the opening/closing member 41 . A linear gear 56 is provided on a side edge of the opening/closing member 41 and the linear gear 56 of the opening/closing member 41 meshes with the gear 55 . A position meter 53 is mounted to the rotational center of the gear 55 and serves to detect the rotational angle of the gear 55 . Thus, when the opening/closing member 41 moves up and down, the gear 55 rotates (see solid arrow A 6 ) and the position meter 53 detects the movement amount of the opening/closing member 41 in the form of the rotational angle of the gear 55 . As a result, the opening degree of the ventilation passage 40 can be detected.
(7) Although in the embodiment described above, the ventilation passage 40 is opened and closed by sliding the opening/closing member 41 linearly up and down, it is also acceptable to open and close the ventilation passage 40 by rotating an opening/closing member 48 as shown in FIG. 14( a ). The opening/closing member 48 has a circular shape and is mounted to the upper portion of the front face 21 such that its center is positioned between the intake port 44 and the exhaust port 45 . Two openings 481 , 482 corresponding to the intake port 44 and the exhaust port 45 are provided in the opening/closing member 48 . When the opening/closing member 48 rotates (see the solid arrow A 7 ), the two openings 481 , 482 overlap the intake port 44 and exhaust port 45 and thereby open the intake port 44 and exhaust port 45 . When the portions of the opening/closing member 48 other than the openings 481 , 482 overlap the intake port 44 and exhaust port 45 , the intake port 44 and exhaust port 45 are closed. In FIG. 14( a ), the two openings 481 , 482 are positioned such that the ports are completely closed. When an opening/closing member 48 like that shown in FIG. 14( a ) is rotated 90 degrees from a position where the portions of the opening/closing member 48 other than the openings 481 , 482 are aligned with the intake port 44 and exhaust port 45 , the ventilation passage 40 is completely closed. When the opening/closing member 48 is rotated 90 degrees further or 90 degrees in the opposite direction to a position where the two openings 481 , 482 are aligned with the intake port 44 and exhaust port 45 , the ventilation passage 40 is completely open. A position meter 53 is mounted to the center of the gear 48 and serves to detect the rotational angle of the opening/closing member 48 as the movement amount of the opening/closing member 48 , i.e., as the opening degree of the ventilation passage 40 .
It is also acceptable to provide the position meter 53 in a position separated from the position meter 53 instead of at the center of the opening/closing member 48 . For example, as shown in FIG. 14( b ), an opening degree detecting device 50 comprising a wire winding drum 52 and a position meter 53 arranged at the center of the wire winding drum 52 can be arranged in a position separated from the opening/closing member 48 and a wire 51 can be used to transmit the rotation of the opening/closing member 48 to the wire winding drum 52 . It is also acceptable to provide a circular gear 57 , 58 (transmitting means) at the center of each of the opening/closing member 48 and the position meter 53 and to provide another circular gear 59 (transmitting means) that is positioned between and meshes with the gears 57 , 58 , as shown in FIG. 14( c ). With this arrangement, too, the rotation of the opening/closing member 48 is transmitted to the position meter 53 by the gears 55 , 57 , 58 , 59 and the opening degree of the ventilation passage 40 can be detected. When a wire winding drum 52 or gears 57 , 58 , 59 are used as described above, the resolution with which the movement amount of the opening/closing member 48 is detected can be changed easily by changing the diameter of the wire winding drum 52 or the gear ratio of the gears 57 , 58 , 59 .
(8) In the embodiment described above, the intake port 44 and the exhaust port 45 are provided closely adjacent to the first chamber R 1 and the second chamber R 2 , respectively. However, due to various circumstances, there are cases in which the intake port 44 and the exhaust port 45 are provided in positions separated from the first chamber R 1 or second chamber R 2 . In such cases, a duct joining the intake port 44 and first chamber R 1 and a duct joining the exhaust port 45 and second chamber R 2 can be provided. For example, consider a case in which the exhaust port 45 and intake port 44 are provided in the lower portion of the front face 21 such that the intake port 44 is separated from the first chamber R 1 , as shown in FIG. 15 . In such a case as this, it is acceptable to provide a duct 49 that runs from the first chamber R 1 , passes through the second chamber R 2 , penetrates the thermally insulated wall 26 and the front face 21 , and connects to the intake port 44 . In this way, even though the intake port 44 is in a position separated from the first chamber R 1 , air drawn into the intake port 44 from the exterior OS can be delivered to the first chamber R 1 by the duct 49 (see solid arrow A 6 ).
In the case of marine freight containers C, there are times when the refrigerator unit for container runs at terminals and the like in order to keep the freight cool after disembarkation. In such cases, a generator G is often installed on the upper portion of the front face 21 as shown in FIG. 15 because a power supply is not available. Consequently, the intake port 44 and exhaust port 45 cannot be provided in the upper portion of the front face 21 and must be provided in the lower portion of the front face 21 . Therefore, particularly in cases where ventilation is accomplished by utilizing pressure differences, it is effective to provide a duct(s) 49 as just described in order to ventilate the container.
(9) Although in the embodiment described above, ventilation quantities calculated based on the opening degree data are outputted to the display panel 76 of the control panel 72 and the output unit 78 , it is also acceptable to output such ventilation data as opening degree data.
(10) Although in the embodiments described above, such data as opening degree data, air speed data, output data, pressure difference data, and freight quantity data that indicate the ventilation quantity indirectly are detected and logged, it is also acceptable to provide a ventilation quantity sensor that detects the ventilation quantity directly and log the detected ventilation quantity.
(11) Although in the embodiments described above, the ventilation quantity is logged in a controller 7 arranged in the exterior storage space SP 1 , it is also acceptable to log the ventilation quantity in an external computer terminal, such as a desktop computer or notebook computer.
By using a refrigerator unit for container in accordance with the present invention, the quantity of air ventilated in the interior of a container can be known because recorded ventilation data related to the quantity of ventilated air can be reviewed afterwards.
|
A refrigerator unit is configured for a container in which it is possible to know the quantity of air that is ventilated. The refrigerator unit is equipped with a ventilation mechanism, an opening degree detecting mechanism, and a recording unit. The ventilation mechanism ventilates the air inside the container. The opening degree detecting mechanism acquires ventilation data related to the quantity of air ventilated by the ventilation mechanism. The recording unit records the ventilation data acquired by the opening degree detecting mechanism.
| 5
|
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to abating noise during the release of high pressure fluids and, in particular, to an improved system, method and apparatus for fluidic effectors that provide enhanced exhaust plume mixing for jet engines.
2. Description of the Related Art
A nozzle exhaust has high temperature and high velocity. The high temperature of the exhaust plume reduces the durability of the nozzle material, and the high velocity produces a significant amount of jet noise. As shown in FIG. 5 , a conventional nozzle 51 produces an exhaust plume 53 having a core 55 . Small-scale eddies 57 produce high frequency noise downstream from nozzle 51 , and large-scale eddies 59 produce low frequency noise further downstream from nozzle 51 .
A common way to reduce the exhaust plume temperature and the jet noise is to use an ejector nozzle. Ejector nozzles mix ambient air with the nozzle exhaust. This type of nozzle is typically heavy, bulky and complex, and inherently reduces performance of the engine.
For example, FIG. 1 depicts an aircraft nozzle 11 that incorporates an internal ejector mixer. A lobed mixer 13 ( FIG. 2 ) also may included. A scoop 15 is formed in the nozzle 1 to duct ambient air flow 17 into the exhaust stream 19 . The exhaust stream and the ambient air channeled through multiple lobes 21 in the mixer 13 that alternate hot and cold jets to mix the fluids within a constrained duct 23 . However, ejector nozzle 11 may be located internally or externally with respect to a jet engine. To incorporate this design inside a jet engine, the internal nozzle geometry is typically modified to a larger diameter than the basic engine. As a result, this solution requires a heavier and more expensive configuration to handle the thermal environment. This design also has an associated thrust-loss penalty at the nozzle (i.e., internal) and a drag penalty (i.e., externally) because of the increase in size requirements.
FIG. 3 illustrates an ejector nozzle solution having delta-shaped tabs 31 (e.g., one shown) protruding into the core exhaust stream at the nozzle exit 33 . This design produces many small vortex pairs and has an associated thrust-loss penalty as the exit flow is impeded. Moreover, this solution has limited applicability due to the extreme thermal environment inflicted on the tabs 21 .
FIG. 4 depicts one or more saw-toothed trailing edges 41 , 43 (e.g., two shown) on an aircraft engine 45 . Depending on the application and by-pass ratio (BPR), this design imparts weight penalties and constant drag. In addition, this solution generates the least beneficial stream-wise vorticity of these conventional designs. Thus, an improved design for fluidic ejector nozzles that provides enhanced plume mixing would be desirable.
SUMMARY OF THE INVENTION
Embodiments of a system, method and apparatus for fluidic effectors that provide enhanced plume mixing. The invention may comprise a fluidic effector having one or more rows of angled air jet injectors on both the external and internal nozzle/cowl surfaces. With the injectors angled in opposite directions, large scale vortices are induced and sustained. These vortices mix actuation air with the exhaust plume to produce ejector action. The plume mixes out quickly, thereby lowering jet noise and jet exhaust temperature.
The invention is also well suited for any application having a high velocity jet stream, such as steam valves and high pressure blow-off valves typically used in chemical or petroleum industrial environments. Microturbines also benefit from more efficient exhaust systems that require less volume and losses. For example, microturbine applications include distributed heat and power applications, hybrid electric vehicles, gas turbines or turbo generators used for power generation or as seagoing vessel power plants.
Instead of mechanical actuation (e.g., tabs, lobes, etc.), embodiments of the invention use fluidic injectors that can be positioned in the hot gas stream to mix the actuation and exhaust air flows. For example, synthetic, engine compressor-bleed or engine fan-bypass air flow may be provided to the fluidic injectors. The invention increases the shear magnitude between the two fluid streams, and forces greater rotation (i.e., vorticity) and increases penetration of the streams into each other than can be achieved with conventional designs.
The stream-wise vortices generated have more momentum (i.e., an increased mixing rate) and are able to penetrate further into the exhaust plume since more surface area is available for mixing to occur. The mixing also persists longer because of the increased surface area, resulting in the generation of a uniform velocity aft of the nozzle faster and more affordably than with traditional methods.
The jet arrays may be tailored with respect to orientation and injection rate, or adjusted to allow variable mixing rates for use at different flight and engine conditions. For example, the system may be adjusted for aircraft take-off low level approach or cruise at altitude. The fluidic ejector system may be turned on and off as needed, so the performance penalties are not carried at all flight conditions. In contrast to the heavy, bulky and complex conventional ejector nozzles, this design is simpler and much lighter in weight. The acoustic and thermal reduction benefits are attractive for non-aviation applications as well, such as other gas turbine applications like power generation and industrial applications involving high pressure fluids.
The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features and advantages of the present invention are attained and can be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is an isometric view of a conventional ejector nozzle;
FIG. 2 is an isometric view of a conventional lobed mixer for the nozzle of FIG. 1 ;
FIG. 3 is a partial isometric view of another conventional ejector nozzle design;
FIG. 4 is an isometric view of an aircraft engine that incorporates another conventional ejector nozzle design;
FIG. 5 is a schematic side view of a conventional nozzle and exhaust plume;
FIG. 6 is an isometric view of one embodiment of an aircraft constructed in accordance with the invention;
FIG. 7 is a split schematic end view of two embodiments of an exhaust nozzle of the aircraft of FIG. 6 and is constructed in accordance with the invention;
FIG. 8 is a schematic top view of the exhaust nozzle of FIG. 7 and is constructed in accordance with the invention; and
FIGS. 9 and 10 are schematic end views of other embodiments of exhaust nozzles constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 6-10 , embodiments of a system, method and apparatus for fluidic effectors that provide enhanced plume mixing are disclosed. In one embodiment, the invention may be used in an aircraft 61 ( FIG. 6 ) having an engine exhaust system 63 . The invention is well suited for abating noise and reducing the exhaust temperature during the emission of the high pressures, velocities and temperatures of the fluids from the engine exhaust system. Although the invention is depicted in use with round engine exhaust nozzles in FIGS. 6 and 7 , other shapes such as elliptical and trapezoidal nozzles (see FIGS. 9 and 10 ) are also suitable for use with the invention.
As shown in FIGS. 7 and 8 , the engine exhaust system 63 has a nozzle or aperture 81 ( FIG. 8 ) with an inner surface 71 and an outer surface 73 . Depending on the application, the aperture may comprise the engine exhaust nozzle exit lip which is located aft of the nozzle throat 83 and any other location near areas where exhaust-washed and external surfaces meet. A source of actuation air 75 is provided for the engine exhaust system. The source of the flow of actuation air may comprise synthetically-generated or engine compressor-bleed or fan-bypass air flow.
At least one inner effectors or air jets 77 (a plurality is shown) is mounted to the engine exhaust system adjacent the aperture at the inner surface 71 . The inner effectors 77 are coupled to the source of actuation air 75 for emitting an inner air jet stream 79 through the inner effectors 77 in a first direction. Two different embodiments are depicted in the upper and lower halves of FIG. 7 . The upper configuration of FIG. 7 generates large counter-rotating vortex pairs that persist over time and have a longer duration. The lower configuration of FIG. 7 generates smaller regions of vorticity, but may be desirable in some applications.
As shown in FIGS. 7 , 8 and 9 , the inner effectors 77 may emit the inner actuation air flow 79 in similar or different directions. Directional characteristics and flow rate of the actuation air flow, such as jet azimuth, elevation and mass flow, can be tailored for specific integrations to allow an optimized system. FIG. 9 illustrates the effect of multiple jet arrays that may be used to set up a large scale vortex on each “edge” of the aperture.
The engine exhaust system 63 also comprises at least one outer ejector effector 85 (a plurality is shown) that is mounted thereto adjacent the aperture at the outer surface 73 . The outer effectors 85 also are coupled to the source of actuation air 75 for emitting an outer air jet stream 87 through the outer effectors 85 in a second direction that is different than (e.g., opposing) the first direction. The inner and outer effector air flows 79 , 87 combine with the fluid flow from the engine exhaust and the free stream air to reduce a noise level generated by the device. The actuation air flows from the inner and outer effectors provide enhanced plume mixing to induce and sustain large scale vortices 89 ( FIG. 7 ), and reduce an exhaust temperature generated by the engine exhaust.
In some embodiments, each of the inner and outer effectors 77 , 85 comprises a row of angled air jet injectors on the internal and external cowl surfaces 71 , 73 , respectively, of the engine exhaust nozzle. At least some of the angled air jet injectors 77 on the internal cowl surface 71 may be positioned in the hot gas stream. The inner and outer effectors increase a shear magnitude between the fluid flow (e.g., exhaust) and the flow of actuation air, force vorticity and increase penetration of the fluid flow and actuation air flows into each other.
In other embodiments, the invention further comprises controls 91 for adjusting a mixing rate between the fluid flow and the actuation air flow based on flight conditions of the aircraft, or power setting of the engine, including selectively activating and deactivating the system based on need for the system. The controls 91 may further comprise controlling an air jet orientation and injection rate of actuation air flow through the inner and outer fluidic effectors 77 , 85 , depending on the application.
The invention provides numerous advantages. For example, in some embodiments the mixing rate of multiple fluid streams of differing velocities is enhanced to reduce jet noise and thermal impact to airframe surfaces, as well as increase propulsive efficiency. Entrainment of surrounding free stream air is increased without adding the weight and complexity of a traditional ejector or noise suppressor integration. The reliability, maintainability and supportability of such a system has reduced life cycle costs, and reduces the vehicle drag associated with current noise and thermal abatement systems. The present design also has increased applicability to all engines with any bypass ratio (BPR) and any installation (e.g., fuselage-integrated or pod configurations). Although most commercial aircraft engine designs have a medium to high BPR, and military designs are typically less than one, the invention is well suited for both applications.
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. For example, even through the invention has been shown and described in use with aircraft or other gas turbine propulsion integrations, the device that employs the invention also may comprise a valve, such as a steam valve, high pressure blow-off valve, etc., typically used in chemical or petroleum industrial environments. Microturbines also benefit from more efficient exhaust systems that require less volume and losses. For example, microturbine applications include distributed heat and power applications, hybrid electric vehicles, gas turbines or turbo generators used for power generation or as seagoing vessel power plants.
|
A fluidic effector provides enhanced plume mixing for an aircraft engine. Air jet injectors are located on both the external and internal cowl surfaces and angled in opposite directions to induce large scale vortices in the exhaust plume. The vortices mix actuation air with the exhaust plume to produce ejector action. The plume mixes out quickly, thereby lowering jet noise and jet exhaust temperature. The injectors have orientations and injection rates that are adjustable to allow variable mixing rates for use at different flight and engine conditions.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
Individuals subject to cataractogenic radiation, both short and long term exposure, suffer eye damage. This damage manifests itself primarily as a tumor and a nuclear or cortical lens cataract. The lens cataractogenic dose has been recently identified as 200 REMS with Gamma or X-radiation for acute exposure and between 450 REMS and 750 REMS for fractionated exposure. Damage to an eye begins at the time of the exposure, and continues to occur for several weeks thereafter, due to the generation of free radical toxins in the eye tissue. Secondary to X-ray induced cataracts, concurrent or subsequent exposure to Ultra-Violet (UV) light will cause photochemical cataracts, while reducing the cataractogenic dose for all types of radiation. Therefore, the danger is increased whenever more than one type of harmful radiation exposure to the eye exists with cumulative effects. Also, shorter wavelength infrared radiation will promote cataract formation. Such an infrared cataract has been termed a glass blower's cataract.
At risk are dental patients undergoing various procedures (including C.T. scan, fluoroscopic, tomographic, cephalometric, panagraphic, full mouth series, bite wing, and occlusal X-ray procedures, and UV radiation induced curing processes), medical patients (as with C.T. scan, fluoroscopic, tomographic, and like techniques), and the dental and medical practioners performing radiation related procedures. Additional at risk individuals include airline pilots, astronauts, people living at higher elevations, nuclear accident or conflict victims, and those persons found in environments where radiation is prevalent.
Various protective eye wear devices exist, but not for reducing all types of cataractogenic radiation, while providing for interdiciplinary use. In each case, only one form of harmful radiation is stopped, allowing the other forms to damage the eye. Combination Gamma, UV, X-radiation, and near blue light protective goggles are desperately needed. The subject invention structure provides the combined protection while incorporating additional desirable elements. More particularly, this device relates to sterilizable goggles having a novel composition and construction comprising a frameless, circularly curved leaded polymer, Gamma, UV, near blue light, and X-ray opaque, yet visible light transmissive lens having an outer perimeter edge associated with a leaded vinyl radiation opaque boot, adjustable and interchangable ear pieces, and a detachable variably sized nose rest.
2. Description of the Background Art
Given sufficient exposure, most radiation is capable of inducing damage to sensitive eye tissue. However, it is documented that the most dangerous range of radiation (in terms of generating tumors, cataracts, and general retinal injury) is near blue visible light and wavelengths less than 525 nm, such as UV-A (320-400 nm), UV-B (280-320 nm), and UV-C (180-280 nm) in the case of photochemical cataract (see, The New England Journal of Medicine, H. R. Taylor, et al., 319(22), pp. 1429-1433 (1988) and Documenta Ophthalmologica, S. Zigman, 55, pp. 375-391 (1983)), and Gamma and X-ray (see, Pathology of the Eye, D. vonDomarus, et al., pp. 227-234, Springer-Verlag, New York (1986), Oral Surgery, S. Antoku, et al., 41(2), pp. 251-260 (1976), Radiation Physics, J. T. Littleton, et al., 129, pp. 795-798 (1978), and Ophthalmology, L. T. Chylack, Jr., 91(6), pp. 596-601 (1984)). Additionally, the foregoing articles establish a cause and effect relationship between radiation exposure and eye damage (tumor, cataract, and retinal injury), while providing data of actual measured dose exposure to eye tissue in REMS (biological equivalent of radiation absorbed dose: ionizing energy transfer of 100 ergs per gram of eye tissue) resulting from irradiation procedures and environmental exposure.
Until now, the problem of combined and cumulative effect multi-type radiation exposure of the eye has not been solved. Traditionally, protective eye devices for preventing UV and X-radiation damage are either totally opaque to visible light, such as a shield of lead foil, or transmissive to visible light and selectively restrictive to either UV or X-radiation. Additionally, most of the prior art devices are not suited for interdiciplinary use because they are cumbersome and heavy, thereby inhibiting easy movement of the wearer, while failing to protect from all angles of exposure.
In general, medical and dental patients fear what they can not see. Some of the prior devices overlooked the desirability and necessity of having a patient observe a procedure so that they may be aware of and respond to spatial commands of head positioning. Due to undesirable angles and construction features, many of the prior art designs that relied on complete visible light, UV and X-ray blockage are not adaptable to visible light transmissive versions. In addition, the problem of lens fogging with condensation occurs with prior art goggles that provide peripheral exposure protection. Further, the prior art goggles do not shield the eyes from all types of cataractogenic radiation.
Disclosed in U.S. Pat. No. 4,024,405 is an X-ray eye shield for protecting eye tissue during dental radiography. The lens cups are constructed of lead encased plastic. These lens cups fit snugly over the patient's eye sockets, therefore, all visible, UV, and X-ray radiation is blocked and the free circulation of condensation preventing air is stopped and fogging occurs.
U.S. Pat. No. 4,635,625 relates a surgical eye mask for laser treatment fabricated from highly reflective metal, preferably aluminum, foil and having eye pads of cotton gauze for maintaining eye moisture. Adhesive means are provided to seal the mask against the patient's face during laser irradiation. Given the radiolucent qualities of aluminum foil, X-radiation is not adequately blocked and all vision is completely blocked.
A hand-held light filter is presented in U.S. Pat. No. 4,640,685. This shield must be held by a dental assistant in front of a patient's mouth during UV irradiation procedures involved in curing dental resins in the patient's mouth. From particular angles, incident scatter UV light may be reflected by the shield back into the patient's eyes with harmful effects. In addition, harmful radiation of less than 400 nm or greater than 525 nm (near blue light) is free to pass through the specific material disclosed in '685.
Depicted in U.S. Pat. No. 4,701,129 is a visible light transmissive face shield device for protecting a dentist's face from debris, bacteria, and the like, including UV radiation from resin curing procedures. Large shoulder supports hold the device in place during use and restrict movement.
U.S. Pat. No. 4,758,079 discloses an eye shield that resembles a pair of ordinary sunglasses. However, the lenses in the device are coated with reflecting and absorbing materials that completely block only direct UV and visible light transmission, while allowing harmful peripheral scatter rays to reach the eye. Additionally, the lens material does not effectively block X-radiation.
Offered for sale in Catalog G-5 from Nuclear Associates (A Division of Victoreen, Inc., 100 Voice Road, Carle Place, NY, 11514-1593) are two types of visible and UV light transmissive, but X-ray opaque glasses. On page 34 is offered, for medical personnel, prescription and nonprescription Radiglasses™ which resemble normal eyeglasses with side shields of the same X-ray opaque heavy leaded glass as used in the front viewing lenses. Close examination reveals that complete peripheral ray protection from many angles is not provided. Additionally, the X-ray opaque frame interferes with the images of important anatomical landmarks necessary for diagnosis in medicine and dentistry. A set of protective lens cups for a patient are offered alternatively on page 48. These lens cups fit tightly over the contours of the orbits of the eye to block peripheral radiation, thereby preventing the exchange of moist air to produce fogging.
SUMMARY OF THE INVENTION
An object of the present invention is to produce safety goggles that effectively reduce, by over 90%, eye exposure to all known types of cataractogenic radiation (near blue light, UV-A, UV-B, UV-C, Gamma, and X-radiation) from all angles of incidence found in the wearer's surrounding environment, while providing unimpaired forward and peripheral vision.
An additional object of the present invention is to create safety goggles that conform to all facial curvatures of a wearer, from children to adults, while providing a peripheral seal.
Another object of the present invention is to make safety goggles that are sterilizable to prevent possible contamination to multiple user patients from organisms that cause A.I.D.S., hepatitis, and other communicable diseases.
Yet another object of the present invention is to fabricate safety goggles that are inexpensive to produce, since the component parts are very inexpensive and no drilling or screws are required for assembly, thereby facilitating widespread adoption and interdiciplinary use.
Yet a further object of the subject invention is to manufacture goggles that have multipurpose applications in dentistry as; UV light curing, X-ray shielding, and general safety goggles, thereby eliminating the need for three different types of glasses in clinical practice.
Yet still another object of the subject invention is assemble goggles with a surrounding UV, Gamma, and X-ray impervious boot that provides ventilation to prevent fogging, yet adapts automatically to a wearer's facial contours to form a peripheral shield.
Yet still a further object of the subject invention is to make protective goggles that have both a radiolucent polymer frame and a lens positioned to avoid blocking critical anatomical landmarks used for graphic calculations in orthodontic and cephalometric X-ray procedures.
Yet still an additional object of the subject invention is to make protective goggles that will encourage an interdiciplinary use to shield astronauts and high altitude pilots from solar flares and storm radiation, and also to provide all purpose goggles for the general public to shield the wearer's eyes from high intensity solar radiation at high elevations.
Disclosed is a pair of protective safety goggles for effectively shielding a user's eye tissue from cataractogenic radiation, comprising a sterilizable, generally flattened and essentially UV, Gamma, and X-ray radiopaque leaded polymer lens having a generally oblong lens-on profile with an elongated outer perimeter border with upper and lower long edges and two opposing short side edges. The frameless lens is formed to curve in the arc, or a circle coextensive with said long edges, over the surface of the user's face to substantially cover both eyes of the user from both frontal and profile views. A sterilizable radiolucent polymer nose rest is reversibly attached in a receiving notch in the lower long edge of the lens midway between the opposing side edges of the lens. Two sterilizable, partially removable, and adjustable radiolucent polymer ear pieces are associated with the lens. Specifically, one of the ear pieces is attached to each of the opposing short side edges of the lens. Additionally, an UV, Gamma, and X-ray radiopaque boot is fastened to the upper and lower long edges of the lens. This boot comprises a plurality of flattened elongated strips of flexible leaded polymer with each of the strips having first and second opposing long margins and opposing short margins, with a tab projecting from at least one short margin of each strip. The first long margin of a strip is secured to the upper long edge and the first long margin of at least two other of the strips is secured to the lower long edge of the outer perimeter border of the lens with all of the strips extending from the outer perimeter lens border to proximate the user's face at the second long margin of each of the strips producing an enclosure. To aid in fastening the strips, the tabs are secured in receiving slots in each hinge piece. The enclosure spans between the opposing short side edges of the lens along the upper and lower long edges having an air vent proximate each of the short side edges, near the area where the tabs are secured. These air vents provide an essentially water condensation free environment within the goggle enclosure.
Other objects, advantages, and novel features of the present invention will become apparent from the detailed description that follows, when considered in conjunction with the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective illustration of the subject invention having a surrounding protective boot.
FIG. 2 is a top view of the subject invention.
FIG. 3 is a bottom view of the subject invention.
FIG. 4 is a front view of the subject invention.
FIG. 5 is a rear view of the subject invention.
FIG. 6 is a side view of the subject invention.
FIG. 7 is a cross sectional view of a nose piece mounted in a lens of the subject invention.
FIG. 8 is a view of the hinge region of an ear piece of the subject invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-8, there is shown a preferred embodiment of protective safety goggles 4 of the subject invention. This device is for blocking harmful radiation with a lens 8 having sufficient filtering properties to effectively limit the amount of UV, Gamma, and X-ray radiation that passes through the lens 8 to contact the eye tissue of a wearer. The subject device is intended for utilization by a user or wearer in all environments where UV, Gamma, and X-ray radiation exposure may be encountered and is intended to shield a wearer's eye tissue from such dangerous radiation. Since one use for the subject device is eye protection from UV and X-ray radiation for various patients undergoing dental or medical procedures and any one of these patients might be infected with a communicable disease (such as hepatitis, aids, and like afflictions), the lens 8, all other components, and attachment means of the subject invention are fabricated from materials that resist standard chemical and heat sterilization procedures.
The subject invention, as illustrated in particular in FIGS. 1-6, comprises a lens 8 that is capable of blocking essentially all UV, Gamma, and X-ray radiation that might strike the goggles during an intended use. Blocking essentially all UV radiation is defined for purposes of this device as between about 70% and about 100% of the encountered UV radiation being stopped from passing the goggles 4. For effectively blocking X-rays, the defined level for this device is between about 90% and about 100% elimination of encountered X-rays from striking a user's eye tissue. Gamma rays are effectively blocked by eliminating greater than about 70% of the rays.
The structure of the lens 8 comprises elongated form of generally uniform thickness usually from about 1 mm to about 9 mm, more preferably from about 2 mm to about 8 mm, and preferably about 7 mm. The thickness is dependent upon the ability of the lens 8 to filter harmful UV, Gamma, and X-ray radiation. The lens may be constructed from any suitable material (e.g., glass or polymers that are doped with sufficient quantities UV blockers and lead or similar elements to decrease the transmission of X-rays and Gamma rays) that transmits visible light, but is essentially radiopaque to UV, Gamma, and X-rays. Suitable lens 8 materials comprise between about 20% and about 40% lead by weight. A preferred material for the construction of the lens 8 is an acrylic polymer that contains 30% lead by weight. Although any suitably doped (with X-ray and Gamma ray shielding substances and optionally, known UV blocking agents) plastic polymer would be within the contemplation of this disclosure, a specific example is a 30% lead by weight acrylic copolymer known as CLEAR-Pb® from Nuclear Associates (Nuclear Associates is a division of Victoreen, Inc., 100 Voice Road, Carle Place, N.Y. 11514-1593) which provides a lead thickness equivalence of about 0.3 mm lead. It is well known that plastic polymers are effective blockers of UV radiation. For example, a 7 mm thickness of the CLEAR-Pb®, treated with UV blocking agent, effectively filters greater than 70% of UV radiation. The lens may be formed by standard techniques such as casting, thermo-molding, or injection molding.
Surrounding the outer extent of the lens 8 is an elongated outer perimeter border. The lens 8 has two opposing essentially parallel short edges 16 and opposing outwardly or convexly curved upper 20 and lower 24 long edges. The upper 20 and lower 24 long edges appear to bulge away from the lens 8. The lens 8 is formed so that it curves in a smooth arc, coextensive with the long edges 20 and 24, over the surface of a user's face. This curved lens 8 substantially covers both eyes of the user. Since an individual wearer's face does not drastically change in curvature from childhood to adulthood (only enlarges in size, not curvature), one pair of goggles may be used for both children and adults.
In the lower long edge 24, midway between the short side edges 16 is a nose rest receiving notch 26. As seen in particular in FIGS. 1, 4, 6, and 7, mounted within the nose rest receiving notch 26 is a nose rest. To prevent the nose rest from interfering with X-ray pictures, the nose rest is constructed from radiolucent materials such as structurally acceptable polymers and natural and synthetic rubbers. The nose rest comprises a body 31 (preferably constructed of a plastic material) and at least a portion that is a detachable member 32 (preferably constructed of a rubber substance) for easy removal (see, FIG. 7). Because individual wearers of the goggles 4 will have variably sized noses, the detachable member 32 comes in different thicknesses and proportions to accommodate all nose sizes and shapes. The detachable member 32 is secured to body 31 of the nose rest by means that are easily employed, such as grooves, slots, snaps, Velcro® mating strip, and equivalent devices, and preferably by pins 34 projecting from the body 31 of the nose rest that fit within receiving holes 35 in the detachable member 32. Further, the ability to easily remove the nose rest detachable member 32 allows for ready sterilization (one of the subject invention pieces most likely to carry a contagious agent, the other pieces being the ear pieces described below) by standard techniques without sterilizing the entire pair of goggles 4.
To attach the nose rest within the nose rest receiving notch 28 a radiolucent means is utilized. As with the nose rest itself, the attachment means must be essentially transparent to X-ray radiation. Depending upon the exact medical or dental usage, anatomical reference points are possibly blocked if a radiopaque nose rest or attachment means are employed. Essentially transparent to X-ray radiation is defined for this device to be greater than about 70% transmissive of X-rays. This attachment means is preferably acrylic glue (Super-Glue®) or equivalent material, but it is well within the realm of this disclosure to employ alternative similar means such as heat, screws, rivets, and the like or to form the nose body 31 as an extension of the lens 8.
Depicted in FIG. 7 is an additional lens coating 37 that may be optionally applied to the surfaces of the lens 8. Primarily, this lens coating 37 is to filter UV and near blue visible radiation (525 nm to UV) from passing through the lens 8. Even though plastic polymer lenses filter UV radiation, additional protection in the range of about 70% to 100% UV blockage is achieved by applying an appropriate standard blocker as a lens coating. Also, it is known that near blue radiation can cause eye damage. A typical lens coating that essentially blocks near blue visible radiation is TLS blue-blocking tint (available from North American Coating Laboratories of California, Inc., 695 S. Raymond Ave., Pasadena, Calif. 91105). Such a near blue coating is applied by standard techniques such as immersion of the lens 8 into a heated (208° F.) bath of TLS for two minutes. Further, infrared blocking tints are commonly available that prevent the passage of radiation in the range of 700 nm to 800 nm and would be applied by standard techniques.
Attached to each lens short side edge 16 is an ear piece. The attachment is by radiolucent means that is similar to or equivalent with the attachment means used to secure the nose rest body 31. As above with the nose rest, depending upon the exact medical or dental usage, anatomical reference points are possibly blocked if radiopaque ear pieces and attachment means are employed. Preferably, the radiolucent attachment means is acrylic glue (Super-Glue®) or its equivalent, that securely fastens the ear pieces while allowing at least 70% of X-ray radiation to pass. Preferably, the ear pieces are fabricated from radiolucent plastic polymer, but similar materials are contemplated to be within this disclosure.
Each ear piece has a front surface 40, a back surface 44, an upper edge 48, a lower edge 52, a first end region 56, and a second end region 60. At the terminal portion of the first end region 56 closest the lens 8 is where the attachment to the lens short side edge 16 occurs (see, FIG. 8). At the opposite terminal portion of the first end region 56 is one half of a hinge 64 for allowing a user to bend the ear piece. Preferably, the hinge is radiolucent and is either an additional piece added to the ear piece or is formed as a continual element of the polymer ear piece material. At one terminal portion of the second end region 60 is the other half of the hinge 64. Standard hinge technology is employed to couple the two halves of a hinge into a pivotable form. At the opposing terminal portion of the ear piece second end region 60 is a typical area having a form adapted for fitting over or behind a user's ear to secure the goggles 4 in place.
Additionally, the ear pieces are adjustable (not only the terminal portion of the second end region 60, that fits over the user's ear). Each ear piece is able to be lengthened or shortened and secured about a telescoping connection 66, having male and female components, located between the hinge 64 and the terminal portion of the second end region 60. Ear piece length adjustability is achieved by a pressure fit of the telescoping connection 66, wherein, preferably, a plurality of knob-hole interlocking means 67 are positioned along the telescoping connection 66, however, other equivalent means for producing ear piece adjustability are considered to be within the realm of this disclosure. At least one knob on the male component of the connection 66 fits into a hole on the female component of the telescoping connection 66. To fit children or adults, the ear pieces may be extended to an appropriate length and secured by the knob-hole interlocking means 67. (also, a suitable detachable nose rest member 32 would be selected). Since the curvature of a wearer's face stays essentially constant during growth, the extension of the ear pieces can accommodate an adult over a child. Further, the telescoping connection 66 may be separated and at least part of the second end region 60 (from the male component of the connection 66 to the terminal user ear fitting area) removed from the remainder of the goggles 4 for easy immersion cold sterilization.
Within each first end region 56 is an ear piece tab receiving slot 72. This tab receiving slot 72 is formed through the front surface 40 of an ear piece and into the ear piece proximate the first end region 56. The slot 72 extend from the upper ear piece edge 48 to the lower ear piece edge 52. The purpose of a tab receiving slot 72 is to receive a tab that projects from an element of a radiopaque boot to aid in securing the boot to the lens 8.
The preferred embodiment of the subject device includes a radiopaque boot that produces an enclosure that extends from the lens 8 to proximate a user's face, and may touch the skin of the face. Since harmful radiation can enter an individual's eyes from other than essentially straight on, a radiopaque boot or skirt is attached to the upper 20 and lower 24 long edges of the lens 8. Visible light need not pass through this boot.
The boot comprises a plurality of flattened elongated strips of flexible leaded polymer. The boot is preferably fabricated from lead-vinyl or equivalent materials. Lead-vinyl is commonly available in various thicknesses and for suitable flexibility characteristics a thickness of about 1/32 inch is preferred. Such a thickness, 1/32 inch, is equivalent to about 0.25 mm of lead. This thickness, 1/32 inch, or generally in the range of about 1/64 inch to about 1/16 inch, effectively blocks X-ray and Gamma radiation and all UV radiation.
Although the preferred embodiment of the subject invention boot comprises three elongated strips, other combinations of strips are contemplated to be within this disclosure. Specifically, the boot comprises a first strip 80 having first 84 and second 88 opposing long side margins. Further, the first strip 80 has two opposing short side margins 92. The short side margins 92 may have essentially straight parallel, divergent, or convergent borders or may be of irregular contour. Each short side margin of the first strip 80, regardless of its general border shape, has a tab 96 that projects away from the short margin 92. The first strip tab 96 is disposed toward the first long side margin 84.
Creating the upper portion of the boot is the first strip 80. The first long side margin 84 is secured to the top surface of upper long edge 20 of the lens 8 by appropriate fastening means such as glue (specifically acrylic glue like Super-Glue®), heat, screws, rivets, or similar agents. The tabs 96 at each end of the first strip 80 and a limited portion of the first strip 80 protrude past each lens short side edge 16 to permit the tabs 96 to be inserted into and secured within the ear piece receiving slots 72. As above, the tabs 96 are preferably secured by gluing. The distance between the first strip first long side margin 84 and the second long side margin is selected to approximate the distance between the lens 8 and the face of a wearer and is usually between about 1 cm and about 4 cm and more usually about 2 cm to about 3 cm.
Two radiopaque strips produce the lower portion of the boot. A flattened and elongated second strip 100 is comprised of opposing second strip first 104 and second 108 long side margins 104 and opposing second strip first 112 and second 116 short side margins. The second strip first short side margin 112 has a second strip tab 120 projecting away from the first short side margin 112. The second strip first long side margin 104 is secured (secured by means described above for the first strip 80) to the lens lower long edge 24 and oriented to have the tab 120, and a limited amount of the second strip 100, protruding past a lens short side edge 16. This tab 120 is inserted into and secured within an ear piece tab receiving slot 72. Attached immediately next to the nose rest body 31 or beneath the nose rest body 31 in a recess or indentation in the lens lower long edge 24 is the second strip second short side margin 116. The second strip second long side margin 108 extends to near or touching the user's face.
Additionally, a flattened and elongated third strip 122, comprising opposing third strip first 124 and second 128 long side margins 124 and opposing third strip first 130 and second 134 short side margins. The second 100 and third 122 strips are related to one another by mirror image symmetry and (as with the second strip 100 by analogy) the third strip 122 is secured by the third strip first long side margin 124 to the lens lower long edge 24 (on the opposite side of the nose rest receiving notch). The third strip first short side margin 130 has a third strip tab 138 projecting away from the first short side margin 130. The third strip first long side margin 124 is secured (secured by means described above for the first strip 80) to the lens lower long edge 24 and oriented to have the third strip tab 138, and a limited amount of the third strip 122, protruding past a lens short side edge 16. This tab 138 is inserted into and secured within an ear piece tab receiving slot 72. In mirror image analogy to the second strip 100 above, attached immediately next to the nose rest body 31 or beneath the nose rest body 31 in a recess or indentation in the lens lower long edge 24 is the third strip second short side margin 134. The third strip second long side margin 128 extends to near or touching the user's face.
The distance between the second and third strip first long side margins 104 and 124 and the opposing second long side margins 108 and 128 is selected to span the average distance between the lens 8 and a user's face. This distance is usually from about 1 cm to about 5 cm and more usually between about 2 cm and 4 cm.
As seen in particular in FIGS. 1, 4, and 5, an air vent 142 is created proximate each lens short side edge 16 by the three boot strips 80, 100, and 122 that extend from the outer perimeter lens border to proximate the user's face. The enclosure that spans between the lens opposing short side edges 16 along the lens upper 20 and lower 24 long edges provides additional UV, Gamma, and X-ray radiation protection for the user. Additionally, the air vents 142 allow for a ready exchange of air, thereby producing an essentially water condensation free environment for the inside surface of the lens 8.
A typical method of use for the subject device comprises first fitting a user with the above described goggles 4. This process involves selecting the correct detachable nose rest member 32 and adjusting the ear piece adjustment means 66 by extending or contracting the telescoping mechanism. Additionally, each ear piece second end region 60, opposite the half hinge, may need to be bent to fit over a user's ear. Secondly, the goggles are worn where excessive UV, Gamma, or X-ray radiation is encountered. Also, an additional step of sterilization may precede the wearing of the goggles 4.
The invention has now been explained with reference to specific embodiments. Other embodiments will be suggested to those of ordinary skill in the appropriate art upon review of the present specification.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be obvious that certain changes and modifications may be practiced within the scope of the appended claims.
|
Safety goggles that effectively filter possibly dangerous levels of all types of cataractogenic radiation including near blue light, UV-A, B, and C, Gamma, and X-radiation are disclosed comprising an UV, Gamma, and X-ray radiopaque frameless leaded polymer lens formed to curve over a user's face having a radiolucent polymer nose rest and ear pieces and a radiopaque boot extending from the lens to proximate the user's face to produce a vented peripheral enclosure to cover both eyes of the user and shield the user's eyes from all angles of harmful radiation exposure, but allow unobstructed forward and peripheral vision.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to erosion control devices for shorelines.
2. Prior Art
Erosion of shorelines as a consequence of wave action is a well recognized phenomenon. The prior art is replete with numerous attempts and various structures to minimize this problem. Generally, erosion is a function of a persistent wave action exerted on beaches comprised of sand or fine shingled material and is most frequently encountered along shorelines of large bodies where such action can be generated. As a consequence of this persistnet wave action, material on the shore tends to be loosened by the wave action and the continuous reciprocating movement along that shoreline causes such materials to generally erode away. The problems of erosion are well known and are emphasized in situations of exceptionally long shorelines where the phenomena of littoral drift is enhanced. In those situations, breakwaters and the like only tend to emphasize downstream erosion problems.
In view of the fact that the dynamics of the problem are well understood and that erosion is a commonplace occurrence, the prior art has been highly developed in this area. Despite that development, various problems exist in these devices which have generally resulted in no one proposal being widely accepted. Accordingly, erosion control is the subject of continuing research.
One class of prior art devices attempts to deal with the problem by means of massive bulwarks or other large structures. These devices are very cumbersome, expensive and difficult to install.
To overcome the problems of installation and general size, various prior art attempts have been made to modularize components. One such attempt is shown in U.S. Pat. No. 3,875,750 wherein a modular device having a series of peaks and depressions is shown to break up various wave action phenomena. The return paths 44 and 46 shown in FIG. 2 of that patent allow water from the dissipated wave to return back to the body. Various arrangements of these components are utilized to build up a continuous breakwater for dissipation of waves. Also, as a consequence of the use of a return path for water, sand and loose material carried by the waves is allowed to build up behind the barricade, thereby building up the shoreline on the land side of the sea wall. One difficulty with the device shown in this prior art patent is that its orientation is critical vis-a-vis the wave action, and in the case of extraordinary waves, if the device is tipped over on its side, it will be rendered inoperative. Also, the costs of construction might be high in view of the intricate patterns involved.
To overcome the cost problem, U.S. Pat. No. 3,894,397 defines an erosion device utilizing ordinary concrete blocks having courses interlocked between them. As in the case of other prior art devices, extraordinarily large wave action may disorient or tip such a device thereby rendering it inoperative and leading to its early destruction by wave action. Another problem tending to increase the cost of such a device is the fact that because ordinary concrete building blocks are utilized, the path for water is exceptionally large and the dissipation of kinetic energy in the wave is relative inefficient. Therefore, additional elements in the form of flappers 30 shown in FIGS. 5 and 6 are required to dissipate wave action to a greater extent than that attained solely by the concrete block pattern and also to facilitate the removal of entrained materials in the waves themselves. Bonding techniques are weak, and blocks become loose.
Other types of prior art erosion devices are typified by mechanical structures which are erected and anchored in the shoreline to interrupt and disperse wave action by means of a series of baffles. U.S. Pat. Nos. 3,309,876 and 3,845,630 typify this class or prior art devices. Such devices, which require anchoring to the seabed, are expensive and difficult to maintain. Additionally, while located below the low means water level at the particular area of installation, such devices, nevertheless, present a menace to navigation since they are generally unmarked and unknown to mariners.
A third class of devices is typified by U.S. Pat. No. 3,952,521 and relate to portable erosion control devices. As is readily apparent, the device as typified by that patent is large, complicated in shape, and generally expensive. While the advantage of mobility ensues with those devices, their general expense and unmanageability have condemned attempts in that direction.
SUMMARY OF THE INVENTION
This invention builds on these prior art attempts at devising a suitable erosion control system by utilizing an easy to fabricate modular construction of symmetrical relationship. The use of modular construction techniques enhances the fabrication at the erosion site, yet reduces the cost of manufacture. Manufacturing costs are reduced because a multitude of identical elements are coupled together to form the completed unitary structure. Additionally, the design of the present invention departs from the prior art by utilizing a symmetrical shape adaptable for use in any orientation vis-a-vis the wave action such that tipping over of the device will result in the same action, that is, wave control, taking place as in any other orientation. The only requirement is that the axis of alignment of the individual modules lays generally parallel to that of the wave line.
The present invention utilizes a series of baffles and passageways to produce a turbulent flow pattern thereby resulting in the deposits of sand or loose shale material in the area around the erosion control device. Accordingly, entrained materials carried by the waves are deposited on the beach about and behind the control device to establish and fortify existing beach topology. Because these devices are placed on the beach themselves, the problem of erosion downstream as a function of the littoral drift patterns is eliminated.
Accordingly, it is an object of this invention to produce an inexpensive yet workable beach erosion control system.
It is yet another object of this invention to define a modular erosion control system having unitary parts which are identical and easily handled.
Still another object of this invention is the provision of an erosion control system of modular construction, utilizing low cost concrete materials to reduce manufacturing costs.
A further object of this invention is to provide for a beach control device which breaks up wave action yet allows the deposit of entrained materials carried by the waves.
These and other objects of this invention will be shown in the drawings and preferred embodiment herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an assembled beach erosion control device showing one completed unit.
FIG. 2 is an end view of one module of the erosion control device.
FIG. 3 is an end view of the module shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the figures, a modular device is shown as element 10 in FIG. 1. The structure may comprise any number, and in FIG. 1 six identical modules 12 which are aligned along an axis 14 are shown for illustration. The axis 14 defining the alignment of the modular 10 is disposed in a general parallel relationship to a wave line shown schematically as 16. The completed modules are assembled at the beach site and are located at the position to receive waves on the beach at a mean position at a mean tide location. Accordingly, some waves may not reach the erosion control device while others, in view of intensity of storm action, may actually submerge the device. However, a significant percentage of waves will be effectively dissipated by such a device. While one module 10 is shown, it is apparent that a succession of modules can be built up and placed in any orientation to follow the beach line and wave pattern.
As shown in FIGS. 2 and 3, the individual sections 12 are shaped as equilateral triangles having equal sides 18, 20 and 22. The importance of a general symmetrical shape in these devices is crucial since wave actions have a tendency to move or topple conventional erosion control devices. Accordingly, if, for example, the module 10 as shown in FIG. 2 is resting on base 22, wave action incident on face 20 may cause the device to rotate clockwise such that face 18 then becomes the base. Even in such an orientation, it is apparent that the symmetrical design would yield identical performance in this new orientation. At each corner of each section is disposed a flange or projection 24, 26 and 28. Within these projections are a series of holes 30 to enable tie rods 32 to be placed therein. Tie rods 32 disposed in each projection are suitably coupled by means, for example, of washers 34 and nuts 36 to lock the individual sections together forming a complete module.
As will be explained herein in more detail, these projections, form recesses 38 between the sections for purposes of generating turbulence in the wave action which is incipient on the erosion control device. On one face of the section are a series of turbulence inducers 40 shown best in the pattern in FIG. 1. While twelve such turbulence inducers are shown, it is readily apparent that any convenient number can be used in any convenient design. As wave action, for example, strikes on face 20, kinetic energy is dissipated as the wave moves through and over the structure. As water moves through the cavity 38, turbulence inducers 40 introduce a series of eddies and discontinuities into the flow generally dissipating the kinetic energy contained therein. A center opening 42 is placed in each section to allow free fluid communication between the sections comprising the module. Accordingly, the build-up of water in any particular section of the module can be dissipated by flow through the center projections 42 to other parts of the module.
As shown in FIGS. 2 and 3, reinforcing rods can be placed in the interior of each section. One such reinforcing rod 44 is placed about the periphery of the section to strengthen the peripheral edges. A second reinforcing rod 48 may be placed concentric with the central opening 42 to add strengthening material in the center of each section.
Each individual section may be cast utilizing concrete materials with the reinforcing elements, if desired, placed in the mold during the pouring process.
Because each section contains one flat or back side 50, molding is rendered especially easy. In that regard, molding can take place at any convenient site with the sections cast in a simple two-part mold. While dimensions are not crucial, each section may be typically 2-6 feet on a side depending on wave action and the beach to be built up. Each section could be approximately one foot in width or thickness.
The tie rods 32 and various assembly components such as washers 34, nuts 36 should preferably be fashioned from a material having a generally good property against corrosion in a salt air environment. Typically, stainless steel rods and hardware can be used. To improve the bonding between sections, epoxy glue may be utilized on the projections 24, 26 and 28 to facilitate a bond between the sections 12.
While the turbulence inducers 40 are shown as having a general tapered or air foil shape, it is apparent that other shapes may be used. The general requirement is that these devices exhibit a high propensity for inducing turbulence into incipient flow of water thereby destroying the kinetic energy in the wave itself.
In operation, wave action with entrained sand or loose shale material strikes the composite module 10 and kinetic energy in the wave is dissipated. Accordingly, about and behind the erosion device deposits of sand or the like material will be placed since with decreased kinetic energy, those materials will precipitate out of the wave by the effects of gravity. Water will then return through various channels 38 and opening 42 in the section to the water line 16. During this reverse cycle, any sand or material which still remains in the water will be further removed by the action of the turbulence inducers 40. Hence, a deposit of sand will take place on the seaward side of the erosion control device.
While concrete is the preferred material for ease of fabrication and cost considerations, it is apparent that other materials may be used. For example, fiberglass composite material may be used, or each section may be hollow and filled with water to add the necessary weight component necessary to anchor the material in the beach. Also, although not shown in the figures, additional anchoring materials such as braces or extensions can be used and attached to the tie rods 32 at convenient locations in the assembly.
It is readily apparent that other modifications and alterations may be derived from this disclosure without departing from the essential aspects of this invention.
|
A modular unit for erosion control due to wave action is disclosed. The system utilizes a series of symmetrical units linked together to dissipate the kinetic energy of incoming waves. Symmetry of building blocks enables the device to work in any orientation. Energy dissipators on each block allow the wave action to be broken up while allowing passage of water through the unit.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/863,025 filed on Aug. 7, 2013.
FIELD OF THE INVENTION
[0002] The present invention relates to a process and system for the production of aromatics from a heavier hydrocarbon stream. In particular, this process provides for increasing yields and flexibility of the production of aromatics and light olefins from hydrocarbon feedstock.
BACKGROUND
[0003] The reforming of petroleum raw materials is an important process for producing useful products. One important process is the separation and upgrading of hydrocarbons for a motor fuel, such as producing a naphtha feedstream and upgrading the octane value of the naphtha in the production of gasoline. However, hydrocarbon feedstreams from a raw petroleum source include the production of useful chemical precursors for use in the production of plastics, detergents and other products.
[0004] The upgrading of gasoline is an important process, and improvements for the conversion of naphtha feedstreams to increase the octane number have been presented in U.S. Pat. Nos. 3,729,409; 3,753,891; 3,767,568; 4,839,024; 4,882,040; and 5,242,576. These processes involve a variety of means to enhance octane number, and particularly for enhancing the aromatic content of gasoline.
[0005] Processes include splitting feeds and operating several reformers using different catalysts, such as a monometallic catalyst or a non-acidic catalyst for lower boiling point hydrocarbons and bi-metallic catalysts for higher boiling point hydrocarbons. Other improvements include new catalysts, as presented in U.S. Pat. Nos. 4,677,094; 6,809,061; and 7,799,729. However, there are limits to the methods and catalysts presented in these patents, and which can entail significant increases in cost.
[0006] Light olefins have traditionally been produced through the process of steam or catalytic cracking, and comprise ethylene and propylene. Light olefins are also derived from the same feedstocks as gasoline. Because of the limited availability and high cost of petroleum sources, the cost of producing light olefins from such petroleum sources has been steadily increasing. The ability to shift components in the feedstock for light olefins and gasoline pools enables producers to economically choose the most important product line and to shift some of the hydrocarbon components in an efficient manner.
SUMMARY
[0007] A process for improving gasoline yields is presented. A first embodiment of the invention is a process for converting a treated hydrocarbon feedstream, comprising passing the treated hydrocarbon feedstream to a separation unit to generate an extract stream enriched in normal paraffins, and a raffinate stream having a reduced normal hydrocarbon content; passing the extract stream to an extract separation system to generate an extract overhead stream comprising nC5 and nC6 compounds, an extract intermediate stream comprising nC7 to nC11 compounds, and an extract bottoms stream comprising desorbent; passing the raffinate stream to a raffinate separation system to generate a raffinate overhead stream comprising iC5 and iC6 compounds, an intermediate raffinate stream comprising aromatics and non-normal hydrocarbons in the C6 to C11 carbon range, and a raffinate bottoms stream comprising desorbent; and passing the intermediate raffinate stream to a reforming unit to generate an aromatics stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising passing a hydrocarbon feedstream to a fractionation unit to generate an overhead stream comprising C4 and lighter hydrocarbons, and a bottoms stream comprising C5+ hydrocarbons; hydrotreating the bottoms stream to generate the treated hydrogenated stream; passing the treated hydrogenated stream to the separation unit. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising passing a portion of the extract overhead stream to an isomerization unit to generate an isomerized stream comprising C5 and C6 compounds. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising passing the isomerized stream to the separation unit.
[0008] A second embodiment of the invention is a process for converting a naphtha feedstream, comprising fractionating the naphtha feedstream to generate a naphtha overhead stream comprising C4 and lighter hydrocarbons, and a naphtha bottoms stream comprising C5+ hydrocarbons; hydrotreating the naphtha bottoms stream to generate a hydrogenated stream having a reduced acetylene, diolefins, sulfur and nitrogen content; passing the hydrogenated stream to a separation unit to generate an extract stream enriched in normal hydrocarbons and a raffinate stream; passing the extract stream to a extraction separation system to generate an extract overhead stream comprising nC5 and nC6 compounds, an extract intermediate stream comprising nC7 to nC11 compounds, and an extract bottoms stream comprising desorbent; passing the raffinate stream to a raffinate separation system to generate a raffinate overhead comprising iC5 and iC6 compounds, an intermediate raffinate stream comprising C6 to C11 aromatics and non-normal hydrocarbons, and a raffinate stream comprising desorbent; passing the intermediate extract stream and the naphtha overhead stream to a naphtha cracking unit to generate light olefins; and passing the intermediate raffinate stream to a reforming unit to generate an aromatics stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising passing a portion of the extract overhead stream to an isomerization unit to generate an isomerized stream comprising C5 and C6 compounds. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising passing the isomerized stream to the separation unit.
[0009] Other objects, advantages and applications of the present invention will become apparent to those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 is a flow schematic of the process; and
[0011] FIG. 2 is a specific embodiment of the present process.
DETAILED DESCRIPTION
[0012] The present embodiment provides an efficient use of hydrocarbon feedstocks. The production of useful higher value products from lower value hydrocarbon feedstocks is important for the economics of a petroleum processing plant. Flexibility in the production of higher-value products is desirable for responding to shifting demands in different product lines.
[0013] The present embodiment provides flexibility in the processing of a hydrocarbon feedstream for the production of light olefins and/or aromatics. The process, as shown in FIG. 1 , includes passing a treated hydrocarbon stream 8 to a separation unit 10 . The separation unit 10 generates an extract stream 12 enriched in normal hydrocarbons, and a raffinate stream 14 having a reduced normal hydrocarbon content. The extract stream 12 is passed to an extract separation system 20 to generate an extract overhead stream 22 . The extract separation system 20 can also generate an extract intermediate stream 24 , and an extract bottoms stream 26 .
[0014] Normal components in the hydrocarbon stream are more readily cracked to form light olefins than non-normal components. The normal components are also more difficult to reform to aromatics than non-normal components. The separation of normal and non-normal components, combined with passing the different stream to appropriate downstream processing units improves flexibility and the economics of cracking and reforming naphtha. The ability to convert normal components to non-normal components allows the shifting of hydrocarbon components from the stream fed to a cracking unit to a stream for generating gasoline components.
[0015] The extract overhead stream 22 can comprise normal C5 and C6 compounds, the extract intermediate stream 24 can comprise normal C7 and heavier compounds, and the extract bottoms stream 26 can comprise a recycle stream passed back to the separation unit 10 . The extract intermediate stream 24 is passed to a cracking unit 40 to generate light olefins. In one embodiment, the cracking unit 40 is a naphtha steam cracking unit.
[0016] In one embodiment, the separation unit 10 is an adsorption separation unit, and the recycle stream 26 is the desorbent recycle from the extract separation system 20 to the separation unit 10 . The extract separation system 20 can comprise one or more fractionation columns for separating the extract stream from the desorbent. The extract separation system 20 can also separate the extract stream 12 into multiple streams. Options in the separation process include a divided wall column, or other means for separating hydrocarbon streams.
[0017] The raffinate stream 14 is passed to a raffinate separation system 30 to generate a raffinate overhead stream 32 , an intermediate raffinate stream 34 and a raffinate bottoms stream 36 . The raffinate overhead stream 32 will comprises isopentanes and isohexanes, the intermediate raffinate stream 34 comprises aromatics, naphthenes, and non-normal hydrocarbons in the C6 to C11 range, and the raffinate bottoms stream 36 comprises a recycle stream that is returned to the separation unit 10 .
[0018] With an adsorption separation system 10 , the raffinate recycle is the desorbent used in the adsorption separation process. The intermediate raffinate stream 34 is passed to a reforming unit 50 to generate a reformate stream 52 , comprising aromatics.
[0019] In a specific embodiment, the process, as shown in FIG. 2 , processes a naphtha feedstream. A naphtha feedstream comprises many hydrocarbon components, and is often passed to a cracking unit for the production of light olefins. However, the composition of a naphtha stream includes components that do not crack well to light olefins and this leads to further processing. A naphtha feedstream also include useful hydrocarbons for converting to aromatics. The present embodiment seeks to separate a naphtha feedstream to increase the yields and efficiencies of naphtha cracking units and reforming units. A naphtha feedstream 76 is passed to a fractionation unit 70 to generate an overhead stream 72 comprising C4 and lighter hydrocarbons, and a bottoms stream 74 comprising C5 and higher hydrocarbons. The overhead stream 72 is passed to a cracking unit 40 to generate a light olefins product stream 42 .
[0020] A naphtha feedstream will typically comprise hydrocarbons in the C4 to C11 range. The adsorption separation unit 10 will therefore utilize an appropriate desorbent, which is normally outside this range. One desorbent that works for a light naphtha having components in the C4 to C11 range is n-C12.
[0021] The naphtha bottoms stream 74 is passed to a hydrotreating unit 80 to generate a treated hydrocarbon stream 8 . The hydrotreating of the naphtha bottoms stream 74 removes sulfur impurities and nitrogen impurities. The hydrotreating can also perform some hydrogenation of reactive components, such as acetylenes and diolefins. The hydrotreated, or hydrogenated, stream 8 is passed to an adsorption separation unit 10 to generate an extract stream 12 and a raffinate stream 14 . The adsorbent in the adsorption separation unit 10 is selected for separating normal hydrocarbons, and in particular normal paraffins, from non-normal hydrocarbons. The extract stream 12 comprises normal hydrocarbons and the raffinate stream 14 comprises non-normal and aromatic hydrocarbons.
[0022] The raffinate stream 14 is passed to a raffinate separation system 30 . The raffinate separation system 30 generates a raffinate overhead stream 32 , an intermediate raffinate stream 34 and a raffinate bottoms stream 36 . The raffinate separation system 30 can comprise two fractionation columns, a divided wall column, or other means for separating a mixture into two or three streams. Fractionation is preferred, as the components in the raffinate stream are readily separated by their boiling point differences. The adsorption separation system 10 uses a desorbent, and the raffinate bottoms stream 36 comprises desorbent that is recycled to the adsorption separation system 10 . The raffinate overhead stream comprises iC5 and iC6 compounds, and can be used for downstream processing, including adding to a gasoline blending pool. The intermediate raffinate stream 34 , comprising aromatics and non-normal hydrocarbons that have higher boiling points than iC5 or iC6 compounds, is passed to a reforming unit 50 to generate a reformate 52 having an increased aromatics content.
[0023] The extract stream 12 is passed to an extraction separation system 20 to generate an extract overhead stream 22 , an extract intermediate stream 24 , and an extract bottoms stream 26 . The extract separation system 20 can comprise multiple fractionation columns, with a preferred system using a divided wall column. The extract bottoms stream 26 includes desorbent that is recycled to the separation unit 10 . The extract intermediate stream 24 is passed to a cracking unit 40 to convert the normal paraffins to light olefins 42 . A typical cracking unit is a naphtha steam cracking unit, but can also comprise a catalytic cracking unit. The extract overhead stream 22 can also be passed to the cracking unit 40 , but in an alternative, the extract overhead stream can be passed to an isomerization unit 60 .
[0024] The isomerization unit 60 converts the overhead stream 22 having normal C5 and C6 paraffins to a isomerized stream 62 having a mixture of normal and iso-C5 and C6 paraffins. The isomerized stream 62 is passed to the separation unit 10 , where the non-normal components of the isomerized stream 62 are then removed in the raffinate stream 14 . This provides for more hydrocarbons passed to either the reforming unit 50 to increase reformate 52 , or to the raffinate overhead stream 32 for downstream processing, including passing to the reforming unit 50 as an option.
[0025] A preferred embodiment is for the integration of a separation system, an isomerization system, and a catalytic reforming process into an integrated refinery-petroleum operation. The process provides for shifting hydrocarbons between a cracking process to generate light olefins, and a reforming process for generating aromatics. Thus providing flexibility for a plant to generate a desired product stream.
[0026] In a preferred embodiment, the extract separation system, or the raffinate separation system will utilize a divided wall column to produce three separate streams. This will save on capital and operating costs. This process will allow flexibility in the area of gasoline production, through shifting of hydrocarbon components, and in particular C5 and C6 components in a naphtha feedstream, from a cracking stream to a reforming stream, or for directing to a gasoline blending pool.
[0027] While the invention has been described with what are presently considered the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
|
A process for increasing the yields of hydrocarbon components to gasoline blending pools from a hydrocarbon feedstock is presented. The process includes separating a naphtha feedstock to components to a first stream that are more readily processed in a cracking unit and to components in a second stream that are more readily processed in a reforming unit.
The process includes the ability to convert components from the cracking stream to the reforming stream.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority based on U.S. provisional application 60/916,338, which was filed May 7, 2007.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates generally to faucets with spray heads. More particularly it relates to such a faucet in which there is a pull-out sprayer mounted on a swivelable harbor.
In one aspect of known faucets with spray heads/handles, prior designs (e.g. as shown in U.S. Pat. No. 6,757,921) include a separate elbow which is linked at its lower end to inlet hot and cold lines and an outlet line, and to a mixing valve at its vertical side which is connected to an actuation handle. This required the outer housing to bulge in order to accommodate the elbow plus the other relevant connections, and thus created design constraints. It is desirable to have a more compact assembly for connecting the inlet and outlet lines to a side mounted mixing valve.
In another aspect of known faucets with spray heads/handles, prior designs included a control handle with an exposed set screw which could be inadvertently loosened or corroded by water, and/or reduced the aesthetic appeal of the handle. Some of these handles were also formed with an unsightly visible cutaway to permit tilting of the handle to occur (e.g. the valve required both rotation and tilting motion of a control lever). Hence, it is also desirable to improve the exterior aesthetics of such control handles without compromising functionality.
In yet another aspect of known faucets with spray heads/handles, prior designs had a “harbor” for the pull-out spray, the harbor then being swingable like a standard kitchen faucet. When the housings for the harbor or valve base were non-circular in cross section, it became somewhat difficult to easily align the parts to the forward position between uses. U.S. patent application publication 2006/0157127 sought to address this concern. However, it had a variety of deficiencies, such as placing a wear point on the spout hub, which could result in the need to replace an expensive outer part.
Thus, there is a desire to improve various aspects of such faucet assemblies.
SUMMARY OF THE INVENTION
In one aspect the invention provides a faucet assembly having a mixing valve and an inlet/outlet assembly connected to the mixing valve. The inlet/outlet assembly has inlet and outlet lines that are permanently affixed to a face plate (e.g. integrally formed therewith or welded/brazed thereto), particularly where the face plate is positioned transverse to the longitudinal axis of the lines.
In another aspect the invention provides a mixing valve with a valve stem and a control handle connected thereto. The control handle has a set screw bore separated from a visible bore. The visible bore provides access to a set screw within the set screw bore which attaches an inner wall of the handle to the valve stem, while the visible bore extends through an outer wall of the handle. The visible bore is circumferentially aligned with the set screw bore.
In this form of the invention there can be a cap which removably covers the visible bore, such as by using an O-ring to help seal the bore. The handle can have a lever arm that extends radially outward from a side of the handle, and the visible bore can be positioned at an opposed side of the handle from the lever arm.
In yet another preferred form of the invention there can be a bushing with a cutout that is mounted at least in part between the control handle and the mixing valve. This cutout can have a continuous contour (e.g. a keyhole shape) which provides a clearance access to the set screw at a plurality of angular positions of the valve stem.
In still another form the invention provides a faucet assembly with a spray head harbor having an inner contour. There is a bearing having an outer contour and a base, the outer contour being mateable with the inner contour of the spray head harbor, the base including one of a projection and a detent. There is also a valve housing including a shaft extending from a land for the base, the land having an other of the projection and the detent.
The bearing is rotatable on the shaft between a position where the projection is within the detent, and another position where the projection is not within the detent. In a preferred form of this aspect of the invention one of the projection and the detent are connected to a spring arm, and the positioning of the detent and projection are such as to define a properly aligned forwardly directed position for the faucet between uses.
The present invention has, in various embodiments, various advantages. For example, one embodiment will provide a compact configuration for the outer housing adjacent the linkage between the control valve and inlet and outlet lines. Another embodiment provides a decorative handle exterior, while still providing set screw access. Still another embodiment can provide positive selection feel when positioning the swivel, particularly when the spout harbor is being returned to its forwardly directed rest position.
These advantages are achieved in an inexpensive manner (both with respect to cost of production of the parts and cost of assembly). Further, the parts used to achieve the assembly are believed to have good reliability over a prolonged period.
These and still other advantages and features of the present invention will be apparent from the following and the attached drawings. Of course, the following discussions relates only to preferred embodiments. For a more comprehensive understanding of the full intended scope of the invention one should look to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of a faucet assembly according to the present invention;
FIG. 2 is an exploded perspective view of the faucet assembly of FIG. 1 ;
FIG. 3 is a cross-sectional view taken along section line 3 - 3 in FIG. 1 ;
FIG. 4 is a cross-sectional view similar to FIG. 3 , but with a control handle tilted to another position;
FIG. 5 is a fragmentary perspective view of an inlet/outlet assembly used with the FIG. 1 faucet assembly;
FIG. 6 is a cross-sectional view taken along section line 6 - 6 of FIG. 1 ;
FIG. 7 is a fragmentary side elevational view of a bearing of the FIG. 2 faucet, partially mounted to a valve housing;
FIG. 8 is a view similar to FIG. 7 , but with bearing fully mounted to the valve housing;
FIG. 9 is a partial cross-sectional view taken along section line 9 - 9 in FIG. 8 ;
FIG. 10 is a cross-sectional view taken along section line 10 - 10 in FIG. 9 ;
FIG. 11 is a vertical sectional view of the FIG. 1 faucet assembly;
FIG. 12 is a frontal view of a FIG. 5 inlet/outlet assembly;
FIG. 13 is a side view of the FIG. 5 inlet/outlet assembly;
FIG. 14 is a rear view of the FIG. 5 inlet/out assembly; and
FIG. 15 is a perspective view of a bearing of the FIG. 1 faucet assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly first to FIGS. 1 , 2 and 11 , there is shown a faucet assembly 20 which includes spray head 22 connected to a flexible outlet line 24 which is routed through spray head harbor 26 . Spray head 22 may optionally include a spray control pushbutton 28 , and may also include other controls. Spray head harbor 26 is connected to valve housing 30 via bearing 32 .
Mixing valve 34 is connected to control handle 36 , as also shown in FIGS. 3 and 4 . Tilting and/or rotation of control handle 36 determines the combination of hot and cold water and/or the volume of water available to spray head 22 via flexible outlet line 24 . The valve used for this purpose may be any of a number of conventional mixing valves.
Inlet/outlet assembly 38 (see particularly FIGS. 2 , 5 and 12 - 14 ) is in fluid communication with mixing valve 34 . The inlet/outlet assembly 38 has inlet lines 40 and outlet line 24 permanently affixed to a face plate 42 as by casting to integrally form them together, or by welding/brazing to essentially permanently bond them together.
It is highly preferable to form face plate 42 transverse to the longitudinal axis of inlet lines 40 . Face plate 42 extends vertically without the need for a separate elbow, and each of the three lines bends from the vertical to the horizontal in a way that minimizes the need for a bulge. In this regard, it is particularly desirable that the lines have a sideways bend in them which permits a more compact front-to-back bending because part of the radius is extended side-to-side rather than just front-to-back.
As may be best appreciated from FIGS. 5-6 and 12 - 14 , lines 24 , 40 each include a first bend 39 and a second bend 41 adjacent the first bend 39 ; wherein at the first bends 39 , the inlet and outlet lines 24 , 40 bend sideways adjacent their junctions with face plate 42 . Lines 24 , 40 each are further shown to include a first portion 43 , a second portion 45 , and a third portion 47 , the first portion 43 between face plate 42 and the first bend 39 , the second portion 45 between the first bend 39 and the second bend 41 , and the third portion 47 opposite the second bend 41 from the second portion 45 . The first portion 43 has a longitudinal axis that extends in a first direction. The second portion 45 has a longitudinal axis that extends in a second direction. The third portion 47 has a longitudinal axis that extends in a third direction.
As may be best appreciated from FIGS. 2-6 , valve housing 30 includes a bore 53 configured to receive inlet/outlet assembly 38 and a cavity 57 for the passage of inlet lines 40 and outlet lines 24 , therethrough. The bore 53 has a longitudinal axis, and the cavity 57 having a longitudinal axis. The longitudinal axis of the bore 53 is skew (e.g., off-center from, neither intersecting nor parallel, etc.) the longitudinal axis of the cavity 57 , and the first bend 39 of each line 24 , 40 bends the line 24 , 40 from face plate 42 towards the cavity 57 , and the second bend 41 of each line 24 , 40 bends the line 24 , 40 in the direction of the longitudinal axis of the cavity 57 .
One of inlet lines 40 is designed to be connected to a hot water supply and the other of inlet lines 40 is designed to be connected to a cold water supply. The inlet lines 40 are in fluid communication with the respective inputs of mixing valve 34 . Flexible outlet line 24 is in fluid communication with an outlet of mixing valve 34 . Appropriate movement of control handle 36 regulates the mixing of the hot and cold inputs, and can also control the flow volume, which are available to spray head 22 via flexible outlet line 24 .
Flexible outlet line 24 extends downwardly from the mixing valve 34 at face plate 42 , through valve housing 30 , then upward back through valve housing 30 , spray head harbor 26 , to link to spray head 22 . Flexible outlet line 24 has weight 44 slidingly adapted thereto to bias flexible outlet line 24 in a downward orientation thereby facilitating the automatic retraction of flexible outlet line 24 when spray head 22 is returned to a home position in spray head harbor 26 .
As may be best appreciated from FIGS. 3 and 4 , control handle 36 includes a set screw bore 46 , which is threaded, which is separate, but circumferentially aligned with a visible bore 48 in an outer wall of the handle. As shown, visible bore 48 is axially aligned with the set screw bore 46 . Visible bore 48 provides access to tighten a set screw 50 within set screw bore 46 , which attaches an inner wall 52 of handle 36 to a valve stem 54 of mixing valve 34 . As shown, a cavity 51 is located between the visible bore 48 and the set screw bore 50 . In the embodiment shown, the cavity 51 has a volume that is larger than either the set screw bore 46 or the visible bore 48 .
In order to control the mixing of the hot and cold inputs, and the volume of flow output from valve 34 , valve stem 54 rotates and tilts. A bushing 55 is included with a keyhole shaped cutout 56 (see FIG. 2 ) thereby providing a greater range of motion of handle 36 , without the need for an exposed cutaway in handle 36 .
To further improve the decorative nature of the assembly, and also to prevent moisture from reaching the set screw connection, there can be a cap 58 which removably covers visible bore 48 . It may be made of a flexible plastic. Further, as shown in FIG. 3 , an O-ring seal 49 may be mounted on the cap to help keep water out from the handle interior.
Referring now mostly to FIGS. 7-10 and 15 , bearing 32 has an outer contour 60 and a base 62 . Outer contour 60 is mateable with an inner contour of spray head harbor 26 . Base 62 includes a projection 64 mounted on a flexible arm 74 .
Valve housing 30 has a tubular shaft 68 extending up from a land 68 for base 62 . Land 68 has a detent/depression 70 . Bearing 32 is rotatable on shaft 66 between a position where projection 64 is within detent 70 ( FIG. 10 ), and another position where projection 64 is not within detent 70 (phantom line in FIG. 9 ). When the projection 64 aligns with the detent 70 , the spray head harbor 26 will be perfectly aligned automatically with the valve housing below it.
Another feature of bearing 32 is that it includes a vertical slit 72 so that it can be compressed to be jammed into spray head harbor 26 . Projection 64 on the bottom of bearing 32 is supported by a spring arm 74 . When bump projection 64 aligns with detent 70 , it therefore snaps into it, notifying the user that they have the right positioning. However, further swiveling force on the support or spray head can reinstate the swinging movement by driving the bump out of the recess. Of course, alternatively, detent 70 can be on base 62 and projection 64 can be on land 68 .
The preferred embodiments of the present invention can also include a variety of other fittings, bushings, nozzles, washers, nuts and other fasteners, and other desirable plumbing components, as will be appreciated by those skilled in the art.
In a typical installation the faucet assembly 20 will be mounted on a rear mounting ledge of a double basin kitchen sink, or directly behind a multiple basin kitchen sink. Of course, the present invention could be otherwise installed in connection with other plumbing fixtures and fittings. For example, it could be used with a laundry sink.
Various other alternatives are intended within the scope of the invention. For example, in some embodiments the swivel locator could be used without the inlet/outlet assembly or the decorative handle features. In other embodiments the inlet/outlet assembly could be used without the swivel locator or the decorative handle features. In any event, the present invention is not to be limited to the features of just the most preferred embodiments.
INDUSTRIAL APPLICABILITY
The present invention provides faucets, preferably pull-out spray faucets, with the capability of linking supply and outlet lines in a compact manner, attaching a decorative control handle, and having positive feel positioning for the swivel spout.
|
Disclosed is a swivel faucet, such as one having a pull-out sprayer. In one aspect the inlet and outlet lines are formed in an integral structure with a transverse plate that faces a mixing valve. In another aspect the control handle for the faucet is provided with a concentric visible bore and hidden set screw bore combined with a bushing having a cutout to facilitate their use. In still another aspect there is provided a bearing that mounts to a pivotable sprayer and provides distinct swivel positions through the use of a detent connection to a land.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional patent application No. 60/784,436, filed Mar. 21, 2006, and titled “Retractable Mirror.” The disclosure of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to retractable mirrors and their use in doors of motor vehicles.
BACKGROUND OF THE INVENTION
Adjustable mirrors are used on various types vehicles to adjust the position of the mirror. Having an adjustable mirror allows for, among other things, compensation for different sized drivers, and for changing the seat position inside the vehicle. When a different person operates a vehicle it may be necessary to change the position of the mirror to compensate for that person's height, or other characteristic that may affect how they view the reflection in the mirror. Also, it is common for seats to be adjustable in passenger vehicles as well. Changing the seat position will also have an effect on how the reflection is seen in the mirror. If the mirror is adjustable, these problems can be compensated for by adjusting the mirror so that the desired image is reflected in the mirror.
Another problem relevant to mirrors is that vehicles used for shipping, construction, and other industrial-type applications are often very large, and it is an advantage to have a mirror that is not only adjustable, but retractable into the vehicle body as well. The purpose of having an adjustable mirror is to allow for the vehicle to comply with packaging constraints. It is common for mirrors on large vehicles, such as trucks, to be prohibited from extending outwardly from the vehicle. Thus, the retractable mirror allows the vehicle to comply with the regulations since the retractable mirror does not extend outwardly from the vehicle.
Furthermore, mirrors that extend outwardly, beyond the width of the vehicle's frame, can prevent the vehicle from accessing certain locations, such as a garage. Thus, the vehicle can fit into tight spaces, such as a garage, with greater ease when the mirrors are retractable and reduce the overall width of the vehicle. In addition, mirrors cause wind resistance, which reduces the fuel efficiency of the vehicle, due to extending outwardly from the vehicle frame. The fuel efficiency can be increased by retracting the mirrors and reducing the overall width of the vehicle and thus the wind resistance.
However, when a mirror is retracted or extended outwardly from the vehicle the image in the mirror is changed. Thus, after the vehicle occupant has adjusted the mirror they are hesitant to retract or expand the mirror because the mirror image is altered and the mirror must be readjusted. Therefore, it is desirable to develop a retractable/expandable mirror assembly that maintains the same image in the mirror as the mirror is being retracted or expanded.
SUMMARY OF THE INVENTION
The present invention relates to a retractable mirror assembly for a vehicle which retracts towards and extends away from a vehicle body. As the mirror retracts or expands, the mirror assembly compensates for the change in viewing range of the mirror by changing the angle of the viewing surface as the mirror retracts or expands so as to allow for what is seen in the mirror to remain constant.
The present invention accomplishes this compensation for change in viewing angle by pivoting the mirror about a vertical axis at the center of the mirror as it retracts toward the vehicle. The mirror is supported by a first support bracket at which the mirror can pivot about a vertical axis. Mounted on the backing plate on the portion of the backing plate closest to the side of the vehicle is another support bracket which has a groove. The groove is used in conjunction with a roller pin. The roller pin is stationary, with respect to the backing plate. As the mirror is retracted, the roller pin slides through the groove and the groove is configured such that as the mirror changes position, the mirror rotates about its vertical axis.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a plan view of a preferred embodiment of a mirror assembly; and
FIG. 2 is a plan view of an alternate embodiment of the mirror assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to FIG. 1 , an exterior mirror assembly for a motor vehicle is generally shown at 10 . A vehicle body 12 has an inlet 14 in which a mirror housing 16 is inserted and removed from the inlet 14 . Thus, the mirror housing 16 is received and projects from the vehicle body 12 . The mirror housing 16 encloses a mirror backing plate 18 which has a reflective element or mirror glass 20 mounted on a exterior side 22 of the mirror backing plate 18 . In a preferred embodiment, the mirror housing 16 encloses all sides of the mirror backing plate 18 except for the side of the exterior side 22 on the mirror backing 16 . Thus, the mirror glass 20 that is mounted to the exterior side 22 is visible and not enclosed by the mirror housing 16 . In a preferred embodiment, the mirror housing 16 is made of a material with adequate strength to withstand the forces applied to an exterior vehicle mirror. Similarly, the mirror backing plate 18 is preferably made of a material with adequate strength to support other components of the mirror assembly 10 , described below.
A first support bracket 24 is mounted to the mirror backing plate 18 . In a preferred embodiment, the first support bracket 24 is mounted to the center of the mirror backing plate 18 in order to give the mirror glass 20 the maximum amount of support. An arm 25 is connected to the first support bracket, such that the arm 25 retracts and expands the mirror assembly 10 into and from the vehicle body 12 through the inlet 14 . Thus, the arm 25 is operably connected to a device (not shown) in the vehicle body 12 which changes the position of the arm 25 . In a preferred embodiment, the arm 25 telescopically expands and retracts upon itself as the arm 25 moves the mirror housing 14 . However, the arm 25 can also have hollow cylindrical piece so that electrical wiring for mirror lights (not shown), a mirror heater (not shown), or similar components extend through an axial bore (not shown) in order for the components to be electrically connected to the vehicle's electrical system. Preferably, the mirror housing 16 is connected to the first support bracket 24 so that the mirror housing 16 moves with the first support bracket 24 as the arm 25 is extended and retracted. The mirror housing 24 can also be connected to the portion of the arm 25 that is not telescopically retracted into the arm 25 .
In addition, a second support bracket 26 is mounted to the mirror backing plate 18 . In a preferred embodiment, the second support bracket 26 is mounted to the mirror backing plate 18 between the first support bracket 24 and the vehicle body 12 . Thus, the second support bracket 26 is mounted on the same side as the mirror backing plate 18 as the first support bracket 24 . However, the second support bracket 26 can be mounted anywhere on the mirror backing plate 18 so long as the remaining components of the mirror assembly 10 are configured accordingly.
Moreover, a stationary bracket 28 , which is separate from the mirror backing plate 18 , is connected to the second support bracket 26 . The second support bracket 26 and the stationary bracket 28 move in relation to one another so that the mirror glass 20 changes positions when the mirror housing 16 is inserted or removed from the vehicle's body 12 . As the arm 25 moves with respect to the vehicle body 12 , the mirror housing 16 also moves with respect to the vehicle body 12 . As the position of the mirror housing 16 is altered, the angle of the mirror glass 20 with respect to the mirror backing plate 16 is changed. Therefore, the image in the mirror glass 20 remains the same when the mirror housing 16 changes positions.
In a first embodiment, the second support bracket 26 has a groove 30 which extends along the length of the second support bracket 26 . The stationary bracket 28 has a roller pin 32 at the end of an extension 30 of the stationary bracket 28 . The extension 30 extends from the bracket 28 and contacts the second support bracket 26 , such that the groove 30 accepts the roller pin 32 . Thus, the roller pin 32 slides along the groove 30 when the second support bracket 26 and the stationary bracket 28 move in relation to one another as the arm 25 retracts or expands the mirror assembly into or from the vehicle body 12 . In a preferred embodiment, the groove 30 is shaped so that the angle of the mirror glass 20 will be altered as the mirror housing 16 is inserted or removed from the vehicle body 12 . Thus, the image reflected in the mirror glass 20 will not be altered as the mirror housing 16 is changing position. In order for the mirror glass 20 to reflect the same image as the mirror assembly 10 is being retracted or expanded, the mirror glass 20 moves about a vertical axis of the first support bracket 24 while the roller pin 32 slides along the groove 30 . In a preferred embodiment, the groove 30 is shaped so that the angle of the mirror glass 20 will be altered approximately 3° as the mirror assembly 10 moves into and out of the vehicle body 12 . Thus, the angle alteration of 3° is sufficient to maintain the same image in the mirror while the mirror assembly 10 is being moved.
In an alternate embodiment of the invention shown in FIG. 2 , the exterior mirror assembly for a motor vehicle 10 also comprises of a first support bracket 24 , a second support bracket 26 , and a stationary bracket 28 . However, in this embodiment the second support bracket 26 has an extension 34 that extends from the back of the mirror backing plate 18 towards the arm 25 . At the end of the extension 34 , the second support bracket 26 has a roller pin 32 which connects to the stationary bracket 28 in the groove 30 . Thus, the groove 30 of the stationary bracket 28 has a groove 30 which accepts the roller pin 32 , and the roller pin 32 slides along the groove 30 as the mirror assembly 10 is changing positions. Similar to the embodiment described above, the groove 30 has a particular shape so that as the roller pin 32 slides about the groove 30 the second support bracket 26 will cause the mirror glass 20 to change positions in order to maintain the same image while the mirror assembly 10 is being moved.
Therefore, the mirror glass 20 maintains the same image or view perspective as the mirror assembly 10 changes positions with respect to the vehicle body 12 . As the arm 25 moves the first support bracket 24 , the first support bracket 24 moves the mirror backing plate 18 . As the mirror backing plate 18 moves the stationary bracket 28 causes the second support bracket 26 to move in a particular direction. This is caused by the roller pin 32 sliding along the groove 30 which is formed in a particular shape in order to cause the mirror backing plate 18 to move in the particular direction. Thus, the mirror backing plate 18 and the mirror glass 20 move along a vertical axis of the first support bracket 24 in order to maintain the same view perspective.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
|
A retractable mirror assembly for a vehicle which retracts towards and extends away from a vehicle body wherein the mirror compensates for the change in position so that the same perspective is maintained. The mirror assembly comprises the vehicle body in which a mirror housing that surrounds a mirror backing plate having a mirror glass is retracted and expanded to and from the vehicle body. A second support bracket and a stationary bracket are connected and move in relation to one another in order to rotate the mirror backing plate and mirror so that the mirror maintains the same perspective while the mirror assembly is being retracted and expanded to and from the vehicle body.
| 1
|
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of co-pending application U.S. Ser. No. 10/115,150, filed Apr. 3, 2002.
FIELD OF THE INVENTION
[0002] The present invention is directed toward the recovery of hydrocarbons heavier than methane from liquefied natural gas (LNG) and in particular to a two step separation process where the C 2 + hydrocarbons recovered in the first separation stage are split and a portion is heated before entering the second separation stage to aid in the recovery of the heavier than methane hydrocarbons.
BACKGROUND OF THE INVENTION
[0003] Natural gas typically contains up to 15 vol. % of hydrocarbons heavier than methane. Thus, natural gas is typically separated to provide a pipeline quality gaseous fraction and a less volatile liquid hydrocarbon fraction. These valuable natural gas liquids (NGL) are comprised of ethane, propane, butane, and minor amounts of other heavy hydrocarbons. In some circumstances, as an alternative to transportation in pipelines, natural gas at remote locations is liquefied and transported in special LNG tankers to appropriate LNG handling and storage terminals. The LNG can then be revaporized and used as a gaseous fuel in the same fashion as natural gas. Because the LNG is comprised of at least 80 mole percent methane it is often necessary to separate the methane from the heavier natural gas hydrocarbons to conform to pipeline specifications for heating value. In addition, it is desirable to recover the NGL because its components have a higher value as liquid products, where they are used as petrochemical feedstocks, compared to their value as fuel gas.
[0004] NGL is typically recovered from LNG streams by many well-known processes including “lean oil” adsorption, refrigerated “lean oil” absorption, and condensation at cryogenic temperatures. Although there are many known processes, there is always a compromise between high recovery and process simplicity (i.e., low capital investment). The most common process for recovering NGL from LNG is to pump and vaporize the LNG, and then redirect the resultant gaseous fluid to a typical industry standard turbo-expansion type cyrogenic NGL recovery process. Such a process requires a large pressure drop across the turbo-expander or J.T. valve to generate cryogenic temperatures. In addition, such prior processes typically require that the resultant gaseous fluid, after LPG extraction, be compressed to attain the pre-expansion step pressure. Alternatives to this standard process are known and two such processes are disclosed in U.S. Pat. Nos. 5,588,308 and 5,114,457. The NGL recovery process described in the '308 patent uses autorefrigeration and integrated heat exchange instead of external refrigeration or feed turbo-expanders. This process, however, requires that the LNG feed be at ambient temperature and be pretreated to remove water, acid gases and other impurities. The process described in the '457 patent recovers NGL from a LNG feed that has been warmed by heat exchange with a compressed recycle portion of the fractionation overhead. The balance of the overhead, comprised of methane-rich residual gas, is compressed and heated for introduction into pipeline distribution systems.
[0005] The present invention provides another alternative NGL recovery process that produces a low-pressure, liquid methane-rich stream that can be directed to the main LNG export pumps where it can be pumped to pipeline pressures and eventually routed to the main LNG vaporizers. Moreover, our invention uses a two step separation process where the C 2 + hydrocarbons recovered in the first separation stage are split and a portion is heated before entering the second separation stage to aid in the recovery of the heavier than methane hydrocarbons as described in the specification below and defined in the claims which follow.
SUMMARY OF THE INVENTION
[0006] As stated, our invention is directed to an improved process for the recovery of NGL from LNG which avoids the need for dehydration, the removal of acid gases and other impurities. A further advantage of our process is that it significantly reduces the overall energy and fuel requirements because the residue gas compression requirements associated with a typical NGL recovery facility are virtually eliminated. Our process also does not require a large pressure drop across a turbo-expander or J.T. value to generate cryogenic temperatures. This reduces the capital investment to construct our process by 30 to 50% compared to a typical cryogenic NGL recovery facility.
[0007] In general, our process recovers hydrocarbons heavier than methane using low pressure liquefied natural gas (for example, directly from an LNG storage system) by using a two step separation process where the C 2 + hydrocarbons recovered in the first separation (recovery) stage are split and a portion is heated before entering the second separation stage and the other portion is used as a reflux stream in the second separation step. This aids in the recovery of the heavier than methane hydrocarbons, thus producing high yields of NGL. The C 1 -C 2 rich stream recovered overhead in the second separation step is recycled to the first separation step to produce a methane-rich stream. This methane-rich stream from the first separation step is routed to the suction side of a low temperature, low head compressor to re-liquefy the methane-rich stream. This re-liquefied LNG is then split, with a portion being used as the second reflux in the first separation stage and the remaining portion directed to main LNG export pumps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic flow diagram of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Natural gas liquids (NGL) are recovered from low-pressure liquefied natural gas (LNG) without the need for external refrigeration or feed turboexpanders as used in prior processes. Referring to FIG. 1 , process 100 shows the incoming LNG feed stream 1 enters pump 2 at very low pressures, typically in the range of 0-5 psig and at a temperature of less than −200° F. Pump 2 may be any pump design typically used for pumping LNG provided that it is capable of increasing the pressure of the LNG several hundred pounds to approximately 100-500 psig, preferably the process range of 300-350 psig. The resultant stream 3 from pump 2 is physically fed to cold box 4 where it is cross-exchanged with substantially NGL-free residue gas in line 9 obtained from the discharge of compressor 8 . In those circumstances where additional cooling is necessary in cold box 4 , an external refrigerant line 32 may be employed to increase the cooling capacity. Although the exact nature of the external refrigerant is not critical to the invention, a high pressure LNG stream may be the most convenient to use. The heated stream of the LNG feed is removed from cold box 4 as stream 5 .
[0010] After being warmed and partially vaporized, the LNG in stream 5 can be further warmed, if needed during process start-up, with an optional heat exchanger (not shown) and then fed to the first separator or recovery tower 6 . Separator 6 may be comprised of a single separation process or a series flow arrangement of several unit operations routinely used to separate fractions of LNG feedstocks. The internal configuration of the particular separator(s) used is a matter of routine engineering design and is not critical to our invention. Stream 5 is separated in separator 6 into an NGL rich bottom stream 11 which is removed via pump 12 and stream 13 . Stream 13 is split into two portions to create streams 14 and 15 . The relative portions of streams 14 and 15 are dependent on the amount of ethane recovery desired and the composition of the feed LNG. A preferred split would be 15-85% in stream 14 and 15-85% in stream 15 . Stream 14 is eventually heated before being routed via line 31 as feed to deethanizer 16 . A preferred method of heating stream 14 is to return it to cold box 4 where it is cross-heat exchanged with compressed LNG from stream 9 . Stream 15 is used directly as a reflux stream in deethanizer 16 to increase the recovery of the desired heavy components. Deethanizer 16 may be heated by a bottom reboiler or a side reboiler 27 .
[0011] A methane-rich overhead stream 17 is removed from deethanizer 16 and routed to the recovery tower 6 . Routing this stream back to recovery tower allows any ethane and heavy components in this stream to be recovered. A recovered NGL product stream 19 is removed from deethanizer 16 and routed to NGL storage or pumped to an NGL pipeline or fractionator (not shown). A methane-rich overhead stream 7 , substantially free of NGL, is removed from separator 6 and fed to a low temperature, low head compressor 8 where it forms compressed LNG stream 9 . Compressor 8 is needed to provide enough boost in pressure so that exiting stream 9 maintains an adequate temperature difference in the main gas heat exchanger (cold box) 4 to form re-liquefied methane-rich gas (LNG) exit stream 10 . Compressor 8 is designed to achieve a marginal pressure increase of about 75 to 115 psi, preferably increasing the pressure from about 300 psig to about 350-425 psig. The re-liquefied methane-rich (LNG) in stream 10 is split into two portions forming stream 30 and 33 . Stream 30 is used as an external reflux to separator 6 . This reflux is necessary to achieve very high levels of ethane recovery. The relative portions of stream 30 and 33 are dependent on the LNG feed composition and the amount of ethane recovery required. A preferred split would be 2-10% in stream 30 and 90-98% in stream 33 . The re-liquefied methane-rich (LNG) in stream 33 is directed to the main LNG export pumps (not shown) where the liquid will be pumped to pipeline pressures and eventually routed to the main LNG vaporizers.
[0012] As one knowledgeable in this area of technology, the particular design of the heat exchangers, pumps, compressors and separators is not critical to our invention. Indeed, it is a matter of routine engineering practice to select and size the specific unit operations to achieve the desired performance. Our invention lies with the unique combination of unit operations and the discovery of using untreated LNG as external reflux to achieve high levels of separation efficiency in order to recover NGL.
[0013] While we have described what we believe are the preferred embodiments of the invention, those knowledgeable in this area of technology will recognize that other and further modifications may be made thereto, e.g., to adapt the invention to various conditions, type of feeds, or other requirements, without departing from the spirit of our invention as defined by the following claims.
|
A process for the recovery of natural gas liquids (NGL) from liquefied natural gas (LNG) is disclosed. The LNG feed stream is subjected to a two stage separation process where the bottoms from the first stage separation containing C 2 + hydrocarbons is split into two portions, with one portion being heated and used as a reflux during the second stage separation to recover the NGL product.
| 5
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to thermoplastic, high molecular weight polyester resin fibers comprising renewable components. Such fibers find utility in flooring applications including carpet fibers, non-woven fiber mats, and reinforcing fibers.
SUMMARY OF THE INVENTION
[0002] An object of the invention is to provide a crystalline polyester fiber comprising an aromatic diacid component and a renewable aliphatic diacid component. Such a fiber may be used in flooring applications, such as carpet fibers, non-woven fiber mats, and reinforcing fibers.
DETAILED DESCRIPTION OF THE INVENTION
[0003] In some embodiments, the thermoplastic, polyester resin has a number average molecular weight (Mn) of a least 5,000, and in other embodiments the polyester resins have a molecular weight (Mn) of at least 10,000.
[0004] In one embodiment, the polyester resin from which fibers are formed comprise aromatic and aliphatic diacid components and aliphatic diol components. In one embodiment the aromatic diacid component is terephthalic acid. In some embodiments, an amount of phthalic acid, phthalic anhydride or isophthalic acid may be used in combination with the terephthalic acid to control the crystalline melt temperature—Tm. In some cases an amount of trimellitic anhydride may also be used.
[0005] The aliphatic diacid and diol components preferably come from renewable sources and have a Biobased Content. Renewable aliphatic diacid and aliphatic diol components may include but are not limited to Bio-PDO (1,3-propanediol), 1,4-butanediol, sebacic acid, succinic acid, adipic acid, azelaic acid, glycerin and citric acid. To further increase the renewable content and to improve other properties, these materials may also be modified by reaction with epoxidized soybean, epoxidized linseed oil, or other natural oils, or by being mixed with epoxidized soybean, epoxidized linseed oil, or other natural oils.
[0006] The polyesters may be pre-reacted with epoxidized natural oils, or the reaction can by a dynamic vulcanization. Dynamic vulcanization is the process of intimate melt mixing of a thermoplastic polymer and a suitable reactive rubbery polymer to generate a thermoplastic elastomer. These reactions are particularly of interest for acid terminated polyesters.
[0007] Other diacid and diol components from renewable resources will become available as the need for renewable materials continues to grow. The diol components may also include diols which are branched or hindered to modify crystallinity in the final polyester fiber. These can include neopentyl glycol and glycerin.
[0008] Renewable components based on plants, animals, or biomass processes have a different radioactive C 14 signature than those produced from petroleum. These renewable, biobased materials have carbon that comes from contemporary (non-fossil) biological sources. A more detailed description of biobased materials is described in a paper by Ramani Narayan, “Biobased & Biodegradable Polymer Materials: Rationale, Drivers, and Technology Exemplars,” presented at American Chemical Society Symposium, San Diego 2005; American Chemical Society Publication #939, June 2006.
[0009] The Biobased Content is defined as the amount of biobased carbon in the material or product as fraction weight (mass) or percent weight (mass) of the total organic carbon in the material or product. ASTM D6866 (2005) describes a test method for determining Biobased content.
[0010] In one embodiment, the high molecular weight polyester resin is crystalline and comprises a crystalline melting temperature Tm between about 100° C. and 150° C. In yet another embodiment, the polyester has a Tm greater than about 150° C. In yet another embodiment, the polyester resin has a Tm of at least 190° C. In another embodiment, the polyester compositions include modifying traditional thermoplastic aromatic polyester resins useful as fibers by the addition of an amount of a renewable aliphatic diacid to help control crystalline regions and Tm.
[0011] The thermoplastic, high molecular weight polyester resin may also be branched. For example, utilizing aliphatic alcohols that have more than two functional groups, such as glycerin, or aromatic acids having more than two functional groups such as trimellitic anhydride may be used to produce branched polyesters.
[0012] Although, the above diacid components are described, it is understood that their simple diesters such as from methanol or ethanol can be used to prepare the thermoplastic, high molecular weight polyesters via known transesterification techniques.
[0013] The high molecular weight polyesters may be prepared by several known methods. One method involves esterification of a diacid and a diol components at elevated temperature. Typically, an excess of diol is employed (see Example 1A). After essentially all of the acid functional groups have reacted, a high vacuum is applied and excess diol is stripped off during transesterification, thereby increasing molecular weight. In some embodiments the diacid components comprise a mixture of aromatic diacid and renewable aliphatic diacid components. In some embodiments, renewable 1,3-PDO is the diol of choice to build high molecular weight in this step of the process.
[0014] It has also found that high molecular weight polyester resin can be made by esterification of a diacid and diol at elevated temperature using an excess of diacid (See example 1B). After all the hydroxyl groups are reacted, a high vacuum is applied to build molecular weight. The mechanism by which high molecular weight is achieved is not clear.
[0015] Another method for obtaining high molecular weight polyesters involves the co-reaction of a renewable polyester with recycle polyesters such as PET (polyethylene terephthalate), PBT (polybutylene terephthalate), PPT (polypropylene terephthalate) or other polyester resins. In these co-reactions an aliphatic polyester comprising renewable ingredients was first prepared as described in Example 1. In one embodiment, the aliphatic polyester has a Biobased Content of 100%. The recycle polyester resin was then mixed with the aliphatic polyester and transesterification between the two polyesters was accomplished at high temperature and preferably under high vacuum. In one embodiment, the polyester co-reaction resin product had a Tm between 100° C. and about 150° C. In another embodiment, the polyester co-reaction resin product has a Tm greater than about 150° C. In yet another embodiment, the polyester co-reaction resin product has a Tm greater than 190° C. It is obvious that these transesterification reactions may be carried out on virgin PET, PPT or PBT resin if desired.
[0016] Molecular weight of the polyester resins was determined by Gel Permeation Chromatography (GPC) using the following procedure. The polyester resin was dissolved into THF, quantitatively diluting to ˜30 mg/ml and filtering with a 0.45 micron filter. Two drops of toluene were added to each sample solution as an internal flow rate marker.
[0017] Samples soluble in THF were run by the following conditions. GPC analysis was run on the TriSec instrument using a four column bank of columns with pore sizes: 10 6 , 2 mixed D PLGel and 500 Angstroms. Three injections were made for the sample and calibration standards for statistical purposes. Universal Calibration (UC) GPC was used to determine MW. UC is a GPC technique that combines Refractive Index (RI) detection (conventional GPC) with Intrinsic Viscometry (IV) detection. Advantages of UC over conventional GPC are:
[0018] MW is absolute (not relative only to standards).
[0019] Yields information about branching of molecules.
[0020] The mobile phase for the THF soluble samples was THF at 1.0 ml/min. The data was processed using the Viscotek OmniSec UC software. The instrument is calibrated using a series of polystyrene narrow standards. To verify calibration, secondary standards were run. They include a 250,000 MW polystyrene broad standard, and a 90,000 MW PVC resin. The calculated molecular weight averages are defined as follows:
[0000]
M
n
=
∑
(
Area
i
)
∑
(
Area
i
)
/
(
M
i
)
M
w
=
∑
[
(
Area
i
)
×
(
M
i
)
]
∑
(
Area
i
)
M
2
=
∑
[
(
Area
i
)
2
×
(
M
i
)
]
[
(
Area
i
)
×
(
M
i
)
]
Area
i
=
The
area
of
the
i
th
slice
of
polymer
distribution
M
i
=
The
molecular
weight
of
the
i
th
slice
of
polymer
distribution
Polydispersity
(
Pd
)
=
a
number
value
used
to
describe
the
molecular
weight
distribution
and
is
obtained
by
Mw
Mn
[0021] Highly crystalline or some high molecular weight samples insoluble in THF were dissolved in a 50/50 (wt.) mixture of tetrachloroethylene (TTCE)/phenol. The column set is 104 and 500 Angstrom 50 cm Jordi columns. The mobile phase was 50/50 (wt.) mixture of TTCE/phenol at 0.3 ml/min. flow rate. The slower flow rate is due to the greater back pressure of the solvent system on the columns. The data was processed using the Viscotek UC OmniSec software.
[0022] Since MW data must be compared from one column set to the other, standards and selected samples were run on both column sets in THF for comparison. A calibration curve was made for each column set. There is good agreement of the standards between the two sets.
[0023] Fibers can be prepared from the above described polyester resins by any well known technique, including melt spinning techniques. Optimization of fiber physical properties by orientation and annealing techniques may also be employed. These fibers can be subsequently utilized in the manufacture of carpet products, non-woven fiber webs, and as reinforcing fibers.
EXAMPLE 1
Procedure for Preparation of High Molecular Weight Polyesters from Diacids and Diols
[0024] 1A: This example describes the general procedure utilized to make thermoplastic, high molecular weight polyesters from diacids and diols. A desired polyester formulation was developed based upon mole equivalent weight of the diacid and diol functional groups. An excess of diol of the most volatile diol component of the formulation was employed in the formulation. In one embodiment, 1,3-propanediol is the excess diol of choice. The diacid and diol ingredients were added into a stainless steel vessel of a RC1 automated reactor (Mettler-Toledo Inc, 1900 Polaris Parkway, Columbus, Ohio), stirred and heated under a continuous flow of pure, dry nitrogen. Typically, the ingredients were heated to 200° C. for 2 hours and temperature increased to 230° C. for an additional 4 to 6 hours until essentially all acid end groups were reacted and theoretical amount of water removed. Subsequently, the nitrogen was stopped and a high vacuum was applied. The mixture was heat and stirred under high vacuum for an additional 4 or more hours at 230° C. to 300° C. In some cases the temperature of the transesterification step was increased to 250° C. or higher. Depending upon the experiment, a vacuum in the range of 5 mm of mercury was utilized. Subsequently, the polymer was allowed to cool to 150° C. to 200° C. and physically removed from the reactor under a flow of nitrogen and allowed to cool to room temperature.
[0025] It is understood that removal of the volatile diol component during transesterification leads to high molecular weight. High molecular weight may be obtained faster if higher vacuum (below 1 mm of mercury) is utilized. It is also known that as the melt viscosity increases due to increased molecular weight, the removal of diol becomes more difficult. The increase in molecular weight can become diffusion dependent because of the high viscosity of the molten polyester. This means that the released volatile diol from the transesterification reaction reacts back into the polymer before it can diffuse out of the melt, and be removed. Renewing the surface of the melt can facilitate the loss of diol and increase molecular weight. The polyesters obtained from this procedure generally have terminal hydroxyl end groups.
[0026] Although, diacid components are described above, it is understood that their simple diesters such as from methanol or ethanol can be used to prepare the thermoplastic polyester resin via known transesterification techniques. The polyesters from this procedure generally have ester terminated end groups.
[0027] 1B: The same general procedure as in 1A is employed. A desired polyester formulation was developed based upon mole equivalent weight of the diacid and diol functional groups. An excess of around 0.01 to 0.5 mole excess of diacid was typically employed in the formulation. The ingredients were mixed and heated as in 1A above, except that the temperature was generally held below 200° C. to keep acid/anhydride from being removed until all hydroxyl groups were reacted. Subsequently, a high vacuum was applied as in 1A and the mixture heated to 230° C. and 280° C. and stirred as in Example 1A. The resultant high molecular weight polyester was removed from the reactor and cooled as in 1A.
[0028] The mechanism of achieving high molecular weight is not clear. In some formulations containing phthalic acid or anhydride, phthalic anhydride was identified as being removed from the mixture. The use of a nitrogen sparge below the surface of the molten polyester during the vacuum step also helped produce high molecular weight polyesters. The polyesters obtained from this procedure generally have terminal acid end groups.
EXAMPLE 2
Preparation of High Molecular Weight Polyesters by Co-Reaction with Recycle Crystalline Polyesters
[0029] The following formulation was processed as per Example 1A to prepare the aliphatic polyester EX-1 comprising 100% renewable components and a Biobased Content of 100%.
[0000]
TABLE 1A
Ex-1
1,3-Propanediol
400.5
Sebacic acid
600
T-20 Catalyst
0.4
[0030] The aliphatic polyester EX-1 was mixed with clear PET bottle recycle resin obtained from Nicos Polymers & Grinding of Nazareth, Pa., and catalyst added as listed below.
[0000]
TABLE 1B
EX-2
Amt (g)
PET recycle bottle
100
EX-1
100
T-20 Catalyst
0.13
[0031] The mixture was heated and stirred under nitrogen at 265° C. for a period of about 3 hours, and a high vacuum applied as in Example 1A for an additional 3 hours at 265° C. Subsequently, the resultant polyester having 50% renewable content and 50% recycle content was shown to have a molecular weight Mn of 17,200 with a Tg of −9° C. and a Tm of 114° C. Molecular weight Mn of the starting PET recycle bottle resin was determined by GPC techniques described above and found to be 14,000. A sample of PET film obtained from Nicos Polymers & Grinding was also analyzed by GPC and molecular weight Mn determined to be 17,300.
EXAMPLE 3
Additional Polyesters Made by Transesterification Between High Molecular Weight Aliphatic, Renewable Polyesters and Recycle Polyester Resin
[0032] High molecular weight, renewable polyesters comprising the compositions of Table 2A were made according to Example 1A.
[0000]
TABLE 2A
1,4-
Sebacic
Azelaic Acid
Butanediol
Acid
T-20
Total
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Ex-1
674
325.74
0.5
1000
EX-2
511
489
0.4
1000
EX-3
582
417.6
0.4
1000
EX-4
400.5
600
0.4
1001
EX-5
471.2
528
0.4
1000
Ex-6
354
529
0.4
883
[0033] The polyesters of Table 2A, were each mixed with recycle PET bottle resin obtained from Nicos Polymers & Grinding of Nazareth, Pa., and 0.1% T-20 catalyst added and transesterification conducted as per Example 1. In some examples, transesterification was also carried out on PBT resin Celanex 1600A obtained from Ticona (formerly Hoechst Celanese Corp.), Surnmit, N.J. Table 2B shows some of the resultant polyester co-reaction products and their Tm. The Tm of the resultant co-reaction product can be controlled by the ratio of the recycle polyester resin and the co-reactant polyester resin. It is obvious that these transesterification co-reactions may be carried out on virgin PET or PBT type resin.
[0000]
TABLE 2B
Polyester
PE
ID used in
Recycled
melt range
Mid-point
Transesterification
Transesterification
Bottle
PBT
PB
Ecoflex
PB
(° C.) trans
mp (Tm)
Rxn #
Rxn
PET
Celanex
Azelate
FBX7011
Sebacate
product
° C.
Nicos
255-259
256
Scrap PET
EX-8
EX-3
70
30
138-154
145
EX-9
EX-4
50
50
84-105
94.9
EX-10
EX-4
70
30
140-159
146
EX-11
EX-5
50
50
99-126
102.9
EX-12
EX-5
70
30
155-170
160
EX-13
EX-6
50
50
101-125
109
EX-14
EX-6
70
30
149-156
151
EX-15
EX-1
50
50
100-111
105
EX-16
EX-1
70
30
133-141
136
EX-17
EX-7
50
50
92-106
97
EX-18
EX-7
70
30
110-170
140
EX-19
EX-3
75
75
135-141
137
EX-20
EX-7
75
75
145-166
156
EX-21
EX-5
180
120
79-153
87
EX-22
EX-1
180
120
73-108
79
EX-23
Ecoflex
180
120
122-158
137
FXB7011
[0034] Co-reacted polyesters with higher Tm may be produced by using less renewable, aliphatic polyester than described in the Table 2B above. The melting points listed in Table 2B were determined using an “Optimelt” automated unit. Theoretical Biobased Content was calculated for the above co-reacted products. The Biobased Content ranged from 56.5% to 58.3% for the 50:50 blends, and 35.8% to 37.5% for the 70:30 blends. The Biobased Content can be varied from about 5% by weight to 95% by weight.
[0035] Of course, non-recycled, virgin PET, PBT and PPT can be used instead of the recycled PET. In that case, the renewable resin should be at least 5% by weight.
EXAMPLE 4
Aromatic/Aliphatic Crystalline Polyester Preparation
[0036] Another approach to control the crystalline melting point (Tm) and degree of crystallinity in the polyesters useful as fibers, is to modify the traditional high Tm polyester fiber resins by incorporating aliphatic diacids into the polymer. Although any aliphatic diacid can be employed, it is preferred to utilize a diacid from renewable resources that has a Biobased Content. Two series of high molecular weight polyesters (Table 4A and 4B) were prepared according to Example 1A.
[0000]
TABLE 3A
Raw Material
EX-24
EX-25
EX-26
Ingredient
Amt (g)
Amt (g)
Amt (g)
Sebacic acid
127.03
127.03
148.16
Terephthalic acid
156.48
156.48
133.85
Phthalic acid
13.04
Isophthalic acid
13.04
12.17
1,3-Propanediol
119.49
119.49
111.5
Glycerin
4.82
4.82
4.5
1,6 Hexanediol
27.83
27.83
25.97
CHDm*
12.6
T-20
1.31
1.31
1.26
Total
450
450
450
Tm(mid point)
124
125
102
*cyclohexane dimethanol
[0037] Tm listed in Table 3A were determined the same as Example 2 using the Optimelt automated unit.
[0038] The series of high molecular weight polyesters of Table 3B was also prepared as per Example 1A. This table shows that Tm can be controlled by the addition of renewable diacid as described above, as well as addition of aromatic diacids that breakup the crystallinity of the resultant polyester.
[0000]
TABLE 3B
EX-27
EX-28
EX-29
EX-30
Trade Name
Amt (g)
Amt (g)
Amt (g)
Amt (g)
1,6-hexanediol
156.41
0
0
0
1,3-propanediol
137.86
257.74
219.19
249.61
Terephthalic acid
393.77
425.34
466.78
411.93
Phthalic anhydride
61.95
66.92
64.03
0
Sebacic Acid
0
0
0
88.46
T-20
1.50
1.50
1.50
1.50
Total
751.48
751.50
751.50
751.50
Tm(max)° C.**
135
195
197
200
**The crystalline melting temperatures listed in Table 3B were determined by Differential Scanning Calorimetry (DSC) techniques.
[0039] The series of high molecular weight polyesters of Table 3C was also prepared as per Example 1A. This table shows that Tm can be controlled by the addition of renewable diacid as described above.
[0000]
TABLE 3C
Raw Material
EX-31
EX-32
EX-33
EX-34
EX-35
Ingredient
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Amt (g)
Sebacic acid
304.55
94.97
387.72
314.53
277.15
Terephthalic acid
250.28
442.28
318.63
387.71
422.98
CHDm*
445.07
462.65
Bio-PDO
288.84
298.89
294.95
Glycerine
4.71
4.78
4.81
Fascat 4100
0.20
0.10
0.10
0.10
Fascat 2001
0.6
Total
1000.10
1000.50
1000.00
1000.01
999.99
Tm(mid point)
204
242
153
167
176
*cyclohexane dimethanol
|
Thermoplastic, high molecular weight polyester resin fibers comprise renewable components. Such fibers find utility in flooring applications including carpet fibers, non-woven fiber mats, and reinforcing fibers.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrochemical cells and more particularly relates to a gel containing an electrolyte.
2. Background of the Invention
Devices that convert chemical energy into electrical energy are commonly referred to as batteries. Primary batteries contain compounds of high chemical energy which are converted to compounds of low chemical energy when electrical energy is withdrawn. These batteries are discarded when exhausted. Fuel cells are a special class of primary batteries.
With secondary batteries, electrical energy may be put back into the battery to convert the low energy compounds back to the high energy compounds. This process, known as recharging, allows secondary batteries to be used over and over.
Batteries may be of one or more individual electrochemical cells. A cell includes a negative electrode (anode) and a positive electrode (cathode) separated by an electrolyte solution. Ions migrate through the electrolyte solution between the anode and the cathode.
Commonly used liquid electrolytes are sulfuric acid in lead-acid batteries and potassium hydroxide in nickel-cadmium and silver-zinc batteries. Liquid electrolytes have the advantages of excellent contact between the electrodes and the electrolyte solution and ease of transport of ionic species through the solution so that very high conductivity is achieved. (In the present disclosure, conductivity is given by the term S×cm -1 wherein S designates siemans (reciprocal ohms)). Disadvantages associated with liquid electrolytes are the potential for leakage and the requirement that the battery be used in a prescribed (usually vertical) position.
Electrically conductive solids with ionic carriers have been disclosed for potential applications where liquid electrolytes cannot be used. Most solid electrolytes are inorganic materials such as ceramics or compacted tablets. With such materials, difficulties are often encountered in maintaining close contact with the electrodes and in developing sufficient conductivity.
One type of solid electrolyte which has been proposed is a polymer containing ions. Exemplary of these polymeric electrolytes are ionic species such as hydrated perchlorates in polyacrylonitrile, polyethyleneoxide, and polyvinylidene fluoride. Conductivities in the range of 10 -7 to 10 -2 S cm -1 have been reported, and deformation under stress which helps maintain close electrolyte-electrode contact has been claimed.
Gels have also come into use to immobilize electrolyte systems in batteries for consumer applications, such as emergency lighting and alarm-security systems. Exemplary of such systems is a thixotropic gel obtained by mixing sodium silicate, demineralized water and dilute sulfuric acid.
While much progress has been made in overcoming the disadvantages of liquid electrolytes by using solid electrolytes and crosslinked gels, there remains a need for a self-supporting electrolyte having the conductivity of a liquid electrolyte. It is toward solution of this problem that this invention is directed.
SUMMARY OF THE INVENTION
A thermally reversible conducting gel includes an ether of a polyhydroxy compound and an electrolyte in an organic solvent. Preferred components are sorbitol ethers as the gelling agents and ammonium perchlorates as the electrolytes. Preferred solvents are acetonitrile, propylene carbonate and dichlorobenzene. The gel may also include a polymer for improved strength and dimensional stability.
The conducting gels disclosed herein are noncorrosive, self supporting, dimensionally stable and not subject to leakage. They have conductivities which are substantially the same as the non-gelled liquids. These features make the gels of the invention ideally suited for use in consumer products requiring batteries to be used in any position.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a plot showing the relationship of viscosity to temperature for electrolytes of the invention in gel and liquid forms.
DETAILED DESCRIPTION
While this invention is satisfied by embodiments in many different forms, there will herein be described in detail preferred embodiments of the invention, with the understanding that the present disclosure is to be considered as exemplary of the principles of the invention and is not intended to limit the invention to the embodiments illustrated and described. The scope of the invention will be measured by the appended claims and their equivalents.
In accordance with the present invention, conducting electrolyte gels are formed by dissolving a gelling agent and an ionic electrolyte in a suitable solvent at a temperature above the gelation point and cooling the solution. The gels of the invention are useful as electrolyte mediums in batteries, fuel cells and various sensing devices which measure current flow.
Suitable gelling agents in accordance with the invention are ethers of polyhydroxy compounds such as xylitol, mannitol, pentaerythritol and sorbitol. Particularly preferred gelling agents are ethers of 1,3:2,4-sorbitols such as dibenzyl sorbitol, dibenzylidene sorbitol (DBS) and ring substituted derivatives of DBS such as 4,4'-dimethyl dibenzylidene sorbitol (MDBS), 4,4'-dichlorodibenzylidene sorbitol (CDBS) and 4,4'-bis(methylthio)dibenzylidene sorbitol (MTDBS). As known in the art, these compounds are clarifying agents for polymeric compositions. A concentration of about 0.01 to 2.0, preferably about 0.1 to 0.2% by weight of the gelling agent may be used.
Any substance which is soluble and ionized in the organic solvent may serve as the electrolyte. Metal salts or preferably ammonium salts may be used, such as lithium, sodium and potassium perchlorates, fluoroborates and tetraphenylborates. Preferred salts are substituted ammonium perchlorates, most preferably tetrabutyl ammonium perchlorate (TBAP). The concentration of the salt may be about 0.001 to 5 molar, preferably about 0.05 to 1 molar.
A variety of organic solvents may be used in formation of the gel of the invention. Any solvent which forms a stable gel with the gelling agent and which dissolves an ionic electrolyte may be used. A representative, but not exhaustive, list of suitable solvents is acetonitrile (AN), chloroform, dichloromethane, propylene carbonate (PC), nitrobenzene and o-dichlorobenzene (DCB). Other solvents will be readily evident to one skilled in the art. Dimethylformamide and pyridine did not form gels with DBS and partial gels were formed in benzene and toluene.
A mixture of the gelling agent, electrolyte and solvent may be heated to any suitable temperature above the gelling temperature to dissolve the electrolyte and gelling agent. Generally, a temperature of 50° to 150°, most preferably about 80° to 120° C. is sufficient to give a homogeneous composition. The temperature of gelling depends on the nature of the gelling agent and solvent and the concentration of the gelling agent.
For some applications, it maybe advantageous to add a polymer to the solution prior to gelling to provide additional mechanical strength and dimensional stability to the gel. Suitable polymers are, for example, polyvinyl acetate, polyvinylchloride, polystyrene, polymethylmethacrylate, and polyvinylpyridine. The polymer may be added in amounts ranging from about 1-20, preferably about 10 percent by weight based on the weight of solvent.
Conductivity of the gel may be determined by impedance measurements in an electrochemical cell using platinum electrodes, as described in Example II. It was found that pure solvent and the corresponding DBS gel, in the absence of electrolyte, gave the same very low conductivities, indicating that DBS is electrochemically inactive in the gel form. The inert electrochemical nature of DBS was confirmed by cyclic voltammetry studies, as described in Example III.
It is believed, but not yet substantiated, that the gel of the invention forms by precipitation of DBS into a dense, open network of twisted filaments in which the solvent is entrapped by capillary forces to prevent leakage and allow fast transport of both ionic and neutral molecular species.
EXAMPLE I
A. Preparation of Gels.
DBS, 0.1 g, was added to 10 ml of each of the solvents listed below, and the mixtures heated on a hot plate until all DBS dissolved. The solutions gelled on cooling. The gelation process was thermo-reversible. The gels were colorless and clear or slightly cloudy.
______________________________________SOLVENT GELATION______________________________________o-dichlorobenzene yesacetonitrile yesnitrobenzene yespropylene carbonate yeschloroform yesmethylene chloride yestoluene partialxylene partialdimethylformamide nopyridine no______________________________________
B. Characterization of Gels
The rotating spindle of an LVT SYNCHRO-LECTRIC™ Brookfield Viscometer (Brookfield Engineering Laboratories, Stoughton, Mass.) was immersed in a beaker containing 100 ml of a 1% solution of DBS in o-dichlorobenzene at 110° C. The solution was cooled at 0.5° C./min. with continuous monitoring of the viscosity. The gelation transition point occurred at 88°-89° C. as evidenced by a sudden increase in the fluid viscosity. At this temperature, the mixture became semisolid and stopped the spindle. The gel was converted back to the liquid form at about 110° C. The results of this experiment are shown in the FIGURE.
EXAMPLE II
Determination of Conductivity
Duplicate solutions (10 ml) of 0.125M TBAP in acetonitrile, propylene carbonate and o-dichlorobenzene were prepared, and 0.1 g of DBS was added to one solution of each solvent. The solutions containing DBS gelled as described in Example I. Two platinum electrodes were placed 1 cm apart in each solution and gel to form an electrochemical cell, and impedance measurements were made at ambient temperature using a SOLARTRON™ (Fornborough, England) 1250 frequency analyzer and a SOLARTRON™ 1186 electrochemical interface operating at 10 mV root mean squared at a frequency range from 65 kHz to 0.5 Hz. Conductivities were calculated using the high frequency real-axis-intercept values. The data obtained is set forth in the Table.
TABLE______________________________________Conductivity (S × cm.sup.-1) Pure + DBS gel +Solvent Pure DBS gel TBAP TBAP______________________________________AN 2 × 10.sup.-8 1 × 10.sup.-5 4 × 10.sup.-2 4 × 10.sup.-2PC 3 × 10.sup.-5 3 × 10.sup.-5 8 × 10.sup.-3 7 × 10.sup.-3DCB 5 × 10.sup.-7 5 × 10.sup.-7 7 × 10.sup.-4 7 × 10.sup.-4______________________________________
It is seen that pure solvent and the corresponding DBS gel give substantially the same low order of conductivity in the absence of the electrolyte. In the presence of electrolyte, conductivity of pure solvent and gel are likewise substantially the same for each solvent and up to 1000 fold higher than in the absence of electrolyte.
EXAMPLE III
Voltammetry Studies
Cyclic voltammetry studies were performed with an EG&G PAR 363 (Princeton Applied Research, Princeton, N.J.) potentiostat controlled by an EG&G PAR 175 programmer and the data were collected using a Nicolet 310 digital oscilloscope (Madison, Wis.) Platinum coated molybdenum wire (0.457 mm o.d.) was used for both working and counter electrodes, and Ag wire (0.5 mm o.d.) served as a quasi-reference electrode. The electrode area was 0.36 cm 2 and the scan rate was fixed at 200 mV/s during the experiments.
Plots of current vs voltage of 0.125M TBAP in acetonitrile and the corresponding gel with DBS were compared. It was found that the two curves were substantially superimposable, showing that DBS in the gel is electrochemically inert and has substantially no effect on the conductivity of the solvent-electrolyte system.
|
A self supporting gel includes a gelling agent and an electrolyte dissolved in a solvent. The gel is conducting and may be used in a battery.
| 7
|
FIELD
[0001] The present disclosure relates generally to medical devices, and, in particular, to a system of improved irrigation and aspiration catheters used in the containment and removal of material resulting from therapeutic treatment of occlusions within blood vessels.
BACKGROUND
[0002] Human blood vessels often become occluded or blocked by plaque, thrombi, other deposits, or emboli which reduce the blood carrying capacity of the vessel. Should the blockage occur at a critical place in the circulatory system, serious and permanent injury, and even death, can occur. To prevent this, some form of medical intervention is usually performed when significant occlusion is detected.
[0003] Balloon angioplasty and other transluminal medical treatments are well-known and have been proven efficacious in the treatment of stenotic lesions in blood vessels. The application of such medical procedures to certain blood vessels, however, has been limited, due to the risks associated with creation of emboli during the procedure. For example, angioplasty is not the currently preferred treatment for lesions in the carotid artery because of the possibility of dislodging plaque from the lesion, which can enter the various arterial vessels of the brain and cause permanent brain damage. Instead, surgical procedures such as carotid endarterectomy are currently used, wherein the artery is split open and the blockage removed, but these procedures present substantial risks of their own.
[0004] Other types of intervention for blocked vessels include atherectomy, deployment of stents, introduction of specific medication by infusion, and bypass surgery. Each of these methods are not without the risk of embolism caused by the dislodgement of the blocking material which then moves downstream. In addition, the size of the vessel may limit access to it.
[0005] There is also a need to efficiently remove occlusions from a patient without excess undesired removal of native blood and tissue within the system. Constant flow suction or vacuum pressure is effective at removing freed or dislodged occlusions, but typically remove unnecessary amounts of blood in the process. Thus, there is a need for a system to effectively contain and remove such emboli without undesired consequences, such as excess removal of blood and tissue from the vessel.
[0006] Vessels as small as 3 mm in diameter are quite commonly found in the coronary arteries, and even certain saphenous vein graph bypass vessels can also be as small as 3 mm or 4 mm; although some can range as high as 7 mm. Certain of the carotid arteries also can be as small as 4 mm in diameter; although, again, others are larger. Nevertheless, a successful emboli removal system must be effective within extremely small working areas.
[0007] Another obstacle is the wide variety in emboli dimensions. Although definitive studies are not available, it is believed that emboli may have approximate diameters ranging anywhere from tens of micrometers to a few hundred micrometers. More specifically, emboli which are considered dangerous to the patient may have diameters as large as 200 to 300 micrometers or even larger. Thus, an effective emboli removal system must be able to accommodate relatively large embolic particles and, at the same time, fit within relatively small vessels.
[0008] Another difficulty that must be overcome is the limited amount of time available to perform the emboli removal procedure. That is, in order to contain the emboli produced as a result of intravascular therapy, the vessel must be occluded, meaning that no blood perfuses through the vessel to the end organs. Although certain perfusion systems may exist or may be developed which would occlude emboli while permitting the substantial flow of blood, at present, the emboli may be contained only with a complete occlusion as to both blood flow and emboli escapement. Thus, again depending upon the end organ, the complete procedure, including time for the therapeutic treatment as well as exchanges of angioplastic balloons, stents, and the like, must be completed within a short time. Thus, it may be difficult to include time for emboli removal as well. This is particularly true in the larger size vessels discussed above wherein a larger volume results in additional time required for emboli evacuation.
[0009] Additionally, there has been a long felt an unmet need to provide a catheter that is adept at removing harder material, such as calcium (e.g. harder than thrombus and plaque). Cutting and removal of such harder materials generally requires additional procedure time and increased risks.
[0010] Moreover, it is important that an emboli containment and removal system be easy to use by physicians, and compatible with present therapeutic devices and methods.
SUMMARY
[0011] These and other needs are addressed by the various aspects, embodiments, and configurations of the present disclosure.
[0012] In various embodiments, a laser cutting and aspiration atherectomy system is provided, the system comprising a catheter comprising a ring or distribution of fibers that provide a cutting function and an inner lumen through which aspirated material is removed from a patient. It is contemplated that material be removed from the lumen by, for example, a pulsed aspiration system and an in-line filter for material collection as described herein. Embodiments of laser cutting and aspiration atherectomy systems of the present disclosure provide for a wide array of benefits, including providing the ability to create visibly smoother lumens faster than conventional laser ablation methods and systems. Embodiments of the present disclosure ablate less native tissue, separate the lesion from the vasculature in pieces or plugs, and aspirate material through the catheter. With a deflection component, this design can be used to both create a pilot channel and subsequent larger channels, faster than conventional bulk ablation. Devices of the present disclosure create a pilot channel and larger lumens in a faster manner than convention bulk ablation methods and devices.
[0013] Embodiments of the present disclosure contemplate various mechanical cutting features provided in combination with a catheter, either in addition to or in lieu of laser ablation means. Such mechanical cutting features include, but are not limited to, various bladed or shearing devices provided at or proximal to a distal end of the catheter. Such mechanical cutting features are contemplated as being substantially fixed to a distal end of a catheter, such as the periphery of an annular distal end, or selectively retractable/extendable from the distal end such that the cutting features are only provided in a position of use when desired. An example of a device that include a mechanical sheath for extending a cutting blade from the distal end of the sheath are described and illustrated in U.S. Pat. No. 5,651,781 to Grace, which is hereby incorporated herein by reference in its entirety for all that it teaches and for all purposes.
[0014] In one embodiment, a laser cutting and aspiration atherectomy catheter is provided, the catheter comprising an outer jacket with a tapered outer band, an inner lumen or channel for passage of material, and at least one ring or circular array of cutting fibers. A narrowed orifice or inner band is provided at the distal tip of the catheter. In a preferred embodiment, the catheter comprises a flexible tip with deflection items such as pull wires or shaping wires. Such deflection items are provided in addition to or in lieu of a distal outer jacket. The outer jacket provides a rigid member for communication of various user-applied forces including, but not limited to, torque, compression, and tension forces. The inner lumen provides a reinforced, lubricious lumen for material aspiration. The lumen, in certain embodiments, comprises a coil reinforced polytetrafluoroethylene/polyimide composite. Cutting fibers provide or transmit laser energy for cutting plaque and other occlusive material. In preferred embodiments, the fibers comprise 100 μm fibers provided in concentric arrangements (with respect to one another and/or the catheter).
[0015] In various embodiments, one or more catheters of the present disclosure are provided to remove cores or plug-shaped features from an occluded vessel. Devices and methods of the present disclosure contemplate cutting and removing of discrete portions of an occlusions, such as substantially cylindrical portions generally corresponding to the shape/diameter of a catheter distal end and inner lumen. Accordingly, and in contrast with prior art systems and devices, the present disclosure comprises the ability to remove discrete plugs or sections of an occlusion and minimize particulate that may be translocated to different locations within a system and cause additional complications. Annular cutting features, such as ablative lasers and/or mechanical cutting features, inner lumen removal systems, and structural features of catheters that enable application of axial of compression force to the catheter, for example, provide means for extracting discrete plugs or clogs of material from an occlusion and restoration of blood flow through an occlusion.
[0016] A method for removing occlusions from a vessel is provided, the method comprising the steps of providing an aspiration catheter comprising: (i) a distal end of substantially annular construction, the substantially annular construction defining an inner lumen for conveyance of material; (ii) at least one cutting element provided coincident or distal with the inner lumen; and (iii) a vacuum pump in fluid communication with the inner lumen and operable to transmit material therethrough; inserting the distal end of the aspiration catheter into a blood vessel navigating the distal end to a site of stenosis, selectively activating appropriate cutting element parameters, activating the vacuum pump, manipulating the aspiration catheter to extract a stenotic material, the stenotic material comprising a cross-sectional substantially the same as a cross-section of the inner lumen, and conveying the stenotic material through the length of the catheter.
[0017] The narrowed orifice provides a limiting orifice for material transport and clog resistance and, in certain embodiments, comprises a thin wall, stainless steel hypotube. The outer band provides fiber reinforcement and radio-opacity and, in certain embodiments, comprises a platinum-iridium band.
[0018] In one embodiment, a catheter is provided comprising an outer jacket, the outer jacket providing protection for internally-disposed fibers and aiding in maintaining the integrity of the inner lumen(s). The outer jacket further provides enhancements in control of the device, including flexibility of the catheter, track-ability along a path, and enhanced ability to accommodate and/or transmit torque and compression. Preferably, a tricoil arrangement is provided. In alternative embodiments, braided Pebax®, braided polyimide, and Pebax® jackets are provided.
[0019] As used herein, a “tricoil” arrangement comprises a shaft comprising coiled wire in a plurality of layers. In certain embodiments, construction of a tricoil includes wrapping at least one round or flat wire in one direction, either clockwise or counter-clockwise around a core mandrel. The wires are wrapped side by side and secured when an appropriate length is achieved. A second layer of at least one round or flat wires is wound in the opposite direction on top of the first layer and secured. The final layer of at least one round or flat wire is wound in the opposite direction of the second layer (or the same direction as the first layer) and secured. The assembly is then welded together at the ends of the shaft to create the component. Wire dimensions and count can be varied in construction for various attributes.
[0020] Tricoils contemplated by the present disclosure include, but are not limited to 1-4-4 and 1-6-6 filar count by layer, with flat wires from 0.0014″×0.010″ to 0.002″×0.016″. Benefits of tricoils include extreme torquability (approaching 1:1 ratio of torque input to torque output, even in bends), kink resistance, inner lumen protection, and durability, to name a few.
[0021] Alternative catheter shaft constructions include, but are not limited to Pebax, Braided Pebax, Braided Polyimide, Bicoils, and various combinations thereof.
[0022] Inner lumens of catheters of the present disclosure provide a conduit or pathway for aspirating cut or ablated material out of the body. In various embodiments, a vacuum-sealed, lubricious inner surface is provided that does not substantially deform or kink, so as to facilitate consistent removal of material without clogging the device. In certain embodiments, the lumen comprises a coil-reinforced, polytetrafluoroethylene/polyimide composite that provides sufficient hoop strength while allowing for a lubricious inner surface. In additional embodiments, a braid-reinforced PTFE/polyimide composite is provided for the inner lumen. In yet additional embodiments, the inner lumen may have ridges formed in a rifle-like manner to further control the removal of the material.
[0023] In certain embodiments, a catheter is provided comprising an internal rifled feature. A catheter jacket is contemplated as comprising an internal feature of a spiral and/or spinning helix or screw configuration. The jacket, which may be a polymer extrusion, comprises a helical rib or rifle such that rotation of the catheter about a longitudinal axis aspirates and/or macerates material. Extension and/or rotation of the catheter induces rotation of the helix structure, thereby freeing material and enabling removal. Freed material may be conveyed from a vessel via a central lumen of the catheter, for example.
[0024] The design of the inner lumen is essential to the removal of material without clogging. Requirements for the inner lumen include ovaling/kink resistance, vacuum compression resistance, and inner surface lubricity. Inner lumens that we have tried have been mostly composed of some type of Polyimide construction. We have used pure Polyimide lumens, PTFE/Polyimide Composite lumens, Pure PTFE inner liner with a PTFE/Polyimide composite outer layer. Reinforcement to the inner lumens has consisted of stainless steel wire braids and coils embedded into the walls of the lumen. These reinforcements prevent kinking, ovaling, and vacuum compression. Inner lumen design could consist of any combinations of components listed in the shaft design section.
[0025] Fibers of the present disclosure are provided to deliver laser energy, including that produced by a Spectranetics® CVX-300 and related interface circuit, for example. It is contemplated that fibers of the present disclosure be protected from damage and oriented correctly at the distal tip of the catheter for laser ablation. In various embodiments, approximately fifty to one hundred fibers are provided in concentric annular rings. In a preferred embodiment, seventy four 100 μm fibers are provided in concentric circles. This particular embodiment provides for sufficient energy to ablate tissue, while leaving enough room for a sufficiently large inner lumen space. It will be recognized, however, that the present disclosure is not limited to a particular number or arrangement of fibers. Indeed, various alternative arrangements and quantities of cutting fibers are contemplated as within the scope and spirit of the present disclosure. In alternative embodiments, any combination of fiber size can be utilized, including but not limited to 61/100/130 μm fibers, either in substantially circular or ovoid cross-section.
[0026] In various embodiments, a narrowed orifice/inner band is provided that creates a limiting orifice at the distal tip of the catheter. The narrowed orifice helps ensure that if material can pass through it, it will fit down the remainder of the inner lumen. Additionally, the narrowed orifice provides a rigid inner member for fiber support and prevents inner lumen degradation and damage. In one embodiment, a short, thin wall stainless steel hypotube is provided for the narrowed orifice. The shortness of the orifice decreases the chances of clogging at the tip, while the thin wall design reduces the amount of dead space for laser ablation.
[0027] In various embodiments, an outer band is provided at the distal end of the catheter, the outer band providing a rigid structure for fiber support and protection as well as ease of manipulation of fiber placement within the distal end. The present disclosure contemplates one or more bands or rows of fibers. One, two, or three or more substantially concentric rows of fibers may be provided for ablating material.
[0028] In one embodiment, a Pt/Ir band of approximately 2.0 mm diameter is provided that tapers to approximately 2.3 mm in diameter. Although various embodiments contemplate Pt/Ir bands, any biocompatible material including, but not limited to, stainless steel, plastic, etc. may be used to confine fibers. Outer band embodiments of the present disclosure provide for grouping of at least the distal ends of the fibers proximate an inner band, thus focusing the laser energy and allowing for more of the laser energy to create smaller plugs of material. It is further noted that such embodiments provide for a manufacturing “stop” when the flared inner lumen fits into the preferably tapered portion of the band. Although various embodiments contemplate a tapered outer band, non-tapered bands are also contemplated by the present disclosure.
[0029] Catheters of the present disclosure comprise one or more polished surfaces that dictate the interaction of the tip with a surface encountered by the tip. Various embodiments comprise flat polished faces that engage tissue concentrically. Preferably, a flat polish is provided that allows not only the fiber faces to engage tissue at the same time, but also allows the inner lumen to form a vacuum seal on tissue that fills the distal face.
[0030] Deflection means are provided in various embodiments of the present disclosure for user-selective manipulation of a distal end of a catheter. In various embodiments, deflection means comprise features involved in offsetting or deflecting the catheter tip, such that a larger lumen may be created in an occlusion, as compared with non-deflective or offset manipulation of the catheter. It is contemplated that deflection means of the present disclosure provide for between approximately 2-5 mm offsets from an initial or aligned positioned, and preferably for between approximately 3-4 mm offsets, particularly for “above the knee” procedures.
[0031] In certain embodiments, one or more pullwires are provided as deflection means. Pullwires of the present disclosure comprise wires that run down the length of the catheter and are attached to the distal tip for manipulation thereof. When a tension force is applied to at least one deflection means of such embodiments, the wire(s) causes deflection of the flexible distal end of the catheter. In one embodiment, a wire component is provided in the catheter that is permanently fixed to the distal portion of the catheter. User manipulation of the wire, for example at a user-proximal portion of the catheter, is effective to shape the wire and catheter to a particular desired shape for larger lumen creation. In an additional embodiments, a balloon feature is provided comprising a non-compliant balloon fastened to the distal tip that, when inflated, causes deflection preferentially to one side of a corridor. Additionally, ramped features, such as those shown an described in U.S. Pat. No. 5,484,433 to Taylor et al., which is hereby incorporated by reference in its entirety may be included within catheters of the present disclosure.
[0032] Embodiments of the present disclosure also contemplate a flexible tip provided in combination with deflection means such as a shaping spine or pullwire. A flexible portion at the distal tip allows for bends and angled to be induced at the intended site, while the rest of the catheter can remain straight and rigid. In certain embodiments, laser cut hypotubes are provided having a thick enough wall for flexing without buckling and kerf widths (laser cut widths) large enough to allow for the bend angle required. Such tips are attached to the end of the catheter by laser welding (with a tricoil) or a fuse joint (plastics) and can be cut to preferentially bend a certain direction. Additionally, Pebax segments may be provided, such segments being fused to the end of a tricoil and able to deflect using a pullwire and/or shaping wire. Employing polymer tubing, a wire coil, or a combination thereof for the distal body, a guide wire may be used in peripheral or coronary angioplasty applications.
[0033] Various embodiments of the present disclosure also contemplate a spiraled ring ablation device with a mechanical cutting tip at the distal end of the catheter. A laser fiber ring is provided for cutting tissue while a blade or mechanical cutting edge assists in cutting and removal of harder calcium deposits, for example. The distal end may also be rotatable at various speeds to create various motions with the mechanical cutting edge. The edges of a spiral band may further be provided with mechanical cutting features. Thus, in various embodiments, a catheter is provided with a combination of laser and mechanical cutting or ablation features. Cutting efficiencies, particular with respect to calcium deposits, are thus improved.
[0034] Concurrent extension and rotation of at least a distal end of a catheter of the present disclosure is provided as a means for cutting and ablating an obstruction. In one embodiment, a method of removing material from a blood vessel is contemplated, the method comprising the step of concurrently extending a catheter along a length of a vessel and rotating at least the distal end of the catheter. Such methods provide various advantages, including the ability to core out or extract a substantially cylindrical mass of material and providing a fluid flow corridor through an obstruction, thus enabling fluid/blood flow through the corridor even when complete removal or ablation of the obstruction is not performed.
[0035] Various embodiments of the present disclosure contemplate a pulsed vacuum aspiration system to evacuate material removed during an atherectomy procedure and remove material as it is ablated and moved down the shaft of a vacuum device in a pulsed manner.
[0036] Although pulsed aspiration systems are contemplated with various features shown and described herein, the features, systems and methods described herein are not limited to use with pulsed aspiration systems and methods. Indeed, various removal means, devices and methods are contemplated for use with various features of the present disclosure. Such means, devices and methods include, but are not limited to, spinning helixes, rotating screws, Archimedes screws, continuous vacuum aspiration, and various combinations thereof. Additionally, aspiration systems other than a pulsed aspiration systems may be used. For example, an additional embodiment may include the use of a peristaltic pump for material aspiration in conjunction with laser cutting and coring. Use of the peristaltic pump may negate the use of a solenoid valve or pulse width modulator, due to the nature of peristaltic pump material movement. The peristaltic pump embodiment differs mainly from the vacuum pump embodiment in that it relies on a liquid filled system to aspirate or move material, while the vacuum pump system utilizes both air and liquid filled system, leading to potential variability within the system due to the compressibility nature of air. With reference to FIG. 4 , if a peristaltic pump is used, then the vacuum pump 18 would be replaced with a peristaltic pump and the solenoid valve 22 and pulse width modulator 20 would be deleted.
[0037] Other disclosures include using mechanical or laser means to macerate/destroy material as it enters the inner lumen.
[0038] In various embodiments, one or more vacuum pumps are provided to generate the vacuum required to aspirate material down a central lumen of a catheter. Vacuum levels in the range of 10 to 30 in-Hg, and preferably approximately 20 in-Hg, are provided. Vacuum pumps of the present disclosure preferably comprise a disposable collection container.
[0039] Another aspect of the present disclosure comprises a clogging detection means which detects clogging in an aspiration tube or an aspiration catheter during an aspiration operation.
[0040] In certain embodiments, an aspirator includes clogging detection means for measuring a change in a flow rate of an aspirate at one more points in a system. Alternatively, clogging detection means comprise means for measuring a change in a weight of an aspirate sampling bottle and/or a change in an amount of aspiration dropping in an aspirate sampling bottle. In various embodiments, clogging alert means for informing a user that clogging in the aspiration tube or the aspiration catheter has occurred are provided.
[0041] Clogging alert means of the present disclosure include, but are not limited to warning sounds and/or visual indicators that immediately notify a user of a potential clog such that remedial action can be taken immediately.
[0042] In one embodiment, an aspirator is provided with clogging detection means, the clogging detection means comprising a load cell for measuring the weight of an aspirate collection feature, such as a sampling jar. When clogging in the aspiration catheter or the aspiration tube occurs, a rate of increase in the weight of the collection features decreases. Therefore, clogging in the aspiration catheter or the aspiration tube can be detected by measuring a change in weight of the aspirate collection feature with the load cell. Where clogging is detected, a warning indicia is provided to inform an operator that the clogging has potentially occurred.
[0043] In alternative embodiments, detection of clogging is performed by measuring a change in a flow rate of an aspirate at one or more points in the system, such as blood flow in the aspiration catheter and/or the aspiration tube. For example, flow rate in a part of an aspiration tube immediately before an aspirate collection device is continuously measured by a flowmeter, an ultrasonic wave flowmeter, or the like during an aspiration operation. When a flow rate falls to a set value or less, it can be judged that clogging has occurred.
[0044] In still further embodiments, clogging or blockage is detected based on monitoring pressure values at one or more points in a system. Since an aspiration pressure increases when the aspiration catheter or the aspiration tube is blocked, when the aspiration pressure rises to a set value or more, it can be judged that clogging has occurred. It is also possible to set a threshold value for an output to the pressure indicator and emit a warning when the output increases to the threshold value or more.
[0045] When clogging in the aspiration catheter or the aspiration tube has occurred, it is preferable that an operator is informed to that effect immediately, and prompt measures for restart of aspiration are taken. Examples of the clogging alert means emitting a warning indicia include, but are not limited to a buzzer, a bell, various electronic sounds, and artificial voices. The clogging alert means is not specifically limited. If the alert means using a warning sound is adopted, an operator can concentrate on manipulation sufficiently and safety of an operation or a patient is remarkably improved because it is unnecessary for the operator to look at the medical aspirator in order to monitor clogging during the manipulation. Clogging alert means are further contemplated as comprising visual indicia, including various lamps, LEDs, or the like.
[0046] Embodiments of the present disclosure contemplate a vacuum system with clog detection features. Such embodiments comprise means to detect a difference in vacuum pressure, such as when a clog or obstruction is provided in a vacuum line and means to alert a user or operator of the device. Alert means of the present disclosure include, but are not limited to, auditory and visual feedback features to identify to the user that a clog in the vacuum system is present or likely present.
[0047] In one embodiment, alert means comprise a mechanical switch or feature that is activated upon a pressure value in a vacuum system exceeding a predetermined value. For example, a weighted or pressurized element is provided in a manner wherein the element is substantially hidden from a user's view when the vacuum is operating under normal unobstructed conditions. However, upon the pressure value exceeding a predetermined value, such as that corresponding to a significant blockage in the vacuum system, the element is displaced to a position whereby it is visible to a user. Such an embodiment provides a “red flag” warning indicia to a user that the vacuum is not operating normally and an obstruction may be present.
[0048] In a further embodiment, alert means comprise audio and/or visual indicia prompted by a waveform output of vacuum pressure at a particular point in the system. For example, a vacuum system is provided with one or more electromechanical pressure sensing features, such features outputting a waveform corresponding to pressure values at one or more points over time. Where at least one of such pressure values exceeds (thus indicating an upstream blockage) or drops below (thus indicating a downstream blockage) a predetermined value, the detected value prompts an associated audio and/or visual alarm to indicate to a user the presence of one or more blockages.
[0049] A method of operating a vacuum assisted aspiration system is provided, the method comprising the steps of: prepping and priming a catheter for surgery, inserting the catheter into a patient via a sheath, navigating the catheter to a site of stenosis (e.g. via guidewire), selecting appropriate mechanical and/or laser cutting parameters, activating appropriate mechanical and/or laser cutting features, activating a pulsed aspiration system via a foot pedal or similar user-actuation means, manipulating the catheter to core out stenotic material, applying laser energy and/or mechanical means to core material, and transmitting material into a distal tip of the catheter and subsequently conveying the material through the length of the catheter. A user may subsequently repeat various aforementioned steps until a stenosis is adequately removed or remedied. In embodiments comprising clog detection means, wherein a lesion material becomes clogged within the system, vacuum pressure will increase at a point in the system. Wherein such a condition occurs, alert means indicate to a user the presence of a clog. The user may then take correction, such as removing the device from the patient, purging the catheter, and subsequently re-employing the device for subsequent operations.
[0050] In one embodiment, a custom vacuum pump is provided. Alternatively, known and/or commercially available pumps, such as personal patient pumps are provided. It will be recognized that the present disclosure is not limited to any specific pump size, power, displacement etc. Preferably, however, one or more pumps of small, lightweight design that can still create and maintain the required vacuum levels are provided.
[0051] Various vacuum systems of the present disclosure comprise one or more solenoid valves to open and close a line between the vacuum pump and the aspiration lumen of the catheter. Such valves are compatible with blood, are liquid sealed, and have a fast response time for opening and closing at high frequencies.
[0052] In various embodiments, a custom valve is provided that is small, fast responding and can be fully integrated with the pump and other circuitry. The valve(s) may be disposable with the rest of the system or reusable (e.g. with the proper filters).
[0053] One or more filters are provided to collect material being aspirated down the inner lumen of the catheter. Filters of the present disclosure are provided with, for example, Luer valve fittings for ease of use, removal, cleaning, and reattachment. One filter of the present disclosure comprises Luer valve sides of two syringes with a plastic grate inside. The pore size of the grate is large enough to let liquid move through unimpeded, but small enough to prevent material from going through the valve into the disposable collection jar.
[0054] Pulsed vacuum systems of the present disclosure comprise a pulse width modulator to provide various signals to a valve, causing the valve to react faster/slower and remain open/closed for longer amounts of time.
[0055] Pulsing characteristics can be programmed into the vacuum pump/valve, and/or controlled by a user-operable feature such as a manual device or foot-pedal. In certain embodiments, a delay is built into an interface circuit of the present disclosure, the delay provided to allow the vacuum pump to run for a set amount of time after cutting operations have ceased, thereby allowing the inner lumen and other aspiration corridors to clear of material, thus reducing risk of back-flow and providing the benefit of generally clearing or purging the system. The delay may be programmed to allow the vacuum to run various durations. It will be recognized, however, that a preferred duration is one that accounts for length of lumen/corridor and flow rate and thus provides sufficient clearing of the system.
[0056] Preferably, a preset/adjustable custom circuit is provided, the custom circuit designed for pulsed aspiration in combination with additional features. The circuit comprises a user interface for adjustment, or is alternatively completely preset. In one embodiment, an interface circuit is provided that interfaces with a laser excimer system foot pedal, such as that associated with the Spectranetics® CVX-300, allowing for activation of the pulsed aspiration system only when lasing is actively occurring, thus further reducing the amount of undesired or unnecessary fluid transferred from a patient. A delay is built into the circuit to allow the vacuum pump/valve to run for a set amount of time after lasing so that the inner lumen can clear material. Such a delay may be pre-programmed based on various system characteristics including, but not limited to, the length of the inner lumen.
[0057] The present disclosure can provide a number of advantages depending on the particular configuration. Advantages of embodiments of the present disclosure include, but are not limited to, the evacuation of particulate and occlusions from an atherectomy site as such particulate is generate, thus reducing the risk of mere translocation of the particulate to other areas of the circulatory system. Various embodiments of the present disclosure contemplate user-selected pulsation of a vacuum or removal system such that the system may be pulsed only as particulate generation is occurring, decreasing the volume of blood or fluid extracted from a patient.
[0058] Additionally, pulsation features of the present disclosure are capable of providing short duration peak vacuum pressures that enhance the device's ability to evacuate larger or higher friction particles. Pulsed action methods and devices create a stepped motion from the extraction site down a catheter shaft, for example. Pulse width and duty cycle of the vacuum pulse can be varied to optimize the particle aspiration process for highest efficiency and minimum blood and fluid removal.
[0059] In various embodiments, the device of the present disclosure may not only be used for dissecting, coring and aspirating plug-type portions of lesion material, but the device or embodiments of the device of the present disclosure may be used to perform bulk ablation. Bulk ablation generally encompasses the use of catheter having a full face of laser emitters at its distal end, and all of the lesion material contacted by the energy transmitted by the laser emitters is ablated, in comparison to ablating the lesion with a circular or helical arrangement of lasers and coring the tissue. Depending upon the size and type of lesion, the bulk ablation technique may potentially increase the efficiency of the system and removal of debris. Such a technique may be used by a user/physician based on the specific removal needs and may comprise, for example, inserting an additional laser catheter through a central lumen to provide a substantially flat laser ablation distal end of the catheter.
[0060] Various embodiments of the present disclosure contemplate mechanical material removal means, such as helixes and screws. In one embodiment, a method and system is provided comprising a stainless steel hypotube further comprising a helical structure, the helical structure is capable of rotation at, for example, at approximately 15,000 to approximately 100,000 RPM. Such helical structure(s) are capable of macerating and translating material along their length, and thus removing occlusions from a vessel. Helical structures of the present disclosure may be provided in combination with various vacuum systems, laser and mechanical ablation systems, and other features described herein to assist in removal of material.
[0061] In various embodiments, a system is provided with user-selected presets for pulsed vacuum aspiration modes. For example, in one embodiment, a plurality of settings are provided in connection with a pulse width modular such that a user/physician may select between general vacuum aspiration settings including “low,” “medium,” and “high” based on the user's first-hand knowledge of the amount of particulate being evacuated or desired to be evacuated.
[0062] In various embodiments, one or more filters are applied, such as catch filters that allow a physician to visualize and/or analyze material being removed from an aspiration site.
[0063] These and other advantages will be apparent from the disclosure of the aspects, embodiments, and configurations contained herein.
[0064] As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as X 1 -X n , Y 1 -Y m , and Z 1 -Z o , the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., X 1 and X 2 ) as well as a combination of elements selected from two or more classes (e.g., Y 1 and Z o ).
[0065] It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0066] The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.
[0067] A “catheter” is a tube that can be inserted into a body cavity, duct, lumen, or vessel, such as the vasculature system. In most uses, a catheter is a relatively thin, flexible tube (“soft” catheter), though in some uses, it may be a larger, solid-less flexible—but possibly still flexible—catheter (“hard” catheter).
[0068] The term “computer-readable medium” as used herein refers to any storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a medium is commonly tangible and non-transient and can take many forms, including but not limited to, non-volatile media, volatile media, and transmission media and includes without limitation random access memory (“RAM”), read only memory (“ROM”), and the like. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk (including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes, or any other magnetic medium, magneto-optical medium, a digital video disk (such as CD-ROM), any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored. Computer-readable storage medium commonly excludes transient storage media, particularly electrical, magnetic, electromagnetic, optical, magneto-optical signals.
[0069] A “coupler” or “fiber optic coupler” refers to the optical fiber device with one or more input fibers and one or several output fibers. Fiber couplers are commonly special optical fiber devices with one or more input fibers for distributing optical signals into two or more output fibers. Optical energy is passively split into multiple output signals (fibers), each containing light with properties identical to the original except for reduced amplitude. Fiber couplers have input and output configurations defined as M×N. M is the number of input ports (one or more). N is the number of output ports and is always equal to or greater than M. Fibers can be thermally tapered and fused so that their cores come into intimate contact. This can also be done with polarization-maintaining fibers, leading to polarization-maintaining couplers (PM couplers) or splitters. Some couplers use side-polished fibers, providing access to the fiber core. Couplers can also be made from bulk optics, for example in the form of microlenses and beam splitters, which can be coupled to fibers (“fiber pig-tailed”).
[0070] The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0071] A “laser emitter” refers to an end portion of a fiber or an optical component that emits laser light from a distal end of the catheter towards a desired target, which is typically tissue.
[0072] An optical fiber (or laser active fibre) is a flexible, transparent fiber made of an optically transmissive material, such as glass (silica) or plastic, that functions as a waveguide, or “light pipe”, to transmit light between the two ends of the fiber.
[0073] The term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
[0074] It should be understood that every maximum numerical limitation given throughout this disclosure is deemed to include each and every lower numerical limitation as an alternative, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this disclosure is deemed to include each and every higher numerical limitation as an alternative, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this disclosure is deemed to include each and every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0075] The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.
[0077] FIG. 1 is a top perspective view of a distal end of a catheter according to one embodiment of the present disclosure;
[0078] FIG. 2 is an elevation view of a distal end of a catheter according to one embodiment of the present disclosure;
[0079] FIG. 3 is cross-sectional view of a distal end of a catheter according to one embodiment of the present disclosure;
[0080] FIG. 4 is a schematic of a pulsed vacuum system according to one embodiment of the present disclosure;
[0081] FIG. 5 is a perspective view of a distal end of a catheter according to one embodiment of the present disclosure;
[0082] FIG. 6 is an elevation view of a distal end of a catheter according to one embodiment of the present disclosure;
[0083] FIG. 7 is an elevation view of a distal end of a catheter according to one embodiment of the present disclosure;
[0084] FIG. 8 is a perspective view of a distal end of a catheter according to another embodiment of the present disclosure;
[0085] FIG. 9A , is a perspective view of a distal end of a catheter having a cutting blade at its distal tip in a retracted position according to one embodiment of the present disclosure;
[0086] FIG. 9B , is a perspective view of a distal end of a catheter having a cutting blade at its distal tip in an extended position according to one embodiment of the present disclosure;
[0087] FIG. 10A , is a perspective view of a distal end of a catheter having a cutting blade at its distal tip in a retracted position according to another embodiment of the present disclosure;
[0088] FIG. 10B , is a perspective view of a distal end of a catheter having a cutting blade at its distal tip in an extended position according to another embodiment of the present disclosure; and
[0089] FIG. 11A is a cross-sectional elevation view of a catheter according to one embodiment;
[0090] FIG. 11B is a phantom perspective view of a catheter according to one embodiment.
DETAILED DESCRIPTION
[0091] Although a large portion of this disclosure includes a discussion of laser catheters (or catheters having a combination of laser emitters and mechanical cutting tips at the distal end its distal end) used in conjunction with an aspiration system, catheters having mechanical cutting tips may also be used. Laser catheters typically transmit laser energy through optical fibers housed in a relatively flexible tubular catheter inserted into a body lumen, such as a blood vessel, ureter, fallopian tube, cerebral artery and the like to remove obstructions in the lumen. Catheters used for laser angioplasty and other procedures may have a central passageway or tube which receives a guide wire inserted into the body lumen (e.g., vascular system) prior to catheter introduction. The guide wire facilitates the advancement and placement of the catheter to the selected portion(s) of the body lumen for laser ablation of tissue.
[0092] Examples of laser catheters or laser sheaths are sold by the Spectranetics Corporation under the tradenames ELCA™ and Turbo Elite™ (each of which is used for coronary intervention or catheterization such as recanalizing occluded arteries, changing lesion morphology, and facilitating stent placement) and SLSII™ and GlideLight™ (which is used for surgically implanted lead removal). The working (distal) end of a laser catheter typically has a plurality of laser emitters that emit energy and ablate the targeted tissue. The opposite (proximal) end of a laser catheter typically has a fiber optic coupler, which connects to a laser system or generator. One such example of a laser system is the CVX-300 Excimer Laser System, which is also sold by the Spectranetics Corporation.
[0093] Referring now to FIGS. 1-2 , a distal end of a laser catheter 2 for atherectomy procedures in accordance with one embodiment of the present disclosure is shown. The laser catheter 2 may (as depicted in FIGS. 1 and 2 ) or may not include a lumen 14 . If a lumen 14 is included in the laser catheter 2 , a clinician may slide the laser catheter over a guidewire (not shown) through lumen 14 . It may, however, be preferable for the catheter to have a separate guidewire lumen located between the inner band and outer jacket. Incorporation of such a guidewire lumen is generally known to one of ordinary skill in the art, and all such guidewire lumens are within the knowledge of one skilled in the art are considered within the scope of this disclosure.
[0094] As shown, the catheter 2 comprises an outer jacket 4 or sleeve. The outer jacket 4 comprises a flexible assembly with the ability to resist user-applied forces such as torque, tension, and compression. The proximal end (not shown) of the catheter 2 is attached to a fiber optic coupler (not shown) and includes an outer jacket, inner band and a plurality of optical fibers similar to the configuration and orientation of such components depicted in FIGS. 1 and 2 . The distal end 6 of the catheter 2 comprises a tapered outer band 8 , which is attached to the distal end of the outer jacket 4 , a plurality of optical fibers 10 acting as laser emitters, inner band 12 creating an orifice that provides an entrance to an inner lumen 14 that is connected to an aspiration system discussed in more detail below. The energy emitted by the laser emitters 10 cuts, separates, and/or ablates the scar tissue, plaque build-up, calcium deposits and other types of undesirable lesion or bodily material within the subject's vascular system in a pattern substantially similar to that of the cross sectional configuration of the laser emitters 10 .
[0095] The cutting means in this embodiment is a laser ablation means that includes laser emitters 10 embedded within a catheter 2 comprising a lumen 14 . In this particular embodiment, approximately seventy-four laser emitters 10 are provided in a generally concentric configuration. Also provided substantially concentric with and interior to the laser emitters 10 (and optical fibers) is an inner lumen 14 , which provides a potential conduit or passageway for translocation of materials cut or ablated by the laser emitters 10 .
[0096] As the energy emitted by the laser emitters 10 contacts the undesirable bodily material within the subject's vascular system, it separates and cuts such material in a generally concentric configuration. In other words, one of ordinary skill in the art may refer to this technique as coring. And if the bodily material that is cut is substantially solid, it will appear as generally cylindrically looking core or plug. Although FIGS. 1-2 illustrate the laser emitters 10 in a generally concentric configuration, those skilled in the art will appreciate that there are numerous other ways and configurations in which to arrange a plurality of laser emitters. Additionally, although these two figures illustrate an outer jacket 4 and an inner band 12 , those of skill in the art will appreciate that distinct components need not be used, and the optical fibers may be encapsulated within a single sleeve having a lumen. Accordingly, FIGS. 1-2 , as well as FIG. 3 discussed below, are not intended to represent the only way that a laser catheter may be configured and constructed, and all such configurations and constructions are within the knowledge of one skilled in the art are considered within the scope of this disclosure.
[0097] FIG. 3 is a cross-sectional perspective view of a laser catheter according to one embodiment of the present disclosure. A flexible distal tip 2 is provided, the distal tip 2 comprising a central or inner lumen 14 provided substantially concentric with one or more annular arrays of optical fibers 10 and an outer jacket 4 . An inner band 12 is provided at a far distal end of the tip 2 . In the depicted embodiment, the inner band 12 has an orifice comprising an internal diameter that is smaller than a minimum internal diameter of the inner lumen 14 . The smaller size of orifice of the inner band 12 (either alone or in conjunction with the location and configuration of the laser emitters 10 ), in comparison to the size of the lumen 14 , ensures that the material will have a smaller cross section than that of the lumen 14 , thereby reducing the likelihood that the bodily material will become trapped or clogged in the lumen 14 as it is aspirated therethrough. Although FIG. 3 depicts the orifice of the inner band 12 as being less than the minimal internal diameter of the inner lumen 14 , the orifice of the inner band 12 may be equal to or greater than the minimal internal diameter of the inner lumen 14 .
[0098] The inner band 12 comprises a proximal end, a distal end, an interior surface and an exterior surface. When placed within the catheter 2 , the distal end of the inner band 12 is substantially aligned or flush with the far distal end of the tip 15 . The inner band 12 may be attached to the catheter via numerous means known to one of ordinary skill in the art. For example, the dimension of the exterior diameter (or circumference) of the inner band 12 may be slightly greater than the diameter (or circumference) of the lumen at the distal tip of the catheter such that the inner band is press fit into the distal tip of the catheter 2 . Additionally, the inner band 12 may be attached to the lumen by various known adhesives.
[0099] The interior surface of the inner band 12 may be straight or tapered. That is the interior diameters of the inner band may be the same or different (e.g., smaller or larger) in comparison to one another. For example, the interior surface of the inner band 12 may be tapered such that the interior diameter at its proximal end is greater than the interior diameter at its distal end.
[0100] Upon installation of the inner band 12 into the distal tip of the catheter, the interior surface of the proximal end of the inner band 12 may or may not be aligned or be flush with the surface of the lumen. Regardless of the alignment of the two surfaces, the lumen 14 may include a transition portion that is tapered from the point at which the proximal end of the inner band 12 contacts the lumen until a predetermined point located proximally thereof. The taper may either an increasing or decreasing taper as the lumen transitions proximally of the inner band 12 . The tapered portion may also extend distally beyond the proximal end of the inner band 12 and be used to affix the inner band 12 within the catheter. For example, as depicted in FIG. 3 , a portion of the inner lumen 14 may comprise a tapered portion 19 to receive and envelope a proximal portion of the inner band 12 . The inner band 12 may also provide structural support to the distal end of the catheter, and particularly to the distal ends of the fibers 10 , which are surrounded at an outer diameter by a tapered outer band 8 .
[0101] Outer band 8 is tapered from its proximal end to its distal end 2 , thereby facilitating the ease of movement of the catheter within a blood vessel. The outer band 8 abuts outer jacket 4 , and in order to further facilitate movement of the catheter within the blood vessel, it may be preferable that the exteriors of the outer band 8 and outer jacket 4 be aligned.
[0102] The catheter comprises a flexible distal end 2 , the flexible distal end 2 being operable by a user. The position of the distal end is controlled by one or more deflection means 16 which may include, but are not limited to, pullwires, shaping wires, and similar force-transmitting features controlled by a user at a user-proximal location of the device. Actuation of at least one deflection means 16 applies force to the distal tip 2 , thus deflecting the distal tip 2 from a longitudinal axis of the remainder of the catheter device. The deflection means allows the clinician to both create a pilot channel and subsequent larger channels, faster than conventional bulk ablation. For example, the clinician initially cuts the bodily material within the vascular system without deflecting the distal end of the catheter. Then, the clinician deflects the distal end of the catheter using the deflection means and subsequently cuts additional bodily material at the same general location within the subject's vascular system, thereby creating a larger channel therethrough in comparison the channel created initially created.
[0103] FIG. 4 is a schematic depicting a pulsed aspiration system 17 according to one embodiment of the present disclosure that may be connected to the lumen of the catheter to evacuate the ablated or cored bodily material from a subject's vascular system using various embodiments of a catheter comprising a distal tip having laser cutting means and/or mechanical cutting means. As shown, a vacuum pump 18 is provided, the vacuum pump 18 being interconnected to a pulse width modulator 20 in operative communication with at least one solenoid valve 22 , the actuation of which creates one or more pressure differentials to the aspiration system. Accordingly, rather than creating a constant suction pressure within the lumen of a catheter to evacuate cut and/or ablated bodily material from a subject's vascular system, the aspiration system of the present disclosure applies alternative pressure(s), thereby creating pulses of suction pressure within the lumen. Utilizing a series of constant and/or varying pressure pulses is potentially beneficial in aspirating bodily material, particularly when aspirating larger cylindrically looking core or plug like shapes of bodily material.
[0104] A filter 24 is provided upstream of the solenoid valve 22 , the filter 24 provided for filtering debris and aspirated bodily material and also for providing visual feedback to a user related to the type, quantity, and flow rate of material being removed from a patient. Fluid and material is provided to the filter 24 via a catheter 26 interconnected to, for example, an excimer laser system 28 for the treatment of peripheral and coronary arterial disease such as the CVX-300 Excimer Laser System sold by the Spectranetics Corporation.
[0105] In various embodiments, a fluid collection jar 21 may also be provided in fluid communications with the vacuum pump 18 . The fluid collection container 21 , such as a jar, comprises one or more known devices for collecting and filtering fluid removed from a patient. The container 21 preferably comprises transparent sidewalls for providing visual feedback to a user regarding flow-rate, content, coloration, etc. Filter means are also provided for removing particulate from liquids. Those of skill in the art will appreciate that various types of fluid collection containers may be used. The fluid collection container 21 and/or filter 24 may also comprise one or more custom filter features with various mesh sizes, capacities, etc. based on the specific application.
[0106] Pulse width modulator(s) 20 of the present disclosure provides for automatic control and varied application of vacuum pressure to the remainder of the aspiration system, including features and devices of an excimer laser system 28 provided in communication with the aspiration system 17 . It will be recognized that where an excimer laser system 28 is provided for cutting and ablating debris and particulate from a blood vessel of a patient, efficient removal of such debris is still required. The present disclosure provides an aspiration system 17 for use with an excimer laser cutting system 28 wherein blood and debris may be aspirated or removed in a pulsed fashion, thereby minimizing the amount of clean or healthy blood that is unnecessarily removed from a patient.
[0107] A pulse width modulator 20 is provided as a control means for controlling the opening and closing of at least one solenoid valve 22 , the solenoid valve 22 provided for selective application and segregation of a vacuum pressure provided by the vacuum pump 18 from the remainder of a system. Controlling the frequency and duty cycle at which the solenoid valve 22 opens and closes influences the pulse pattern, such as the pulse frequency, the pulse width, the pulse pressure, the rate at which the pulse pressure increases and/or decreases, etc. The settings for the pulse width modulator 20 may be manually adjusted by a user to provide a desired pulse pattern or the settings may be automatically adjusted by parameters stored within computer-readable medium controlled by a CPU. For example, during portions of a procedure where relatively little particulate is being ablated or cut from a patient's vascular system, the pulse width modulator 20 may be manipulated such that applications of vacuum forces are relatively far apart, thus removing a minimal amount of blood and fluid from a patient when such removal is not necessary. Alternatively, where significant amounts of particulate are being ablated and removed from a patient, the pulse width modulator may be manipulated or programmed to provide frequent constant and/or varying vacuum pulses and remove greater amounts of fluid from the patient.
[0108] The filter 24 preferably comprises a transparent device such that a user is provided with some level of visual feedback as to how much plaque or particulate is being removed from a patient. Based on this feedback, for example, a user can selectively manipulate the settings of the pulse width modulator 20 to alter the overall flow rate of material from a patient. In various embodiments, the pulse width modulator 20 and/or solenoid valve 22 settings are controlled by a foot pedal, hand switch, or similar user-actuatable device.
[0109] The filter 24 , vacuum pump 18 , flow sensor(s) (not shown) and/or pressure sensor(s) (not shown) may output signals that are transmitted to the CPU controlling the pulse width modulator 20 . The computer-readable medium may include an algorithm, which receives the output signals and instructs the CPU how to adjusts the parameters at which the solenoid valve opens and closes.
[0110] An interface circuit 31 may also be provided for communication with the pulse-width modulator 20 . The interface circuit is provided to communicate with, for example, the excimer laser system 28 . The computer readable medium and CPU discussed above may be located in the excimer laser system 28 . In addition to controlling the solenoid valve, the excimer laser system may also provide for a clogged aspiration detection system and control for a conduit-clearing mode based on various additional system parameters, including laser cutting operations.
[0111] FIG. 5 is a perspective view of a distal tip 30 of a catheter according to one embodiment of the present disclosure. FIG. 6 is a side elevation view thereof. FIG. 7 is a front elevation view thereof. As shown, the distal tip 30 comprises a combination of a mechanical cutting means and a laser ablation means. Mechanical cutting means of FIGS. 5-7 includes a sharp cutting edge or blade 32 that may be parallel to the longitudinal axis of the catheter or it lumen. Laser ablation means of the depicted embodiments comprise an extending spiral or helix-type array of laser emitters provided in an approximate 360 degree pattern about the longitudinal axis of the catheter and its lumen. The helical array comprises a first terminus 38 at a proximal end of the cutting edge 32 and a second terminus 36 at a distal end of the cutting edge 32 . Provided interior to the helical array is an inner lumen 40 through which material dislodged or ablated by the mechanical cutting feature and/or the laser emitters 34 is removed from a patient.
[0112] In various embodiments, the inner lumen 40 comprises a lumen of substantially circular cross-section with an internal diameter of between approximately 0.050 inches and 0.10 inches. In certain embodiments, the inner lumen comprises a lumen of substantially circular cross-section with an internal diameter of between approximately 0.060 inches and 0.090 inches. In a preferred embodiment, the inner lumen comprises a lumen of substantially circular cross-section with an internal diameter of approximately 0.072 inches. In various embodiments, the distal tip 30 comprises an outer diameter of between approximately 0.080 and 0.10 inches. In preferred embodiments, the distal tip comprises an external diameter of approximately 0.090 inches.
[0113] It will be recognized that distal tips 30 of the present disclosure may be provided with any number of laser emitters. However, in a particular embodiment, a distal tip is provided that comprises 50 optical fibers capable of transmitting light of approximately 130 μm wavelength.
[0114] The cutting edge or blade of the present disclosure may be constructed of, for example, stainless steels, abrasive materials, diamond tip, etc.
[0115] The present disclosure further contemplates that various features of FIGS. 5-7 may be inverted. Referring to FIG. 8 , for example, there is depicted in one embodiment, the laser emitters 808 along surface 804 that may be substantially parallel to the longitudinal axis of the catheter. Also included in this embodiment of the distal portion of the catheter is a sharp cutting edge 812 or blade provided in a spiral or helical configuration as it extends from the proximal end 816 of the surface 804 to the distal end 820 of surface 804 .
[0116] Various distal tip designs are contemplated by the present disclosure. Although particular embodiments are shown and described herein, the present disclosure is not so limited. Features of the present disclosure may be provided in combination with various catheter distal end designs. For example, the configuration of the laser emitters 34 of FIGS. 5-7 may arranged such that they extend spirally or helically but in a patter less than 360 degrees. Similarly, the sharp cutting edge or blade 32 in FIGS. 5-7 by be at an angle or offset from the longitudinal axis of the catheter or it lumen.
[0117] Catheter distal tips of the present disclosure include, but are not limited to, purely mechanical cutting devices provided in: circular, off-set, and semi-circular arrangements; various combinations of mechanical and laser-ablative cutting systems; and purely laser-ablative cutting systems. For example, FIGS. 5-8 include tips capable of applying laser energy and/or mechanical force (or pressure) to core through lesion material and create plug-type objects that can be aspirated through the catheter in their entirety. However, certain aspects of this disclosure may be beneficial to various mechanical and/or other types of macerating type devices and catheter tips. For example, FIGS. 9 and 10 illustrate mechanical tips that may be used to cut and/or macerate lesion-type tissue that may be capable of being aspirated in the manner discussed within this disclosure.
[0118] Referring to FIGS. 9A & 9B , there is depicted a catheter 900 having a tip 904 having a cutting blade with a plurality sharp vanes 908 of capable of cutting and/or macerating lesion tissue. FIG. 9A illustrates the cutting blade in a retracted position so that the catheter can navigate the subject's vasculature with minimal or no exposure of the vanes 908 . FIG. 9B illustrates the cutting blade in the extended position. As the cutting blade extends, the vanes 908 extend and rotate, thereby cutting and/or macerating the tissue with which the vanes 908 contact. Additionally, as the vanes 908 are extending and retracting, the pulsed aspiration system (previously discussed) can aspirate the cut and macerated tissue through the openings 912 between the vanes 908 , the lumen 916 within the center of the blades and/or both. Furthermore, depending upon the internal configuration of the catheter and the channels to the openings 912 and lumen 916 , one or more aspiration systems may be used in conjunction with the catheter.
[0119] Depending upon its use, the catheter may have differently shaped cutting blades and vanes. For example, if it is desirable to use a catheter for lead extraction, it may be preferable that the size of the lumen be increased, such as illustrated in FIGS. 10A-10B , thereby altering the size and configuration of the blades. Similar to FIGS. 9A and 9B , FIGS. 10A and 10B depict a catheter 1000 having a tip 1004 having a cutting blade with a plurality sharp vanes 1008 capable of cutting and/or macerating lesion tissue. However, in comparison to FIGS. 9A and 9B , FIGS. 10A and 10B have a larger lumen 1016 and larger openings 1012 between the vanes 1008 because there are fewer vanes. Although these two figures illustrate two types of cutting blades that can be used in conjunction with the aspiration system(s) discussed in this disclosure, those of skill in the art will appreciate that other configurations and types of cutting blades may be used in cooperation therewith. Accordingly, FIGS. 9-10 are not intended to represent the only ways that a mechanical, cutting-type catheter may be configured and constructed, and all such configurations and constructions are within the knowledge of one skilled in the art are considered within the scope of this disclosure.
[0120] FIG. 11A is a cross-sectional elevation view of one embodiment of a catheter 50 comprising an outer surface 52 and an inner surface 54 . The inner surface 54 of the catheter 50 may comprise a helical structure 56 extending from its distal to it proximal ends either continuously or for portions thereof. The helical structure 56 may comprise a polymer extrusion or metal insert extending radially inwardly from an inner diameter of the inner surface 54 and along a length of the catheter 50 in a helical or spiral manner. Alternatively, however, the helical structure 56 is provided as a recessed feature along the internal surface 54 of the catheter 50 . As the lesion material, either in the form of a plug or in macerated form enters the lumen formed by the inner surface 54 , the helical structure 56 facilitates the spinning of the material within the lumen as it is aspirated, thereby potentially reducing the potential for clogging. Additionally, the helical structure 56 may also macerate or further macerate the material, thereby potentially aiding and/or increasing the material's unimpeded travel from the distal to the proximal end.
[0121] A portion of a catheter 50 is depicted in FIGS. 11A-11B and no limitation with respect to which portion or specific length is provided or implied. FIGS. 11A-11B are provided to depict the feature of the helical structure 56 along an internal surface of the catheter 50 . Such a structure 56 may be provided along any length of the catheter, including a distal end of the catheter. Additionally, although not depicted in FIGS. 11A-11B , various additional features as shown and described herein may be provided in combination with the features of FIGS. 11A-11B . For example, the catheter 50 may further comprise distal end cutting features such as laser ablative means and/or mechanical as shown and described herein. Additionally, vacuum pulsing and detections systems as shown and described may be provided in combination with the catheter 50 . It will be recognized that the helical structure 56 depicted in FIGS. 11A-11B comprises a feature that may be integrated with or provided in combination with various features shown and described herein.
[0122] It will be recognized that the helical structure 56 of the catheter 50 generally comprises an internal threaded feature. The helical structure 56 may comprise various different thread characteristics, including overall length, pitch, diameter, etc. Preferably, however, the pitch and ramp angle of the helical structure 56 is shallow enough to effectively ablate occlusions within a blood vessel.
[0123] A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.
[0124] The present disclosure, in various aspects, embodiments, and configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the various aspects, aspects, embodiments, and configurations, after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.
[0125] The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more, aspects, embodiments, and configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and configurations of the disclosure may be combined in alternate aspects, embodiments, and configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspects, embodiments, and configurations. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.
[0126] Moreover, though the description of the disclosure has included description of one or more aspects, embodiments, or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
|
Catheters for ablation and removal of occlusions from blood vessels are provided. Laser cutting systems and mechanical cutting systems are provided in catheter devices, the cutting systems operable to ablate, cut, dislodge, and otherwise remove occlusions within a blood vessel that may limit or prevent proper circulation. A helical or partially-helical inner surface structure is provided in the catheter, the structure operable to remove or translate dislodged material(s).
| 0
|
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to the production of hollow titanium alloy articles, particularly alpha+beta and near alpha titanium alloy articles.
Recent developments in the design of high bypass gas turbine engines have increased the need for the production of lighter, yet stiffer rotating components, such as fan blades and compressor blades. Hollow titanium alloy parts are the prime choice due to their high strength-to-weight ratio and high fatigue resistance. However, the manufacture of hollow titanium alloy components presents several problems.
The most common method for fabricating aerodynamic blades and vanes is by forging solid blanks, followed by machining to achieve the desired shape and contours. While net precision forgings may be produced, these require the use of special alloys known in the art, but the latter are not as efficient as the wrought alloys. In the case of larger vanes, builtup brazed assemblies are typically produced. Each of these present methods is relatively costly and produces structures which are heavier than desirable.
Conn, U.S. Pat. No. 3,936,920, describes the fabrication of an aerodynamic blade or vane comprising an internally stiffened shell structured panel and a root fitting. Fabrication of this blade comprises fabrication of a panel blank composed of top and bottom face sheets diffusion bonded to a honeycomb core. The panel blank is rough trimmed to size, then shaped, by crushing, to an initial aerodynamic shape. The shaped panel blank is tack welded to the root fitting to assure that the parts will maintain their spatial relationship during the die loading step. The panel/root assembly is then vacuum die pressed to diffusion bond the leading and trailing edges and to mechanically interlock the panel to the root fitting. Following the forming and bonding step, the blade requires removal of surplus flashing and, possibly, machining. Conn, U.S. Pat. No. 4,043,498, describes fabrication of a shaped panel blank. Both of these methods require a plurality of component parts and considerable handling of the various components. Both methods are replete with opportunity for contamination of the component parts, which is very adverse to diffusion bonding.
Hollow components can be produced by superplastic forming/diffusion bonding (SPF/DB) of two or more segments in such manner that will produce a hollow internal cavity with optional internal webbing or reinforcement. One way to produce such segments is by investment casting. However, SPF/DB of cast titanium alloy structures is not generally possible due to the coarse microstructure of the as-cast segments. The as-cast microstructure of alpha+beta titanium alloys consists of coarse transformed beta structure. It typically exhibits large beta grains separated by grain boundary alpha phase and colonies of similarly aligned and crystallographically-oriented alpha plates within the beta grains. SPF/DB requires fine two-phase microstructure.
Accordingly, it is an object of this invention to provide a method for producing hollow alpha+beta and near-alpha titanium alloy articles.
Other objects and advantages of the invention will be apparent to those skilled in the art.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a method for producing hollow titanium alloy articles which comprises casting a plurality of segments which can be joined to provide a unitary, hollow article, treating the cast segments in such manner as to refine the microstructure of the segments and superplastic forming/diffusion bonding the segments into the desired hollow article.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing,
FIG. 1 illustrates a hollow turbine blade;
FIG. 2 is a plan view along line 2--2 of FIG. 1;
FIG. 3 illustrates the cast segments of the blade of FIG. 1;
FIG. 4 illustrates bonding of the segments; and
FIG. 5 illustrates an internally stiffened hollow blade.
DETAILED DESCRIPTION OF THE INVENTION
The alloy to be used in the practice of this invention can be an alpha+beta or near-alpha titanium alloy. Typical alloys include the following: Ti-6Al-4V, Ti-6Al-6V-2Sn, Ti-8Mn, Ti-7Al-4Mo, Ti-4.5Al-5Mo-1.5Cr, Ti-6Al-2Sn-4Zr-6Mo, Ti-5Al-2Sn-2Zr-4Mo-4Cr, Ti-6Al-2Sn-4Zr-2Mo-2Cr, Ti-3Al-2.5V, Ti-5Al-2.5Sn, Ti-8Al-1Mo-1V, Ti-6Al-2Sn-4Zr-2Mo-0.1Si, Ti-6Al-2Nb-1Ta-0.8Mo, and Ti-2.25Al-11Sn-5Zr-1Mo. The alloy may further contain up to about 6 weight percent of a dispersoid such as boron, thorium or a rare earth element.
Referring to the drawing, FIG. 1 illustrates a hollow turbine blade 10 including an airfoil portion 12 and a root portion 14. The complex nature of the airfoil portion 12 is best seen from the plan view in FIG. 2.
Blade 10 is fabricated from two segments 16 and 18, as shown in FIG. 3. Segment 16 consists of a root portion 20 and an airfoil portion 22. Segment 18 consists of a root portion 24 and an airfoil portion 26. When segments 16 and 18 are joined together, root portion 14 comprises items 20 and 24 and airfoil portion 12 comprises items 22 and 26.
Airfoil portion 22 of segment 16 comprises mating surfaces 28 and a concave region 30. Airfoil portion 26 of segment 18 has complementary mating surfaces, not shown, and may have a concave, convex or flat region.
Segments 16 and 18 can be cast using any casting technique known in the art. For complex shapes, such as turbine blades, investment casting is the presently preferred technique.
Investment casting is adaptable to automation and production of large-quantity runs. Investment casting is capable of producing true net shapes, with accurate dimensions and very good surface finish, that require almost no further machining or surface finishing. In this method, a wax pattern is produced by injection molding. The pattern assembly is dipped in a ceramic slurry, stuccoed and dried. This is repeated several times to build a ceramic shell with sufficient strength to sustain the molding pressure. After drying, the wax pattern is removed and the ceramic shell is fired. The ceramic shell is then filled with the titanium molding material, using a suitable apparatus. After casting, the ceramic shell is removed.
Following recovery of the casting from the mold, the casting may, optionally, be densified by Hot Isostatic Pressing (HIP). Titanium alloys dissolve their own oxides at high temperatures allowing a complete closure of all non-surface-connected porosity by diffusion bonding. The Hot Isostatic Pressing of titanium alloys may be carried out at about 50° above to 200° C. below the beta-transus temperature of the alloy at pressures of 10-45 Ksi for 2-4 hours. The term "beta-transus" refers to the temperature at the line on the phase diagram for the alloy separating the β-phase field from the α+β region where the α and β phases coexist. Hot Isostatic Pressing can enhance critical mechanical properties such as fatigue resistance, while causing no serious degradation in properties such as fracture toughness, fatigue crack growth rate or tensile strength.
The microstructure of the cast segments is then refined by one of three methods: BUS, as set forth in U.S. Pat. No. 4,482,398; TCP, as set forth in U.S. Pat. No. 4,612,066; or HTH, as set forth in U.S. Pat. No. 4,820,360, all of which are incorporated herein by reference.
Briefly, the BUS method comprises beta-solution treatment of a casting with rapid cooling to room temperature, preferably by quenching, followed by a relatively high temperature, relatively long aging heat treatment. The beta-solution treatment is accomplished by heating the casting to approximately the beta-transus temperature of the alloy, i.e., about 3% below to about 10% above the beta-transus temperature (in °C.), followed by rapid cooling. The casting is then aged by heating to about 10 to 20 percent below the beta-transus (in °C.) for about 4 to 36 hours, followed by air cooling to room temperature.
The TCP method comprises beta-solution treatment of a casting with rapid cooling to room temperature, preferably by quenching, followed by hydrogenation/dehydrogenation of the article. Titanium and its alloys have an affinity for hydrogen, being able to dissolve up to about 3 weight percent (60 atomic percent) hydrogen at 590° C. While it may be possible to hydrogenate the article to the maximum quantity, it is presently preferred to hydrogenate the article to a level of about 0.1 to 2.3 weight percent of hydrogen.
Hydrogenation is conducted in a suitable, closed apparatus at an elevated temperature by admitting sufficient hydrogen to attain the desired concentration of hydrogen in the alloy. The hydrogenation step is conducted at a temperature of about 50% to 96% of the beta-transus temperature of the alloy. Heating of the article to the desired temperature is conducted under an inert atmosphere. When the hydrogenation temperature is reached, hydrogen is added to the atmosphere within the apparatus. The partial pressure of hydrogen added to the atmosphere and the time required for hydrogenation are dependent upon such factors as the size and cross-section of the article, the temperature of hydrogenation and the desired concentration of hydrogen in the article.
After hydrogenation, the admission of hydrogen to the apparatus is discontinued, and the apparatus is flushed with a non-flammable mixture of inert gas and about 4% hydrogen. The article is allowed to equilibrate at the hydrogenation temperature for about 10 to 20 minutes, and then furnace cooled.
Dehydrogenation is accomplished by heating the article, under vacuum, to a temperature of about 50% to 96% of the beta-transus temperature of the alloy. The time for hydrogen removal will depend on the size and cross-section of the article and the volume of hydrogen to be removed. The time for dehydrogenation must be sufficient to reduce the hydrogen content in the article to less than the maximum allowable level. For the alloy Ti-6Al-4V, the final hydrogen level must be below 120 ppm (0.012 weight percent) to avoid degradation of physical properties such as room temperature ductility.
The HTH method comprises hydrogenation of the article, cooling the hydrogenation article at a controlled rate to room temperature, dehydrogenating the article and cooling the dehydrogenated article at a controlled rate to room temperature. Conditions for hydrogenation/dehydrogenation are similar to the conditions set forth previously. The rate of cooling is about 5° to 40° C. per minute.
Following refinement of the microstructure, the cast segments are bonded together. The bonding operation is illustrated in cross-section in FIG. 4. Rigid dies 40 and 42 have the contour of the airfoil portion 12 of the final part. The segments 16 and 18 are placed within the dies which are then closed with the application of temperature, time and pressure sufficient to bond the mating surfaces 28. Typical SPF/DB conditions include a temperature about 10° to 100° C. below the beta-transus temperature of the alloy, a pressure of about 10 to 100 MPa (1.5 to 15 Ksi) and time about 15 minutes to 24 hours. It is also within the scope of the invention to produce a hollow article having internal stiffening 32, as shown in cross-section in FIG. 5.
Although the invention has been described and illustrated in terms of an aerodynamic blade or vane, it will be apparent to those skilled in the art that the method of this invention is applicable to the fabrication of any hollow titanium alloy article. The advantages of this invention include precision casting of the article segments, minimal handling of the segments and opportunity for inspection of the internal surfaces of the hollow segments.
Various modifications may be made to the invention as described without departing from the spirit of the invention or the scope of the appended claims.
|
A method for producing hollow titanium alloy articles which comprises casting a plurality of segments which can be joined to provide a unitary, hollow article, treating the cast segments in such manner as to refine the microstructure of the segments and superplastic forming/diffusion bonding the segments into the desired hollow article.
| 1
|
BACKGROUND OF THE INVENTION
Related Applications
The present application claims priority from GB 9205661.3 filed Mar. 14, 1992 and assigned to the assignee of this application and is a continuation-in-part of copending U.S. patent application Ser. No. 07/873,260 filed Apr. 24, 1992 (EP 92303169.4), now abandoned and assigned to the assignee of this application.
FIELD OF THE INVENTION
The present invention relates to a clutch actuator control system for controlling the engagement and disengagement of clutches, such as normally engaged vehicular master clutches, in response to command output signals from a microprocessor based control unit or the like. More particularly, the present invention relates to a clutch actuator control system for automatically controlling the engagement and disengagement of the vehicular master clutch by means of a mechanical push or pull rod wherein the actuator includes a piston which is driven pneumatically and which drives a clutch operator through push/pull rod linkage. The rod is carried on the pneumatic piston by a hydraulic self-adjust mechanism whereby the value of a parameter indicative of the relative axial positioning of the pneumatic piston is a relatively accurate indication of the degree of engagement (such as "touch point") of the controlled master clutch.
DESCRIPTION OF THE PRIOR ART
Automatic actuator control systems for controlling the engagement and disengagement of vehicular master clutches are well known in the prior art and are often incorporated into automated or semi-automated transmission systems. Typically, such actuator control systems have comprised electric, pneumatic and/or hydraulic clutch operators controlled by microprocessor based electronic control units, i.e., ECUs, which process a plurality of input signals according to predetermined logic rules to issue command output signals to various control devices such as solenoid control valves and the like. Examples of such control systems may be seen by reference to U.S. Pat. Nos. 4,595,986; 4,081,065 and 4,361,060, the disclosures of which are hereby incorporated by reference.
In the automatic control of vehicular master clutches, especially during the reengagement of such clutches, an important control parameter is the current value of a controllable variable at the point of reengagement of the clutch known as the "touch point" or the point of "incipient engagement" of the clutch. Typically, during reengagement of vehicular master clutches, especially during reengagement of a master clutch for a start from stop operation, the master clutch is rapidly moved from the fully disengaged position thereof to the point of incipient engagement, and thereafter the clutch is reapplied in a modulated fashion according to predetermined logic rules. Control methods/systems for determining the value of controllable parameters corresponding to the incipient engagement point of a vehicular master clutch are known in the prior art and may be seen in greater detail by reference to U.S. Pat. Nos. 4,646,891 and 4,899,858, the disclosures of both of which are hereby incorporated by reference.
Vehicular master clutch control systems utilizing an actuator having two pistons rigidly connected together and running in separate cylinders wherein one piston is driven pneumatically and the other piston drives a clutch operator through a hydraulic linkage are known in the prior art and an example thereof may be seen by reference to European Patent No. EP 324,553B, the disclosure of which is hereby incorporated by reference.
The prior art devices were not totally satisfactory as, due to wear, constant recalibration was required to calibrate various feedback signals to selected operational positions of the clutch and/or clutch condition sensors were required at the clutch which required complicated and/or expensive wiring and/or wiring harnesses and required sensors exposed to difficult vibrational and heat conditions and the like and/or the clutch actuators were not self-compensating for wear.
SUMMARY OF THE INVENTION
In accordance with the present invention, the drawbacks of the prior art vehicular master clutch actuator control systems are minimized or overcome by the provision of an actuator control system for controlling the engagement and disengagement of a vehicular master clutch which is self-compensating for wear and other free play of the master clutch, and which allows clutch operating position to be accurately determined as a function of the axial position of a remote pneumatically operated clutch actuator piston.
The above is accomplished by providing an actuator control system for vehicular master clutch wherein the actuator includes a piston which is driven pneumatically against a resilient return spring bias and which is coupled to a push (or pull) rod control linkage by a self-adjusting hydraulic coupling. The present invention proposes to use the well-known ability of a hydraulic coupling to correct for mechanical free-play and wear by means of a reservoir with the object of avoiding having to constantly correct input signals according to sensed mechanical variations. By utilizing the piston structure described above, the present invention is effective to achieve accurate operating condition of the clutch by accurately positioning the remotely controlled pneumatic piston face.
Preferably, the present invention includes a cylinder assembly in which the pneumatically operated piston is pneumatically driven and having a hydraulic reservoir for providing automatic compensation for mechanical free-play and wear of the controlled vehicular master clutch by adjusting the position of the push/pull rod relative to the pneumatic piston. As is well known, vehicular master clutches are typically spring biased to a fully engaged position and moveable by some type of clutch operating device against the spring bias into a fully disengaged position. Preferably, the pneumatic cylinder assembly includes an actuator housing and will include a transducer located in the interior of said housing to generate signals indicative of the position of the piston. Pneumatic valving, operated in accordance with command output signals from the electronic control unit, is utilized to provide controlled pneumatic drive of the piston in dependence upon the transduced position--indicating signals. It is preferred that the pneumatic valves and/or the transducer may be installed with manifolding and electrical connections to the valves and the transducer in the pneumatic cylinder assembly housing structure.
In the preferred embodiment, at least two solenoid control valves are provided for connecting a chamber of the pneumatic cylinder associated with the actuation piston to either a high pressure source or a low (atmosphere) source. Preferably, two pairs of solenoid valves, a fine flow valve and a course flow valve, are provided for selectively pressurizing and exhausting the pneumatic operating chamber. As is known, control of the valves may be by a pulse width modulation method or the like.
Accordingly, it may be seen that a new and improved pneumatically operated actuator control system for controlling the engagement and disengagement of a vehicular master clutch is provided which allows the clutch position to be accurately determined as a function of the axial position of a remote actuator device, such as a pneumatic piston and which is self-compensating for wear and free-play of the clutch thereby eliminating the necessity for relatively frequent recalibration of the clutch control system.
These and other objects and advantages of the present invention will become apparent from a reading of the detailed description of the preferred embodiments taken in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the clutch actuator of the present invention.
FIG. 2 is a more detailed schematic illustration of the pneumatic control valving of the present invention.
FIGS. 3 is a partial illustration of a push/pull rod type clutch actuation linkage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the preferred embodiment, certain terms will be used for convenience and reference only and are not intended to be limiting. The terms "upwardly", "downwardly", "rightwardly" and "leftwardly" will designate directions in the drawings to which reference is made. The words "inwardly" and "outwardly" will refer to directions towards and away from, respectively, the geometric center of the device and designated parts thereof. The above applies to the words above specifically mentioned, derivatives thereof and words of similar import.
The present invention relates to a pneumatically operated actuator of the mechanical push/pull rod type which is suitable for an automatic or semi-automatic vehicular master clutch actuation system.
A portion of a typical push rod mechanical clutch operation linkage 20 is illustrated in FIG. 3. Rod 7 is engageable with clutch release lever 22 which is pivotably fixed about pivot point 26 with the clutch release bearing 24. A return spring 28 is provided to bias the lever 22 and bearing 24 into the clutch engaged positions thereof.
The operating rod 7 of the invention is moved axially in any known manner, by pneumatic power applied to a primary piston in a cylinder, in some arrangement (such as automatic or semi-automatic actuation), where the degree of engagement of the clutch needs to be reliable and repeatably sensed. Thus the primary piston should maintain its relative position with respect to the operating stroke of the clutch, whatever the degree of mechanical wear in the clutch or in the clutch friction surfaces. If a computer type control (electronic control unit, "ECU") does not "know" when a clutch is just beginning to bite, or is 50% engaged, for example, operation will be unpredictable, rough or lead to over-rapid wear of the drive, or of the driven device e.g. the vehicle.
Some types of clutches wear such that the incipient engagement position of the control rod lies further in the push direction; the effects of wear on other types (sometimes called pull clutches) however, lead to engagement occurring earlier, perhaps tending to cancel any lost motion. The present invention is aimed to be applicable to compensate for either type for wear.
Referring to FIG. 1, a first primary piston 1 moves in a pneumatic cylinder 8 when pneumatic pressure is supplied via connection 5 to a piston chamber 8A of the cylinder and is thus applied to drive piston 1 against a spring 9. A clutch may be disengaged pneumatically and engaged by the spring, or vice-versa. Spring 9 may supplement or be replaced by the return spring 28 illustrated in FIG. 3.
The primary pneumatic piston 1 is integral with a secondary hydraulic cylinder 10, in which a second piston 2 moves and which can form a sort of piston as well, since it moves in a third hydraulic cylinder 11. The third cylinder 11 is integral with the primary cylinder 8 and has a port 14 for connection to a hydraulic supply or reservoir conduit 6. The third cylinder 11 holds an amount of hydraulic fluid which is increased and then reduced with every stroke of the secondary cylinder and hence of the first piston.
Internally, the secondary cylinder 10 has an adjustment chamber A which contains a charge of hydraulic fluid, which is used to transmit the movements of the second cylinder 10 in the third cylinder 11 to a clutch push rod 7 through second piston 2, this operating rod 7 being moved leftwardly to disengage or to engage a clutch through a linkage mechanism. The clutch plates and/or the linkage mechanism may be, or may gradually become, defective or worn. The leftward drive of the rod is produced by pneumatic pressure and is against the usual bias (28) acting on the clutch or rod, and also against the spring 9 acting on piston 1.
The end wall 12 of the second cylinder 10 has a passage 10A therethrough opening to the third cylinder 11 in which is mounted a normally closed valve 3 which has a stem 15 abutted whenever the return spring 9 drives piston 1 rightwardly after a disengagement of the clutch, and hence the end wall 12 of the secondary cylinder 10 is driven adjacent to or against the end wall 13 of the third cylinder. This point is arranged as a datam point, in that the clutch is designated as just fully engaged, so that an end point can be calibrated on a position sensor 4. The hydraulic exhaust or supply conduit 6 is now connected to chamber A through chamber 11 and passage 10A because the stem 15 of the valve is abutted and the valve opens. If wear has caused engagement to be too early, oil will flow out of A. If wear has caused too late an engagement, or a nonengagement at the designated fully engaged position, the fluid will flow back into 6 to relieve A.
In all presently preferred embodiments, the throw of the pneumatic piston 1 will be from a leftward position such as that shown, to a fully rightward position abutting the end wall 16 of cylinder 8. When at the latter position, the clutch has not been fully engaged by spring 9, the aforementioned release springs 28 of the clutch will drive rod 7 and piston 2 rightwards, to drive hydraulic oil out of adjustment cylinder A. There may also be a compression spring 17 in the position shown, acting between piston 1 and piston 2, assisting the driving out of the hydraulic fluid or oil. This spring 17 would have been charged up by the disengagement stroke of the clutch. If the clutch had been of the push type where wear caused early engagement, the spring 17 would be replaced on the right hand side as viewed of the piston 2, thus acting against the inside of the end wall of cylinder 10 (or on some other suitable abutment in this cylinder).
In fact, the aforementioned designated end position is preferably a little beyond full engagement, to give a predetermined small amount of free play before the disengagement stroke begins to disengage the clutch. In this case a spring such as that shown at 17 is almost certainly essential, to locate the starting position of the piston 2.
When piston 1 and cylinder 10 are driven leftwardly, the valve stem 15 is no longer abutted, and will provide an assisting check-valve effect to keep the normally closed valve 3 closed by hydraulic compression within chamber A. The piston 2 and the rod 7 itself are driven leftwardly, with primary piston 1, by the fluid of A, and the position of the clutch is accurately indicated by the piston position signalled by sensor 4.
Hydraulic self-adjustment assemblies similar that described above are known in the prior art as may be seen by reference to U.S. Pat. No. 5,009,299, the disclosure of which is in incorporated herein by reference.
The pneumatic valve assembly 30 for selectively venting and exhausting pneumatic chamber 8A is controlled by a microprocessor based ECU 32 which receives inputs 34 from various sensor such as clutch position sensor 4 and sensors indicative of engine speed, vehicle speed, transmission shaft speeds and the like. ECU 32 will process these inputs according to predetermined logic rules to issue command output signals to various actuators such as to the valve assembly 30.
FIG. 2 schematically illustrates the high pressure and exhaust pneumatic solenoid control valves 38-44 of valve assembly 30. As illustrated, pressurized air is provided through valves 38 and 40 which may control a course fill or fine fill orifice, respectively, while exhaust may be controlled by solenoid valves 42 and 44 which in like manner may control a course or fine orifice. Alternatively, the solenoid valves themselves may have a course On/Off control and a fine On/Off control respectively. The control of the valve may be by the width of pulses in a power-amplified square pulse wave. Such pulse width modulation valve and the use of parallel course and fine fill or course or fine exhaust controlled conduit is, of course, known in the prior art.
The course controlled valves could use a different type of valve which need only be suitable for On/Off control. The pulse valves which must be of a quicker reacting type, which will closely and continuously follow the duty cycle of the modulation. It will often be preferable to use only one exhaust valve and/or one high pressure feed valve, if they can be operated at 100% duty cycle for On/Off operation and also at duty cycles graded down to 5% or even 0. Such solenoid valves controlled by pulse width modulation are available from the Honeywell Corporation.
There are many control methods and systems for the automatic operation of vehicular master clutches as may be seen by reference to above-mentioned U.S. Pat. Nos. 4,081,065; 4,361,060; 4,646,891 and 4,899,858, the disclosures of all of which are hereby incorporated by reference.
Typically, such control system involved a calibration or learning process where various clutch operating positions of interest, such as the point of incipient engagement, the point of full engagement, etc., are determined with time and a controlled or monitored clutch actuator parameter is calibrated thereto. Such a calibration procedure is discussed in U.S. Pat. No. 5,014,832, the disclosure of which is hereby incorporated by reference. According to the present invention, the clutch operational position is monitored by observation of the pneumatic drive piston/secondary cylinder 10 axial position by means of transducer 4.
From the foregoing, it is believed that those familiar with the art will recognize and appreciate the novel concepts and features of the improved actuator control system for vehicular master clutches of the present invention. While the present invention has been described in relation to only a single preferred embodiment, numerous variations, changes and substitutions of equivalents will present themselves to persons skilled in the art and may be made without departing from the scope and spirit of the present invention.
|
A self-adjusting pneumatically operated vehicular master clutch actuator is provided. A pneumatically operated primary actuation piston (1) carries a push/pull rod (7) for operation of a master clutch linkage (22). The push/pull rod (7) is mounted to the primary piston (1) by a hydraulic adjustment assembly (2, 10, 12, 11) for axial movement therewith. Sensing device (4), at least partially interior of the primary cylinder housing (8), for sensing the axial position of the primary actuation piston are also provided.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates generally to screens for separating undesirable material from desirable material. More particularly, the present invention relates to screens for screening material used in the production of paper, board, and the like. Such screens are known in various designs and used world-wide in the paper industry.
Screens are known where blades mounted on a rotor have a cross-section shaped, in direction of rotation, similar to the wing of an aircraft and which begins with a bulb-like curve in the direction of rotation, then converges towards the rear and ends in the shape of a narrow droplet. These blades extend in the form of bars and are the same length as the rotor or screen basket. Normally a cylindrical rotor is provided. In the screens known, the surface of the blade facing the screen basket provided for the pulp particle suspension to pass through is curved such that the radial clearance between the function-bearing blade surface and the screen basket surface facing it is reduced first of all to a minimum in the leading sector of the blade. After a brief stretch where the minimum clearance to the facing screen basket surface remains approximately the same, the radial clearance then rises again towards the rear end or rear edge of the blade. The purpose of this is to squeeze the screening material suspension through the openings in the screen basket, assisted by dynamic pressure, in the leading front area of the blade with diminishing clearance to the screen basket. In the rear trailing sector of the blade, whose clearance to the screen basket surface facing it gradually increases, a kind of suction effect is generated on the suspension material already pushed through to the other side of the screen basket in order to achieve a backwashing and rinsing off action of the impurities on the screen basket. This suction effect is known and experts shared the opinion hitherto that blades with a cross-section similar to a narrow, curved droplet have the optimum shape for effectiveness of the rotor and the blades to achieve a substantial backwashing effect and obtain the lowest possible flow resistance as the blade moves through the fibre pulp.
In the present description of the state of the art, it should be added that there are two basic types of screen: There are screens with a screen basket which is fed suspension to be screened from the inside and which have blades inside the screen basket, known as “centrifugal screens”, and there are screens with blades rotating outside the screen basket and brushing over it on the outside with low clearance, where these so-called “centripetal screens” feed the material to be screened to the screen basket from the outside and the cleaned pulp suspension is carried off the inside of the screen basket.
In centripetal screens with screen basket on the inside and blades rotating on the outside of it, the rotating shank of the rotor has a star or disc-shaped support in the inlet or top section of the screen basket, overlapping outwards over this screen basket, and with extensions protruding downwards to which the blades rotating round the screen basket are secured.
SUMMARY OF THE INVENTION
The present invention is now based on the observation that the hitherto conventional airfoil shape of the blade surface closer to the screen basket, particularly the planned reduction in clearance between blade and screen basket in the leading sector of the blade is not the optimum design, neither in terms of fluid mechanics and energy efficiency, nor with regard to efficiency of the separation process, flow rates and separation performance.
It was discovered unexpectedly that a substantial improvement can be achieved in the operating results and quality of the cleaned material by modifying the clearance between the surface of the individual blades facing the screen basket and the screen basket surface facing each blade, and by selecting a special shape of blade cross-section.
Thus, the subject of the invention is a screen as described above, where the radial clearance between the leading sector of the blade, viewed in the direction of rotation, particularly the front end or the front edge of the surface of the blade facing the screen basket, and the surface of the screen basket is a minimum clearance and rises to a maximum clearance towards the rearmost sector, or the rear edge, of the blade.
The arrangement of the individual blades according to the invention and the continuous widening in clearance between the screen basket and the surface of the blades succeed in avoiding any pressure build-up. It has been demonstrated that the pressure exerted on the suspension to be screened in order to transport it through the screen is more than adequate to push sufficiently large quantities of pulp suspension through the openings in the screen basket and that no additional increase in pressure by special shaping of the rotor blade leading sector with diminishing clearance to the screen basket surface is required to implement this procedure effectively.
On the contrary, the increased suction effect now applied by the entire blade as a result of the widening clearance to the suction basket surface further back on the blade creates much more effective backwashing and, as a result, better removal of the particles and impurities separated from the screening material from the walls of the screen basket. The blades arranged and shaped according to the invention exert lower pressure or “underpressure” in the pulp suspension over their entire length and span in the direction of rotation, i.e. over the entire surface, compared to the pressure they otherwise apply in the screen casing. As a result, the inverse suction effect on a portion of the pulp suspension that has already passed through the openings in the screen basket is increased and backwashing occurs through the openings in the screen basket. Due to improved removal of the impurities retained, the separation behavior and performance of the screen according to the invention is enhanced. Due to the offset arrangement of the blades there is practically always vorticity at every point of the screen basket, which has the effect of cleaning the screen surface. The liquid flow from the feed may also be influenced favorably with a rotor shaped as a paraboloid of revolution.
The principal advantages of the screen and blades according to the invention are as follows:
Lower energy consumption as a result of the lower pressure build-up in the leading sector of the blade and thus, less flow resistance.
Lower pulsation generated by positioning the narrowest flow cross-section between blade and screw basket walls directly at or in the vicinity of the blade front edge.
Higher turbulence generated at the edges of the individual blades and thus, improved screen exposure for higher throughput and separation performance.
Low pressure shocks towards the screen surface and the area behind it, thus significant improvement in screening quality.
Lower rotor speed at constant throughput and thus, lower energy requirement.
The front or leading sector of the blade forms virtually no or only a small angle with the screen basket surface with minimum clearance to the blade. In those areas where the invention dictates a small angle, this configuration allows a high backwashing rate and the stronger suction effect ensures more effective removal of particle material from the screen basket surface.
The curvature of the blade surface facing the screen basket is important for the desired backwashing and for the suction effect. It has been shown that improved backwashing can be obtained with different curvature at the front and rear sectors, viewed in the direction of rotation, of the individual blades. That is, when the surface of the blades facing the screen basket are more curved in the leading sector than in the trailing sector. Preferably the curvature of the surface of the blade is greater at the front sector by some 5 to 20%, especially by 10 to 15%, than the curvature of the surface of the screen basket and the curvature of the surface of the blade is greater in its trailing sector by some 0 to 9%, preferably by 0 to 4%, than the curvature of the surface of the screen basket, and where preferably the transition zone from the preferably circular cylindrical curvature of the leading sector of the blade to the preferably circular cylindrical curvature of the trailing sector extends over the middle third of the length of the blade, where the transition from the strongly curved, leading sector to the less curved trailing sector takes place steadily. Such design boosts the effectiveness when separating the pulp suspension from the impurity particles.
The choice of different curvatures for the various sectors of the blade surface facing the screen basket allows the blade surface to be adapted effectively to cope with different operating conditions and material compositions. Maintaining a ratio of 0.05 to 0.5, preferably 0.1 to 0.3, between the minimum clearance and the maximum clearance between the surface of a blade and the screen basket also provides an advantage in this connection.
In detailed investigations aimed at optimizing the cross-sectional shape of the rotor blade it was established that the conventional configuration used hitherto with airfoil-shaped cross-section, which is both expensive and relatively complicated to implement technically, is not only unnecessary, but can even hamper effectiveness. Blades of a plate-type design, preferably with the same material thickness from the front edge or tip to the rear edge, provide a simpler and effective blade design which can be manufactured at reasonable cost. The lower centrifugal forces resulting from the plate-type blade cross-section—avoiding an airfoil shape—permit a cost-saving, light-weight design, virtually for the first time, and these can also be used with lighter-weight blade holding devices. Advantageously, the blades will have a thickness of 2 to 8 mm, particularly 5 to 6 mm, where preferably the blades are made of curved sheet metal, particularly, with their inner and outer surfaces parallel to one another.
In addition it was found that certain design details are capable of further enhancing the advantageous effects of the present invention. This is true, for example, of the shaping of the front edge of the rotor blade, viewed in direction of rotation, as a narrow rectangle, where the two front, corner edges can be rounded off it necessary.
Various different contours have proved favorable for the shape or form of the blade. For example, the contour of the blades may be narrower in a horizontal projection in their leading front sector than in their rear trailing sector or at the rear edge. The blades may have largely, triangular, deltoid, trapezoidal or dovetailed contours in a horizontal projection. The side edges of the blade may extend in a straight line from a front tip or narrow front edge and diverging at an angle towards the rear, forming an angle of 40 to 120°, preferably between 60 and 90°. If the contour is shaped in steps, these steps or indentations need not be located in a straight line by any means, but may describe a concave or convex curve. For the purposes of the invention, the blade contour widening from the front end towards the rear can have edges converging at an angle again in its rearmost third. The blade contour shapes described also contribute towards reducing the flow resistance when the blades move through the pulp suspension.
Furthermore it was established that the suction effect can be further increased if measures are implemented to ensure that the blade surfaces contain strip-like elevations extending at right angles to the direction of rotation of the rotor and on the far side of which an increased suction effect is generated locally in each case in contrast to the conventional suction effect of the blade surface.
The rotor itself can be formed in one piece. It can be expedient to use a design where several individual rotor modules are put together to form a rotor with any desired axial span. The rotor may have several blade supports, for example web plates, extending outwards from its shaft or the rotor body, mounted with uniform clearance to one another. Such features permit a highly robust construction in operation and also mechanical stability.
Additionally the invention includes a blade shaped as a bent or curved plate, preferably with the same material thickness from the front edge or tip to the rear edge. With conventional blades it was considered a disadvantage that these components were solid and heavy structures, particularly because these blades had an airfoil-shaped cross-section. With a blade design of the inventive type it is possible to manufacture a lightweight blade and lend the blades the desired shape by simple means, as well as to adapt the blades to suit different applications.
To facilitate changing the blade, particularly in order to insert blades that have been adapted to suit different rotor speeds or pulp suspensions, the blade may have a base section attached to its inner surface, on which fastening devices are provided. Alternatively, the blade may have screw holes for screwing it to a support.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:
FIG. 1 is a schematic sectional view of a first type of conventional screen;
FIG. 2 is a cross-sectional view of the screen of FIG. 1;
FIG. 3 is a cross-sectional view of a second type of conventional screen;
FIG. 4 is an enlarged view of the blade and basket of FIG. 1;
FIG. 5 is a schematic sectional view of a blade, web plate, and basket in accordance with a first embodiment of the invention;
FIG. 6 is a schematic sectional view of a blade and basket in accordance with a second embodiment of the invention;
FIG. 7 is schematic view of a first blade arrangement in accordance with the invention;
FIG. 8 is schematic view of a second blade arrangement in accordance with the invention;
FIG. 9 is schematic view of a third blade arrangement in accordance with the invention;
FIG. 10 is a horizontal projection of a first blade in accordance with the invention;
FIG. 11 is a horizontal projection of a first blade in accordance with the invention;
FIG. 12 is a horizontal projection of a second blade in accordance with the invention;
FIG. 13 is a horizontal projection of a third blade in accordance with the invention;
FIG. 14 is a horizontal projection of a fourth blade in accordance with the invention;
FIG. 15 is a horizontal projection of a fifth blade in accordance with the invention;
FIG. 16 is a horizontal projection of a sixth blade in accordance with the invention;
FIG. 17 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a first apparatus for fastening the blade to the web plate;
FIG. 18 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a second apparatus for fastening the blade to the web plate; and
FIG. 19 is an enlarged schematic sectional view of a blade and web plate in accordance with the invention illustrating a third apparatus for fastening the blade to the web plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The screen 100 shown schematically in a horizontal and a vertical sectional view in FIGS. 1 and 2 has a casing 5 with an inlet 51 for a screening material suspension, with an outlet 52 for accept pulp that has been freed of impurities. At the base of the casing 5 there is an outlet 53 or similar for discharging the impurities separated from the screening material. In the inner chamber 500 of the roughly barrel-shaped or cylindrical casing 5 there is a concentrically mounted, cylindrical screen basket 2 with round or slot-type screening openings 204 for the clean pulp suspension to pass through. In the inner chamber 200 of the screen basket 2 there is a rotor 300 and mounted on a pivoting bearing on a shaft 381 driven by a motor 6 through a vertical axis of rotation a3. Web plates 382 extend from the rotor 300 , particularly in radial direction, and each carry a blade 3 which can be moved past the inner surface 20 of the screen basket 2 at the end of the web plate 382 closest to the screen basket 2 . The screening material that is fed in through the inlet 51 under pressure, enters the screen basket's 2 inner chamber 200 , whose cross-section in this case becomes more and more constricted concentrically in the downward direction because of the paraboloid shape of the rotor 300 . The accept pulp, comprising fibrillated material free of impurities, is pushed by the action of the pressure introduced into the pulp suspension through the openings 204 in the screen basket 2 outwards into the inner chamber 500 of the casing 5 that surrounds the screen basket 2 and from where the suspension is discharged through the outlet 52 . The openings 204 in the screen basket 2 are dimensioned such that the impurity particles in the screening material suspension, such as glass splinters, coarser sand grains, small stones, metal particles, and similar, are retained in the screen basket 2 , particularly that they adhere to its inner surface 20 at the screening openings 204 . Without appropriate counter-measures the openings 204 would clog up and fibrillated accept suspension free of impurities would be prevented from passing through them. To prevent this from happening, the cross section of the known blades 3 is shaped like an aircraft wing and the trailing sector 33 —viewed in the direction of rotation dr—of their outer surface 30 exerts suction on the suspension as a result of its increasing clearance from the inner surface 20 of the screen basket 2 . This results in a small part of the accept suspension filtered immediately beforehand through the screen basket or pushed out of the screen basket, respectively, being washed back into the screen basket 2 . Due to this backwashing effect the impurities clogging the openings 204 are detached from the inner surface 20 of the screen basket 2 , fall to the floor of the screen basket 2 and eventually reach the outlet 53 .
The screen 100 shown in FIG. 3 works according to an operating principle that is inverse to that of the screen 100 shown in FIGS. 1 and 2. The casing 5 has an inlet 51 at the bottom for the pulp suspension to be screened, an outlet 52 at the top for the pulp suspension after it has been freed from impurities, and also a relatively high outlet 53 for impurities. In the casing 5 a rotor 300 with a conical cross-section is mounted that can be rotated round the axis a3 with a motor 6 . The top end of the rotor 300 supports a support disc or arms/web plates 382 extending radially in a star shape. Extending from the support disc or arms 382 there are blade supports 380 pointing downwards which hold the inwardly projecting blades 3 ′. The inner surfaces 30 ′ of the blades 3 ′ rotate round the screen basket 2 or rather round its outer surface 20 ′ with relatively little clearance. The separation of accept and impurities takes place in the same way as described in connection with FIGS. 1 and 2. The screen 100 illustrated in FIG. 3 and with the design known also has blades 3 ′ which are largely airfoil-shaped and display the disadvantages discussed above of higher energy consumption and lack of optimum backwashing effect, leading to less effective cleaning of the screen basket 2 and unplugging of the openings 204 .
The schematic drawing in FIG. 4 shows part of the screen basket 2 with its screening openings 204 for the accept suspension. The radial clearance ar between the surface 30 of the blade 3 facing the screen basket and the inner surface 20 of the screen basket 2 varies along the length of the blade 3 . The blade 3 with airfoil-shaped cross-section has relatively large radial clearance arv at its leading edge 310 and/or in the foremost, initial sector 31 . Between this initial sector 31 of the blade 3 and a relatively narrow middle zone 32 the radial clearance ar decreases to a minimum arm. From this zone 32 the radial clearance ar increases towards the rear sector 33 and trailing edge 330 up to a maximum value arh. At the front edge 310 and along the front sector 31 there is a pressure build-up extending to the middle zone 32 when the blade 3 is moved in the direction of rotation dr. Only in the trailing section 33 where the clearance between surface 30 and surface 20 of the screen basket 2 increases is an important suction effect generated for backwashing of the impurities. The blade 3 has a flat inner surface 3001 .
Detailed investigations have shown that an airfoil is not the optimum shape for the blade 3 in terms of the energy required to rotate the rotor 300 , the effectiveness of backwashing, and clearing of any impurities from the screening openings 204 . Since it is state of the art for the blade 3 with airfoil-shaped cross-section to have a front section 31 —viewed in the direction of rotation dr—where the clearance ar diminishes approximately as far as the sector where the web plate 382 is attached (FIG. 1 ), there is a dynamic pressure counter-effect in the pulp suspension which hampers rotation, thus increasing the energy consumption for rotation. Furthermore, only part of the entire blade surface 30 , to be precise the trailing sector 33 , is available for backwashing to clean the screen basket openings 204 .
The blade 3 shown in the sectional view in FIG. 5, mounted and designed according to the invention, has a convex outer surface 30 facing the cylinder jacket-shaped surface 20 of the screen basket 2 . The blade 3 is of plate-type design, e.g. made from sheet metal or synthetic material of even thickness ms. It is an advantage if the inner surface 3001 runs parallel to the outer surface 30 , that is to say these two surfaces 30 and 3001 have the same curvature.
In practice the blade 3 is some 5 to 6 mm thick, the screen basket 2 is usually 400 to 3000 mm in diameter and some 500 to 1500 mm high.
The small auxiliary sketches pertaining to FIG. 5 provide three examples of the preferred shape of front edge 310 of the blade 3 , where the face end has a rectangular cross-section in a), a similar cross-section shape with rounded edges in b) 3101 , and is rounded off 3102 in sketch c).
The blade 3 according to the invention, which differs substantially from state-of-the-art blades, is mounted in relation to the facing surface 20 of the screen basket 2 such that the clearance between the surface 30 of the blade 3 and the surface 20 gradually increases from the blade's leading edge 310 towards its trailing edge 330 and the radial clearance ar increases from the front to the rear. The smallest radial clearance arv is found at the leading edge 310 , and the largest clearance arh is at the trailing edge 330 .
According to FIG. 5, the curvature radius rsk of the surface 20 of the screen basket 2 is greater than each of the two curvature radii rf1 and rf2 of the leading sector 31 and the trailing sector 33 of the surface 30 of the blade 3 . It is an advantage that the surface 30 runs virtually parallel to surface 20 in the vicinity of the front edge 310 . A tangent plane etf drawn at the front sector 31 in the direct vicinity of the front edge 310 forms an acute angle ∝ of a few degrees with the corresponding radial tangential plane ets drawn at the surface 20 . This acute angle is determined by the radius rf1 of the curvature at the front edge 310 .
The radial clearance ar of the surface 30 rises from the minimum clearance arv continuously to a maximum clearance arh and, due to this “pitch” of the blade 3 in relation to the direction of rotation dr and compared with the screen basket 2 , the suction effect that comes to bear during backwashing when the blade 3 moves in relation to the screen basket 2 is guaranteed over the entire span of the blade in the direction of rotation dr.
According to a special design shape, the radius rf1 of the curvature of the front sector 31 of the surface 30 can be smaller than the radius rf2 of the curvature in the trailing sector 33 , with a transition area being provided in the intermediate zone 32 between the two different curvatures. It is not desirable to have an edge approximately following the path of a generator of the surface 30 between the strongly curved leading sector 31 and the less curved trailing sector 33 of the surface 30 .
The modification described to the degree of curvature over the span of the blade 3 yields advantageous changes to the flow conditions and leads to favorable changes in pressure in the suspension. The curvatures should preferably have a circular cylindrical shape, but can also be oval or elliptical.
It is a particular advantage if the tangential plane etf drawn at the leading sector 31 of the surface 30 , 30 ′ facing the screen basket or at the area around the tip of the front edge 310 of the blade 3 , 3 ′ forms an angle ∝ of 0 to 15°, preferably between 0 and 8°, particularly between 0 and 2°, with the tangential plane ets drawn at a corresponding radial generator ezs of the surface 20 , 20 ′ of the screen basket 2 facing the blade 3 , 3 ′. As a result, the surface 30 obtained has more favorable fluid mechanics properties and the suction effect is improved. This sizing applies for blades 3 , 3 ′ rotating both inside and/or outside the screen basket 2 .
It can be an advantage if the curvature at the front or leading sector 31 of the surface 30 of the blade 3 adjacent to the screen basket is 5 to 20%, preferably 10 to 15%, larger than the curvature of the facing surface 20 of the screen basket 2 and if the curvature at the rear or trailing sector 33 of the surface 30 of the blade 3 is between 0 and 9%, preferably between 0 and 4%, larger than the curvature of the surface 30 of the screen basket 2 .
FIG. 6 shows a schematic view of the screen basket 2 of a centripetal screen with blades 3 ′ rotating around the outside of the screen basket 2 , with surfaces 30 ′ which have less curvature than the outer surface 20 of the screen basket 2 and whose convex surface 30 ′ faces the outer surface 20 ′ of the screen basket 2 . The broken line indicates that the curvature of the blade 3 ′ can possibly also be “infinite” in the front sector 31 ′, i.e. that the angle ∝ at the front edge 310 could be equal to the limiting value 0°.
FIG. 7 shows a rotor 300 with blades 3 offset in relation to each other in height, in a zigzag arrangement, and designed according to the invention. By contrast, FIG. 8 shows a rotor 300 with blades 3 offset in relation to each other round the circumference. FIG. 9 shows a rotor 300 fitted according to the invention with blades 3 arranged along an ascending spiral line.
FIGS. 10 to 16 show blades 3 , 3 ′ according to the invention with trapezoidal, triangular and basically trapezoidal overall contours, shown in the order of listing. On its surface 30 the blade 3 according to FIG. 12 has turbulence bumps 308 in strip form, arranged at angle γ to the blade generator ezf, where γ is preferably between 10 and 45°, particularly between 15 and 30°, in this case approximately parallel to the lower side edge 35 , to form a corrugated surface. Groove-shaped indentations can also be formed in the blade 3 instead of these bumps 308 .
The angle ω formed by the diverging side edges 35 against the direction of rotation dr measures between 20 and 60°, preferably 25 to 50°. The approximately strip-shaped bumps 308 or the indentations on the surface 30 of a blade 3 cause local underpressure turbulence when the blade 3 moves and this assists in detaching the impurity particles adhering to the screen basket 2 .
At the blade 3 in FIG. 13 the side edges 35 are convex with an obtuse angle and the sections 351 directly adjoining the short, front edge 310 together form the angle ω. The side edges 35 of the blade 3 in FIG. 14 are designed with even steps 352 . The graduated side edge 35 substantially increases its overall length and thus enhances the turbulence in the pulp suspension when the blade 3 rotates.
The contour shape of the blade 3 in FIG. 15 has diverging side edges 35 in its front sector which then begin to deflect inwards approximately in the rearmost third of the surface 30 , then run towards each other in two short branches to the rear at an angle and terminate at the rear edge 330 . The blade 3 shown in FIG. 16 has a dovetailed contour with a short front edge 310 .
FIGS. 17, 18 , and 19 show diagrams of blades 3 , 3 ′ which can be connected in various ways by means of arms, web plates 382 or supports 384 extending out from the rotor 300 . The blades 3 , 3 ′ are made of curved sheet metal, particularly with a parallel outer surface 30 and inner surface 3001 . According to FIGS. 17 and 18, a base section 383 is shaped onto the blades 3 , 3 ′. The base section 383 in FIG. 17 has an internal, sleeve-shaped recess 385 , into which the prolongation 386 of the support 382 is inserted. Lateral projections 387 enclose the side limitations 388 of the recess 385 . The projection 386 and the recess 385 are connected by a screw—as intimated.
In the blade 3 , 3 ′ design shown in FIG. 18, the final sector of the base section 383 has a projection 389 which interacts with a projection 390 in the web plate 382 . The projections 389 and 390 are screwed together—as intimated at 384 .
According to FIG. 19, the blade 3 , 3 ′ can be screwed to a supporting member 391 secured to the support or web plate 382 using the screws intimated at 384 .
The designs illustrated allow easy replacement of the blades 3 , 3 ′ so that a screen fitted with this type of blade can be adapted quickly to handle different operating conditions.
|
A screen, for screening material used in the production of paper, board and the like, having a screen basket and a rotor supporting several blades which can be moved along the wall of the screen basket when the rotor rotates. The blades having a convex curvature on the side facing the screen basket. The radial clearance between the surface of the blade facing the screen and the screen being lowest between the front sector, viewed in the direction of rotation, and increasing towards the rear edge of the blade.
| 3
|
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. patent application Ser. No. 09/958,201, filed Oct. 5, 2001, now pending, which is the U.S. National Phase of PCT/US01/01369, filed Jan. 16, 2001, now pending, which claims the benefit of Provisional U.S. Patent Application No. 60/182,002, filed Feb. 11, 2000, and Provisional U.S. Patent Application No. 60/224,314, filed Aug. 10, 2000.
BACKGROUND OF THE INVENTION
[0002] A degree of realism can be added to games, especially war and fantasy games, through the use of miniature figures to represent characters in the games. Each participant in the game manipulates characters, each represented by a miniature figure and each being endowed with certain characteristics, e.g., strength and range of movement, that enter into the resolution of a given event, such as a battle or other interface between characters. As the complexity of each character and each scenario grows, and as the number of characters increases, the complexity of the game increases.
[0003] Traditionally, miniature figures are made of metal and sold individually or in sets. Typically, the packaging of the figures is at least partially transparent allowing the consumer to view the shape and identity of each figure prior to purchasing. Alternatively, when the packaging is not transparent, the contents of the package are clearly identified. Therefore, because purchasers are allowed to choose a specific figure for their collection, the potential market for trading these figures is minimized.
FIELD OF THE INVENTION
[0004] The invention relates to games involving the use of miniatures to represent characters in the games, and to apparatus for use in such games.
BRIEF SUMMARY OF THE INVENTION
[0005] The more complicated prior art games require voluminous rules of play manuals. These manuals include massive amounts of rules and statistics for all of the figures in the game. The number of included statistics makes it difficult for a player to find a specific figure's statistics. In addition, a player is limited to figures included in their specific manual. Further, the rules often entail detailed record keeping by the players, which are often recorded on miscellaneous slips of paper that can become misplaced or disorganized.
[0006] One challenge of miniature games for a broad audience has always been the size and complication of the rules and the need for record keeping for each figure within the game. In addition, due to the nature of the packaging, the manufacturer of the figures has little control over the collectibility of the figures.
[0007] The solution to these problems is to: (i) take both the statistics pertaining to a specific character and the recording of game effects upon that character and incorporate them within each figure; and (ii) modify the packaging to conceal the randomly inserted figures to encourage the collectability of the figures.
[0008] Accordingly, the invention described herein provides a method and an apparatus by which rules and record keeping are incorporated onto the game piece base of the miniature figures themselves with a self-contained record-keeping device. Therefore, a player can use the purchased figures immediately in a game, as opposed to first finding the correct statistics book for that specific character. This device includes counter-wheels having numbers, colors, or other indicia that reflect the nature and values of a character's characteristics and how they change as a game progresses. Values can be customized for each character by providing differently-numbered wheels for the game piece bases.
[0009] According to the present invention, the game pieces are preferably molded in plastic, pre-painted, and randomly inserted into opaque packages. The packaging is designed to conceal the identity of the figure from the purchaser. These game pieces are produced in different quantities. As a result, some are designed to be rare and very collectible. The players buy packages of game pieces to try to collect the army that the player wants to amass and play with. Typically, the rareness of a game piece corresponds to the value of that game piece. In other words, a rarer game piece is more effective in the game. This method of packaging, selling, and collecting game piece miniatures has the advantage of being unique. The game playing, manufacturing, packaging, selling, and collecting may be performed using game piece bases with or without an attached figure.
[0010] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims, and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0011] FIG. 1 is an exploded schematic representation of a game piece base embodying the invention.
[0012] FIG. 2 is a perspective view of the game piece base illustrated in FIG. 1 .
[0013] FIG. 3 is a plan bottom view of a base disk of the game piece base illustrated in FIG. 1 .
[0014] FIG. 4 is a plan top view of a selector disk of the game piece base illustrated in FIG. 1 .
[0015] FIG. 5 is a cross-section view taken along line 5 - 5 in FIG. 2 .
[0016] FIG. 6 is a cross-section view taken along line 6 - 6 in FIG. 2 .
[0017] FIG. 7 is a perspective view of alternate embodiment of the game piece base illustrated in FIG. 1 , including a representational figure.
[0018] FIG. 8 is a sample of combat data for a selection of human characters to be represented by such game piece bases as illustrated in FIG. 1 .
[0019] FIG. 9 is an exploded perspective view of a method of packaging a game piece base such as that illustrated in FIG. 7 .
[0020] FIG. 10 is a sample of a special abilities card to be used in conjunction with a game piece base such as that illustrated in FIG. 1 .
[0021] Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Miniature figures are often used in games, especially war and fantasy games, to represent characters in the games. These characters, for example, can be a Roman legionnaire, a Civil War Union soldier, a magician, or a mythical beast, depending on the game. Games can be played to re-enact historical battles, such as the Spartan defense of Thermopylae against the invading Persian army under King Xerxes, or to create a fantastical battle such as one pitting elves and humans against trolls and orcs. Each participant in the game commands an army of characters, each represented by a miniature figure. Each character is endowed with certain strengths and weaknesses, all of which enter into the resolution of a given battle. To add interest to the battle, other factors such as magic and terrain can also be included.
[0023] As the complexity of each character and each scenario grows, and as the number of characters increases, the complexity of the game increases. The challenge of miniature games for players is the extensive and complicated nature of the rules and the need for record keeping for each figure within the game. In this description, the terms warrior and game piece are used interchangeably to describe the invention.
[0024] FIG. 1 illustrates a game piece base 10 designed to ease the complexity of such games. Each game piece base 10 is a self-contained record-keeping device that includes a base disk 20 , a label 25 , and a selector disk 30 .
[0025] The selector disk 30 includes an upper surface 34 , a post 38 mounted in the center of the selector disk 30 , and a plurality of fingers 42 mounted at the periphery of the selector disk 30 . The plurality of fingers 42 includes six short fingers 46 alternating with six long fingers 50 . In alternate embodiments, any other suitable number or sizing of fingers may be used. One of the short fingers 46 includes a button 54 formed therewith and rising vertically from the upper surface 34 .
[0026] The label 25 including an aperture 58 is attached to the upper surface 34 of the selector disk 30 such that the aperture 58 aligns with the post 38 . A series of numbers in twelve columns of three appears on the label (not shown). Each column is spaced at approximately thirty-degree intervals around the label. In alternate embodiments, any other suitable arrangement of numbers can be used.
[0027] The base disk 20 includes an L-shaped stat slot or aperture 62 that allows one column of numbers and additional data from the label 25 to be seen at a given position of the base disk 20 relative to the selector disk 30 . As illustrated in FIG. 3 , the base disk 20 also includes a bottom surface 66 , and a plurality of indentations 70 in the periphery of the bottom surface 66 . The number of indentations should match the number of fingers 42 on the selector disk 30 . The base disk 20 also includes an upper surface 74 .
[0028] When assembled, as illustrated in FIGS. 5 and 6 , the label 25 is applied to the upper surface 34 of the selector disk 30 , and the base disk 20 fits within and is captured by the fingers 42 of the selector disk 30 . The center of the bottom surface 66 of the base disk 20 is supported by the post 38 . This arrangement allows the selector disk 30 to be rotated relative to the base disk 20 . The button 54 interacts with the indentations 70 such that the button 54 resides partially within an indentation 70 when that indentation 70 is aligned with the button 54 . The fingers are sufficiently flexible to allow the button 54 to snap into and out of an indentation 70 as the selector disk 20 is rotated relative to the base disk 20 . Such an arrangement ensures that the base disk 20 will only occupy a given number of discrete indexed positions relative to the selector disk 30 , where the given number of discrete positions is equal to the number of indentations 70 , and where each discrete position allows a player to look through the slot 62 to see whatever numbers, symbols, or colors may appear on the label 25 at that location. In other words, the two disks 20 , 30 are typically aligned such that a column of numbers appears in the slot 62 . The fingers 42 provide a gripping surface such that a player can manually rotate the selector disk 30 relative to the base disk 20 .
[0029] As illustrated in FIG. 7 , a figure 80 may be attached to the upper surface 74 of the base disk 20 to form a game piece or warrior 90 . The figure 80 may be any representational figure representing a character in a game.
[0030] In other embodiments (not shown), the described game piece base 10 may be any record-keeping device, such as mechanical and electronic counters that are suitable for recording and conveying information. Specifically, the game piece base 10 allows for the variation of indicia during the course of play. In still other embodiments, the figure 80 may be any suitable type of figure, including humans, animals, and mythical, mechanical, or fantastical creatures. The game piece base 10 may be made available in conjunction with or separately from the figure 80 to allow for interchangeability between figures 80 and bases, or to allow one to acquire a base to match a figure 80 one already has.
[0031] As is described in more detail below, the design of the game piece base 10 means that each game piece base 10 carries with it a complex two dimensional table that reflects a character's performance statistics at up to twelve stages of damage, where each discrete location of the base disk 20 with respect to the selector disk 30 represents a stage of damage. In alternate embodiments, other numbers of discrete locations can indicate other stages of damage. Examples of such tables are shown in FIG. 8 for a selection of human characters. Thus, the game piece base 10 provides both the table and the current performance of the character, eliminating voluminous rulebooks and record keeping.
[0032] The game pieces 90 are preferably molded in plastic, pre-painted, and randomly inserted into opaque packages 94 that are preferably glued closed or shrink wrapped to prevent opening. The package 94 is designed to conceal the identity of the warrior 90 from the purchaser. These game pieces 90 are produced in different quantities. As a result, some are designed to be rare and very collectible. The players buy packages 94 to try to collect the game pieces 90 that the player wants to amass and play with. Typically, the rareness of a game piece 90 corresponds to the value of that game piece 90 . In other words, a rarer game piece 90 is more effective in the game. This method of packaging, selling, and collecting game piece miniatures has the advantage of being unique.
[0033] These packages 94 can either include a single warrior 90 , as shown in FIG. 9 with a plastic insert 98 , or multiple warriors 90 . Preferably, the figures 80 are supplied in sets of five (booster packs) or ten (starter sets) because it improves the purchaser's chances of getting a desired figure 80 . When the multiple figures 80 are sold in a single package, retailers are more likely to carrying the product line because consumers are more likely to buy in volume. Retailers also appreciate that the concealing packages use minimal shelf space and only require a single stock keeping unit (“SKU”) as opposed to the one hundred and sixty SKU's (i.e., one for each character) that would be necessary if the warriors were sold in individual non-concealing packages.
[0034] The booster pack includes five figures 80 and five stickers to place on the bottom of each figure 80 on which the owner can write their name. The starter set includes ten figures 80 , a rulebook, a comic book to explain the fiction of the game world, a pair of dice, a flexible ruler for measuring distances, and 10 identifying stickers. The purpose for each of these items will be discussed in more detail below.
[0035] Alternatively, the packages can be configured to reveal the identity of the warrior 90 to allow the purchaser to select specific characters for their collection. But to facilitate trading of such figures 80 , the individual characteristics printed on the label 25 can be concealed by the packaging and varied between identical characters. These different printed labels 25 can be produced in varied quantities. As a result, some can be designed to be rare and very collectible. For example, identical characters can have different indicia printed on the label 25 making one figure 80 faster, stronger, and less susceptible to injury than another according to the rules of the game. Therefore, the more valuable warriors 90 of this embodiment would be those with more favorable numerical characteristics. The purchaser would then have the opportunity to more easily acquire the different warriors 90 and still be encouraged to trade for those warriors 90 that possess superior numerical characteristics.
[0036] Although the invention described herein may be used for a wide variety of games, a game called MAGE KNIGHT REBELLION will be used as an example to illustrate the invention. In MAGE KNIGHT REBELLION, a player takes on the role of a powerful warlord, king, baron, or high wizard who sends his warriors 90 out to do battle with opposing armies. MAGE KNIGHT REBELLION is a game of tabletop combat using collectible MAGE KNIGHT REBELLION figures 80 . Each figure 80 is called a warrior 90 , and is a member of one of eight different factions: Atlantis Guild, Elemental League, Necropolis Sect, Black Powder Rebels, Knights Immortal, Orc Raiders, Draconum, or Mage Spawn. A player builds an army from his or her collection of warriors 90 . A game may be played using game piece bases 10 with or without an attached figure 80 .
[0037] A warrior 90 is composed of two main pieces, the figure 80 and the game piece base 10 . The game piece base 10 shows sets of numbers that tell a player how good a warrior 90 is at doing certain things. Each time a warrior 90 takes a point of damage during a game, the player clicks the selector disk 30 clockwise to the next set of numbers. Each point of damage taken by a warrior 90 changes the warrior's game piece base numbers, reducing the warrior's effectiveness. Each time a warrior 90 takes a click of healing during the game, the player clicks the selector disk 20 counter-clockwise to the previous set of numbers. When three skulls show up on the game piece base, the warrior 90 has been eliminated and is removed from the battlefield.
[0038] Each warrior's game piece base 10 contains important information. This information includes the warrior's: a) name, b) point value (1-50), c) rank (weak, standard, tough), d) front arc (white), e) rear arc (gray), f) collector's number (1-160), g) faction symbol, and h) combat values. Each warrior's base also has a stat slot (to see numbers on the label 25 ). If a warrior 90 does not have a rank, then it is a unique figure 80 . Each warrior 90 has five combat values, four that change during the game and one that stays the same. The four values that change are speed, attack, defense, and damage. These four values are on the game piece base 10 , and can be seen through the warrior's stat slot 62 . The fifth value, range, never changes and is printed on the base 10 .
[0039] Game Items:
[0040] In addition to a player's MAGE KNIGHT REBELLION warriors 90 and a rules sheet, a player needs the following items to play a MAGE KNIGHT REBELLION game: a) an eighteen inch flexible ruler and b) two six-sided dice. Additionally, a two-foot-long piece of string and a few pennies (used as tokens during the game) may be used as will be further discussed below. Optionally, a player may also collect simple terrain items.
[0041] Blank stickers are provided with each pack of MAGE KNIGHT REBELLION warriors 90 for ownership identification. A player writes their initials on the stickers and places them on the bottom of each of that player's warriors 90 . This helps a player to sort out which warriors 90 are that player's at the end of each battle.
[0042] Building A Player's Army: All of the players must agree to a build total of each player's army. The build total is the total of a player's point values and is always in multiples of 100 points. Each MAGE KNIGHT REBELLION warrior 90 has a point value printed on its game piece base 10 . Once a player knows how many points that player has to build an army, that player chooses which of that player's warriors 90 will participate in the game. A player's army may contain two or more of the same figure 80 , unless that figure 80 is unique. However, the same unique figure 80 can appear in opposing armies. The total of the player's warriors' point values cannot exceed the build total value.
[0043] Beginning the Game:
[0044] MAGE KNIGHT REBELLION can be played on a flat tabletop. The players designate a square area to play that is at least three feet long on each side. A game can be played with any number of people, but the game is best when there are two, three, or four different armies. Each player selects one edge of the battlefield to be the player's, and then the game piece bases 10 of each warrior 90 are manipulated such that a green square is showing through the stat slot 62 . Each player places up to two terrain items in a pile off to the side of the battlefield. The purpose of the terrain will be described in greater detail below. Next, each player rolls two six-sided dice where the highest roll determines the first player. The first player places a terrain item from the pile onto the battlefield in a desired location. This continues in clockwise order until all of the terrain items are positioned on the battlefield. Each player then places a warriors 90 on the battlefield within three inches of the player's edge and at least 8 inches away from any other edge of the battlefield, starting with the first player and rotating clockwise until all of the players are positioned.
[0045] Turns and Actions:
[0046] In MAGE KNIGHT REBELLION, players alternate moving their warriors 90 and attacking opposing figures 80 to win the battle. At the beginning of a players turn, the player has a certain number of actions. This number is set for the entire game and is dependent upon the build total of the armies. A player gets one action for every one hundred points of that person's build total. For example, if the build total is 200 points, the player receives 2 actions per turn. During each players turn, that player decides which warriors 90 to give actions, however, the same warrior 90 may not be given two actions in the same turn. Actions include moving one warrior 90 , performing ranged combat with one warrior 90 , performing close combat with one warrior 90 , or passing. Once a player has completed their allotted actions, it becomes the next player's turn, and the next player gets the same number of actions. Play proceeds with each player taking a turn.
[0047] If a player gives an action (other than pass) to the same warrior 90 on two consecutive turns, that warrior 90 takes one point of damage after completing its subsequent action. This damage represents the fatigue caused by taking actions on two consecutive turns. A player may not give any warrior 90 an action (other than pass) on three consecutive turns. If a player has trouble remembering which warrior 90 that player has given an action to on a previous turn, that player can mark that warrior 90 with a token, such as a penny, to remind that player.
[0048] Game Concepts:
[0049] Distances measured for set-up, movement, or ranged combat, are always measured from the center of the game piece base 10 . Two or more warriors 90 are in base contact when the bases of each are touching. Friendly figures 80 are warriors 90 that are controlled by the same player or allied teammates, and cannot target other friendly figures 80 . Opposing figures 80 are any warriors 90 that are controlled by an opponent. Status of friendly and opposing figures 80 are set at the beginning of the game and cannot change by treaties or agreements.
[0050] Special Abilities:
[0051] There are special colored blocks on each warrior's game piece base 10 . These colors represent special abilities that warrior 90 has while they are displayed. There are four areas in which a player can find colored blocks representing the warrior's special abilities. These four areas are: 1) behind the move value, 2) behind the attack value, 3) behind the defense value, and 4) behind the damage value through the stat slot 62 on the warrior's game piece base 10 . Descriptions of these special abilities appear on the MAGE KNIGHT REBELLION Special Abilities Card, an example of which is shown in FIG. 10 . If a special ability is described as optional, the owning player decides if the ability is, or is not, used for the turn.
[0052] Movement:
[0053] A warrior's speed value is shown on its game piece base 10 . This is the maximum number of inches the warrior 90 may move when given a move action. When a player moves a warrior 90 , the player physically moves the warrior 90 across the battlefield along the exact movement path. This distance can be measured by the flexible ruler. The game piece bases 10 of other warriors 90 block movement, so a player's warrior 90 may not touch or cross the game piece base 10 of any other warriors 90 during its move. When a player finishes moving a warrior 90 , the figure 80 may be faced in any direction. The direction that the FIG. 80 is facing is important because the warrior 90 may only attack (ranged combat and close combat) out of its front arc and it is at a disadvantage when attacked in close combat through its rear arc.
[0054] If a player gives a move action to a warrior 90 that is in contact with the game piece base 10 of an opposing warrior 90 , the player must break away from the contact. To break away, the player must roll a six-sided die. If the player rolls a 1, 2 or 3, the warrior 90 fails to break away and may not move this turn, although the warrior 90 may be rotated if desired. If the player rolls a 4, 5, or 6, the player warrior 90 has successfully broken away and may move normally.
[0055] If a player's warrior's movement takes it into base contact with one or more opposing figures 80 , those opposing figures 80 immediately have the option to spin in place to bring any portion of their front arcs into contact with the moving warrior 90 .
[0056] Ranged Combat:
[0057] Ranged combat attacks represent everything from bows and gunfire, to magical spells and mind attacks. Each warrior 90 has a range value printed on its game piece base 10 . If this value is greater than zero and the warrior 90 is not in contact with the game piece base 10 of an opposing warrior 90 , then a player may give that warrior 90 a ranged combat action. This number represents the maximum number of inches that the warriors 90 ranged attack can reach. The number of arrow symbols shown with the warrior's range value is the maximum number of different targets the warrior 90 may attack with each ranged combat action. Certain special abilities allow ranged combat to be resolved against an increased number of targets.
[0058] When a player gives a ranged combat action to one of the player's warriors 90 , the player marks the warrior's range in inches on a string with a pen or marker (or just holds it with a player's fingers). The player places the end of the string at the center of the figure's game piece base 10 and extends the string to the center of the target's game piece base 10 . The path of the string is called the line of fire. If a player is firing at more than one target, the player must draw a line of fire to each of them.
[0059] The line of fire must pass through the attacking warrior's front arc, and each target must be within the range a player has marked on the string. The line of fire is blocked if it crosses any warrior's game piece base 10 (friend or foe) other than a target. If the line of fire is blocked, a player may not attack the target warrior 90 . A player may check to see if a line of fire is blocked at any time. The attacking player rolls two six-sided dice and adds their values to the warrior's attack value. If the result is equal to or greater than the target's defense value, as shown on its game piece base 10 , then the target is hit and damaged. When a player's warrior 90 hits a target with an attack, the target must take a number of clicks of damage equal to the attacker's damage value.
[0060] When a warrior 90 is attacking more than one target with a ranged combat attack, which is allowed when the warrior's range value is shown with more than one arrow, a player only rolls the dice once. The total of the dice plus the warrior's attack value is compared to every target's defensive value. Some targets with low defensive values may be damaged by the attack, while others with high defensive values may not be. Whenever a ranged combat action is used to attack more than one single target, the damage value of the attack, if successful, is always one, despite the warrior's normal damage value.
[0061] Close Combat:
[0062] Close combat represents hand-to-hand and melee weapon attacks. If a player gives the close combat action to a warrior 90 , the front arc of the warrior's game piece base 10 must be touching the target's game piece base 10 . The attacking player rolls two six-sided dice and adds their values to the warrior's attack value. If the result is equal to or greater than the target's defense value as shown on its game piece base 10 , then the target is hit and damaged. The player adds one to the dice roll if the warrior 90 is in contact with the rear arc of the target warrior's game piece base 10 .
[0063] Damage:
[0064] When a warrior 90 hits a target with a ranged or close combat attack, the warrior 90 inflicts damage in the amount of the warrior's damage value. This is the number of clicks of damage the warrior 90 has delivered to the target. The opposing player must click the target's game piece base 10 clockwise that number of clicks. The damage inflicted reduces the target's abilities, and may even eliminate the target from the game.
[0065] Rolling a “2” or a “12”:
[0066] Whenever a warrior 90 is making a ranged or close combat attack and rolls a “2,” the warrior 90 automatically misses the target. This is called a critical miss, and-the warrior 90 must take one click of damage representing a self-inflicted wound caused by the miss. If a player rolls a “12,” the warrior 90 has automatically hit the target and does one extra click of damage. Alternatively, if a player is trying to heal a warrior 90 and rolls a “12,” then the healing is automatically successful and delivers one extra click of healing.
[0067] Healing:
[0068] By using special abilities such as magic healing, regeneration, and vampirism, a player may repair clicks on a figure's base 10 . When repairing, click the selector disk 30 counter-clockwise, but never past the figure's starting position.
[0069] Capturing:
[0070] A player has the option in close combat of capturing a target instead of damaging the target. A player must declare a capture attempt before rolling the close combat dice. The defense value of the target warrior 90 is increased by two if a player is attempting to capture it. If a player hits the target, the player doesn't damage the target, but the target is captured and a player's opponent may no longer give the target an action.
[0071] Each warrior 90 may only have one captured figure 80 under that warrior's control. The capture is shown by keeping the captured figure's game piece base 10 in contact with the controlling warrior's game piece base 10 at all times. No warrior 90 , friend or foe, may target a captured figure 80 for any purpose. The captured figure 80 always moves with the captured figure's controlling warrior 90 using the lowest of the two figures' movement values. The controlling warrior 90 may only be assigned a move action or a pass action; it may not initiate any further combat. The controlling warrior 90 may not be the target of an opponent's capture attempt. If a warrior 90 with a captured target is eliminated, the captured target may immediately begin operating normally.
[0072] Formations:
[0073] An action that a player gives to one of the player's warriors 90 can affect other warriors 90 in a player's army of the same race by using formations. Note that a player can never be forced to use a formation if the player does not want to. A formation may never contain figures 80 from different factions, although a player may use different figures 80 from the same faction in a formation. Mage spawn figures 80 may never use formations.
[0074] Movement Formation:
[0075] If three to five of a player's warriors 90 are grouped so that each one's game piece base 10 is touching the game piece base 10 of another, then the player can call this group a movement formation. When a player gives a move action to just one of these warriors 90 , all of the warriors 90 in the movement formation may move at the same time and as part of that same action. At the end of the move, each warrior's game piece base 10 must still be touching the game piece base 10 of another warrior 90 in the formation. Therefore, the speed value of the slowest warrior 90 in the movement formation will restrict how far a player's warriors 90 will move. Movement formations are good because one move action allows a player to move several warriors 90 instead of just one. If any figure 80 in a movement formation fails to break away, that figure 80 may not move individually other than rotating to a new direction.
[0076] Ranged Combat Formations:
[0077] If three to five of a player's warriors 90 have their game piece bases 10 touching, a player may declare a ranged combat formation. When a player gives a ranged combat action to just one of these warriors 90 , all of the warriors 90 in the ranged combat formation contribute to the attack. The target figure 80 must be within the range value of each of a player's warriors 90 , and no line of fire may be blocked. The warrior 90 that a player gives the ranged combat action to is called the primary firer. To resolve the attack, a player uses the primary firer's attack value and damage value. Each additional warrior 90 in the ranged combat formation adds one to the attack dice roll. There is no damage bonus. Ranged combat formations are good because they allow a player to hit and at least do some damage to target warriors 90 with very high defensive values. Even if only one warrior 90 in the formation is given the ranged combat action, all warriors 90 are considered to have performed an action.
[0078] Close Combat Formations:
[0079] If two or three of a player's warriors 90 have their game piece bases 10 touching each other and a game piece base 10 of a single opposing warrior 90 , a player may declare a close combat formation against that opposing warrior 90 . When the player gives a close combat action to just one of a player's warriors 90 , all of the warriors 90 in the close combat formation contribute to the attack. The warrior 90 that the player gives the close combat action to is called the primary attacker. To resolve the attack, the player uses the primary attacker's attack value and damage value. Each additional figure 80 in the close combat formation adds one to the combat dice roll. There is no damage bonus. Close combat formations are good because they help overcome the difficulty in capturing an opponent's warrior 90 or damaging a warrior 90 with a high defensive value. Similar to ranged combat formations, if one warrior 90 in the formation is given the close combat action, all warriors 90 are considered to have performed an action.
[0080] If a “2” is rolled during a close combat or ranged combat formation, only the primary attacker rotates his base clockwise one click.
[0081] Tabletop Terrain:
[0082] Players are not required to use terrain when fighting a MAGE KNIGHT REBELLION battle, but adding terrain to the tabletop will make the game more challenging and interesting. There are four types of terrain in MAGE KNIGHT REBELLION: a) clear, b) hindering, c) blocking, and d) elevated. An empty tabletop is considered to be clear terrain.
[0083] Hindering Terrain:
[0084] Examples of hindering terrain are brush, low walls, and debris. A player can represent these with construction paper, pieces of felt, fabric, or scale models. Hindering terrain should lie flat on the table so that the terrain does not interfere with the placement of a player's warriors' game piece bases 10 . If a line of fire passes through any amount of hindering terrain or any number of hindering terrain features, one is added to the target's defensive value, this is called a hindering terrain modifier. Close combat attacks are not affected by hindering terrain. A player's warriors 90 can move into and through hindering terrain, but there are restrictions. If a player's warrior 90 begins a move with any part of the warrior's game piece base 10 touching clear terrain, the warrior's movement must end immediately when the warrior's game piece base 10 crosses completely into a hindering terrain feature. If a player's warrior 90 begins a move with any part of the warrior's game piece base 10 touching hindering terrain, the warrior's speed value is cut in half for the turn.
[0085] A firer in hindering terrain is not penalized by the modifier if its front arc lies entirely outside of the hindering terrain boundary and the line of fire does not pass into or through any other hindering terrain features. This represents use of the hindering terrain as protection while firing from the edge of the hindering terrain.
[0086] Blocking Terrain:
[0087] Examples of blocking terrain are large trees, high walls, and buildings. A player can represent them with common items such as salt shakers, cups, and stacks of books, or the player can use scale models. Blocking terrain blocks movement, so a warrior 90 may not move through it. Also, blocking terrain blocks any line of fire crossing it.
[0088] Elevated Terrain:
[0089] All elevated terrain is assumed to represent the same level of height above the battlefield. Elevated terrain features include hills and low plateaus. Elevated terrain may include areas of hindering and/or blocking terrain, but is otherwise assumed to contain clear terrain. Players can represent elevated terrain with stacks of books and magazines, or use scale models. All figures 80 must stop as soon as they move up into elevated terrain, or down out of elevated terrain (as if they were entering a hindering terrain feature). When measuring a player's move, don't measure any vertical distance traveled, just the horizontal portion of the warrior's 90 move along the tabletop or elevated terrain feature.
[0090] Elevated terrain features block lines of fire unless the firer or target or both are on the elevated terrain. If both the firer and target are on elevated terrain, nothing affects the line of fire except elevated hindering and blocking terrain features and other elevated figure 80 bases. If the firer or target is on elevated terrain, but the other is not, the line of fire is blocked if it crosses a different elevated terrain feature. Intervening blocking terrain features also block the line of fire, whether elevated or not. Intervening elevated figure 80 bases will also block these lines of fire, but those off of elevated terrain can be ignored. Hindering terrain modifies the attack only if either the firer or target is in hindering terrain, otherwise it too can be ignored.
[0091] Special Terrain:
[0092] Shallow water features like streams, fords, and ponds are treated as hindering terrain for movement, but have no effect on ranged combat actions. Deep water features like rivers and lakes are treated as blocking terrain for movement, but have no effect on ranged combat actions.
[0093] Low walls are special types of hindering terrain. Movement stops when a player's warrior 90 reaches the far side of a low wall, and speed is never halved on subsequent turns when that player's warrior 90 moves away from a low wall. Ranged combat attacks use the hindering terrain modifier for crossing the low wall, except if the firer is in base contact with the low wall. Close combat attacks are allowed between adjacent figures 80 on opposite sides of a low wall as if they were in base contact.
[0094] Abrupt elevated terrain such as raised parapets, flat rooftops, and plateaus flanked by cliffs are treated like normal elevated terrain except that close combat attacks are not allowed. Formations are also not allowed to be broken between levels of an abrupt elevated terrain. Figures 80 may only move onto or off of such terrain if they have special abilities or a ladder or stairway exists.
[0095] Height Advantage:
[0096] When a firer that is not on elevated terrain makes a ranged combat attack against an elevated target, the target's defense value is increased by one. This is the height advantage modifier. When using a ranged combat formation, only the primary attacker's line of fire is subject to the height advantage modifier and the hindering terrain modifier.
[0097] Close combat between figures 80 at different elevations is allowed if the bases 10 would be in contact if not for the height difference. If the target of a close combat attack is elevated while the attacking warrior 90 is not, the target gets the height advantage modifier.
[0098] Ending the Game:
[0099] The game ends when any of the following occur: a) Only one player remains with a warrior 90 on the battlefield; b) A predetermined time limit for the game expires; or c) All remaining players agree to end the game. A player may also decide to withdraw during their turn. If a player decides to withdraw, the player removes all of the player's remaining warriors 90 from the game.
[0100] The winner of the game is determined by the player with the highest number of victory points. Victory points are accumulated by eliminating opposing warriors 90 , maintaining captured warriors 90 , and by one's own surviving warriors 90 . The points awarded for eliminating an opposing warrior 90 is the point value of that warrior 90 . The points awarded for holding a warrior 90 captive at the end of the game is twice the point value of the captured warrior 90 . The points accumulated for each surviving warrior 90 is equal to that warrior's point value. After the game, all players retrieve their eliminated and captured figures 80 .
[0101] Various features of the invention are set forth in the following claims.
|
A method and an apparatus by which rules and record keeping in games employing miniature figures as game pieces are incorporated onto the base of the miniature figures themselves. Counters or wheels keep track of a character's characteristics and how they change as a game progresses. Values can be customized for each character by providing differently numbered wheels for the bases. Also, a method for providing collectable game pieces with varied features by providing them to the consumer concealed in packaging.
| 0
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.