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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to an articulating mast that may be transported from one well drilling site to another, and more particularly to a folding mast wherein sections of the mast may be moved from an open, in-use position to a reduced width configuration for storage and transportation and then moved from the reduced width configuration to an open position for use.
[0003] 2. Description of the Related Art
[0004] In oil and gas operations, well drilling rigs are utilized to drill for reserves. Many times, drilling does not result in a productive well. Other times, a producing well will be exhausted. It has been estimated that over two million boreholes have been dug worldwide.
[0005] Masts or derricks are well known for use in oil and gas and other drilling operations. A mast or derrick of a drilling rig supports a vertically moving block and tackle in order to raise and lower drill pipes. A mast may extend up to 200 feet and is usually comprised of structural steel framework, which supports a crown assembly. The crown assembly is an arrangement of sheaves at the top of the mast or derrick directly above the well bore. Various drilling structure arrangements are known, although one arrangement includes a pair of sides with a back face joining the sides and an open front face. A mast is typically braced on three sides with an open front face to receive pipe sections.
[0006] Once a drilling project has been completed, moving the drilling rig from one location to another is required. In one known arrangement, the entire drilling rig is disassembled piece by piece, then transported to the next location, and then reassembled.
[0007] As a technological advance on the complete disassembly and reassembly of the mast, a folding gin pole arrangement was developed, wherein the mast was lowered to the ground and disassembled. Normally, the mast sections are transported by trailer. Disassembly of the sections is normally required due to roadway limits as to height and width. For example, certain highway regulations limit the width of the load to twelve feet.
[0008] As a further technological advance on the folding gin pole arrangement wherein the mast had to be disassembled to fit onto trailers, an articulating mast was developed. This articulating mast is described in Assignee's patent, Brittain et al., U.S. Pat. No. 6,594,960. The mast therein had an articulating back face, such that the mast sections could be folded to a width acceptable for roadway requirements. Disassembly of each section required only the removal of six pins prior to folding, and assembly required only the insertion of six pens following unfolding. One drawback to the Brittain et al. articulating mast is that any guide track system, top drive, and/or traveling block used on the mast must be removed from the mast prior to disassembly, and reinstalled after assembly.
[0009] Based on the foregoing, it would be desirable to provide a mast that may be divided into sections that may be folded to meet roadway requirements for weight, width, and height. Furthermore, it would be advantageous to provide a mast wherein sections may be folded to a width acceptable for roadway requirements.
[0010] It would further be desirable to provide a mast having sections that may be moved between an open, in-use position and a more compact reduced width configuration for storage and transportation. It would further be desirable to provide a mast having sections that may be locked in either an open, in-use position or a reduced width, transport or storage configuration.
[0011] It would further be desirable to provide an articulating mast wherein the required disassembly and subsequent reassembly time is reduced.
[0012] It would further be desirable to provide an articulating mast wherein a guide track system, top drive, and/or traveling block may remain in place on the mast during disassembly, transport, storage, and reassembly.
SUMMARY OF THE INVENTION
[0013] In general, in a first aspect, the present invention relates to an articulating mast comprising: an open face; a pair of opposed sides, each side having a front leg and a rear leg; a back face extending between the rear legs; a pair of back face vertical supports running parallel to each other; a plurality of back face horizontal supports, each horizontal support having a first and second opposed end, each horizontal support first end pivotally attached to one back face vertical support and each horizontal support second end pivotally attached to one rear leg; a plurality of back face diagonal supports, each diagonal support having a first and second opposed end, each diagonal support first end pivotally attached to one back face vertical support adjacent one horizontal support first end; a plurality of pins; and a plurality of pin receivers on the rear legs adjacent the horizontal support second ends, such that each diagonal support second end may be attached to one rear leg by inserting one pin through the diagonal support second end and one pin receiver.
[0014] The articulating mast may be folded from an open position to a closed position by removing the plurality of pins from the plurality of diagonal support second ends and pin receivers to allow the diagonal support first ends, the horizontal support first ends, and the horizontal support second ends to pivot such that the plurality of back face horizontal supports and the plurality of back face diagonal supports move within a plane defined by the back face to lie relatively closer to the back face vertical supports, such that, when the articulating mast is in the closed position, the rear legs remain parallel to the back face vertical supports and within the plane defined by the back face, but are located relatively closer to the back face vertical supports and vertically offset from their location when in the open position.
[0015] The articulating mast may further comprise a plurality of pin receivers on the rear legs located such that each diagonal support second end may be secured with one pin to one pin receiver when the articulating mast is in the closed position. Furthermore, transport locks may be located on the horizontal supports such that the transport locks may be pinned to the rear legs when the articulating mast is in a closed position such that the articulating mast cannot easily accidentally unfold during transport.
[0016] The articulating mast may further comprise an integral guide track system, a top drive mounted on the integral guide track system, and a traveling block mounted on the integral guide track system. The top drive and the traveling block may be secured when the articulating mast is in the closed position such that they may not travel along the integral guide track system during transport.
[0017] The articulating mast may comprise a plurality of vertical sections and connectors between such sections, such that such sections may be disconnected from adjacent sections prior to folding or unfolding the articulating mast.
[0018] The articulating mast may be folded by removing the plurality of pins from the plurality of pin receivers and diagonal support second ends and pulling the rear legs downward such that the horizontal support first ends, horizontal support second ends, and diagonal support first ends pivot such that the horizontal supports and diagonal supports move within a plane defined by the back face to lie relatively closer to the back face vertical supports, while the rear legs remain parallel to the back face vertical supports and within the plane defined by the back face but are located relatively closer to the back face vertical supports and are vertically offset from their prior position. The method may further comprise separating the articulating mast into sections prior to removing the plurality of pins from the plurality of pin receivers and diagonal support second ends. If the articulating mast further comprises transport locks located on said horizontal support second ends and a plurality of pin receivers on said rear legs vertically offset from said horizontal support second ends, such that each said diagonal support second end and each transport lock may be attached to one said rear leg by inserting one said pin through said diagonal support second end, said transport lock, and one said pin receiver, the method may further comprise pinning the diagonal support second ends and transport locks to the pin receivers to secure the articulating mast from unfolding. If the articulating mast further comprises an integral guide track system, a top drive, and a traveling block, the method may further comprise securing the top drive and traveling block to the back face prior to removing the plurality of pins from the plurality of pin receivers and diagonal support second ends.
[0019] The articulating mast may be unfolded by removing the pins from the diagonal support second ends, transport locks, and pin receivers; and pulling the rear legs upwards such that the horizontal support first ends, horizontal support second ends, and diagonal support first ends pivot such that the horizontal supports and diagonal supports move within a plane defined by the back face to lie relatively further from the back face vertical supports, while the rear legs remain parallel to the back face vertical supports and within the plane defined by the back face but are located relatively further from the back face vertical supports, and such that the horizontal supports lie generally perpendicular to the back face vertical supports. The method may further comprise pinning the diagonal support second ends to the rear legs. If the articulating mast further comprises an integral guide track system, a top drive, and a traveling block, the method may further comprise releasing the top drive and traveling block from the back face after pinning the diagonal support second ends to the rear legs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a rear view of a fully assembled articulating mast;
[0021] FIG. 2 is a side view of a fully assembled articulating mast;
[0022] FIG. 3 is a rear view of an articulating mast separated into sections;
[0023] FIG. 4 is a rear view of an articulating mast separated into sections and folded for transportation or storage;
[0024] FIGS. 5A , 5 B, and 5 C are a series of rear views of a section of an articulating mast being unfolded;
[0025] FIGS. 6A , 6 B, and 6 C are a series of rear views of a section of an articulating mast being folded;
[0026] FIG. 7A is a perspective view of a section of an articulated mast in a closed, reduced width configuration; and
[0027] FIG. 7B is a perspective view of a section of an articulated mast in an open, unreduced width configuration.
[0028] Other advantages and features will be apparent from the following description and from the claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The devices and methods discussed herein are merely illustrative of specific manners in which to make and use this invention and are not to be interpreted as limiting in scope.
[0030] While the devices and methods have been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the construction and the arrangement of the devices and components without departing from the spirit and scope of this disclosure. It is understood that the devices and methods are not limited to the embodiments set forth herein for purposes of exemplification.
[0031] Referring to the figures of the drawings, wherein like numerals of reference designate like elements throughout the several views, FIGS. 1 and 2 show an articulating mast that is fully assembled. FIG. 1 shows the articulating mast from the rear and FIG. 2 shows the articulating mast from the side. The articulating mast shown in the figures is made up of four sections, although any number of sections may be utilized depending on the desired height of the articulating mast. The sections may be attached to each other via connectors 15 . FIGS. 3 and 4 show the articulating mast broken into sections, with FIG. 3 showing the articulating mast in an open position ready for use and FIG. 4 showing the articulating mast in a closed position, ready for transportation or storage.
[0032] Each section of the articulating mast has a pair of opposed sides 1 , each with a front leg and a rear leg 2 , and a back face 3 extending between the two rear legs 2 . The sides 1 and the back face 3 may be at right angles to each other, such that they form three sides of a rectangle with the fourth side open. The back face 3 may have a pair of back face vertical supports 4 running parallel to each other and to the rear legs 2 . The back face vertical supports 4 may be a guide track. The back face 3 may have a plurality of supports 5 attached to and extending between the back face vertical supports 4 in any desired configuration. Each section of the articulating mast may have a plurality of back face horizontal supports 6 . Each back face horizontal support 6 may be pivotally attached on one end to one of the back face vertical supports 4 and pivotally attached on the other end to one of the rear legs 2 . Each section of the articulating mast may also have a plurality of back face diagonal supports 7 , where one end of each back face diagonal support 7 is pivotally attached to one of the back face vertical supports 4 adjacent one of the back face horizontal supports 6 .
[0033] The rear legs 2 may have a plurality of pin receivers 8 adjacent the back face horizontal supports 6 . The end of each back face diagonal support 7 that is not pivotally attached to one of the back face vertical supports 4 may attach to one of the rear legs 2 by inserting one of a plurality of pins through the end of the back face diagonal support 7 and one of the pin receivers 8 . Each back face diagonal support 7 may angle downward from the back face vertical support 4 to the rear leg 2 , such that the end pivotally attached to the back face vertical support 4 is located adjacent a back face horizontal support 6 at a higher level than the back face horizontal support 6 to which the end of the back face diagonal support 7 that is attached via pin receiver 8 to rear leg 2 is adjacent.
[0034] The articulating mast may be folded from an open position to a closed position by first removing the plurality of pins from the plurality of pin receivers 8 and back face diagonal supports 7 . Next, as seen in FIGS. 6A , 6 B, and 6 C, where FIG. 6B is a transition stage, the rear legs 2 may be pulled downward such that the ends of the back face diagonal supports 7 that are pivotally attached to the back face vertical supports 4 and both ends of the back face horizontal supports 6 pivot such that the back face horizontal supports 6 and back face diagonal supports 7 all move within a plane defined by the back face 3 to lie relatively closer to the back face vertical supports 4 . This allows the rear legs 2 to remain parallel to the back face vertical supports 4 and within the plane defined by the back face 3 , but to be located relatively closer to the back face vertical supports 4 and vertically offset from their original position. A bridle line 11 may be used to pull the rear legs 2 .
[0035] Once the articulating mast is in a closed position, it may be secured by pinning the ends of the back face diagonal supports 7 to a plurality of pin receivers 9 located on the rear legs 2 at a higher position than the pin receivers 8 . The mast may be further secured by pinning a plurality of transport locks 10 located on the back face horizontal supports 6 to the pin receivers 9 . Securing the back face diagonal supports 7 and the transport locks 10 to the pin receivers 9 prevents the articulating mast from accidentally unfolding during transport.
[0036] The articulating mast may be folded from a closed position to an open position by first removing the pins from the pin receivers 9 , transport locks 10 , and back face diagonal supports 7 . Next, as seen in FIGS. 5A , 5 B, and 5 C, where FIG. 5B is a transition stage, the rear legs 2 may be pulled upward such that the ends of the back face diagonal supports 7 that are pivotally attached to the back face vertical supports 4 and both ends of the back face horizontal supports 6 pivot such that the back face horizontal supports 6 and back face diagonal supports 7 all move within a plane defined by the back face 3 relatively further from the back face vertical supports 4 . This allows the rear legs 2 to remain parallel to the back face vertical supports 4 and within the plane defined by the back face 3 , but to be located relatively further away from the back face vertical supports 4 . It also allows the back face horizontal supports 6 to lie generally perpendicular to the back face vertical supports 4 . A bridle line with a spreader 12 may be used to pull the rear legs 2 . Once the articulating mast is in an open position, it may be secured by pinning the back face diagonal supports 7 to the pin receivers 8 .
[0037] As can be seen in FIGS. 5 , 6 , and 7 , each of the sections of the articulating mast requires only four pins to secure in either the closed or open position, as opposed to six required in prior art folding masts, thus reducing required labor for disassembly and reassembly. Furthermore, neither the middle of the back face 3 nor the sides 1 are altered by folding the articulating mast, and thus a guide track system, top drive, and/or traveling block may remain in place on the mast during disassembly, transport, storage, and reassembly. A crown assembly 13 may be seen in dashed lines in FIGS. 1 through 4 . A guide track system may be integrated into the back face 3 , and a top drive and traveling block 14 may be mounted on the integral guide track system, as shown in dashed lines in FIG. 2 . The top drive and traveling block 14 may be secured to the back face 3 when the mast is in a closed position so that it does not travel along the integral guide track system during transport.
[0038] Whereas, the devices and methods have been described in relation to the drawings and claims, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.
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The present invention relates to an articulating mast having sections that may be moved between an open, in-use position and a more compact reduced width configuration for storage and transportation.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a process for improving oil recovery in carbonate reservoirs. More specifically, embodiments of the present invention utilize an initial waterflooding step having a first water solution with subsequent waterflooding steps employing water solutions having reduced saline concentrations as compared to the first water solution.
BACKGROUND OF THE INVENTION
[0002] Waterflooding is a method of secondary recovery in which water is injected into a reservoir formation to displace mobile oil within the reservoir formation. The water from injection wells physically sweeps the displaced oil to adjacent production wells, so that the oil can be collected from the production wells. Generally, the water used in a waterflooding process is taken from nearby water sources, which is usually either seawater or produced water.
[0003] It is known that a reduction in salinity values of the injected water can increase oil production for sandstone reservoirs. However, the low salinity floods have only been shown to work if the reservoir contains clays and with water having salinity values that are less than 5,000 ppm.
[0004] Carbonate reservoirs do not contain such clays. As such, the low salinity water flooding teachings known heretofore specifically teach away from the successful use of low salinity water for carbonate reservoirs. See A. Lager et al., “ Low Salinity Oil Recovery—An Experimental Investigation ,” paper presented at the Society of Core Analysts, September 2006 (“Finally it explains why LoSal™ does not seem to work on carbonate reservoirs.”). See also A. R. Doust et al., “ Smart Water as Wettability Modifier in Carbonate and Sandstone ,” paper presented at 15 th European Symposium on Improved Oil Recovery, April 2009 (“The wettability modification in carbonates can take place at high salinities, i.e. SW salinity. If SW is diluted by distilled water to a low saline fluid, ˜2000 ppm, the oil recovery will decrease due to a decrease in the active ions.”).
[0005] It would be desirable to have an improved process for waterflooding carbonate reservoirs that was simple and efficient. Preferably, it would be desirable to have a process that did not require the use of complicated chemicals or gases such as carbon dioxide, surfactants, polymers, or the like. Additionally, it would be beneficial if the process for an improved waterflooding could be implemented with existing infrastructure.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a process that satisfies at least one of these needs. In one embodiment, the process for improving tertiary hydrocarbon recovery in carbonate reservoirs includes the steps of introducing a first water solution into the carbonate reservoir, recovering an amount of hydrocarbon from the carbonate reservoir, introducing a second water solution into the carbonate reservoir, and recovering a second amount of hydrocarbon from the carbonate reservoir. The first water solution has a first salt concentration, and the second water solution has a second salt concentration that is lower than the first salt concentration. In one embodiment, the first water solution has an ion composition that includes at least two ions selected from the group consisting of sulfate, calcium, and magnesium. In another embodiment, the ion composition comprises three ions: sulfate, calcium, and magnesium.
[0007] In one embodiment, the ratio of the second salt concentration to the first salt concentration is in a range from about 0.1 to 0.9. In another embodiment, the ratio of the second salt concentration to the first salt concentration is in a range from about 0.5 to 0.75. In another embodiment, the ratio of the second salt concentration to the first salt concentration is about 0.5. In an embodiment, the first salt concentration is within a range of 35,000 to 70,000 ppm by weight. In another embodiment, the second salt concentration is within a range of 3,500 to 60,000 ppm by weight. In another embodiment, the second salt concentration is within a range of 17,500 to 52,500 ppm by weight. In another embodiment, the second salt concentration is within a range of 17,500 to 35,000 ppm by weight. In another embodiment, the process is conducted at a reservoir temperature of between 70° C. and 100° C.
[0008] In another embodiment of the invention, the process can further include introducing a third water solution into the carbonate reservoir, and recovering a third amount of hydrocarbon from the carbonate reservoir. The third water solution has a third salt concentration that is lower than the second salt concentration. In one embodiment, the ratio of the third salt concentration to the first salt concentration is in a range from about 0.05 to 0.1. In another embodiment, the third salt concentration is within a range of 1,750 to 7,000 ppm by weight. In another embodiment, the third salt concentration is within a range of 3,500 to 7,000 ppm by weight. In one embodiment, the third amount of hydrocarbon is recovered until there is at least a 9% improvement in incremental oil recovery as compared to the second amount of hydrocarbon recovered.
[0009] In one embodiment, the carbonate reservoir is substantially free of clay. In another embodiment, the carbonate reservoir has an absence of clay. In yet another embodiment, the carbonate reservoir has an absence of sandstone rock. In another embodiment, the temperature within the carbonate reservoir is above 70° C. In another embodiment, the temperature within the carbonate reservoir is about 100° C.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it can admit to other equally effective embodiments.
[0011] FIG. 1 shows data collected from an experiment in accordance with an embodiment of the present invention.
[0012] FIG. 2 shows data collected from an experiment in accordance with an embodiment of the present invention.
[0013] FIG. 3 shows data collected from an experiment in accordance with an embodiment of the present invention.
[0014] FIG. 4 shows data collected from an experiment in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0015] While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all the alternatives, modifications and equivalence as may be included within the spirit and scope of the invention defined by the appended claims.
[0016] In one embodiment, the process for improving tertiary hydrocarbon recovery in carbonate reservoirs includes the steps of introducing a first water solution into the carbonate reservoir, recovering an amount of hydrocarbon from the carbonate reservoir, introducing a second water solution into the carbonate reservoir, and recovering a second amount of hydrocarbon from the carbonate reservoir. The first water solution has a first salt concentration, and the second water solution has a second salt concentration that is lower than the first salt concentration. In one embodiment, the first water solution has an ion composition that includes at least two ions selected from the group consisting of sulfate, calcium, and magnesium.
[0017] The present invention is illustrated by the following examples, which are presented for illustrative purposes, only, and are not intended as limiting the scope of the invention which is defined by the appended claims.
Example 1
[0018] A coreflooding study was conducted to demonstrate an embodiment of the invention. The experimental parameters and procedures were well designed to reflect the initial conditions commonly found in carbonate reservoirs, as well as the current field injection practices.
[0019] The core material was selected from a carbonate reservoir in Saudi Arabia. Core plugs (1-inch in diameter, and 1.5-inch in length) were cut from whole cores. One composite core was selected for the coreflood experiments. Table I shows the petrophysical properties of the selected cores. The average porosity and liquid permeability are 25% and 41 milli-Darcy, respectively.
[0000]
TABLE I
Basic Petrophysical Properties for Core Plugs
Air
Brine
Pore Volume
Perme-
Perme-
by Routine
Length
Dia.
ability
ability
Porosity
Core analysis
Sample #
(cm)
(cm)
(mD)
(mD)
(%)
(cc)
10
4.04
3.81
51.00
36.29
22.10
10.07
13
4.25
3.81
78.50
55.55
20.80
10.03
73
4.02
3.80
71.90
47.74
28.90
13.06
74
3.93
3.80
47.60
31.91
28.70
12.71
Total
20.66
3.80
63.6
40.8
25.26
45.87
[0020] The most predominant mineral in the selected carbonate cores is calcite (more than 90 wt %). Other minerals are dolomite (trace up to 9 wt %), and minor amount (<1 wt %) of quartz.
[0021] Two brines primarily were used in this study, including field connate water to establish initial or irreducible water saturation (Swi) for composite cores, and different salinity slugs of seawater as injected waters to displace oil out of cores. All brines were prepared from distilled water and reagent grade chemicals, based on geochemical analysis of field water samples. Table II depicts the geochemical analysis and the corresponding chemicals concentration for each type of brine. For the experiments described below, the seawater had a salinity of about 57,700 ppm by weight, and initial connate water is very saline with salinity of 214,000 ppm by weight.
[0000]
TABLE II
Geochemical Analysis and Salt Concentrations for Major Sources of Water
Field Connate
Ions
Water
seawater
Sodium
59,491
18,300
Calcium
19,040
650
Magnesium
2,439
2,110
Sulfate
350
4,290
Chloride
132,060
32,200
Carbonate
0
0
Bicarbonate
354
120
TDS
213,734
57,670
The salt recipes for major sources of water
UTMN Connate
Qurayyah
Salts
Water
seawater
NaCl, g/L
150.446
41.041
CaCl 2 •2H 2 O, g/L
69.841
2.384
MgCl 2 •6H 2 O, g/L
20.396
17.645
Na 2 SO 4 , g/L
0.518
6.343
NaHCO 3 , g/L
0.487
0.165
[0022] Other dilute versions of seawater were also prepared by mixing with different volumes of deionized water. This includes:
Twice dilutes (50% salinity of seawater) 10 times dilutes (10% salinity of seawater) 20 times dilutes (5% salinity of seawater) 100 times dilutes (1% salinity of seawater)
[0027] The effect of salinity as well as ion composition on physical properties (density and viscosity) of prepared waters was studied. The density and viscosity properties were measured at reservoir temperature of 212° F. Table III shows the density and viscosity of different water types.
[0000]
TABLE III
Density and viscosity of different water types
Field
Twice
10 Times
20 Times
100 Times
Connate
Diluted
Diluted
Diluted
Diluted
Property
Water
Seawater
Seawater
Seawater
Seawater
Seawater
Density (g/cc)
1.1083
1.0152
0.9959
0.9812
0.9782
0.9779
Viscosity (cp)
0.476
0.272
0.242
0.232
0.212
0.193
[0028] Reservoir oil samples were collected from one carbonate reservoir. Crude oil filtration was conducted to remove solids and contaminants to reduce any experimental difficulties during coreflood experiments. In this coreflood experiment, live oil was used in which it was recombined from a separator of oil and gas such that the experimental conditions more closely resembled reservoir conditions in order to increase the accuracy of the experiment. As used herein, live oil is oil containing dissolved gas in solution that can be released from solution at surface conditions. Oil in reservoirs usually contains dissolved gas, and once it reaches the surface, gas tends to evolve out due to the lower pressures at the surface as compared to within the reservoir. As used herein, dead oil is oil at sufficiently low pressure that it contains no dissolved gas. Oil at the surface is typically considered dead oil. Total acid number, as well as other oil properties are listed in Table IV.
[0000]
TABLE IV
Reservoir Oil Properties for Collected oil Samples
Component
Amount
Saturates
39.17%
Aromatics
48.30%
Resins
7.04%
Asphaltenes
5.50%
Total Acid Number
0.25 mg KOH/g oil
Saturation pressure, psia @ 212° F.
1804
Gas oil ratio, SCF/STB
493
Stock tank oil gravity °API @ 60° F.
30.0
Dead oil density at room temperature, lb/ft 3
54.50
Dead oil viscosity at room temperature, cp
14.59
Live Oil Viscosity @ 212° F.
Pressure (psig)
viscosity (cp)
4000
0.716
3000
0.691
14.7
2.03
Live Oil Density @ 212° F.
Pressure
Density, lb/ft 3
3200
45.7
3000
45.5
2000
45.0
1766
44.9
[0029] The pore volume of cores, original oil in place, and connate water saturation of selected composite core plugs were determined using a centrifuge apparatus. The procedure for preparation of each core was as follows:
1. Measure dry weight of the core sample. 2. Saturate core plug under vacuum for 5-7 days with field connate water to achieve ionic equilibrium with the core samples. 3. Measure wet weight. 4. Determine pore volume by weight difference and the density of field connate water at room temperature. 5. Centrifuge each core plug at 5000 rpm for 12 hrs to drain the water in the pores and establish the initial water saturation. 6. Measure weight of centrifuged core sample. 7. Determine weight difference of the original oil in place (OOIP) and initial water saturation—prior and post centrifuge—and the density of field connate water.
[0037] Table V shows the pore volume calculation results using the centrifuge method with the initial water saturation for core plugs used in coreflood experiment. The total pore volume for the composite was 36.46 cc, and original oil in place (OOIP) was 32.79 cc. The average initial water saturation for the composite was 10.06%. The position of each core plug in the composite sample is ordered by a harmonic arrangement and the plugs are organized in the table as the first plug from the inlet to the last plug from outlet of the coreholder.
[0000]
TABLE V
Pore Volume Determination for Core Samples
Pore
Dry Wt
Wet Wt
Liquid
Volume
Sample #
(g)
(g)
Wt (g)
(cc)
13
101.53
110.76
9.23
8.04
74
81.22
92.48
11.26
9.81
73
81.95
93.93
11.98
10.44
10
92.88
102.26
9.38
8.17
[0000]
TABLE VI
Water Saturation Results for Coreflooding Experiment
Wet Wt
Fluid
after 5000
Remaining
RPM for
Difference
Produced
in Rock
Sample #
12 hrs (g)
Wt (g)
Fluid (cc)
(cc)
Swi (%)
13
102.74
8.02
6.99
1.05
13.1%
74
82.15
10.33
9.00
0.81
8.3%
73
82.72
11.21
9.76
0.67
6.4%
10
94.18
8.08
7.04
1.13
13.9%
[0038] A coreflooding apparatus was then used to mimic reservoir conditions during a waterflood experiment. The experimental procedure followed is described below:
[0039] Fill all accumulators of the coreflooding apparatus with injected fluids including dead oil, live oil, and brines. Calibrate the three-phase separator to determine the oil production during waterflooding. Assemble and load the composite core plugs into a rubber sleeve and load into the core holder. Maintain a confining pressure of about 4500 psi on the composite core plugs by filling the core holder confining annulus. Set the back pressure regular at 200 psi. Flush dead oil through the composite core to displace gas and ensure complete fluid saturation. Maintain the dead oil flush until the pressure drop across the composite is stabilized. This can take as much as 1-2 weeks.
[0040] Set the reservoir temperature to approximately 212° F. and allow the composite to age at the reservoir temperature until the pressure drop across the composite is stabilized. This step can also take as long as 1-2 weeks. Set pore pressure for the composite to reservoir pressure (3000 psi for experiment). Inject live oil into the composite to displace the dead oil, and allow the composite plugs to age for 1-2 weeks until the pressure drop is stabilized. The composite plug now replicates the reservoir in terms of fluid saturations, temperature, pressure, and wettability status.
[0041] Conduct seawater flooding while monitoring: the amount of oil produced, the pressure drop across the composite, and the injection rate of the seawater as a function of time. Water was injected at a constant rate of approximately 1 cc/min until no more oil was produced. The injection rate was increased to 2 cc/min, and then to 4 cc/min to ensure all mobile oil was produced. The original seawater was then diluted with distilled water to make the salinity value 50% of the original. The 50% diluted seawater was then injected into the core sample following the same injection procedure as described above. The injection procedure was then repeated with diluted seawater having dilution ratios of 10:1, 20:1, and 100:1. The results from this experiment are shown in FIGS. 1-2 .
[0042] FIG. 1 displays an incremental oil production curve. The oil production by seawater flooding is about 23 cc. The additional oil production by twice diluted seawater is about 2.3 cc; the additional oil production by 10 times diluted seawater is 3.0 cc; additional oil production by 20 times diluted seawater is about 0.6 cc; and no production observed by 100 times diluted seawater. Therefore, the incremental oil production by stepwise salinity reduction of seawater is 5.9 cc.
[0043] FIG. 2 displays an oil recovery curve expressed in percentage of oil recovered. The oil recovery by seawater flooding is about 67% in terms of original oil in place (OOIP); this targets mobile oil in the cores, and represents the secondary oil recovery. The additional oil recovery, over secondary recovery, was ˜7% of OOIP with twice diluted seawater, ˜9% with 10 times diluted seawater, ˜1.5% with 20 times diluted seawater, and no significant oil recovery by 100 times diluted seawater. Therefore, the total incremental oil recovery, beyond conventional waterflooding, was approximately 17.5% by stepwise salinity and ion content reduction of injected water. This incremental oil recovery represents tertiary oil recovery.
Example 2
[0044] New composite cores (6 core plugs) were selected from the same carbonate reservoir to confirm and validate the results reported in Example 1. The types and properties of used fluids are the same as in Table III and Table IV from Example 1. The experimental procedure and parameters are also the same as indicated in Example 1.
[0045] Table VII lists the petrophysical properties of the selected cores. The average porosity and liquid permeability are 24.65% and 68 milli-Darcy, respectively.
[0000]
TABLE VII
Basic Properties for Core Plugs
Pore Volume
Air
Brine
by Routine
Perme-
Perme-
Core
Length
Dia.
ability
ability
Porosity
analysis
Sample #
(cm)
(cm)
(mD)
(mD)
(%)
(cc)
159
3.94
3.81
110.96
74.34
22.57
10.14
55
4.16
3.81
88.72
59.44
27.73
13.15
91
3.83
3.81
109.35
73.26
24.97
10.91
66
3.77
3.81
96.28
64.51
25.65
11.02
61
4.02
3.81
109.33
73.25
26.60
12.19
128
3.93
3.81
97.40
65.26
20.36
9.12
Total/Avg
23.65
3.81
102.0
68.3
24.65
66.53
[0046] Table VIII and Table IX show the pore volume calculation results using centrifuge method with the initial water saturation for core plugs used in coreflood experiment. The total pore volume for the composite was 63.23 cc, and original oil in place (OOIP) was 54.12 cc. The average initial water saturation for the composite was 14.4%. The position of each core plug in the composite sample is ordered by a harmonic arrangement and the plugs are organized in the tables as the first plug from the inlet to the last plug from outlet of the coreholder.
[0000]
TABLE VIII
Pore Volume Determination for Core Samples
Pore
Wet Wt
Liquid Wt
Volume
Sample #
Dry Wt (g)
(g)
(g)
(cc)
159
91.2
102.72
11.52
10.03
55
89.39
103.45
14.06
12.25
91
83.21
95.19
11.98
10.44
66
82.75
94.85
12.1
10.54
61
87.6
100.69
13.09
11.40
128
94.25
104.07
9.82
8.55
[0000]
TABLE IX
Water Saturation Results for Coreflooding Experiment
Wet Wt after
Difference
Fluid
5000 RPM
Wt
Produced
Remaining
Sample #
for 12 hrs (g)
(g)
Fluid (cc)
in Rock (cc)
Swi (%)
159
92.65
10.07
8.77
1.26
12.6%
55
91.45
12.00
10.45
1.79
14.7%
91
84
11.19
9.75
0.69
6.6%
66
85.05
9.80
8.54
2.00
19.0%
61
89.91
10.78
9.39
2.01
17.6%
128
95.79
8.28
7.21
1.34
15.7%
[0047] FIG. 3 displays the incremental oil production curve for Example 2. The oil production by seawater flooding is about 41 cc. The additional oil production is 4.6 cc with twice diluted seawater, 5.4 cc with 10 times diluted seawater, 0.6 cc with 20 times diluted seawater, no production with 100 times diluted seawater. Therefore, the total oil production beyond conventional waterflooding is about 10.6 cc by stepwise salinity and ionic content reduction of injected water.
[0048] FIG. 4 displays an oil recovery curve expressed in percentage of oil recovered for Example 2. The oil recovery by seawater flooding is about 74% in terms of original oil in place (OOIP); this targets mobile oil in the cores, and represents the secondary oil recovery. The additional oil recovery, over secondary recovery, was ˜8.5% of OOIP with twice diluted seawater, ˜10% with 10 times diluted seawater, ˜1% with 20 times diluted seawater, and no recovery observed with 100 times diluted seawater. Therefore, the total incremental oil recovery, beyond conventional waterflooding, is 19.5% by stepwise salinity and ion content reduction of injected water. Therefore, the trend is very consistent with Example 1 and the incremental oil recovery is even higher in this case. Therefore, these results confirmed and validated that significant additional oil recovery beyond seawater flooding can be achieved by stepwise salinity and ionic content reduction of the injected seawater in carbonate rock reservoir.
[0049] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. The present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed.
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A method for increasing oil production in a carbonate reservoir by conducting a step-wise reduction of salinity of the injected salt water that is injected into the carbonate reservoir. The method provides for increased oil production as compared to conventional waterflooding techniques.
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TECHNICAL FIELD
The present invention concerns an implant, especially a dental implant having a porous surface for the at least partial insertion into a bone, which has improved osteointegration characteristics. The implant therein is ceramic, but can also be metallic. Furthermore, the present invention concerns a method for the production of such an implant as well as uses of such an implant.
BACKGROUND OF THE INVENTION
Injured or damaged parts of the hard- and/or soft tissue of the human body are restored the best by using autologous hard- and/or soft tissue. This is not always possible for various reasons, which is why in many cases synthetic material is used as a temporary (biodegradable or post-operatively removable, respectively) or permanent replacement material.
Implants which are anchored in hard- and/or soft tissue, serve the temporary or permanent replacement or the support of parts of the musculoskeletal system which have been damaged by accident, use, deficiency or disease, or which have been otherwise degenerated, including especially parts of the chewing apparatus. A synthetic, chemically stable material, which is introduced into the body as a plastic replacement or for mechanical enforcement is normally called an implant (see e.g. Roche Lexikon Medizin, Urban & Fischer (Pubis.); 5 th edition 2003). The support- and replacement function in the body is taken over on the basis of the mechanical features and the implant design. Hence, for instance hip- and knee joint prostheses, spine implants and dental implants have been clinically used successfully for many years.
For the anchoring of the implant and the compatibility of the implant at the interface between the implant surface/neighboring tissue, the implant surface has a great significance. Hence, measurements have shown that, almost independently of the basic material used, implants with a smooth surface are anchored only poorly in the bone (poor osteointegration), while implants with a structured surface enter into a good mechanical- and, in case of a corresponding design of the surface, also a good biological connection with the surrounding hard- or soft tissue (see e.g. Titanium in Medicine, Material Science, Surface Science, Engineering, Biological Responses and Medical Applications Series: Engineering Materials, Brunette, D. M.; Tengvall, P.; Textor, M.; Thomsen, P. (Eds.)).
The time necessary for a sufficient ingrowth, which is an important and central feature for implants, is termed osteointegration time, or, in the dental field also osseointegration time, respectively. Thereby, the time is described, which passes by until the bone substance has connected with sufficient force and durably with the implant surface, so to speak, until it has virtually integrated into the implant surface.
Various methods are used for surface treatment and surface structuring, see e.g. A Guide to Metal and Plastic Finishing (Maroney, Marion L.; 1991); Handbook of Semiconductor Electrodeposition (Applied Physics, 5) (Pandey, R. K., et al.; 1996); Surface Finishing Systems: Metal and Non-Metal Finishing Handbook-Guide (Rudzki, George J.; 1984); Titanium in Medicine, Material Science, Surface Science, Engineering, Biological Responses and Medical Applications Series: Engineering Materials, (Brunette, D. M.; Tengvall, P.; Textor, M.; Thomsen, P. (Eds.)); and Materials and Processes for Surface and Interface Engineering (NATO Asi Series. Series E, Applied Sciences, 115, Pauleau, Ives (Editor); 1995); and the references cited therein.
Implants nowadays are produced of various materials, such as for example of titanium, niobium, zirconium, tantalum, of alloys such as e.g. titanium alloys, implant steel, of CoCr alloys, of various polymers and ceramics e.g. on the basis of zirconium oxides, aluminium oxides, titanium oxides, etc.
Besides the mechanical methods of treatment, implants for example can also be produced by a combination of casting and sintering. These methods are known for metal as MIM (Metal Powder Injection Molding) and for ceramics as CIM (Ceramic Injection Molding), such as e.g. from US 2004/0038180.
For the production of dental implants, both methods can also be coupled, as is described in EP 1 570 804 A1. Furthermore, a combination with mechanical treatment of the implant produced by MIM or CIM is possible, such as for example is described in EP 1 570 804 A1, that, following sintering, the surface can be post-treated either by a blasting treatment or by chemical surface modification (e.g. acid etching).
For many implants, especially for dental implants, mainly titanium and its alloys are used, as these materials have a sufficiently low elasticity module and a relatively high stability. However, measurements have shown that titanium implants with a smooth surface structure are only insufficiently anchored in the bone, while implants with a roughened surface result in a noticeably improved bone implant connection with respect to the traction- and torsion resistance.
In EP 0 388 576 A1, it is thus suggested to apply in a first step a macro-roughness onto a metallic implant surface by sand blasting, and to subsequently overlay it with a micro-roughness by a treatment in an acid bath. Thereby, the implant surface can be roughened by sand blasting and subsequently treated with an etching agent, e.g. hydrofluoric acid or a hydrochloric acid/sulphuric acid mixture. By this structuring of the surface, a safe connection between hard tissue and metal is achieved.
In the area of dental implants, titanium, especially in the visible front oral area, is unsuitable for aesthetic reasons, as the material optically differs from the hard- and the visible soft tissue environment. It is therefore desirable to use a different material which doesn't show these disadvantages. Ceramic materials, such as zirconium oxide, titanium oxide or aluminum oxide or mixtures thereof, materials are available, which show an extremely high stability, especially, if the form bodies are compressed hot-isostatically or post-compacted hot-isostatically. A specific yttrium-stabilized zirconium oxide ceramic, which has about 92.1-93.5 weight-% ZrO2, 4.5-5.525 weight-% Y2O3 and 3.8-2.2 weight-% HfO2, is for example known from U.S. Pat. No. 6,165,925. Other prevalent ceramics are discussed in the introductory part of U.S. Pat. No. 6,165,925 extremely high stability,
The use of ceramics, for example of a zirconium oxide ceramic, a titanium oxide ceramic, or an aluminium oxide ceramic, as a material for the production of an implant anchored in the hard- or soft tissue, is tedious, as it is necessary for a sufficient mechanical stability of the ceramic to be produced without measurable porosity, normally simultaneously resulting in a smooth, extremely hard surface.
For smooth ceramic surfaces, no direct and sufficiently mechanically stable connection with the surrounding hard tissue is to be expected. Therefore, implants of pure ceramics such as zirconium oxide, titanium oxide or aluminium oxide, or mixtures thereof, have hardly been used so far in the direct contact with hard tissue. For the anchoring in hard tissue, constructive connections with metallic implant materials are used, for example in hip prosthetics or in oral implantology.
For example, in DE 195 30 981 A1, a pre-fabricated fully ceramic implant construction of zirconium dioxide is described for the dental coloured design of artificial crown stubs carried by implants. The actual implant therein consists of surface-structured metallic titanium, the aesthetics of the visible part being displayed via a zirconium oxide ceramic.
In WO 2004/096075 A1, a dental implant of a one-piece base body is described, consisting of zirconium oxide or of a zirconium oxide/aluminium mixture. A surface treatment is not described, and it is questionable whether such an implant structure shows a sufficient osseointegration at all.
FR 2 721 196 A1 describes a one-piece implant based on zirconium oxide. For the improvement of the osteointegration, the corresponding implant part shall be provided with a coating, for example of hydroxyapatite.
In WO 03/045268 A1, a ceramic implant on the basis of zirconium oxide is described. The external surface of the anchoring part is at least partially either roughened by an erosive method, or micro-structured, or provided with a coating. Therein, after a blasting treatment, such as by sand-blasting, also chemical methods, especially etching methods are taken into consideration, which can be applied partially supplementary as a post-treatment to a previous mechanical treatment. Especially preferred is first a blasting treatment, such as by sand-blasting with Al2O3, and subsequently an etching treatment, with phosphoric acid, sulphuric acid, hydrochloric acid, or mixtures thereof. Furthermore, the treated implant can be stored in a suitable fluid, for example de-ionized water, or in a NaCl-solution. Thereby it is avoided that the surface loses its activation completely or partially by components of the air prior to the insertion of the dental implant. This is how an osteointegration is supported.
The problem therein is, that with such a combined treatment, the depth of the roughness remains small due to the high hardness of the zirconium oxide ceramic, and that the ceramic is chemically extremely stable with respect to the treatment with phosphoric acid, sulphuric acid, hydrochloric acid, or mixtures thereof.
In DE 10 2005 013 200, a two-part ceramic implant is described, including a micro- and macro-structuring and the chemical or biochemical/pharmaceutical modification, respectively, of the surfaces or selected surfaces of the implant, respectively. A method for achieving this surface structure or the surface modification is not specifically described.
SUMMARY OF THE INVENTION
One of the underlying objects of the invention, among others, is therefore, to avoid the disadvantages of the state of the art, and to propose implants, which anchor quickly and lastingly in hard- and soft tissue and thus show a good osteointegration or osseointegration, respectively. Specifically therefore, an improved metallic and/or ceramic implant with a structured, especially porous surface for the at least partial insertion into hard tissue, such as into a bone, and/or into soft tissue shall be proposed. Furthermore, a suitable method for the production thereof shall be proposed.
Preferably, a dental implant is concerned. The method for production thus is especially preferably a production method for production of a dental implant.
Likewise, however, also implants outside the field of dental implants are concerned. The method for production thus alternatively is a method for the production of implants outside the field of dental implants.
It thus especially concerns a method for the production of a metallic and/or ceramic implant with a structured, especially porous surface for the at least partial insertion into hard tissue such as in a bone and/or in soft tissue, wherein the implant is produced at least area-wise by the aid of cold-isostatic compression, casting and/or injection molding (CIM, MIM) to a green body with subsequent sintering to an implant. Therein, the method is characterized in that prior to sintering, the surface is changed and/or prepared such that after sintering a macroporous surface is present without any additional post-treatment. However, this does not eliminate the possibility of an additional post-treatment, as far at it is still reasonable or necessary, for example it can be reasonable to subsequently add a chemical post-treatment for the creation of a micro-porosity.
Therein, a macroporous surface is understood in that a topography (topological structuring) and/or pores with an average size of more than 2 μm, preferably more than 5 μm, most preferably >20 μm is/are present.
During the production of an implant by a combination of casting and sintering, or by MIM or CIM, or a combination of both methods, respectively, so far no possibilities are known within this method for the production of a dental implant, to achieve a suitable roughness or porosity, respectively, on the surface of the implant, in the state of the art only methods are to be found, in which the modification of the surface is carried out in a step following the sintering.
With respect to the two methods CIM and MIM, reference is made for exemplary purposes to WO 97/38811 and U.S. Pat. No. 5,482,671, the contents of which is explicitly incorporated into the present disclosure with respect to the two methods.
Basically, in this method for production, one usually proceeds in that first a powder is provided as a starting material, for example as a mixture. Subsequently, the cold-isostatic compression, casting, and/or injection molding, take place, followed by a sintering process, in which the actual ceramic or the actual stable metallic composite, respectively, is formed. Thus, for the production, so-called green parts or green bodies are first formed of artificially produced raw materials. These green bodies normally contain, besides the ceramic or metallic powder mixtures, also moist and organic binding agents. Firstly, the green body is dried. Then normally all component parts, especially of the binding agent, which are volatile, vaporizing or burning at high temperatures, must be removed from the ceramic green body. After drying and burning out or debindering/coking, respectively, the structure of the green body is merely held together by adhesion forces and requires an especially careful handling during the further process steps. Finally, the burning or sintering of the ceramic takes place. In this step, the ceramic body obtains its stability.
According to a first preferred embodiment, the method is characterized in that the green body is modified after the cold-isostatic compression, casting and/or injection molding and prior to the final sintering by blasting of the surface of the green body.
According to a further preferred embodiment, the method is characterized in that an abrasive and/or surface densifying blasting agent is used as a blasting agent for the blasting. Especially preferably, a metallic blasting agent, such as steel balls, a ceramic blasting agent, such as Al 2 O 3 , ZrO 2 , SiO 2 , Ca-phosphates, TiO 2 , NaO 2 , CaO, MgO, an organic or natural blasting agent as nut shells or rice in various particle- and splitter sizes, or mixtures of said blasting agents is used. Alternatively, or in addition, the blasting agent for the blasting can be ice balls or ice particles, organic blasting agents such as stearates, waxes, paraffines, or preferably carbamide, melamine resin, biuret, melamine, ammonium carbonate and ammonium bicarbonate or mixtures thereof.
Preferably, blasting agents are used which can be removed without residues at temperatures up to max. 600° C. or max. 300° C., prior to the final sintering, wherein this removal preferably is carried out in an oxidizing or reducing or inert atmosphere, such as especially under O 2 , N 2 , NH 4 , Ar or in vacuum. A preferred blasting agent in this respect is ammonium bicarbonate, which already sublimes from the surface of the green body at 65° C. and leaves behind the desired structure in the surface.
Typically, the particle size of the blasting agent lies in the ranges of 0.01-0.25 mm, preferably in the range of 10-200 μm, especially preferably in the range of 50-110 μm. Preferably, a blasting pressure in the range of 0.2-7 bar, preferably between 0.2-5 bar, especially preferably in the range of 0.8 bar is selected. Typically, the blasting treatment is carried out during a time period between 15 and 65 seconds, preferably between 35 and 55 seconds, especially preferably in the range of 50 seconds. Therein, it is shown to be advantageous, if the distance from the jet to the implant is selected in the range of 25-80 mm, especially between 25 and 60 mm, especially preferably in the range of 30 mm. It is generally advantageous to select a bore diameter of the jet in the range of 0.8-1.2 mm, preferably 0.8-1.0 mm. The use of a flat jet, i.e. a jet, the outlet of which in its cross-section is not circular, but elongated (rectangular, with or without rounded edges, oval, virtually oval), is especially preferred. The width of the jet opening therein is preferably at least 0.2 times larger than the height, with a possible width in the range of 1.2-1.4 mm and a possible height in the range of 0.6-1.0, preferably 0.8 mm.
According to a further preferred embodiment, a mixture of two blasting agents with different particle sizes is used as a blasting agent. Thereby, among others, a virtually bimodal distribution of the produced roughness can be ensured, in other words resulting in fine as well as rough structures. Different blasting agents in this context are to be understood as different with respect to the material of the blasting agent. It is for example possible to use a mixture of a first component part with a rough distribution of the particle size and a second component part with a fine average particle size of the same material as a blasting agent (explicitly bimodal distribution of one single material).
However, in addition to the different average particle size, a different material, such as for example an organic rough blasting agent and an anorganic fine blasting agent is preferred.
Preferably, the difference in the average particle size of the different blasting agents in the mixture lies in the range of a factor 5-10.
Thereby, for example a first blasting agent can be present in the mixture, which has an average particle size in the range of 0.1-0.2 mm, preferably in the range of 0.2-0.8 mm.
Preferably an organic blasting agent is used, for example of fruit kernels (for example peach pits and/or apricot pits).
Furthermore, a second blasting agent can be present in the mixture, having an average particle size in the range of 0.01-0.1 mm, preferably in the range of 0.03-0.9 mm, wherein it preferably is an anorganic blasting agent, especially on the basis of aluminium oxide (Al2O3).
Generally, the ratio of first to second blasting agent lies in the range of 5:1-1:5, preferably in the range of 3:1-1:1.
Furthermore, it is especially preferred that blasting takes place in at least two steps, wherein in one step the so-called mixture is used and in a subsequent step merely the blasting agent with the smaller particle size is used, preferably as an anorganic blasting agent, wherein preferably the second step is carried out at an at least 5-10 times lower pressure.
Preferably, during the step of using a mixture, a blasting pressure in the range of 2-7 bar, preferably 3-5 bar is used. Furthermore, in this step, the time of treatment is in the range of 15-65 seconds, preferably in the range of 25-45 seconds. Furthermore, the distance from the jet to the implant can lie in the range of 25-80 mm. Furthermore, the bore diameter of the jet can lie in the range of 1.2-2.0 mm.
Preferably, in a possibly present second step, a blasting pressure in the range of 0.2-0.8 bar, preferably in the range of 0.2-0.4 bar can be used. Furthermore, the time of treatment can be in the range of 10-35 seconds, preferably in the range of 15-25 seconds. Furthermore, the distance from the jet to the implant can lie in the range of 30-50 mm. Furthermore, the bore diameter of the jet can lie in the range of 0.8-1.2 mm.
As already mentioned, it is possible that the porous surface is at least area-wise further modified by an erosive chemical or physical treatment following the sintering.
In this context, for example an acid treatment is preferred, for example by the aid of concentrated sulphuric acid, and/or hydrochloric acid, and/or another strong acid at an increased temperature (for example 100° C.-300° C.) and over a time period of more than one minute.
In this context, however, it is also and especially preferred, that this subsequent treatment encompasses a molten salt modification, carried out at least area-wise, preferably, in that the implant is structured by etching at the surface by a molten salt, wherein especially preferably essentially exclusively an erosion of material takes place during the etching in the molten salt.
Especially in the context of the use of an anorganic blasting agent, especially if this is used as a fine blasting agent in a mixture, it is ensured by the subsequent treatment in the molten salt, that any blasting agent still present on the implant is removed. In other words, while the rough blasting agent is already removed during sintering, also the fine blasting agent, which typically is still present on the surface after sintering of the green body, can thereby be removed essentially without residues.
The molten salt can be a molten salt of alkali- and/or alkaline earth-nitrates, hydroxides or halogens, or a mixture of these salts. It is preferred that the molten salt is a molten salt with at least one hydroxide, especially with at least one alkali- and/or alkaline earth-hydroxide, or that the molten salt is a molten salt exclusively consisting of one or more hydroxides, especially of one or more alkali- and/or alkaline earth-hydroxides.
Therein, the molten salt can be a molten salt of potassium hydroxide, and/or sodium hydroxide, and/or lithium hydroxide.
The molten salt can also be a molten salt with at least one chloride, especially with at least one alkali- and/or alkaline earth-chloride, or the molten salt can be a molten salt exclusively consisting of one or more chlorides, especially of one or more alkali- and/or alkaline earth-chlorides.
Preferably, the molten salt for surface modification is a binary molten salt of potassium hydroxide and sodium hydroxide, or of potassium chloride and lithium chloride, preferably in a ratio of 2:1-0.5:1, preferably in the range of 1.5:1-0.75:1, especially preferably in the range of 1:1 or 7:5, wherein the process is preferably carried out at a temperature in the range of 100-600° C., especially in the range of 150-250° C.
In this treatment in a molten salt, the surface can be exposed to a molten salt at least area-wise for a time period of 10 minutes to 300 hours, preferably of at least 2 hours, preferably from 10 to 100 hours, especially from 25 to 35 hours.
Preferably, the implant consists of ceramic, however, it can also, as already mentioned, be of a metallic basis or can comprise a combination of these two materials.
The implant especially preferably is an implant containing zirconium oxide, to which possibly additionally is added yttrium oxide and hafnium oxide, and/or containing aluminium oxide, possibly additionally containing silicium dioxide, ferric (III) oxide, and/or sodium oxide, and/or containing silicium nitride, possibly additionally containing silicium dioxide, ferric (III) oxide and/or sodium oxide, and or containing titanium oxide and/or being formed of mixtures of said materials.
Alternatively or additionally, it is possible to carry out the method such that the green body is changed and/or prepared on its surface by a blasting agent during the cold-isostatic compression, casting, and/or injection molding by a modification of the surface of the cold-isostatic compression-, casting- or injection molding tool prior to compression, casting or injection molding of the starting material to a green body. It is also possible that the green body is changed and/or prepared prior to sintering at least on its surface during the cold-isostatic compression, casting and/or injection molding by addition of a filler material to the starting material. The modification of the tool surface with a filler can be carried out by the adherence of the filler to the tool surface. The temporary binding of the blasting agent or filler material, respectively, to the tool surface can be carried out with binders, for example organic binders such as for example PVA or also with waxes.
In both cases, these treatments are carried out such that the structure of the surface of the cold-isostatic compression-, casting- or injection molding tool is reproduced in the surface of the green body, or that the filler material removed subsequently prepares the surface, respectively.
Preferably, the filler material is selectively arranged only in the surface area, especially preferably in that in a first step starting material with filler material is supplied to the form (preferably such that it is arranged in the form in the future surface area of the implant), and subsequently in a second step starting material without filler material. Compared to methods, which in any case are only known from other fields, not from the field of production of implants (see for example DE 102 24 671 C1), in which a porosity is provided in the entire body by filler material in the entire mass, it is also preferred to design the implant in its core without such fillers, as otherwise a sufficient stability cannot be achieved in this core.
Preferably, the filler material are high-melting organic or anorganic compounds, low-melting metals, especially preferably carbamide (CH 4 N 2 (H 2 N—CO—NH 2 ), biuret (C 2 H 5 N 3 O 2 ), melamine (C 3 H 6 N 6 ), melamine resin, ammonium carbonate ((NH 4 )CO 3 H 2 O) or ammonium bicarbonate (NH 4 HCO 3 ) or mixtures thereof. With respect to possible materials as fillers, reference is made to the disclosure of DE 102 24 671 C1, which in this respect is explicitly included in the present disclosure.
Furthermore, the present invention concerns an implant, producible or produced by a method as described above.
In addition, the present invention concerns the use of such an implant as a dental implant, especially as a crown stub, as a threaded part, screw and/or pin.
Further preferred embodiments of the invention are described in the dependent claims.
This problem is solved in summary in that the structured or porous surface, respectively, is, at least area-wise during the CIM or MIM process, respectively, surface-modified on the green body, i.e. on the intermediate product after casting or injection molding and prior to the final sintering, or is the result of a surface-modification, respectively. The problem is solved by a specifically treated surface of the implant, thereby having specific properties, wherein the treatment can be carried out over the entire implant surface as well as on partial component parts of the implant surface.
Within the scope of this invention, mainly implants are concerned which are based on ceramic materials. However, it is likewise possible to structure implants on a metallic basis by the aid of the processes described below. Accordingly, it is also possible to provide a metallic implant, which has a structured or porous surface, respectively, which at least area-wise during the CIM or MIM process, respectively, is surface-modified on the so-called green body, i.e. on the intermediate product after the cold-isometric compression, casting, or injection molding, and prior to the final sintering, or is the result of a surface modification, respectively. Additionally, the optimization of the surface structure is possible by thermal heat treatments (debindering, sintering, HIP). All embodiments described below correspondingly were able to be used likewise on metallic materials, such as for example implants on the basis of titanium, zinc, niobium, tantalum, or corresponding alloys.
The core of the invention therefore consists in that it was surprisingly found that especially green bodies on the basis of ceramic (slip), but also of metal (slip) based green bodies can be thus modified on the surface prior to sintering, that they subsequently show excellent osteointegration or osseointegration, respectively. It can be shown that the osteointegration or osseointegration, respectively, of a surface thus modified is better than the corresponding values for acid-modified surfaces and/or surfaces especially of mechanically produced ceramics which were merely provided with a macro-roughness by sand blasting, or of ceramics which were produced by CIM and were provided with a macro-roughness by sand blasting after the final sintering.
The so-called green body thus is structured by blasting with various blasting agents prior to the final sintering or preferably prior to a heat treatment prior to the debindering on the surface. This for example can be carried out by a defined blasting process. Furthermore, the possibility exists, to apply the blasting agent to the casting- or injection molding tool prior to casting or injection molding or treat it therewith prior to casting or injection molding. Suitable blasting agents are all known abrasive or surface densifying or natural blasting agents, depending on the desired roughness or porosity of the surface. Therein, it is also found that the surfaces produced according to the invention may contain partially incorporated component parts of the blasting agents used. Advantageously, according to the invention, further blasting agents can be used which can be removed without residues prior to the final sintering. Such suitable blasting agents are for example the so-called organic blasting agents. These blasting agents can be removed without residues at temperatures up to max. 600° C. or max. 300° C. prior to the final sintering or preferably prior to a heat treatment before debindering. Therein, it is advantageous to carry out this treatment in an oxidizing or reducing or inert atmosphere. Ammonium bicarbonate is especially advantageous, which already sublimes from the surface of the green body at 65° C. and leaves behind the desired structure in the surface. The dimension or the particle size, respectively, of the blasting agents determines the dimension of the surface structuring. Typical particle sizes are in the ranges of 10-200 μm, preferably 50-110 μm. These blasting agents have a purely surface structuring effect, (the surface produced according to the invention thereby has no residues of the blasting agents). The resulting topological structure therein, in case of a corresponding setting of the conditions and a corresponding material selection, corresponds to a macro-roughness, in other words a roughness with a dimension of 1 μm to 50 μm, preferably 1 μm-10 μm.
This macro-structured surface can be additionally micro-structured, for example with a treatment in a molten salt, such as e.g. described in CH 01339/06.
Additional coatings, such as for example of apatite, are not necessary and preferably also not present.
The ceramic can be of various types, wherein these are known from the state of the art. For example, a ceramic can be used, which contains titanium oxide or zirconium oxide, which possibly additionally contains yttrium oxide and/or hafnium oxide. In this respect, see for example U.S. Pat. No. 6,165,925, the disclosure of which shall be explicitly encompassed by the disclosure of the present description with respect to the composition and the production of such ceramics on the basis of zirconium oxide.
Alternatively, it is possible to use ceramics, which contain aluminium oxide, to which possibly additionally silicium dioxide, ferric (III) oxide, and/or sodium oxide is added. It is furthermore possible to use a ceramic, which contains silicium nitride, to which possibly additionally silicium dioxide, ferric (III) oxide, and/or sodium oxide is added. Also ceramics based on mixtures or multi-layer systems on the basis of said materials are possible.
According to a preferred embodiment the implant is a dental implant, its surface which is exposed to the bone and/or soft tissue in an implanted state being at least area-wise macro-structured with the aid of the described process, and the macro structure possibly being underlaid with a micro structure, which for example is molten salt- or acid-modified.
SHORT DESCRIPTION OF THE FIGURES
The invention shall be further illustrated below by embodiments in connection with the figures, in which:
FIG. 1-3 show the surface topography of a ceramic implant after injection molding and after blasting with an organic blasting agent prior to sintering in different resolutions;
FIG. 4-6 surface topography of a ceramic implant after injection molding and after blasting with an anorganic blasting agent prior to sintering in different resolutions;
FIG. 7 surface pictures of example 3 in different resolutions prior to etching;
FIG. 8 surface pictures of example 3 in different resolutions after etching;
FIG. 9 surface pictures of example 4 in different resolutions prior to etching;
FIG. 10 surface pictures of example 4 in different resolutions after etching; and
FIG. 11 surface picture of a green body after blasting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention describes the possibility to structure the surface of implants, which especially are produced from ceramic- but also of metallic materials. Aim of the surface modification are a better anchoring of the implants in hard tissue, a better bond between hard tissue and implant surface, a better bond between soft tissue and implant surface, and a better interaction of the implant surface on the interface between implant surface and hard tissue and/or soft tissue.
The production of the zirconium oxide-, titanium oxide- and/or aluminium oxide and/or mixed ceramics for implants, also by the aid of CIM or MIM, is basically known from the state of the art and correspondingly shall not be further discussed. In this context, reference is made to the disclosure of the above mentioned documents.
Preferably, the invention concerns implants which are anchored in the hard- and/or soft tissue and which serve the temporary or permanent replacement or support of accident-, use-, deficiency- or disease-damaged or otherwise degenerated parts of the musculoskeletal system, including the chewing apparatus, especially the dental area with its corresponding, also aesthetic aspects. Hence, for example hip- and knee joint prostheses, spine implants and dental implants have been used clinically for many years. The problem of the improved osteointegration features, or osseointegration features, respectively, is solved according to the invention by a corresponding surface structure or surface treatment, respectively, of the (ceramic-) surface of the implant, wherein the treatment can be carried out over the entire implant surface as well as over partial areas of the implant surface. By way of such a surface structuring, it is ensured that the otherwise bio-inert ceramics, such as preferably zirconium oxide, titanium oxide, or aluminium oxide, or mixtures thereof, can be integrated in the hard- and/or soft tissue.
The structural and functional anchoring, e.g. of a dental implant, in the bone, normally is achieved by applying a macro-roughness, and/or a possibly additional micro-roughness. The macro-roughness can for example be obtained by a mechanical blasting process according to the state of the art, the micro-roughness subsequently for example in an additive process by plasma technique, or in a subtractive process by chemical- or molten salt etching on the surface. The degree of anchoring of the implant in the bone can be determined by mechanical measurements. Numerous tests have shown that the sufficient anchoring of an implant in the bone depends to a great extent on the surface condition of the implant, especially on the roughness at its surface.
The present invention describes a specific and newly created roughness for a preferably enlarged effective surface for a better osteointegration of implants, which are produced of ceramics, preferably of titanium oxide, zirconium oxide, or aluminium oxide, or mixtures thereof. This biologically effective surface according to the invention can be produced by blasting of the green body after casting or injection molding and prior to the final sintering during the CIM or MIM process, respectively, by an additional mechanical subsequent or antecedent chemical treatment, for example etching or similar, or by a combination of such methods.
The surface according to the invention can for example be produced by treating the green body on its surface prior to the final sintering by blasting with different blasting agents, until a corresponding surface structuring results. This for example can be carried out by a defined blasting process.
Furthermore, the possibility exists to apply the blasting agent to the isostatic compression- or casting- or injection molding tool prior to casting or injection molding, or to treat it therewith.
As mentioned, all known abrasive or surface densifying blasting agents are suitable, such as metallic blasting agents, ceramic blasting agents, or natural blasting agents in different particle sizes, depending on the desired roughness or porosity of the surface, respectively. Therein, it is also found that the surfaces produced according to the invention can contain partially incorporated component parts of the blasting agents used. Advantageously, further blasting agents can be used, which can be removed without residues prior to the final sintering. Such suitable blasting agents are for example ice (balls or —particles), organic blasting agents or especially carbamide, melamine resin, biuret, melamine, ammonium carbonate and ammonium bicarbonate. These blasting agents are removed without residues at temperatures up to max. 600° C. prior to the final sintering or preferably prior to a heat treatment prior to the debindering. Therein, it is advantageous to carry out this treatment in an oxidizing or reducing or inert atmosphere. The dimension of the blasting agent(s) determines the dimension of the surface structuring. A mixture of two different agents with two different sizes thus results in “bimodal” structurings with two different structure-dimension-parts, a fine structure and a rough structure.
Series 1
Example 1
A green body in the form of a cylindrical dental implant with a length of 10 mm and a diameter of 4 mm was injection molded from yttrium-stabilized zirconium oxide powder. After injection molding and prior to sintering, the surface was blasted with a mixture of peach- and apricot pits with a particle size of 100-150 μm with a pressure of 0.8 bar for 50 s. The resulting surface was examined by scanning electron microscopy. The surface topography created by the blasting is shown in different resolutions in FIGS. 1 , 2 , and 3 . The macro-roughness thereby produced leads to a good osseointegration of the implant after sintering.
Example 2
A green body in the form of a cylindrical dental implant with a length of 10 mm and a diameter of 4 mm was injection molded from yttrium-stabilized zirconium oxide powder. After the injection molding and prior to sintering, the surface was blasted with aluminium oxide with a particle size of about 250 μm with a pressure of 0.8 bar for 50 s. The resulting surface was examined by scanning electron microscopy. The surface topography created by the blasting is shown in different resolutions in FIGS. 4 , 5 , and 6 . The macro-roughness thereby produced leads to a good osseointegration of the implant after sintering.
Series 2
In a second series of experiments, the green bodies were treated prior to sintering by the use of a blasting agent, which contained two different materials with different particle sizes. Therein, generally the following process management and settings of the parameters are preferred:
Preferred Parameters:
1. passage with ⅔ vol. organic material (peach pits and/or apricot pits in correspondingly ground form) 0.3 to 0.6 mm particle size and ⅓ vol. Al 2 O 3 -220 mesh (about 0.07 mm particle size). Both components are present as a mixture and are blasted simultaneously.
Pressure:
3 bar to 5 bar
Exposition-blasting time:
25 sec to 45 sec
Distance, jet to implant:
25 mm to 80 mm
Bore diameter of the jet:
1.2 mm to 2.0 mm
2. passage with Al 2 O 3 mesh 220, thereby more rough residues of the organic agent can be removed.
Pressure:
0.2 bar to 0.4 bar
Exposition-blasting time:
15 sec to 25 sec
Distance, jet to implant:
30 mm to 50 mm
Bore diameter of the jet:
0.8 mm to 1.0 mm
Especially preferred for the 2. passage are:
Pressure:
0.2 bar
Exposition-blasting time:
20 sec
Distance, jet to implant:
30 mm
Bore diameter of the jet:
1.0 mm
Generally, the parameters shown below can be selected:
1. passage with ⅔ vol. organic material (peach pits and/or apricot pits in correspondingly ground form) 0.3 to 0.6 mm particle size and ⅓ vol. Al 2 O 3 -220 mesh.
Pressure:
2 bar to 7 bar
Exposition-blasting time:
15 sec to 65 sec
Distance, jet to implant:
25 mm to 80 mm
Bore diameter of the jet:
1.2 mm to 2.0 mm
2. passage with Al 2 O 3 mesh 220.
Pressure:
0.2 bar to 0.8 bar
Exposition-blasting time:
10 sec to 35 sec
Distance, jet to implant:
30 mm to 50 mm
Bore diameter of the jet:
0.8 mm to 1.2 mm
Example 3
A green body in the form of a cylindrical dental implant with a length of 10 mm and a diameter of 4 mm was injection molded from yttrium-stabilized zirconium oxide powder. After the injection molding and prior to sintering, the surface was blasted with a mixture of peach- and apricot pits ⅔ vol. (organic agent) 0.3 to 0.6 mm particle size and ⅓ vol. Al 2 O 3 -220 mesh with a pressure of 3.0 bar for 45 s.
Subsequently, 2. blasting passage with Al 2 O 3 mesh 220, thereby more rough residues of the organic agent can be removed, with a pressure of 0.8 bar for 50 s.
The resulting surface was examined by scanning electron microscopy. The surface topography created by the blasting is shown in different resolutions in FIG. 7 ( a - c ). The macro-roughness thereby produced leads to a good osseointegration of the implant after sintering.
The values of the roughness measurements of the surface of the implant thus produced in the state prior to etching, measured at the threaded base, result in the following values:
Measured values in μm
Sa
Sq
St
Sk
Rt
Rq
Ra
1.05
1.25
6.42
3.38
8.67
1.41
1.10
Measurement parameters (also used in all further measurements): Gauss filter with cut off=110 μm; field of measurement about 770 μm×770 μm, object lens L20X, Stitchen 1×1; confocal microscope 3 dimensional measurement method, apparatus: white light microscopy μ-surf.
Subsequently, the implant thus produced was etched in a molten salt, consisting of 50% KOH and 50% LiOH (weight percent) at 200° C. for 30 hours. Thereby, the surface structure was significantly changed, as can be derived from FIG. 8 ( a - b ).
The values of the roughness measurements of the surface of the implant in the state after etching, measured at the threaded base, result in the following values:
Measured values in μm
Sa
Sq
St
Sk
Rt
Rq
Ra
1.12
1.41
7.57
7.87
16.81
3.91
1.23
after etching
Example 4
A green body in the form of a cylindrical dental implant with a length of 10 mm and a diameter of 4 mm was injection molded from yttrium-stabilized zirconium oxide powder. After the injection molding and prior to sintering, the surface was blasted with a mixture of peach- and apricot pits ⅔ vol. (organic agent) 0.3 to 0.6 mm particle size and ⅓ vol. Al 2 O 3 ±220 mesh with a pressure of 3.0 bar for 25 s.
Subsequently, 2. blasting passage with Al 2 O 3 mesh 220, thereby more rough residues of the organic agent can be removed, with a pressure of 0.2 bar for 20 s.
The resulting surface was examined by scanning electron microscopy. The surface topography created by the blasting is shown in different resolutions in FIG. 9 ( a - b ). The macro-roughness thereby produced leads to a good osseointegration of the implant after sintering.
The values of the roughness measurements of the surface of the implant in the state prior to etching, measured at the threaded base, result in the following values:
Measured values in μm
Sa
Sq
St
Sk
Rt
Rq
Ra
1.07
1.31
6.42
3.53
6.93
1.43
1.03
prior to etching
Subsequently, the implant thus produced was etched in a molten salt, consisting of 50% KOH and 50% LiOH (weight percent) at 200° C. for 30 hours. Thereby, the surface structure was significantly changed, as can be derived from FIG. 10 ( a - b ).
The values of the roughness measurements of the surface of the implant in the state after etching, measured at the threaded base, result in the following values:
Measured values in μm
Sa
Sq
St
Sk
Rt
Rq
Ra
1.95
1.53
17.39
4.17
41.11
4.58
1.80
after etching
In FIG. 11 , a green body prior to sintering is shown, wherein it can be seen how the organic and anorganic residues of the blasting agent are still present on the surface.
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The invention discloses a novel implant provided with a macroporous surface on the top surface, and a method for the production of such a metallic and/or ceramic implant having a textured, particularly porous, surface for the at least partial insertion in hard tissue, such as in a bone, and/or into soft tissue. The implant is produced as a green compact, at least in sections, using a cold isostatic pressing, casting, and/or injecting (CIM, MIM) with subsequent sintering to obtain an implant, and is particularly characterized in that the surface is modified and/or prepared before sintering such that a macroporous surface is present after sintering without requiring any finishing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation in part of U.S. patent application Ser. No. 13/433,622, filed 29 Mar. 2012, which is a non provisional patent application of U.S. Provisional Patent Application Ser. No. 61/468,919, filed 29 Mar. 2011.
Priority of U.S. Provisional Patent Application Ser. No. 61/468,919, filed 29 Mar. 2011, hereby incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a carrier that enables a user to support a drink product (canned, bottled, etc.) at a position next to the user's waist or hip area such as upon a belt. More particularly, the present invention relates to an improved beverage carrier for wear at a user's hip or waist area or on an accessory (e.g., backpack, belt, shirt, jacket, vest, purse) wherein a spring loaded locking arrangement secures a specially configured insulated sleeve to a housing or receiver that is mounted on the user's belt or to the user's garment at the waist area, the sleeve supporting a selected beverage container and wherein a user can finger or thumb actuate a release mechanism that frees the sleeve and container from the receiver.
2. General Background of the Invention
Drink products are often carried by individuals over long distances. Hikers, athletes, sports fans, parade attendees, hunters, fishermen, and outdoor workers all carry drink products which must be hand held if another provision is not made for carriage.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a beverage carrier for wear around a user's torso. This carriage apparatus enables a user to support a selected beverage container upon a user's torso, hip or at the waist area, thus freeing the user's hands when the beverage is not being consumed.
The present invention includes a beverage carriage for wear upon a user's body, comprising a clothing accessory that attaches to a user's body, a receiver that depends from the accessory, the receiver having an upwardly positioned socket, a mounted sleeve having a top opening and an interior, said opening enabling a contained beverage to be housed within the sleeve interior, a curved panel that fits inside the sleeve, a projecting member attached to the curved panel and extending through the sleeve to a position spaced externally of the sleeve, a detachable connector that joins the projecting member to the receiver when the detachable connector is lowered into the socket via the open top to define a pivotal connection, a locking member that moves between locking and release positions, the locking member automatically interlocking with the connector when the connector is lowered into the socket, the locking member having a manually operated release portion that when depressed by the hand of a user places the locking member in the release position which enables removal of the connector from the socket, and a cam that depresses the release portion when the sleeve is rotated about said pivotal connection a selected number of degrees that is between about 5 degrees and 90 degrees.
In one embodiment, the locking member is spring loaded.
In one embodiment, the locking member has a cam that moves the locking member laterally away from the socket when the projecting member is lowered into the socket.
In one embodiment, there is a second curved panel that attaches to the outside surface of the sleeve.
In one embodiment, the projecting member has an annular flange and an annular recess.
In one embodiment, the locking member is moved by the projecting member when the projecting member is joined to the receiver.
In one embodiment, the locking member is positioned above the projecting member in the locking position.
In one embodiment, the locking member moves laterally when the release portion is depressed.
In one embodiment, the receiver has a cover and the locking member is a part of the cover.
The present invention includes a beverage carriage for wear upon a user's body comprising an article of clothing that is wearable by a user, a receiver that is removably attachable to the article of clothing, the receiver having a socket, a mounted sleeve having a top opening and an interior, said opening enabling a contained beverage to be housed within the sleeve interior, a first panel that fits inside the sleeve, the sleeve being of a material that is softer than the first panel, a projecting member attached to the first panel and extending through the sleeve to a position spaced externally of the sleeve, a second panel that connects to the projecting member on the outside of the sleeve, a connector that joins the projecting member to the receiver when the detachable connector is lowered into the socket via the open top to define a pivotal connection of the sleeve relative to the receiver, a locking member that moves between locking and release positions, the locking member automatically interlocking with the connector when the connector is lowered into the socket, the locking member having a manually operated release portion that when depressed by the hand of a user places the locking member in the release position which release position enables removal of the connector from the socket, and a cam that depresses the release portion when the sleeve is rotated about said pivotal connection a selected number of degrees that is between about 5 degrees and 90 degrees.
In one embodiment, the locking member includes a biasing means that biases the locking member towards a locking position.
In one embodiment, when the projecting member is lowered into the socket, the locking member moves the locking member laterally away from the socket.
In one embodiment, at least one of the panels has spikes that engage the sleeve.
In one embodiment, the projecting member has an annular flange and an annular recess, the annular recess being closer to the sleeve than the annular flange.
The present invention includes a beverage carriage for wear upon a user's body comprising a clothing accessory that attaches to a user's body, a receiver that depends from the accessory, the receiver having an upwardly positioned socket, a mounted sleeve having a top opening and an interior, said opening enabling a contained beverage to be housed within the sleeve interior, an inner panel that fits inside the sleeve, a projecting member attached to the inner panel and extending through the sleeve to a position spaced externally of the sleeve, an outer panel that attaches to the projecting member externally of the sleeve, and wherein the inner and outer panels sandwich the sleeve therebetween, a detachable connector that joins the projecting member to the receiver to form a pivotal connection when the detachable connector is lowered into the socket via the open top, and a locking member that moves between locking and release positions, the locking member automatically interlocking with the connector when the connector is lowered into the socket, the locking member having an operated release portion that when depressed places the locking member in the release position which enables removal of the connector from the socket, and a cam that depresses the release portion when the sleeve is rotated at the pivotal connection a measure of between about 10 and 90 degrees.
In one embodiment, the locking member moves the locking member laterally away from the socket when the projecting member is lowered into the socket.
In one embodiment, there is at least one of the panels is curved.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a perspective view of a preferred embodiment of the apparatus of the present invention;
FIG. 2 is a perspective view of a preferred embodiment of the apparatus of the present invention;
FIG. 3 is a sectional view taken along the lines 3 - 3 of FIG. 1 ;
FIG. 4 is a sectional view of a preferred embodiment of the apparatus of the present invention;
FIG. 5 is a top partial sectional view of a preferred embodiment of the apparatus of the present invention;
FIGS. 6-11 are sectional elevational views illustrating the receiver and connection thereto of the disk or projecting portion of the insulated sleeve;
FIG. 12 is a perspective exploded view of a preferred embodiment of the apparatus of the present invention showing the sleeve portion when the sleeve is a zippered insulated sleeve;
FIGS. 13-14 are perspective views of a preferred embodiment of the apparatus of the present invention illustrating an insulated drawstring closure for a sleeve or bag;
FIGS. 15-18 are sectional fragmentary views of a preferred embodiment of the apparatus of the present invention illustrating an alternate locking arrangement;
FIG. 19 is a perspective view a third embodiment of the apparatus of the present invention;
FIG. 20 is a perspective view of a third embodiment of the apparatus of the present invention;
FIG. 21 is a perspective view of a third embodiment of the apparatus of the present invention;
FIG. 22 is an exploded partial perspective view of a third embodiment of the apparatus of the present invention;
FIG. 23 is a partial perspective view of a third embodiment of the apparatus of the present invention;
FIG. 24 is a partial sectional view of a third embodiment of the apparatus of the present invention;
FIG. 25 is a perspective view of a third embodiment of the apparatus of the present invention;
FIGS. 26-28 are sectional views illustrating operation of a third embodiment of the apparatus of the present invention;
FIGS. 29 and 30 are partial perspective views of a third embodiment of the apparatus of the present invention;
FIG. 31 is a perspective view of a fourth embodiment of the apparatus of the present invention;
FIG. 32 is an elevation view of a fourth embodiment of the apparatus of the present invention;
FIG. 33 is a fragmentary perspective view of a fourth embodiment of the apparatus of the present invention;
FIG. 34 is a plan view of a fourth embodiment of the apparatus of the present invention;
FIG. 35 is a partial plan view of a fourth embodiment of the apparatus of the present invention;
FIG. 36 is an exploded view of a fourth embodiment of the apparatus of the present invention;
FIG. 37 is a view that has multiple views of a fourth embodiment of the apparatus of the present invention illustrating the receiver portion;
FIGS. 38-39 are fragmentary top ( FIG. 38 ) and side ( FIG. 39 ) views of a fourth embodiment of the apparatus of the present invention showing the receiver/holder/hanger wherein the receiver is attached to the sleeve and the projection or disk is attached to a wearer's belt, clothing item, or accessory;
FIG. 40 contains fragmentary view of a third embodiment of the apparatus of the present invention;
FIGS. 41-42 are perspective views of a fourth embodiment of the apparatus of the present invention; and
FIGS. 43-46 are sequential illustrations showing operation of the fourth alternate embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-14 show a preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 . Beverage carrier 10 employs a generally cylindrically shaped sleeve 11 which can be insulated. Sleeve 11 can be made of closed cell foam. The insulated sleeve 11 can have a cylindrical wall 12 and a circular bottom or end panel 13 . Sleeve 11 could be substituted with another sleeve, using a sleeve 29 or 45 as examples.
Sleeve 11 has an open top 14 for enabling the placement of a selected drink product (such as a canned drink product or a bottled drink product) into the interior 15 of the insulated sleeve 11 via the open top 14 .
In the drawings, a beverage container in the form of a can 16 is shown. However, in any embodiment of FIGS. 1-27 , the container can be a can, bottle or other container. A beverage container in the form of a disposable bottle is also shown, designated by the number 17 . Beverage container 18 shows another type of beverage container in the form of a metal bottle that is a reusable container. In FIGS. 12-14 , alternate sleeves 29 , 45 are shown holding containers 17 , 18 . Zippered sleeve 29 can be opened and closed to insert or remove a container 17 or 18 using zipper 44 . Sleeve 45 can be opened or closed to insert or remove a container 17 or 18 using drawstring 46 .
The parts described herein can be made from injection molded plastic. In FIGS. 1-5 , the sleeve 11 provides an inner curved panel 19 and outer curved panel 20 . Inner curved panel 19 can be a full cylinder that extends completely around the container 16 , 17 , and 18 . Alternatively, the inner curved panel 19 can extend partially around the container 16 , 17 , 18 such as about 40-180 degrees around container 16 , 17 , 18 . A thickened section 21 is provided on the outer curve panel 20 . This thickened section 21 can provide a flat surface 22 to which is supported a projecting portion or disk 23 . Connecting portion 24 joins disk 23 to flat surface 22 .
An annular recess 25 is provided around connecting portion 24 and in between disk 23 and flat surface 22 . This annular recess 25 is receptive of a receiver 30 as will be described more fully hereinafter. Fasteners 26 (e.g., pins, screws, rivets, bolts or the like) join panel/plate 19 to panel/plate 20 as shown.
In FIGS. 1 and 2 , arrow 27 illustrates the placement of disk 23 into the receiver, holder, or receptacle 30 . This action is seen more clearly in FIGS. 6-11 . Receiver 30 provides a housing 31 having a locking member 32 that is mounted to the housing 31 with a pivotal connection or pivot 33 . Locking member 32 has an upper end portion 34 with a projection 35 . The locking member 32 has a lower end portion 36 with a cam 37 . A spring 38 is provided for urging the locking member 32 into the locking position of FIGS. 6 and 9 (see arrow 41 ). Spring 38 can be attached to housing 31 using spring attachment 39 which can be a pair of fasteners as shown.
The locking member 32 is mounted to travel within a recess or slot 40 of housing 31 . In FIGS. 6-8 , arrows 28 illustrate the insertion of disk or projecting member 23 into recess 47 via its open top 48 . While the disk or projecting member 23 and the connecting portion or shaft 24 are the only portions of insulated sleeve 11 shown in FIGS. 6-11 , it will be understood that the connection portion 24 is joined to curve panel/plate 20 and thus to sleeve 11 and the contained beverage or can 16 .
Receiver 30 housing 31 has a flange 50 with edges 51 that travel in annular recess 25 as see in FIGS. 1-11 . In order to release the beverage can or other container 16 and sleeve 11 from recess 47 , a user simply uses his or her finger or thumb 42 to press inwardly on the lower end portion 36 of locking member 32 in the direction of arrow 43 as shown in FIG. 11 . This action rotates the lower end portion 36 of the locking member 32 inwardly toward spring 38 , thus overcoming spring pressure of spring 38 . Locking member 32 rotates about pivot 33 , withdrawing projecting portion 35 of locking member 32 from recess 47 as shown in FIGS. 9-11 . A user can then lift the container 16 , sleeve 11 and disk 23 upwardly as illustrated by arrow 49 in FIG. 11 . Receiver 30 housing 31 can have a clasp 80 for enabling attachment to a belt, accessory, backpack or item of clothing.
FIGS. 15-18 show a different locking arrangement for the receiver, designated as numeral 52 . In FIGS. 15-18 , receiver 52 supports arm 53 which is pivotally attached to receiver body 54 at pivotal or rotary connection 55 . When connecting portion 24 and disk 23 enter socket 58 , spring 56 is pushed which frees arm 53 to rotate to the locking position of FIG. 16 . Arm 53 is rotated in the direction of arrow 57 A until arm 53 partially enters recess or socket 58 thus preventing removal of disk 23 (see FIG. 16 ). In order to release disk 23 and the attached sleeve 11 , a user uses his or her thumb or finger 42 to rotate the arm 53 in the direction of arrow 57 B to compress spring 56 (see FIGS. 15 , 17 ). Locking pin 59 can be compressed by connecting portion 24 or disk 23 to enable rotation of arm 53 . Until pin 59 is depressed, arm 53 remains in the unlocked position of FIG. 15 . Pin 59 can be spring loaded to remain in the extended position of FIG. 15 . Once connecting portion 24 or disk 23 pushes pin 59 downwardly, arm 53 is free to rotate in the direction of arrow 57 A.
FIGS. 19-30 show a third embodiment of the apparatus of the present invention designated generally by the numeral 90 .
Beverage carrier assembly 90 provides an insulated receptacle 91 which can be for example of a closed cell phone construction. Insulated receptacle 91 provides a cylindrical wall 92 , circular bottom 93 and open top 94 . An interior 95 is provided that is receptive of a beverage container such as a can or a bottle, designated by the numeral 96 in FIGS. 19-21 .
An inner curved plate 97 is placed inside interior 95 , engaging the inner surface of cylindrical wall 92 as shown in FIGS. 22-24 . The inner curved plate 97 carries a projecting member 98 which is used to form a locking connection with a clothing or belt mounted receptacle or holder 112 as will be discussed more fully hereinafter. Projecting member 98 extends from plate 97 through opening 99 in the cylindrical wall 92 of insulated receptacle 91 . The projecting member 98 then forms a connection with outer curved plate 103 at opening 104 . Opening 104 can include a circular portion 105 and an elongated slot 106 . In FIG. 22 , arrows 100 schematically illustrate the assembly of inner curved plate 97 , insulated receptacle 91 , and outer curved plate 103 .
Projecting member 98 includes an outer annular flange 101 , outer annular recess 102 , inner annular flange 107 , and inner annular recess 108 . The inner annular flange 107 and inner annular recess 108 enable a connection to be formed with plate 103 as the opening 104 circular portion 105 is of a diameter that is smaller than the diameter of inner annular flange 107 . Thus, the inner annular flange 107 captures the plate 103 behind it and in between inner annular flange 107 and cylindrical wall 92 of insulated receptacle 91 . This arrangement is best seen in FIGS. 22-24 .
The plates 97 and 103 can be provided with teeth or projecting portions or projections 109 that are positioned to engage cylindrical wall 92 . Projecting member 98 has a cylindrical portion 110 that occupies opening 99 as shown in FIG. 24 when the inner curved plate 97 and its projection 98 are inserted connect with plate 103 after the projecting member 98 is placed through opening 99 .
A receptacle or holder 112 can be mounted on a user or wearers 114 belt 113 . Arrow 111 in FIG. 25 illustrates an attachment of insulated receptacle 91 holding a beverage container or can 96 to receptacle or holder 112 . Arrow 115 in FIG. 21 illustrates a removal of insulated receptacle 91 from receptacle of holder 112 .
FIGS. 26 , 27 and 28 illustrate a connecting of insulated receptacle, 91 to receptacle or holder 112 . In FIGS. 29 and 30 , receptacle, receiver, or holder 112 includes inner part 116 and an outer part 117 . Inner part 116 carries a spring 118 . Spring 118 is attached with hinge 119 to plate 123 . Spring 118 enables connection to a user's clothing or belt 113 by depressing push button 120 which moves hook 121 away from opening 122 , thus separating hook 121 from plate 123 as shown in FIG. 28 . By releasing the push button 120 , the hook 121 returns to the position shown in hard lines in FIG. 28 , thus capturing the article of clothing, strap or belt 113 in between the spring 118 and plate 123 .
Inner part 116 is attached to outer part 117 using a plurality of pins and openings. Pins 125 on inner part 116 engage the bore 131 of each sleeve 130 on outer part 117 . Pins 129 on outer part 117 engage openings 124 on inner part 116 . The connections of the pins 125 , 129 to the openings 124 , 131 can be interference fits.
The inner part 116 provides a ramp 126 defined by a plurality of triangular members 127 . Spaced below ramp 126 is stop 128 . A gap in between the stop 128 and the ramp 126 is occupied by upper end 139 of locking arm 138 as shown in FIGS. 26-30 . Ramp 126 is engaged by outer annular flange 101 of projecting member 98 when insulated receptacle 91 moves downwardly toward slot 135 of cover 132 and more particularly its curved wall 134 .
Cover 132 provides curved front wall 134 . An opening 133 and slot 135 are provided to cover 132 front wall 134 having open top 136 and bottom or stop 137 . When the projecting member 98 moves to the bottom or stop 137 , locking arm 138 upper end 139 moves in the direction of arrow 141 to trap projecting member 98 below upper end 139 as shown in FIG. 28 . In this fashion, a user can walk about briskly without fear that his or her beverage container 96 will be inadvertently dislodged and dropped or lost. Arrow 140 in FIG. 27 illustrates that upper end 139 moves away from projecting member 98 as the projecting member 98 moves downwardly in the direction of arrow 142 as seen in FIG. 27 . In order to release projecting member 98 , a user depresses actuator button 144 which is a part of cover 132 as shown in FIGS. 29 and 30 . A slot 143 is provided in cover 132 as shown in FIG. 29 for enhancing the ability of actuator button 144 to move forward and rearward as illustrated by arrow 145 in FIG. 29 .
FIGS. 31-40 show another fourth alternate embodiment of the apparatus of the present invention designated generally by the numeral 60 . In FIGS. 31-40 , beverage carrier 60 provides an insulated sleeve 61 that can include a cylindrical wall 62 in a circular bottom 63 with an open top 64 . The open top 64 enables insertion of a can or container 66 into interior 65 of insulated sleeve 61 . Similarly, a bottle 72 could be placed via open top 64 into interior 65 of insulated sleeve 61 .
A curved plate 67 is positioned within interior 65 of insulated sleeve 61 as shown in FIG. 34 . Projecting member 69 is attached to curve plate 67 using a fastener 68 such as a screw or bolt. Projecting member 69 is attached to circular disk 70 which is spaced away from plate 67 as shown in FIG. 34 . An annular recess or groove 71 is provided around projecting member 69 and generally in between disk 70 and plate 67 . This annular recess 71 is receptive of a locking plate 73 for holding the projecting member 69 , disk 70 and thus, the attached sleeve 61 and its container 66 or 72 on the hip area of a user. The apparatus 60 can thus be carried on the torso, hip or waist area, clothing item, accessory, of a user by threading a belt or strap or other structure through recess 83 which is in between housing sections 79 , 80 . Parts 79 , 80 can be hingedly attached at pivot 89 and spring loaded (e.g. spring 88 ) to easily open and close around a belt, strap, accessory. Spring 88 is shown in FIG. 36 .
In FIG. 36 , locking plate 73 provides a cam 74 , upwardly facing slot 77 and a spring carrier 82 . When a user attempts to insert the combination of container or can 66 , insulated sleeve 61 and projecting member 69 into socket 84 of receiver 75 , the projecting member 69 strikes the cam 74 and overcomes the pressure of spring 78 . The spring carrier 82 compresses the spring 78 as the connecting member 69 and disk 70 are forced downwardly in socket 84 and into slot 77 . Eventually, the connecting portion 69 registers in horizontally extending slot 87 and cam 74 extends over the top of projecting member 69 in a locking position that is shown in FIG. 35 .
In order to release the beverage container 66 , insulated sleeve 61 and connecting portion 69 and disk 70 , a user presses the release button 76 provided on locking plate 73 in order to compress spring 78 so that the cam 74 moves laterally away from the projecting member 69 allowing its release upwardly from socket 84 and receiver 75 . Locking plate 73 travels laterally within housing section 79 . Release button 76 extends through opening 81 and housing section 79 .
Shoulders 85 , 86 in FIG. 35 engage disk 70 as shown to prevent removable of disk 70 and projecting member 69 from receiver 75 unless release button 76 has been depressed.
FIGS. 41-46 show an additional embodiment of the apparatus of the present invention designated by the numeral 146 in FIG. 41 and the numeral 147 in FIG. 42 . In FIGS. 41 , 43 - 46 there can be seen a beverage carry receptacle 146 having the same sleeve/insulated receptacle 11 for carrying a beverage or bottle 17 as with earlier embodiments. The outer curved plate 103 and projecting member 98 are of the same construction as shown in FIGS. 21-30 . In FIG. 41 there is provided an enlarged cam or projection 148 which can be hemispherically shaped or other enlarged projection that has a curved outer surface projecting away from the plate 103 as shown in FIG. 41 .
In FIG. 42 , a mobile telephone carriage 147 is provided that includes case or receptacle 149 for receiving a mobile telephone 150 when the telephone 150 is moved into the case as illustrated by arrows 153 in FIG. 42 . Case or receptacle 149 has a rear surface 152 with an enlarged cam or projection 151 which can be oval shaped or hemispherically shaped.
Either of the embodiments of FIG. 41 or 42 employ the same rotating mechanism to disconnect the sleeve 11 and its bottle 17 (or the combination of case 149 and telephone 150 ) from receptacle/holder/receiver 112 . In order to effect such a disconnection, a user 114 rotates the combination of sleeve 11 and bottle 17 through an arch of about 30-45 degrees as illustrated by curved arrow 156 in FIGS. 44 , 46 . This rotation as illustrated by arrow 156 is in a clockwise direction when looking at the sleeve 11 with the receptacle 112 behind it. This rotating action causes the cam 148 (or 151 in the case of telephone 150 and its receptacle 149 ) to engage the actuator button 144 and depress it (illustrated by arrow 154 in FIG. 44 ). Such a depression of the actuated button 144 provides for release of the sleeve and bottle 11 , 17 or telephone and case 149 , 150 from the receptacle 112 . The user then lifts the sleeve 11 from the receptacle 112 , illustrated by arrows 155 in FIGS. 45 , 46 . If releasing case 149 with phone 150 , the user rotates the combination of phone and case clockwise about 30-45 degrees to depress button 144 with cam 151 and lifts the case 149 and phone 150 upwardly.
The following is a list of parts and materials suitable for use in the present invention:
PARTS LIST:
Number
Description
10
beverage carrier assembly
11
sleeve/insulated receptacle
12
cylindrical wall
13
circular bottom/panel
14
open top
15
interior
16
beverage container/can
17
beverage container/disposable bottle
18
beverage container/reusable bottle
19
inner curved panel/plate
20
outer curved panel/plate/hanger/connector
21
thickened section
22
flat surface
23
disk/projecting member
24
connecting portion/shaft
25
annular recess
26
fastener/screw/rivet/bolt/pin
27
arrow
28
arrow
29
zippered sleeve
30
receiver/holder/receptacle
31
housing
32
locking member/latch
33
pivot
34
upper end portion
35
projection
36
lower end portion
37
cam
38
spring
39
spring attachment
40
recess/slot
41
arrow
42
user's finger/thumb
43
arrow
44
zipper
45
sleeve/bag
46
drawstring
47
recess
48
open top
49
arrow
50
flange
51
edge
52
housing/receiver
53
arm
54
receiver body
55
rotary connection/pivot
56
spring
57A
arrow
57B
arrow
58
socket
59
locking pin
60
beverage carrier
61
insulated sleeve
62
cylindrical wall
63
circular bottom
64
open top
65
interior
66
can/container
67
curved plate
68
fastener
69
projecting member/connecting
portion
70
circular disk/projecting membrane
71
annular recess/groove
72
bottle
73
locking plate
74
cam
75
receiver
76
release button
77
slot
78
spring
79
housing section
80
housing section/clasp
81
opening
82
spring carrier
83
belt/clothing/accessory/recess
84
socket
85
shoulder
86
shoulder
87
horizontally extending slot
88
spring
89
pivot
90
beverage carrier assembly
91
insulated receptacle
92
cylindrical wall
93
circular bottom
94
open top
95
interior
96
beverage container/can/bottle
97
inner curved plate
98
projecting member
99
opening
100
arrow
101
outer annular flange
102
outer annular recess
103
outer curved plate
104
opening
105
circular portion
106
elongated slot
107
inner annular flange
108
inner annular recess
109
tooth/projection
110
cylindrical portion
111
arrow
112
receptacle/holder/receiver
113
belt/clothing/strap
114
user/wearer
115
arrow
116
inner part
117
outer part
118
spring
119
hinge
120
push button
121
hook
122
opening
123
plate
124
opening
125
pin
126
ramp
127
triangular member
128
stop
129
pin
130
sleeve
131
bore/opening
132
cover
133
opening
134
curved front wall
135
slot
136
open top
137
bottom/stop
138
locking arm
139
upper end
140
arrow
141
arrow
142
arrow
143
slot
144
actuator button
145
arrow
146
beverage carry receptacle
147
mobile telephone carriage
148
projection/cam
149
case/receptacle
150
telephone
151
projection/cam
152
flat rear surface
153
arrow
154
arrow
155
arrow
156
curved arrow
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A beverage carriage if provided for wear around a user's waist area. The apparatus includes an accessory that attaches to a user's waist area. A hanger depends from the accessory, the hanger having an upwardly positioned socket. A mounted sleeve has a top opening having an opening that enables a contained beverage to be housed within the sleeve interior. A curved panel/plate fits inside the sleeve. A projecting member is attached to the curved panel/plate and extends through the insulated sleeve to a position spaced externally of the sleeve. A detachable connector joins the projecting member to the hanger when the detachable connector is lowered into the socket via the open top. A locking member moves between locking and release positions, the locking member automatically interlocking with the connector when the connector is lowered into the socket, the locking member having a manually operated release portion that when depressed by the hand of a user places the locking member in the released position which enables removal of the connector from the socket.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is being filed as a U.S. National Stage under 35 U.S.C. 371 of International Application No. PCT/FR2005/003184, filed on Dec. 19, 2005, which claims the benefit of French Application No. 05/00,038, filed Jan. 4, 2005. The contents of both applications are hereby incorporated by reference in their entirety.
The present invention relates to a progressive ophthalmic lens, as well as a method for producing one such lens.
BACKGROUND
Usually, an ophthalmic lens comprises a visual correction that is determined by a prescription established for the wearer of the lens. Such a prescription indicates in particular a value for the optical power and a value for the astigmatism adapted to correct the distance vision of a wearer. These values are usually obtained by combining the anterior face of the lens with a generally spherical or spherotoric posterior face. For a progressive lens, at least one of the two faces of the lens has spherical and cylindrical variations, resulting from variations in optical power and astigmatism, between different observation directions through the lens. The type of variations of optical power and astigmatism of the lens are called design. In particular, the difference in optical power between two points dedicated to distance vision and to near vision is called addition, and its value should also correspond to the value prescribed for a far-sighted wearer.
Currently, a progressive lens is produced in two successive steps. The first step consists of producing a semifinished lens, of which the anterior face has spherical and cylindrical variations initially defined to correspond to the desired design. This is performed in a factory, for example by molding or injection. Semifinished lenses are divided into several models which can differ, in particular, by the base, by the distribution of sphere and cylinder of the anterior face, or by addition. The base is the sphere at the point on the lens corresponding to distance vision. The distance between the near vision and distance vision points, the respective widths of the zones of the lens corresponding to near vision and distance vision, the refractive index of the transparent material that constitutes the semifinished lens etc, can also differ from one model to another. Each combination of these characteristics corresponds to a different model of semifinished lens.
The second step is performed in laboratories located between factory and retail sales center within the distribution chain for ophthalmic lenses. It consists of machining in a separate step a sphere or a spherotoric surface on the posterior face of the lenses, so that each lens corresponds to the prescription of the wearer.
At the present time, a trend has appeared whereby the design of progressive lenses is customized according to supplementary characteristics of the wearer, other than the usual prescription characteristics. Such supplementary characteristics may concern in particular the position of the head of the wearer and that of his eyes for a distance vision situation and a near vision situation. The progressive lens may then, for example, be selected so that the distance vision and near vision points are situated at locations in the lens that are adapted in relation to the positions of the head and eyes of the wearer.
In the organization for producing progressive lens described above, taking into account individual wearers' characteristics for the design of lenses, requires a multiplication of models of semifinished lenses. The series of semifinished lenses for each model that are produced in a factory are then shorter. Their cost price is consequently higher. Moreover, this results in complex stock management in the laboratories, since these must have reserves available for a large number of models of semifinished lenses.
In order to avoid such multiplication of models of semifinished lenses, a novel organization of the production line for progressive ophthalmic lenses has been proposed. According to this novel organization, the design of the progressive lens is provided by the posterior face of the lens. Semifinished lenses then possess an anterior spherical face and the posterior face is machined subsequently according to the prescription and to the design that is adapted to the individual characteristics determined for each wearer. Such an organization is particularly flexible, given that any individual characteristic of the wearer is no longer involved in the selection of the semifinished lens model. In particular, a smaller number of semifinished lens models is sufficient for obtaining all the configurations of finished lenses.
However, in this case, the posterior face of the lens possesses a complex form. Indeed, the design and correction result together from this form. Subsequent machining of the posterior face of the semifinished lens then requires that laboratories be equipped with machines capable of producing such shapes. Such machines, which correspond to what is called a “free-form” method, are themselves complex and therefore costly. For these reasons, subsequent machining of the posterior faces of lenses should be grouped together in a restricted number of specialized laboratories, which goes contrary to customization of lenses moved downstream in the production and distribution chain.
Document U.S. Pat. No. 5,444,503 describes a progressive ophthalmic lens with an anterior face which can be a progressive surface and a posterior face which is formed not only in order to obtain the prescribed correction for the wearer, but also in order to take account of individual conditions of use of the lens. These individual conditions of use include the depth of the eyes, the distance of vision, the inclination of the lens in front of the eye according to the frame into which the lens is fitted, and the shape of the frame. The posterior face of the lens may then also be aspheric or atoric. Customization of the lens is therefore achieved, in addition to the correction of ametropia, without increasing the number of semifinished lens models. However, such customization only takes account of the physical characteristics of the eye and/or of the frame. Now, such characteristics are insufficient for procuring an improvement in the comfort of the wearer under many conditions in which the lens is used.
An object of the present invention is therefore to combine economical production of progressive lenses with customization of the design of each lens according to at least one individual characteristic of the wearer other than his prescription, while procuring an improvement in the comfort of the wearer under a large number of conditions of use.
SUMMARY
To this end, the invention provides a progressive ophthalmic lens comprising an anterior face, a posterior face and an intermediate medium producing variations in optical power and astigmatism when said lens is used by a wearer, in which said variations comprise:
a first contribution resulting from variations of the sphere and cylinder of the anterior face of the lens; and a second contribution resulting from variations of at least one physical parameter of the lens distinct from the sphere and cylinder of the anterior face.
Furthermore, values of the physical parameter at different points on the lens are adapted so that the second contribution produces customization of variations in optical power and astigmatism of the lens as a function of at least one behavioral characteristic of a wearer of said lens.
The behavioral characteristic, as a function of which the values of the physical parameter are adapted, may concern one or more habitual attitudes and/or movements of the wearer. This may in particular be an amplitude of horizontal eye movements with respect to a rotation of the wearer's head, when the wearer scans a field of vision horizontally. This characteristic is preferably measured on the wearer by using suitable instrumentation. Such a behavioral characteristic is not, by its very nature, an optical or physical characteristic of the wearer's eyes, nor a characteristic associated with a frame into which the lens is intended to be fitted.
In addition, in a known manner, the use of the lens by the wearer corresponds to variable directions of observation through the lens. Each direction of observation is referenced by two angles, with respect to a horizontal plane and with respect to a vertical plane respectively. A light ray coming from a given direction of observation intersects each face of the lens at two respective points of intersection, and passes through a center of rotation of the eye that is assumed to be fixed. The points of intersection of the light ray with each face of the lens are determined according to the principles of optical refraction. The optical power and astigmatism values of the progressive lens for a given direction then result from the sphere and cylinder values of each face of the lens at the points of intersection of the optical ray and of the value of the refractive index of the intermediate medium as well as its possible gradient.
Thus, according to the invention, variations in optical power and astigmatism of the progressive lens are obtained partly by the anterior face and partly by means of a physical parameter of the lens that is adjusted in order to customize the lens according to the wearer. The shape of the anterior face of the lens is therefore independent of the customization achieved by means of the physical parameter. Progressive lenses that are customized differently as regards design, can therefore be obtained from identical semifinished lenses. Thus, a reduced number of semifinished lens models is sufficient to meet all the needs for progressive lenses of a population. Semifinished lenses can then be produced economically in large production runs.
According to a preferred embodiment of the invention, the second contribution is less than the first contribution, in absolute values, for the variation of optical power present between a distance vision point and a near vision point of the lens. In other words, customization of the lens that is achieved by means of the physical parameter only slightly modifies the addition of the progressive lens. Adjustment of the design which corresponds to this customization is then limited so that it can be easily achieved subsequently without very specialized equipment being required. Potentially, for the variation of optical power between the distance vision point and the near vision point, the second contribution is substantially zero. The addition of the progressive lens then only results from the first contribution to variations in optical power and it is solely determined by the anterior face of the lens.
The physical parameter of the lens, through which variations in optical power and astigmatism of the lens are customized, may be of various types. In particular, this may be:
a sphere and a cylinder of the posterior face of the lens, in which case the physical parameter is modulated during subsequent machining of the posterior face of the lens; a refractive index of a substantially transparent layer included within the lens. This layer may consist of a material with a refractive index that can be adjusted by irradiation. In this case, the physical parameter is modulated by selectively irradiating different portions of the layer in a variable manner; or a refractive index of the intermediate medium situated between the anterior and posterior faces of the lens. This intermediate medium may consist of a material with a refractive index that can be adjusted by irradiation. In this case, the physical parameter is modulated by selectively irradiating different portions of the intermediate medium in a variable manner.
Possibly, an optical power of the prescription and an astigmatism of the prescription can also result from values of the physical parameter at different points on the lens. Modulation of the physical parameter then makes it possible, in a single production step to obtain simultaneously a correction of ametropia which corresponds to the prescription and a design adapted to the behavior of the wearer.
Alternatively, the prescribed optical power and the prescribed astigmatism, which correspond to the correction of ametropia, can result from values of another physical parameter of the lens at different points thereon. This other physical parameter is distinct from the sphere and cylinder of the anterior face, and from the physical parameter that is the origin of the second contribution to variations in optical power and astigmatism of the lens. Similarly to the later, said other physical parameter of the lens may include a sphere and a cylinder of the posterior face of the lens, a refractive index of a substantially transparent layer included within the lens, or a refractive index of the intermediate medium. Depending on the nature of said other parameter, values thereof at different points on the lens can be fixed during subsequent machining of the posterior face of the lens, or during selective irradiation of different portions of the layer or of the intermediate medium, when one of these consists of a material with a refractive index that can be adjusted by irradiation.
Various customizations of the design of the progressive lens according to the behavioral characteristics of the wearer can be achieved in this way. Among these adaptations, one may cite in particular:
a modification of the width of a field of near vision and/or a field of distance vision, with respect to an effective field of near vision and/or an effective field of distance vision respectively, which would result only from the variations of the sphere and cylinder of the anterior face of the lens; a modification of a maximum value of astigmatism reached in the lateral parts of the lens, with respect to an effective maximum value of astigmatism in said lateral parts which would result only from the variations of the sphere and of the cylinder of the anterior face of the lens; a displacement of the location of a point situated in the lateral parts of the lens at which the maximum value of astigmatism is reached, in relation to an effective location of said point which would result only from the variations of the sphere and cylinder of the anterior face of the lens; a modification in the continuous variation of the optical power of the lens along a meridian line between the distance vision point and the near vision point of the lens, with respect to an effective variation of the optical power between said points which would result only from the variations of the sphere and of the cylinder of the anterior face of the lens; and a lateral displacement of the near vision point of the lens, with respect to an effective location of said point which would result only from the variations of the sphere and of the cylinder of the anterior face of the lens.
The invention also provides a method for producing a progressive ophthalmic lens which comprises an anterior face, a posterior face and an intermediate medium. The method comprises the following steps:
producing a semifinished lens in which the anterior face has variations in sphere and cylinder in order to obtain a first contribution to variations in optical power and astigmatism of the lens when said lens is used by a wearer; measuring at least one behavioral characteristic of the wearer of the lens; determining values of a physical parameter of the lens distinct from the sphere and cylinder of the anterior face, so that a second contribution to the variations in optical power and astigmatism of the lens results from variations of said physical parameters between different points on the lens, said second contribution achieving customization of the variations of optical power and astigmatism of the lens according to the behavioral characteristic measured, and modulating the physical parameter so as to obtain said second contribution.
The semifinished lens can be produced in a factory, the behavioral characteristic of the wearer can be measured at an optician's, and the physical parameter of each lens can be modulated in a laboratory intermediate between the factory and the retail sales center for the lens. For such an organization for producing progressive lenses, the result of the behavioral measurement carried out on the wearer at the optician's is communicated to the laboratory, so that the latter can determine values of the physical parameter that should be generated at each point of the lens. Alternatively, modulation of the physical parameter can be achieved directly in the retail sales center if this center is equipped with apparatus capable of performing this modulation.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become apparent in the following description of nonlimiting examples of embodiments, with reference to the appended drawings in which:
FIGS. 1 a and 1 b are respectively a cross-sectional view and a plan view of a progressive ophthalmic lens;
FIGS. 2 a and 2 b are maps of variations in sphere and in cylinder of an anterior face of a lens according to FIGS. 1 a and 1 b;
FIGS. 3 a and 3 b are maps of optical power and astigmatism of a lens having an anterior face according to FIGS. 2 a and 2 b and a spherical rear face;
FIGS. 4 a and 4 b are maps of the sphere and cylinder of a posterior face of a lens machined according to a first embodiment of the invention;
FIGS. 5 a and 5 b represent variations of sphere and variations of curvature along the prime meridian line of a lens, respectively for an anterior face of the lens corresponding to FIGS. 2 a and 2 b and for a posterior face of the lens corresponding to FIGS. 4 a and 4 b;
FIGS. 6 a and 6 b are maps of optical power and astigmatism of a lens having an anterior face according to FIGS. 2 a and 2 b and a posterior face according to FIGS. 4 a and 4 b;
FIG. 7 a represents variations in optical power and astigmatism of a lens corresponding to FIGS. 3 a and 3 b , along the prime meridian line;
FIG. 7 b represents variations in optical power and astigmatism of a lens corresponding to FIGS. 6 a and 6 b , along the prime meridian line; and
FIGS. 8 a - 8 c are respective cross-sectional views progressive ophthalmic lenses according to alternative embodiments of the invention.
DETAILED DESCRIPTION
According to FIG. 1 a , an ophthalmic lens 10 consists of an intermediate medium 1 , which is limited by an anterior face 2 and by a posterior face 3 . The medium 1 is transparent and can be made of an inorganic or organic material, characterized by a refractive index value. The optical characteristics of the lens 10 result from a combination of this refractive index value with the shapes of the faces 2 and 3 . In a known manner, a lens ready to be fitted into a spectacle frame is obtained by trimming the lens 10 along outline C that corresponds to the shape of the frame ( FIG. 1 b ).
Each face 2 , 3 of the lens can be defined geometrically by the mean sphere and cylinder values for each point on this face. These mean sphere and cylinder values are well known to a person skilled in the art and it will be possible to refer to published documents in order to obtain their mathematical expressions. In a simplified manner, the mean sphere, denoted S in FIGS. 5 a , 5 b and expressed in diopters, corresponds to the mean curvature of a face at a point thereon. The cylinder corresponds to a difference between the two curvatures, denoted respectively C 1 and C 2 , of a toroid tangential to the face of the lens at a given point thereon. For sake of clarity, the mean sphere is denoted in this document only by sphere.
The lens 10 is obtained from a semifinished lens, denoted hereinafter by semifinished, of which the anterior face possesses a definite shape. In other words, the values of the sphere and cylinder of the anterior face 2 are not modified when the lens 10 is subsequently produced from the semifinished. In the example that will be described in detail below, the lens 10 is obtained by machining the posterior face 3 of the semifinished, so as to give the latter values of the sphere and cylinder adapted so as to obtain a particular optical function.
FIGS. 2 a and 2 b are maps respectively of values of the sphere and cylinder of the anterior face 2 of the semifinished. This face is limited by a circular rim of the semifinished and each point thereon is referenced by two rectangular coordinates, denoted X and Y respectively and expressed in millimeters (mm). The lines indicated on FIG. 2 a are isosphere lines, which connect points on the face 2 corresponding to the same value for the sphere. This value is indicated in diopters for some of these lines. Similarly, the lines indicated in FIG. 2 b are isocylinder lines that connect points on the face 2 corresponding to the same value of the cylinder.
Three particular points, denoted CM, VL and VP respectively, are reference points on these maps. The point CM, called the fitting cross, is the point on the lens 10 that must be placed facing the center of the wearer's eye for which the lens 10 is intended. The point VL is the center of a zone of the lens used for distance vision. Similarly, the point VP is the center of a zone of the lens used for near vision. VL is located on a central vertical line of the face 2 passing through CM (corresponding to X=0) and VP is offset laterally (parallel to the X axis) in relation to CM and VL. The direction of lateral offset of VP is reversed between a right lens and a left lens. The lens 10 corresponding to the figures is a lens for the right eye. A line M, called the prime meridian line, connects the points VL, CM and VP. It corresponds to the scanning of the eye of the wearer when he or she successively observes objects situated in front of him or her at variable heights and distances.
Usually, and recalled here by way of a comparative reference, the posterior face 3 of the semifinished is subsequently machined according to the prescription of the wearer in order to obtain the lens 10 . The prescription indicates an optical power value, an addition value and an astigmatism value. The latter is composed, in a known manner, of a datum for the amplitude of the astigmatism and an angular datum, which locates the orientation of the corrective toroid parallel to the lens. Conventional machining gives the face 3 uniform sphere and cylinder values. In other words, the face 3 is not progressive. Variations in the optical power of the lens 10 , which include addition, and variations in astigmatism thus result only from the geometrical characteristics of the anterior face 2 of the lens.
FIGS. 3 a and 3 b illustrate the optical characteristics of a lens 10 of which the posterior face 3 has uniform sphere and cylinder values. For the example considered, the refractive index of the intermediate medium 1 of the lens 10 is 1.665. FIGS. 3 a and 3 b are maps respectively of optical power and astigmatism values of the lens 10 . Each direction of observation through the lens 10 is identified by means of two angular coordinates expressed in degrees: alpha measures the observation height in relation to a horizontal plane, and beta measures the rotation of the eye in this horizontal plane. The origin of this system of angular coordinates (alpha=0; beta=0) corresponds to the point CM on the lens 10 . The directions that correspond respectively to the points VL and VP are also indicated on these maps. The lines indicated in FIG. 3 a are isopower lines which connect the directions of observation through the lens 10 that correspond to the same optical power value. This value is indicated in diopters for some of these lines. For the example considered, the power of visual correction is 3.20 diopters in near vision (point VP) and the difference in optical power of the lens 10 between observation directions which correspond to the points VP and VL is 2.21 diopters (i.e. addition value). Similarly, the lines indicated in FIG. 3 b are isoastigmatism lines, which connect directions of observation through the lens 10 that correspond to the same value of astigmatism. It should be stated that the astigmatism values indicated in FIG. 3 b correspond to actual values from which the prescribed astigmatism value has been subtracted. For this reason, the values indicated are called resultant astigmatism values and they are almost zero for the observation directions which correspond to the points VL and VP. The residual resultant astigmatism value that is possibly present for these two observation directions is by its nature spherical.
According to the particular embodiment of the invention described here, the posterior face 3 of the semifinished is subsequently machined so as to give it a sphere and a cylinder that vary between different points in this face. Thus, contrary to the normal method of producing progressive lenses which has just been recalled, the posterior face 3 of the lens contributes to a variation in optical characteristics of the lens 10 which is obtained from the semifinished. FIGS. 4 a and 4 b correspond to FIGS. 2 a and 2 b respectively, for the posterior face 3 of the lens 10 . Thus, FIG. 4 a indicates the value of the sphere at each point on the posterior face 3 . Similarly, FIG. 4 b indicates the value of the cylinder at each point on the face 3 . The distance between the isosphere lines of FIG. 4 a (respectively isocylinder of FIG. 4 b ) that is greater than the distances visible in FIG. 2 a ( 2 b respectively), indicates that the posterior face 3 of the lens 10 has variations in sphere (respectively in cylinder) that are less than those of the anterior face 2 . For this reason, the face 3 can be machined using a relatively simple machine, which has in particular a reduced number of axes for the movement of the tool. Such a machine is less costly and easier to use. It can thus be installed in a large number of sites close to retail sales centers for lenses, or even in these centers.
FIG. 5 b illustrates the variations in sphere S and in curvatures C 1 , C 2 of the posterior face 3 along the prime meridian line M. The vertical axis locates the displacement along this line, measured in millimeters, and the horizontal axis locates the values of S, C 1 and C 2 , expressed in diopters. The sphere values indicated on this figure correspond to the actual sphere values of the face 3 , from which the sphere value corresponding to the optical power prescription (1.05 diopters in the example considered) has been subtracted. According to this figure, the posterior face 3 has values of sphere S that are substantially identical at the points VP and VL.
As a comparison with FIG. 5 b , FIG. 5 a illustrates variations of sphere S and curvatures C 1 , C 2 of the anterior face 2 along the prime meridian line M, for a lens corresponding to FIGS. 2 a and 2 b . The variations of sphere S and of curvatures C 1 , C 2 for the posterior face 3 are therefore very much smaller than the corresponding variations for the anterior face 2 .
As previously, the optical power and astigmatism of the lens 10 each results from the shapes of the two faces 2 and 3 and of the refractive index of the intermediate medium 1 . However, given that the face 3 also has variations of the sphere and cylinder, variations in optical power and astigmatism of the lens 10 result from the combination of the variations of sphere and cylinder of the two faces 2 and 3 . In other words, the variations of sphere and cylinder of the anterior face 2 , characterized by FIGS. 2 a and 2 b , create a first contribution to the variation of the optical power of the lens 10 that is present between various directions of observation through this lens. They also create a first contribution to the variation of astigmatism of the lens 10 that is present simultaneously between these observation directions. Similarly, the variations of sphere and cylinder of the posterior face 3 of the lens 10 , characterized by FIGS. 4 a and 4 b , create a second contribution to the variation of optical power of the lens 10 , present between the same observation directions, as well as the second contribution to the variation of astigmatism of the lens 10 present between these directions. The variation of optical power of the lens 10 results from the combination of the first and second contributions thereto. Similarly, variation of the astigmatism of the lens 10 results from a combination of the corresponding first and second contributions. To a first approximation, the variations of optical power and astigmatism of the lens 10 are each equal to the oriented sum (that is to say taking account of the local orientation of the cylinders of each of the contributions) of the respective contributions of the two faces 2 , 3 of the lens. Each contribution is evaluated by considering the sphere and cylinder values of the two faces 2 , 3 at the points of intersection of these by the light ray which comes from the observation direction considered and which passes through the center of rotation of the eye.
Given that variations of sphere and cylinder of the face 3 are generally smaller than those of the face 2 , the second contribution (due to the posterior face 3 ) to this variation of optical power of the lens 10 is less than the first contribution (due to the anterior face 2 ) to this variation of optical power, for most pairs of observation directions. Similarly, the second contribution (due to the posterior face 3 ) to the variation of astigmatism of the lens 10 is generally smaller than the first contribution (due to the anterior face 2 ) to this variation of astigmatism.
FIGS. 6 a and 6 b correspond respectively to FIGS. 3 a and 3 b , when the posterior face 3 of the lens 10 is machined so as to give it a shape that correspond to FIGS. 4 a and 4 b . On comparing 3 a and 6 a , it will be noted that the optical power values for the observation direction that correspond to the point VP are substantially identical (3.20 and 3.09 diopters for FIGS. 3 a and 6 a respectively). It is the same for the observation direction that corresponds to the point VL (0.99 and 1.00 diopters for FIGS. 3 a and 6 a respectively). In other words, the posterior face 3 of the lens 10 hardly makes any contribution to the addition of the lens. This addition (approximately 2.1 diopters) is therefore fixed almost only by the anterior face 2 , given that the sphere values of the posterior face 3 at the points VP and VL are practically equal to each other.
By superimposing FIGS. 3 b and 6 b , it becomes apparent that the astigmatism lines of each figure corresponding to values 0.50 to 1.25 diopters have a generally V-shape that is narrower in FIG. 6 b , on either side of the trace corresponding to the prime meridian line M at the height of the point VL. This means that the lens 10 which corresponds to FIGS. 6 a and 6 b has a narrower field of distance vision than that of the lens 10 corresponding to FIGS. 3 a and 3 b . On the other hand, the resultant astigmatism aberrations, present in the right-hand and left-hand parts of the lens 10 are reduced for the lens 10 that corresponds to FIGS. 6 a and 6 b , compared with the resultant astigmatism aberrations present in the lateral parts of the lens 10 corresponding to FIGS. 3 a and 3 b . Indeed, the maximum resultant astigmatism value visible in FIG. 6 b is of the order of 1.75 diopters, while that visible in FIG. 3 b is greater than 2.00 diopters. Moreover, the location of the observation direction for which the maximum astigmatism value is reached has been modified.
Machining the posterior face 3 of the lens according to the invention, that is to say by introducing variations of the sphere and cylinder of this face, has therefore made it possible to reduce the residual astigmatism present in the lateral parts of the lens. Simultaneously, the width of the distance field of vision has been reduced. Such a lens is therefore adapted to a wearer who mainly observes through a vertical central band of the lens. Such visual behavior consists mainly of turning the head rather than the eyes, in order to observe objects situated at the sides.
The invention therefore makes it possible to obtain a progressive lens having a reduced resultant astigmatism, adapted to a wearer who turns his head rather than his eyes, from a semifinished which corresponds to a wider distance field of vision, adapted to a wearer who turns his eyes rather than his head in order to see in the lateral parts of his field of vision. It should be understood that the invention also makes it possible to obtain, conversely, a progressive lens with a wider distance field of vision, adapted to a wearer who turns his head very little, from a semifinished corresponding to a small degree of resultant astigmatism and adapted to a wearer who turns his eyes very little. Lenses corresponding to each of the two types of wearer, namely a wearer who preferably turns his head and a wearer who preferably turns his eyes respectively, can therefore be obtained from semifinished of the same model. In other words, the invention makes it possible to obtain a lens of a given design from a semifinished of a different design. This change of design implemented subsequently makes it possible to adapt the progressive lens according to the behavior of the wearer without the need for a different semifinished model.
Generally, various measurements enabling the behavior of the wearer to be characterized can be taken. In particular, the use of the intermediate vision zone of the lens by a given wearer can be characterized. This zone is located between the distance vision zone and the near vision zone, and is centered on the prime meridian line. It is known that vertical scanning of the intermediate vision zone by the eye can require a certain time for the wearer to adapt. Machining of the posterior face 3 according to the invention also makes it possible to adapt the variation in optical power of the lens in the intermediate vision zone, according to the behavior of the wearer. As an illustration, FIG. 7 a represents variations in optical power (noted P in the figure) when the direction of observation varies along the prime meridian line of a lens according to FIGS. 3 a and 3 b . In the same way, FIG. 7 b illustrates variations in optical power of a lens corresponding to FIGS. 6 a and 6 b . The form of the variation curve of the optical power between the observation directions passing through the points VL and VP of the lens differ between FIGS. 7 a and 7 b , in particular around the direction passing through the point VP. A lens according to FIG. 7 b is more suitable than a lens according to FIG. 7 a for a wearer who moves his eyes vertically rather than his head while reading.
FIGS. 7 a and 7 b additionally indicate the variations in tangential curvature (denoted Tang.) and sagittal curvature (denoted Sagit.) of the lens 10 . These can also be adapted according to the wearer.
Other characteristics of progressive lenses can then be adapted by machining the posterior faces of the lenses. In particular, the lateral offset of the point VP with respect to the point VL, and also the balance between two matched lenses can be modified in this way.
Although the invention has been described in detail within the context of the design of a progressive lens that is customized by machining the posterior face of the lens, it should be recalled that other methods can be used in order to obtain similar customization of the lens. Among these other methods, mention may be made of adaptation of the refractive index of a layer of active material incorporated in the lens 10 . FIGS. 8 a - 8 c illustrate lens structures according to which the layer of active material 4 is respectively on the side of the anterior face 2 of the lens 10 , on the side of the posterior face 3 , or contained within the thickness of the intermediate medium 1 . The layer 4 is substantially parallel to the faces 2 and 3 of the lens 10 . Such a layer is made of an active transparent material with a refractive index which can be modified in a separate step at each point thereof. For some known active materials, such a modification of the refractive index can be obtained by irradiation using a laser beam or a UV lamp. In this case, the anterior face of the lens 10 is again finally formed during production of the semifinished, and the posterior face can be machined according to uniform cylinder and sphere values. Modulations of the refractive index of the layer 4 are then created subsequently during a specific step, by varying the intensity and/or duration of irradiation received between two different points of the layer 4 . These modulations achieve customization of design of the progressive lens according to the behavioral characteristics of the wearer that have been measured.
Yet another method consists in producing the intermediate medium 1 that is itself made of active material.
Finally, the various methods for customizing a progressive lens can be combined together. Similarly, the physical parameter of the lens on which one of these methods is based can be used to give the lens the corrective power that corresponds to the prescription, while the physical parameter of another of these methods can be used for customizing the design of the progressive lens according to the behavioral characteristics of the wearer.
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The invention relates to a progressive ophthalmic lens and to a method of producing one such lens. Variations in the optical power and the astigmatism of a progressive ophthalmic lens ( 10 ) result from (i) spherical and cylindrical variations in the anterior face ( 2 ) of the lens and (ii) variations in another physical unit of the lens. In this way, it is possible to customise the design of the progressive lens as a function of at least one behavioural characteristic of the lens wearer. Said customisation can be repeated by modulating the values of the physical unit between the different points of the lens. As a result, progressive lenses with different designs can be obtained from identical semi-finished lenses. The physical unit can comprise the sphere and the cylinder of the posterior face of the lens ( 3 ).
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This is a Rule 53b Continuation application of Ser. No. 10/194,687 filed Jul. 24, 2002 now U.S. Pat. No. 6,804,791 which is a Rule 53b Divisional application of Ser. No. 09/583,168 filed May 30, 2000 (issued on Mar. 18, 2003, U.S. Pat. No. 6,535,985), which is a Rule 53b Continuation application of Ser. No. 08/283,165 filed Aug. 3, 1994 which is abandoned, which is a Rule 62 Continuation application of Ser. No. 07/671,929 filed Mar. 20, 1991 which is abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data processing apparatus provided with a display device.
2. Description of the Prior Art
Among compact and lightweight microcomputers, portable type computers powered by batteries are now used extensively. Particularly, one of them known as a note-size computer is lighter in weight and smaller in size, yet provides equal capabilities to those of a desktop or laptop computer. The note-size computer powered by batteries is handy for use in a place where a power supply facility is rarely available, e.g. a meeting room or a lecture hall.
However, the disadvantage of such handy use is that the life of batteries is short and limited. When used to record a business meeting or a college lecture, the service duration of such a note-size computer with fully charged batteries is preferably 10 hours nonstop; more preferably, 20 to 30 hours. If possible, more than 100 hours-a standard of hand calculators-is most desired.
So far, the service operation of a commercially available note-size computer lasts 2 to 3 hours at best. This results in battery runout in the middle of a meeting or college lecture causing an interruption during input work. As a result, troublesome replacement of batteries with new ones will be needed at considerable frequency.
Such a drawback of the note-size computer tends to offset the portability in spite of its light weight and compactness.
It is understood that known pocket-type portable data processing apparatuses including hand calculators and electronic notebooks are much slower in processing speeds than common microcomputers and thus, exhibit less power requirements. They are capable of servicing for years with the use of a common primary cell(s) of which life will thus be no matter of concern. The note-size computer, however, has a processing speed as high as that of a desktop computer and consumes a considerable amount of electric energy-namely, 10 to 1000 times the power consumption of any pocket-type portable data processing apparatus. Even with the application of up-to-date high quality rechargeable batteries, the serving period will be 2 to 3 hours at maximum. This is far from a desired duration demanded by the users. For the purpose of compensating the short life of batteries, a number of techniques for energy saving have been developed and some are now in practical use.
The most well known technique will now be explained.
A “resume” function is widely used in a common note-size computer. It works in a manner that when no input action continues for a given period of time, the data needed for restarting the computer with corresponding information is saved in a nonvolatile IC memory and then, a CPU and a display are systematically turned off. For restart, a power switch is closed and the data stored in the IC memory is instantly retrieved for display of the preceding data provided before disconnection of the power supply. This technique is effective for extension of the battery servicing time and suitable in practical use.
However, a specified duration, e.g. 5 minutes, of no key entry results in de-energization of the entire system of the computer and thus, disappearance of display data. Accordingly, the operator loses information and his input action is interrupted. For reviewing the display data or continuing the input action, the power switch has to be turned on each time. This procedure is a nuisance for the operator. The resume technique is advantageous in saving energy of battery power but very disadvantageous in operability of the note-size computer.
More specifically, the foregoing technique incorporates as a means for energy saving a system which de-energizes all the components including a processing circuit and a display circuit. The operator is thus requested to turn on the power switch of the computer at considerable frequencies during intermittent data input action because each no data entry duration of a given length triggers automatic disconnection of the switch. In particular, the data input operation with a note-size computer is commonly intermittent and thus, the foregoing disadvantage will be much emphasized.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved data processing apparatus capable of substantially reducing power consumption while performing required data processing operations.
A data processing apparatus according to the present invention comprises: a data input unit for input of external data; a first processing unit for processing the data inputted through the data input unit; a second processing unit for processing the data inputted through the data input unit and/or an output data of the first processing unit; and a display unit for displaying an output data of the first and/or second processing units, wherein the display unit has a memory function for maintaining a display state without being energized, and the first processing unit has a means for actuating the second processing unit according to a timing or a kind of the input data.
For example, when no data entry continues, the second processing unit or the display unit is inactivated or decreased in clock rate thus diminishing power consumption. Also, the present invention allows the display of data to remain intact. Upon occurrence an input data, the first processing unit activates the second processing unit to process the data. Thus, the operator can prosecute his job without knowledge of an interrupted de-energization. As a result, an appreciable degree of energy saving is guaranteed without affecting the operability and thus, the service life of batteries will largely be increased.
In another aspect, the first processing unit may activate the second processing unit according to the kind of the input data. When the input data is such a data that requires a processing in the second processing unit, the first processing unit activates the second processing unit. The second processing unit, after completing a required operation or processing, may enter an inactive state by itself or may be forced into the inactive state by the first processing unit. Thus, the power consumption will be reduced to a considerable rate without affecting the operability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention;
FIG. 2 is a timing chart;
FIG. 3 is a view showing the arrangement of a display unit;
FIG. 4 is a cross sectional view explaining the operating principle of the display unit;
FIGS. 5 ( a ) and 5 ( b ) are views showing displayed images on the display unit;
FIG. 6 is a flow chart;
FIG. 7- a is a block diagram showing an arrangement of components;
FIG. 7- b is a block diagram showing another arrangement;
FIG. 7- c is a block diagram showing a further arrangement;
FIG. 7- d is a flow chart;
FIG. 8 ( a ) through 8 ( f ) illustrate the operating principle of a reflective device with the use of different reflecting plates;
FIG. 9 is a block diagram showing a second embodiment of the present invention;
FIG. 10- a is a block diagram associated with a first processing unit;
FIG. 10- b is a block diagram associated with a second processing unit;
FIGS. 11- a and 11 - b are flow charts:
FIG. 12 is a timing chart;
FIG. 13 is a view explaining the representation of a cursor;
FIG. 14 is a view showing a sequence of translation procedures;
FIG. 15 is a view explaining data insertion;
FIG. 16 is a view explaining a copy mode;
FIG. 17 is a block diagram showing a modification of the second embodiment;
FIG. 18 is a block diagram showing a third embodiment of the present invention;
FIG. 19 is a flow chart;
FIG. 20 is a block diagram showing a fourth embodiment of the present invention;
FIG. 21 is a timing chart of the fourth embodiment;
FIG. 22 is a block diagram showing a fifth embodiment of the present invention;
FIG. 23 is a timing chart of the fifth embodiment;
FIG. 24 is a block diagram showing a data input unit; and
FIG. 25 is a block diagram showing a combination of the first and second processing units.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described referring to the accompanying drawings.
Embodiment 1
FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention.
The data processing apparatus comprises a data input unit 3 , a first processing block 1 , a second processing block 98 , and a display block 99 .
In operation, a data input which is fed to the data input unit 3 of the data processing apparatus by means of key entry with a key-board or communications interface is transferred to the first processing block 1 in which a first processor 4 examines which key in key entry is pressed or what sorts of data are input from the outside and determines the subsequent procedure according to the information from a first memory 5 .
If no input is supplied to the data input unit 3 throughout a given period of time as shown in FIG. 2- a and also, the action of a second processor 7 has been completed, the feeding of clock signals to the second processor 7 and a display circuit 8 is halted by an interruption controller 6 and/or a process of energy saving is systematically executed.
The energy saving process will now be described referring to FIG. 2 .
As shown in FIG. 2- a , a data input entered at t 1 using an n-th key of the key-board is transferred from the data input unit 3 to the first processor 4 .
The first processor 4 when examining the data input and determining that further processing at the second processor 7 is needed delivers a start instruction via the interruption controller 6 and a start instruction line 80 to the second processor 7 which thus commences receiving the data input from the first processor 4 . The second processor 7 starts processing the data input when t=t 3 as shown in FIG. 2- c and upon finishing, sends an end signal to the first processor 4 . In turn, either the first processor 4 or the interruption controller 6 delivers a stop instruction to the second processor 4 via the startup instruction line 80 . Accordingly, the second processor 4 transfers finally processed data from its RAM memory or register to the second memory for temporary storage and then, stops processing action when t=t 5 as shown in FIG. 2- c or enters into an energy saving mode where a consuming power is sharply attenuated. After t 5 where the actuation of the second processor 7 is ceased, the data remains held in the second memory 9 due to its nonvolatile properties or due to the action of a backup battery. If display change is needed, the second processor 4 sends a display change signal to the first processor 4 . The first processor 4 then delivers a display start instruction via a display start instruction line 81 to the display circuit 8 for starting actuation. When t=t 4 as shown in FIG. 2- d , the command signal is transmitted to the display circuit 8 which in turn retrieves the data of a previous display text from a video memory 82 or the second memory 9 and displays a new image corresponding to the display change signal and data from the second processor 7 . When t=t 6 , the display circuit 8 sends its own instruction or an end signal via the interruption controller 6 to the first processor 4 and upon receiving an instruction from the first processor 4 , stops or diminishes clock generation to enter a display energy saving mode. Thereafter, the power consumption of the display circuit 8 will largely be declined as illustrated after t 6 in FIG. 2- d.
After t 6 , the display circuit 8 stays fully or nearly inactivated but a display 2 which is substantially consisted of memory retainable devices, e.g. ferroelectric liquid crystal devices, continues to hold the display image. The arrangement of the display 2 will now be described. The display 2 , e.g. a simple matrix type liquid crystal display, contains a matrix of electrodes in which horizontal drive lines 13 and vertical drive lines 14 coupled to a horizontal driver 11 and a vertical driver 12 respectively intersect each other, as best shown in FIG. 3 . FIG. 4 illustrates a pixel of the display 2 in action with a voltage being applied.
In each pixel, a ferroelectric liquid crystal 17 is energized by the two, horizontal and vertical lines 13 , 14 which serve as electrodes and are provided on glass plates 15 and 16 respectively.
More particularly, FIG. 4- a shows a state where light is transmitted through. When a signal is given, the ferroelectric liquid crystal 17 changes its crystalline orientation and acts as a polarizer in which an angle of polarization is altered, thus allowing the light to pass through.
When a voltage is applied in the reverse direction, the ferroelectric liquid crystal 17 causes the angle of polarization to turn 90 degrees and inhibits the passage of light with polarization effects, as shown in FIG. 4- b . The ferroelectric liquid crystal 17 also has a memory retainable effect as being capable of remaining unchanged in the crystalline orientation after the supply of voltage is stopped, as shown in FIG. 4- c . Accordingly, throughout a duration from t=t 6 to t=t 14 , explained later, the display remains intact without any operation of the display circuit 8 . While the energy saving mode is involved after t 6 , both the data input unit 3 and the first processor 4 are only in action.
The first processor 4 performs only conversion of key entry to letter code or the like. In general, the key entry is conducted by a human operator and executed some tens times in a second at best. The speed of data entry by a human operator is 100 times or more slower than the processing speed of any microcomputer. Hence, the processing speed of the first processor 4 may be as low as that of a known hand calculator and the power consumption will be decreased to hundredths or thousandths of one watt as compared with that of a main CPU in a desktop computer. As shown in FIG. 2- b , the first processor 4 continues operating while a power switch 20 of the data processing unit 1 is closed. However, it consumes a lesser amount of energy and thus, the power consumption of the apparatus will be low.
When n+1-th key entry is made at t 11 , the first processor 4 examines the data of the entry at t 12 and if necessary, delivers a start instruction via the interruption controller 6 or directly to the second processor 7 for actuation. Upon receiving the start instruction, the second processor 7 starts processing again with the use of clock signals so that the data stored in the second memory 9 , i.e. data at a previous stop when t=t 5 , such as memory data, register information, or display data, is read out and the CPU environment when t=t 5 can fully be restored. When t=t 13 , the data in the first processor 4 is transferred to the second processor 7 for reprocessing. The second processor 7 is arranged to operate at high speeds and its power consumption is as high as that of a desk-top computer. If the second processor 7 is continuously activated, the life of batteries will be shortened as well as in a known note computer. The present invention however provides a series of energy saving mode actions during the operation, whereby the energy consumption will be minimized.
The energy saving mode is advantageous. For example, the duration required for processing the data of a word processing software is commonly less than 1 ms while the key entry by a human operator takes several tens of milliseconds at maximum. Hence, although the peak of energy consumption during a period from t 13 to t 15 is fairly high in the second processor 7 as shown in FIG. 2- c , the average is not more than a tenth or a hundredth of the peak value. It is now understood that the energy saving mode allows lower power consumption.
When t=t 14 , the second processor 7 sends a desired portion of the display data to the display 2 . Before t 14 , the display 2 continues to display the text altered at t 6 due to the memory effects of the ferroelectric liquid crystal 17 while the display circuit 8 remains inactivated. The desired data given through the key entry at t 11 is written at t 14 for regional replacement. The replacement of one to several lines of display text is executed by means of voltage application to corresponding numbers of the horizontal and vertical drive lines 13 and 14 . This procedure requires a shorter period of processing time and thus, consumes a lesser amount of energy as compared with replacement of the entire display text.
The second processor 7 then stops operation when t=t 15 and enters into the energy saving mode again as shown in FIG. 2- c.
At the moment when the operation of the second processor 7 has been finished before t 15 or when a stop instruction from the first processor 4 is received, the second processor 7 saves the latest data in the second memory 9 .
When t=t 14 , the second processor 7 stops operation or diminishes an operating speed and enters into the energy saving mode.
When the input data is fed at short intervals, e.g. at t 21 , t 31 , t 41 , and t 51 , through a series of key entry actions or from a communications port, the second processor 7 shifts to the energy saving mode at t 23 , t 33 , and t 43 as shown in FIG. 2- c . If the first processor 4 detects that the interval between data inputs is shorter than a predetermined time, it delivers an energy saving mode stop instruction to the second processor 7 which thus remains activated without forced de-energization and no longer enters into the energy saving mode. The energy saving mode is called back only when the interval between two data inputs becomes sufficiently long.
Also, when the first processor 4 detects that the key entry is absent during a given length of time, it actuates to disconnect the power supply to primary components including the first processor 4 for shift to a power supply stop mode. The memory data is being saved by the back-up battery while the power supply is fully disconnected.
Before disconnection of the power supply, the first processor 4 however sends a power supply stop display instruction directly or via the second processor 7 to the display circuit 8 for display of an “OFF” sign 21 shown in FIG. 5- b and then, enters into the power supply stop mode. The OFF sign 21 remains displayed due to the memory effects of the display 2 after the power supply is disconnected, thus allowing the operator to distinguish the power supply stop mode from the energy saving mode.
In the energy saving mode, the operation can be started again by key entry action and thus, the operator will perceive no interruption in the processing action.
In the power supply stop mode, the OFF sign 21 is displayed and the operator can restart the operation in succession with the previous data retrieved from the second memory 9 by the second processor 9 when the power switch 20 is turned on. This procedure is similar to that in the conventional “resume” mode.
The foregoing operation will now be described in more detail referring to a flow chart of FIG. 6 . When the power switch 20 is turned on at Step 101 , the first processor 4 starts activating at Step 102 . The input data given by key entry is transferred from the data input unit 3 to the first processor 4 at Step 103 . At Step 104 , it is examined whether the duration of no-data entry lasts for a predetermined time or not. If the no-data entry duration t is greater than the predetermined time, the procedure moves to Step 105 where the actuation of the second processor 7 is examined. If the second processor 7 is in action, the procedure moves back to Step 103 . If not, the entire apparatus is de-energized, at Step 106 , and stops actuating at Step 107 before restarting with Step 101 where the power supply switch 20 is closed.
If the no-data entry duration t is greater than the predetermined time, but is as short as a few minutes, the procedure is shifted from Step 104 to Step 108 . When the processing frequency in the first and second processors 4 and 7 is low, the procedure moves from Step 108 to Step 109 where a back light is turned off for energy saving.
If the no-data entry duration t is not greater than the predetermined time, the operation in the first processor 4 is prosecuted at Step 110 . Also, it is examined at Step 110 a whether the data of text is kept displayed throughout a considerable length of time or not. If too long, refreshing action of the data display is executed at Step 110 b for prevention of an image burn on the screen. At Step 110 c , the processing frequency in the second processor 7 is examined and if it is high, the second processor 7 is kept in action at Step 110 d . If the processing frequency is low, the procedure moves to Step 111 . When it is determined at Step 111 that no further processing in the second processor 7 is needed, the procedure returns to Step 103 .
When further processing in the second processor 7 is required, the procedure moves from Step 111 to Step 112 a where the actuation of the second processor 7 is examined. If the second processor 7 is not in action, a start instruction is fed at Step 112 b to the second processor 7 which is in turn activated at Step 113 by the first processor 4 and the interruption controller 6 . The second processor 7 then starts processing action at Step 114 . If it is determined at Step 115 that a change in the text of display is needed, the procedure moves to Step 116 a where a display change instruction is supplied to both the interruption controller 6 and the first processor 4 . Then, the interruption controller 6 delivers a display energizing instruction to the display block 99 at Step 116 b . The display circuit 8 is activated at Step 116 c and the display change on the display 2 including the replacement of a regional data with a desired data is carried out at Step 117 . After the display change is checked at Step 118 , a display change completion signal is sent to the first processor 4 at Step 117 a . When the display change completion signal is accepted at Step 117 b , the display 2 is turned off at Step 119 .
If no change in the display text is needed, the procedure moves from Step 115 to Step 120 where the completion of the processing in the second processor 7 is examined. If yes, a processing completion signal is released at Step 120 a . As a result, the second processor 7 stops operation at Step 121 upon receiving a stop signal produced at Step 120 b and the procedure returns back to Step 103 .
FIGS. 7- a and 7 - b are block diagrams of a note-size computer according to the first embodiment of the present invention.
As shown in FIG. 7- a , a data input block 97 comprises a keyboard 201 , a communication port 51 with RS232C, and a floppy disk controller 202 . Also, a hard disk unit 203 is provided separately. A first processing block 1 is mainly consisted of a first processor 4 . A second processing block 98 contains a second processor 7 which is a CPU arranged for shift to and back from the energy saving mode upon stopping and feeding of a clock signal respectively and is coupled to a bus line 210 . Also, a ROM 204 for start action, a second memory 9 of DRAM, and a backup RAM 205 which is an SRAM for storage of individual data of returning from the resume mode are coupled to the bus line 210 . Both ends of the bus line 210 are connected to the first processor 4 and a display block 99 respectively. The display block 99 has a graphic controller 206 and a liquid crystal controller driver 207 arranged in a display circuit. There are also provided a video RAM 209 and a liquid crystal display 208 . For energy saving operation, corresponding components only in the arrangement are activated while the remaining components are de-energized. This energy saving technique is illustrated in more detail in Table 1. In general, input operation for e.g. word processing involves an intermittent action of keyboard entry. Hence, the power supply is connected to every component except the communications I/O unit. While a clock signal is fed to the first processing block 1 , no clock signals are supplied to the second processing block 98 and the display block 99 . Power is thus consumed only in the first processing block 1 . If necessary, the second block 98 and/or the display block 99 are activated within a short period of time. If more frequent operations are needed, the second processing block 98 is kept activated for acceleration of processing speeds.
When the key entry is absent for a given time, the second processing block 98 is disconnected and simultaneously, its processing data is stored in a backup memory for retrieval in response to the next key entry.
FIG. 7- b is similar to FIG., 7 - a , except that the first processor 4 having a lower clock frequency is used as a “monitor” for the total system and the processing will be executed by the second processor 7 having a higher clock frequency. The first processor 4 is adapted for operating an event processing method by which the second processor 7 is activated for processing action corresponding to data of the keyboard entry. The second processor 7 stops operation for the purpose of energy saving when the processing action is finished and remains inactivated until another key entry commences. The display block 99 starts operating in response to a display signal from the second processor 7 and stops automatically after completion of display. This procedure can be executed with a common operating system similar to any known operating system, thus ensuring high software compatibility. For example, MS-DOS is designed to run with the use of one complete CPU. Hence, the energy saving effect will hardly be expected during operation with conventional application software programs. It is then a good idea that a specific operating system and a corresponding word processing software which are installed in two CPUs are provided in addition to the conventional operating system. Accordingly, a word processing job can be performed using the specific software with the operating system of the present invention and thus, the power consumption will be reduced to less than a tenth or hundredth. Also, general purpose software programs can work with the conventional operating system-although the energy saving effect will be diminished. It would be understood that about 80% of the job on a note-size computer is word processing and the foregoing arrangement can contribute to the energy saving.
FIG. 7- c is a block diagram of another example according to the first embodiment and FIG. 7- d is a flow chart showing a procedure with the use of a conventional operating system such as MS-DOS. The second processor 7 is a CPU capable of holding data from its register and internal RAM during actuation of no clock or de-energization. When key entry is made at Step 251 , a keyboard code signal from the keyboard 201 is transferred by the first processor 4 to a start device 221 which remains activated, at Step 252 . At Step 253 , the start device 221 delivers a clock signal to a main processor 222 which is de-energized. Both of the register 223 and the internal RAM 224 are coupled to a backup source and thus, start operating upon receipt of the clock signal. At Step 254 , the main processor 222 starts the program which has been on stand-by for key entry. The program is then processed for e.g. word processing according to data of the key entry, at Step 255 . At Step 257 , a display instruction is released for replacement of display text if required at Step 256 . At Step 258 , the graphic controller 206 is activated. The data in the video RAM 209 is thus rewritten at Step 259 . After the liquid crystal controller driver 207 is activated at Step 261 , a desired change in the display text is made on the liquid crystal display 208 formed of ferroelectric liquid crystal. Then, the video RAM 209 is backup energized at Step 262 and the display block 99 is de-energized, at Step 263 , thus entering into the energy saving mode. When the processing in the second processor 7 is completed at Step 270 , the program stops and moves into a “keyboard entry stand-by” stage at Step 271 . At Step 272 , the data required for reactuation of the register 223 and the internal RAM 234 is saved and the second memory 9 is backup energized before a clock in the CPU is stopped. Then, the second processor 7 stops operation, at Step 273 , thus entering into the energy saving mode. As the start device 221 remains activated, the second processor 7 stays on stand-by for input through keyboard entry at Step 251 or from the communications port 5 . As understood, the start device 221 only is kept activated in the second processing block 98 . The CPU shown in FIG. 7- c provides backup of registers with its clock unactuated and ensures instant return to operation upon actuation of the clock. As a single unit of the CPU is commonly activated, a conventional operating system can be used with equal success. Also, existing software programs including word processing programs can be processed with less assignment and thus, private data stock will be permitted for optimum use. Consequently, it would be apparent that this method is eligible. In addition, the consumption of electric energy will be much decreased using a technique of direct control of the first processor 1 on display text change which will be described later with a second embodiment of the present invention. As understood, the resume mode allows most components to remain de-energized when no keyboard entry lasts for a long time.
As a ferroelectric liquid crystal material has a memory effect, permanent memory results known as protracted metastable phenomenon will appear when the same text is displayed for a longer time. For prevention of such phenomenon, a display change instruction is given to the first processor 4 and the power switch 20 upon detection with the timer 22 that the display duration exceeds a predetermined time in the energy saving mode or power supply stop mode. Accordingly, the display circuit 8 actuates the display 2 to change the whole or a part of the display text, whereby permanent memory drawbacks will be eliminated.
If it is happened that the persistence of such permanent memory effects allows no change in the display text on the display 2 , the crystalline orientation of liquid crystal is realigned by heating up the display 2 with a heater 24 triggered by a display reset switch 23 . Then, arbitrary change in the display text on the display 2 will be possible.
Energy saving can be promoted by stopping the clock in the second processor 7 during the energy saving mode. When more or full energy saving is wanted, the power supply to the second processor 7 or the display circuit 8 is disconnected by the interruption controller 6 .
As understood, the power supply stop mode requires a minimum of power consumption for backup of the second memory 9 .
As shown in FIG. 1 , the back light 25 is turned off when the power source is a battery and a reflective device 27 is activated by a reflection circuit 26 for display with a reflection mode.
The reflective device 27 is composed of a film of ferroelectric liquid crystal which provides a transparent mode for transmission of light, as shown in FIG. 8- a , and an opaque mode for reflection as shown in FIG. 8- b , for alternative action. Incoming light 32 is reflected on the reflective device 27 and runs back as reflected light 33 . At this time, polarization is also effected by the polarizers in the display 2 and the reflective device 27 , whereby the number of components will be reduced. Also, a film-form electrochromic display device may be used for providing a transmission mode and a white diffusion screen mode in which it appears like a sheet of white paper.
The reflective device 27 may be of fixed type, as shown in FIGS. 8- c and 8 - d , comprising a light transmitting layer composed of low refraction transmitting regions 28 and high refraction transmitting regions 29 and a reflecting layer 31 having apertures 30 therein.
As shown in FIG. 8- c , light emitted from the back light 25 enters the high refraction transmitting regions 29 where it is fully reflected on the interface between the high and low refraction transmitting regions 29 , 28 and passes across the apertures 31 to a polarizer plate 35 . The polarized light is then transmitted to a liquid crystal layer 17 for producing optical display with outwardly emitted light.
During the reflection mode in battery operation, outside light 32 passes the liquid crystal layer 17 and is reflected by the reflecting layer 31 formed by vapor deposition of aluminum and reflected light 33 runs across the liquid crystal layer 17 again for providing optical display.
The reflective device 27 requires no external drive circuit, thus contributing to the simple arrangement of a total system. It is known that such a combination of high and low refraction transmitting regions is easily fabricated by a fused salt immersion method which is commonly used for making refraction distributed lenses.
Although such a transmission/reflection combination type liquid crystal display is disadvantageous in the quality of a display image as compared with a transmission or reflection speciality type liquid crystal display, the foregoing switching between transmission and reflection allows display of as good an image as of the speciality type display in both the transmission and reflection modes. This technique is thus suited to two-source, battery and AC application.
When the external power source is connected, the back light 25 is lit upon receiving an instruction from the first processor 4 which also delivers a transmission instruction to the reflection circuit 26 and thus, the reflective device 27 becomes transparent simultaneously. Accordingly, transmitting light can illuminate the display as shown in FIG. 8- a.
When the battery is connected, the first processor 4 delivers a reflection signal to the reflection circuit 26 and the reflective device 27 becomes opaque to cause reflection and diffusion. As a result, the display is made by reflected outside light as shown in FIG. 8- b while an amount of electric energy required for actuation of the back light 25 is saved.
Also, the same result as shown in FIGS. 8- c and 8 - d may be provided with the use of a transmitting reflective plate 34 which is formed of a metal plate, e.g. of aluminum, having a multiplicity of tapered round apertures therein, as illustrated in FIGS. 8- e and 8 - f.
As set forth above, the CPU in this arrangement provides intermittent actuation in response to the intermittent key entry and the average power consumption of the apparatus will be declined to an appreciable rate.
Also, the text remains on display during the operation and thus, the operator can perceive no sign of abnormality when the processing unit is inactivated. More particularly, a great degree of energy saving will be ensured without affecting the operability.
More particularly, each key entry action takes several tens of milliseconds while the average of CPU processing durations in word processing is about tens to hundreds of microseconds. Hence, the CPU is activated 1/100 to 1/1000 of the key entry action time for accomplishing the task and its energy consumption will thus be reduced in proportion. However, while the energy consumption of the CPU is reduced to 1/1000, 1/10 to 1/20 of the overall consumption remains intact because the display unit consumes about 10 to 20%, namely 0.5 to 1 W, of the entire power requirement. According to the present invention, the display unit employs a memory effect display device provided with e.g. ferroelectric liquid crystal and thus, its power consumption will be minimized through intermittent activation as well as the CPU.
As the result, the overall power consumption during mainly key entry operation for e.g. word processing will be reduced to 1/100 to 1/1000.
Embodiment 2
FIG. 9 is a block diagram showing a second embodiment of the present invention.
In the second embodiment, the first processor 4 is improved in the operational capability and the second processor 7 of which energy requirement is relatively great is reduced in the frequency of actuation so that energy saving can be encouraged.
As shown in FIG. 9 , the arrangement of the second embodiment is distinguished from that of the first embodiment by having a signal line 97 for transmission of a display instruction signal from the first processing block 1 to the display block 99 . In operation, the first processor 4 of the first processing block 1 delivers a display change signal to the display circuit 8 of the display block 99 for change of the display text on the display 2 . As understood, the second processor 7 delivers such a display change signal to the display circuit 8 according to the first embodiment.
FIG. 10- a is a block diagram showing in more detail the connection of the first processor 4 , in which the first memory 5 comprises a first font ROM 40 for storage of dot patterns of alphabet and Japanese character fonts or the like in a ROM, an image memory 41 , and a general memory 42 .
As shown in FIG. 10 b , the second memory 9 may contain a second font ROM 43 which serves as a font memory.
In operation, a series of simple actions for display text change can be executed using the first processor 4 . Character codes are produced in response to the key entry and font patterns corresponding to the character codes are read from the first 40 or second font memory 43 for display on the display 2 after passing the display circuit 8 . The second memory 9 may also contain a second general memory 44 .
During input of a series of data characters which requires no large scale of processing, the first processor 4 having less energy requirement is actuated for operation of the display text change. If large scale of processing is needed, the second processor 7 is then utilized. Accordingly, the frequency of actuation of the second processor 7 is minimized and energy saving will be guaranteed. Also, as shown in FIG. 11 , the memory size of the first memory 5 can be decreased because of retrieval of font patterns from the second font ROM 43 of the second memory 9 .
The operation according to the second embodiment will now be described in more detail referring to flow charts of FIGS. 11- a and 11 - b . FIG. 11- a is substantially similar to FIG. 6 which shows a flow chart in the first embodiment.
A difference is that as the first processor 4 directly actuates the display circuit 8 , a step 130 and a display flow chart 131 are added. When the first processor 4 judges that the display is to be changed in Step 130 and that a desired data for replacement in the display text is simple enough to be processed by the first processor 4 at Step 111 , the procedure moves to the display flow chart 131 . The display flow chart 131 will now be described briefly. It starts with Step 132 where the display block 99 is activated. At Step 133 , the display text is changed and the change is examined at Step 133 . After the confirmation of the completion of the text change at Step 134 , the display block 99 is de-energized at Step 135 and the procedure returns back to Step 103 for stand-by for succeeding data input. FIG. 11- b illustrates the step 133 in more detail. After the display block 99 is activated, at Step 132 , by a start instruction from the first processing block 1 , the movement of a cursor with no restriction is examined at Step 140 . If yes, data input throughout the cursor movement is executed at Step 141 . If not, it is then examined whether the desired input area on the display 2 is occupied by existing data or not at Step 142 . This procedure can be carried out by reading the data in the image memory 41 with the first processor 4 . If no, partial text replacement with desired data is executed at Step 143 . If yes, the procedure moves to Step 144 where the existing data in the input area of the display block 99 is checked using the image memory 41 and examined whether it is necessarily associated or not with the desired data to be input. If no, overwriting of the desired data is executed at Step 143 . If yes, the existing data is retrieved from the image memory 41 or read from the second font ROM 9 and coupled with the desired data for composition, at Step 145 . At Step 146 , it is examined whether a black/white inversion mode is involved or not. If yes, the data is displayed in reverse color at Step 147 . If no, the text change with the composite data is carried out at Step 148 . Then, the completion of the text change is confirmed at Step 134 and the display block 99 is turned off at Step 99 .
For a more particular explanation, the processing action of corresponding components when the key entry is made is illustrated in FIG. 12 . When the key entry with “I” is conducted at t 1 as shown in FIG. 12- e , the first processor 4 shifts input data into a letter “I” code, reads a font pattern of the letter code from the first font ROM 40 shown in FIG. 10 , and actuates the display circuit for display of the letter “I” on the display 2 . With the memory effect display having ferroelectric crystal liquid, partial replacement in a character can be made. The partial replacement is feasible in two different manners; one for change dot by dot and the other for change of a vertical or horizontal line of dots at once. The dot-by-dot change is executed with less energy requirement but at a higher voltage, thus resulting in high cost. The line change has to be done in the group of dots at once even when one dot only is replaced but at relatively lower voltages. Both manners in this embodiment will now be explained.
When the horizontal and vertical drivers 11 , 12 shown in FIG. 3 accept higher voltages, it is possible to fill the dots forming the letter “I” one by one. Accordingly, the letter “I” can be displayed by having a font data of a corresponding character pattern supplied from the first processor 4 . However, ICs accepting such a high voltage are costly. It is thus desired for cost saving that the operating voltage is low. It is now understood that every data processing apparatus is preferably arranged, in view of capability of up-to-date semiconductors, for providing line-by-line text change operation.
It is also necessary that the first memory 5 of the first processor 4 carries at least data of one text line.
For Japanese characters, the one text line data is equal to 640×24 dots. The writing of the letter “I” thus involves replacement of 24 of 640-dot lines.
In operation, the previous data of a target line is retrieved from the image memory 41 of the first memory 5 and also, the pattern data of the letter “I” is read from the first font ROM 40 . Then, the two data are combined together to a composite data which is then fed to the display circuit 8 for rewriting of one text line on the display 2 . Simultaneously, the same data is stored into the image memory 41 . The input of “I” is now completed.
None of the first font ROM 40 and the image memory 41 is needed when the second font ROM 43 is employed for the same operation, which is capable of processing coded data. In particular, the same text line can be expressed with about 40 of 2-byte characters and thus, 40×2=80 bytes per line. Therefore, the first memory 5 may carry coded data of the entire screen image.
During the processing of data input “I” in either of the two foregoing manners, the second processor 7 provides no processing action as shown in FIG. 12- c.
Similarly, a series of key inputs are prosecuted by the first processor 4 , “space” at t 2 , “L” at t 3 , “i” at t 4 , “v” at t 5 , and “e” at t 6 . Although the first processor 4 is much slower in the processing speed than the second processor 7 , the replacement of one text line on display can be pursued at an acceptable speed with less energy consumption.
As shown in FIG. 12 , t 7 represents the key input of an instruction for processing a large amount of data, e.g. spelling check in word processing, translation from Japanese to English, conversion of Japanese characters into Chinese characters, or calculation of chart data.
When the first processor 4 determines that the processing at the second processor 7 is needed, the second processor 7 is turned on at t 71 . The start-up of the second processor 7 is the same as of Embodiment 1. As shown in FIG. 12- c , the second processor 7 upon being activated at t 71 returns to the original state prior to interruption and starts processing the data of text lines fed from the first processor 4 . As the processing is prosecuted, each character of changed text is displayed on the display 2 through the display circuit 8 as shown at t 72 in FIG. 12- d.
This procedure will now be explained in the form of data entry for translation from Japanese to English. After the letter k is input at t 1 , as shown in FIG. 12- f , and displayed on the screen, as shown in FIG. 12- h . Then, the letter a is input at t 2 and the display reads “ka” as shown in FIG. 12- h.
By then, the second processor 7 remains inactivated as shown in FIG. 12- c . When a key of translating conversion is pressed at t 7 , the second processor 7 starts processing at t 71 . Accordingly, the Japanese paragraph “kareha” is translated to “He is” in English. The resultant data is sent to the display circuit 8 for dot-by-dot replacement for display.
Now, the display reads “He is” as shown in FIG. 12- h . The dot-by-dot character replacement shown in FIG. 12- g requires less electric energy than the text line replacement shown in FIG. 12- d.
For the purpose of saving energy during the movement of the cursor, the black/white inversion or negative mode is used as shown in FIGS. 13- a and 13 - b . This however increases the power consumption in the line replacement. When a bar between the lines is used for display of the cursor as shown in FIGS. 13- c and 13 - d , the replacement of the full line is not needed and thus, energy saving will be expected. Also, the speed of processing is increased and the response will speed up during processing with the low speed first processor 4 . This advantage is equally undertaken in the dot-by-dot replacement.
As shown in FIG. 14- a , the movement of the cursor is expressed by the bar. For ease of viewing, the bar may be lit at intervals by means of control with the first processor 4 . When a key data input is given, a corresponding character is displayed in the reverse color as shown in FIG. 14- b . This technique will also reduce the energy consumption at least during the cursor movement.
FIGS. 14- a to 14 - g illustrate the steps of display corresponding to t 1 to t 7 . FIG. 14- h shows the conversion of the input text.
FIGS. 15- a to 15 - f shows the insertion of a word during dot-by-dot replacement. It is necessary with the use of the second font ROM 43 in the arrangement shown in FIG. 10 that the data of one text line is saved in the image memory 41 because the first font ROM 40 does not carry all the Chinese characters. When the cursor moves backward as shown in FIGS. 15 c and 15 - d , the letter n is called back from the image memory 41 . Accordingly, the data prior to insertion can be restored without the use of the second processor 7 or the second front ROM 43 as shown in FIG. 15- d.
FIGS. 16- a to 16 - g show the copy of a sentence “He is a man”. The procedure from FIG. 16- a to FIG. 16- f can be carried out with the first processor 4 . The step of FIG. 16- g involves an insertion action which is executed by the second processor 7 .
According to the second embodiment, most of the job which is processed by the second processor 7 in the first embodiment is executed by the low power consuming first processor 4 . Thereby, the average energy consumption will be much lower than that of the first embodiment.
The optimum of a job sharing ratio between the first and second processors 4 and 7 may vary depending on particulars of a program for e.g. word processing or chart calculation. Hence, a share of the first processor 4 in operation of a software program can be controlled by adjustment on the program so as to give an optimum balance between the energy consumption and the processing speed. Also, a video memory 82 may be provided in the display block 99 for connection via a connecting line 96 with the first processor 4 . This allows the data prior to replacement to be stored in the video memory 82 and thus, the image memory 41 shown in FIG. 10- a will be eliminated.
Embodiment 3
FIG. 18 is a block diagram showing a third embodiment of the present invention. The difference of the third embodiment from the first and second embodiments will now be described. As shown in FIG. 1 , the first embodiment has the display start instruction line 81 along which both a start instruction and a stop instruction are transferred from the first processing block 1 to the display block 99 while equal instructions are transferred by the start instruction line 80 from the same to the second processing block 98 .
The third embodiment contains no display start instruction line 81 to the display block 99 as shown in FIG. 18 . Also, the start instruction line 80 of the third embodiment allows only a start instruction but not a stop instruction to be transmitted from the first processing block 1 to the second processing block 98 .
The second processor 7 stops itself upon finishing the processing and enters into the energy saving mode. When the second processor 7 determines that the display change is needed, it delivers a display start instruction via a data line 84 to the display block 99 which is then activated. After the display change on the display 2 is completed, the display block 99 stops operation and enters into the display energy saving mode. This procedure will be explained in more detail using a flow chart of FIG. 19 . The flow chart is composed of a first processing step group 151 , a second processing step group 152 , and a third processing step group 153 . At first, the difference of this flow chart will be described in respect to the sequence from start to stop of the second processing block 98 .
There is no control flow from the second processing step group 152 of the second processing block 98 to the first processing step group 151 , unlike the flow chart of the first embodiment shown in FIG. 6 . More specifically, the first processor 4 delivers, at Step 112 , a start instruction to the second processor 7 which is then activated. This step is equal to that of the first embodiment. However, the second processor 7 is automatically inactivated at Step 121 , as compared with de-energization by an instruction from the first processor 4 in the first embodiment. At Step 103 , the second processor 7 is turned to a data input stand-by state.
The difference will further be described in respect to the sequence from start to stop of the display block 99 .
In the first embodiment, a display start instruction to the display block 99 is given by the second processor 7 after completion of display data processing. According to the third embodiment, the start instruction is delivered by the second processing block 98 to the display block 99 , at Step 115 a shown in FIG. 19 . Then, the display block 99 is activated at Step 116 and the display change is conducted at Step 117 . After the display change is examined at Step 118 , the display block 99 stops itself at Step 119 .
As understood, the third embodiment which is similar in the function to the first embodiment provides the self-controlled de-energization of both the second processing block 98 and the display block 99 .
Also, a start instruction to the display block 99 is given by the second processing block 98 . Accordingly, the task of the first processing block 1 is lessened, whereby the overall processing speed will be increased and the arrangement itself will be facilitated.
Embodiment 4
FIG. 20 is a block diagram showing a fourth embodiment of the present invention, in which an energy saving manner is disclosed with the use of an input/output port for communications with the outside. A data processing apparatus of the fourth embodiment incorporates an input/output unit 50 mounted in its data input block 97 . The input/output unit 50 contains a communications port 51 and an external interface 52 . In operation, the unit 50 performs actions as shown in a timing chart of FIG. 21 which is similar to the timing chart of key data entry shown in FIG. 12 . When a series of inputs from the communications port are introduced at t 1 to t 74 , as shown in FIG. 21- a , the input/output unit 50 delivers corresponding signals to the first processing block 1 . The first processor 4 sends an input data at t 1 to the display circuit 8 which in turn actuates, as shown in FIG. 21 - d , for display of a data string as illustrated in FIG. 21- e . If an input at t 7 is bulky, the second processor 7 is activated at t 71 as shown in FIG. 21- c.
The second processor 7 delivers a start instruction at t 72 to the display circuit 8 which is then actuated for data replacement on the display 2 . If the input through the communications port is not bulky, it is processed in the first processor 4 or the input/output unit 50 while the second processor 7 remains inactivated. Accordingly,energy saving during the input and output action will be ensured.
Embodiment 5
FIG. 22 is a block diagram showing a fifth embodiment of the present invention, in which a solar battery 60 is added as an extra power source. The first processor 4 operates at low speeds thus consuming a small amount of electric energy. Accordingly, the apparatus can be powered by the solar battery 60 . While the action is almost equal to that of the first embodiment, the solar battery however stops power supply when the amount of incident light is decreased considerably. If the supply is stopped, it is shifted to from the source 61 . When no key entry is made throughout a length of time and no power supply from the solar battery 60 is fed, the source stop mode is called for as shown in FIG. 23- b . The first processor 4 saves processing data into the first memory 5 and then, stops operation. Thus, the power consumption will be reduced. When a power supply from the solar battery 60 is fed again at t 71 or another key input data is fed from the data input unit 3 , the first processor 4 starts actuating for performance of an equal action from t 72 .
One example of the start procedure of the first processor 4 will now be described. As shown in FIG. 24 , a key input device 62 of the data input unit 3 feeds a voltage from the battery 64 to a hold circuit 63 . The hold circuit 63 upon pressing of a key connects the power source to the first processor 4 for energization. Simultaneously, the key input device 62 transfers a key input data to the first processor 4 and processing will start.
Each key of the key input device 62 may have a couple of switches; one for power supply and the other for data entry.
Accordingly, as the solar battery is equipped, the power consumption will be minimized and the operating life of the apparatus will last much longer.
The solar battery 60 , which becomes inactive when no incoming light falls, may be mounted on the same plane as of the display 2 so that no display is made including text and keyboard when the solar battery 60 is inactivated.
Hence, no particular trouble will arise in practice. In case of word processing in the dark e.g. during projection of slide pictures in a lecture, a key entry action triggers the hold circuit 3 for actuation of the first processor 4 .
As the data processing apparatus of the fifth embodiment provides more energy saving, it may be realized in the form of a note-size microcomputer featuring no battery replacement for years. Also, the first and second processors in any of the first to fifth embodiments may be integrated to a single unit as shown in FIG. 25 .
It was found through experiments of simulative calculation conducted by us that the average power consumption during a word processing program was reduced from 5 w of a reference value to as small as several hundredths of a watt when the present invention was associated. This means that a conventional secondary cell lasts hundreds of hours and a primary cell, e.g. a highly efficient lithium cell, lasts more than 1000 hours. In other words, a note-size computer will be available which lasts, like a pocket calculator, over one year in use of 5-hour a day without replacement of batteries. As understood, intensive attempts at higher-speed operation and more-pixel display are concurrently being prosecuted and also, troublesome recharging of rechargeable batteries needs to be avoided. The present invention is intended to free note-size computers from tangling cords and time-consuming rechargers.
The advantages of high speed and high resolution attributed to ferroelectric liquid crystal materials have been known.
The present invention in particular focuses more attention on the energy saving effects of the ferroelectric liquid crystal which have been less regarded.
No such approach has been previously made. The energy saving effects will surely contribute to low power requirements of portable data processing apparatuses such as note-size computers.
Although the embodiments of the present invention employ a display device of ferroelectric liquid crystal for utilization of memory effects, other memory devices of smectic liquid crystal or electrochromic material will be used with equal success. The liquid crystal display is not limited to a matrix drive as described and may be driven by a TFT drive system.
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A data processing apparatus has a first processing unit for processing an input data, a second processing unit responsive to the data processed by the first processing unit for executing a processing dependent on the data and producing a display data, and a display unit having a display drive unit and a display device for displaying the display data. The second also selectively inactivated and activated under control of the first processing unit to reduce power consumption in the second processing unit. The display drive unit is also selectively inactivated and activated under control of the first processing unit to reduce power consumption in the display unit. The display device has a memory function that maintains its display image even when supply of a display drive signal from the display drive unit is stopped, so that a latest image before inactivation of the second processing unit and/or the display drive unit for power consumption reduction is visible by an operator during the inactivated and low power consumption state of the apparatus.
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BACKGROUND OF THE INVENTION
This invention relates to an improvement in a method of treating a workpiece with electron beams and apparatus therefor.
An apparatus for treating a workpiece with electron beams an exemplified by an electron beam welder includes a vacuum chamber for welding in which the workpiece is placed and a vacuum chamber for an electron beam gun in which an electron beam generator is disposed and which is connected air-tight to the vacuum chamber for welding, and the electron beams are emitted towards the workpiece through an aperture bored on the exterior wall of the vacuum chamber for welding. Such an apparatus is disclosed, for example, in U.S. Pat. No. 3,617,686 granted to Dietrich on Nov. 2, 1971.
In the apparatus of the above-described kind, it is generally necessary to evacuate the vacuum chamber for welding and the vacuum chamber for an electron beam gun by means of a vacuum pump and to maintain them constantly at high vacuum of about 1×10 -4 Torr and about 1×10 -5 ˜1×10 -6 Torr, respectively. However, gas components contained in the workpiece such as hydrogen and oxygen molecules of H 2 gas and O 2 gas and molecules of the workpiece converted into the metal vapor are emitted from the surface of the workpiece during welding and eventually lower the vacuum of both vaccum chambers. If a great number of molecules enter the vacuum chamber for an electron beam gun, insulation in the proximity of anode and cathode lowers whereby micro-discharge and flash-over discharge occur. The micro-discharge results in the formation of blow-holes at the weld zone while the flash-over discharge leads to the formation of recesses of the surface beads, blow-holes and sags. If the flash-over discharge occurs, furthermore, an excess current relay operates to stop the operation of the apparatus in order to protect the same.
These discharge phenomena take place frequently when the thickness of the workpiece exceeds 100 mm because the number of the gas molecules and that of the metal vapor molecules formed during welding increase with an increasing thickness of the workpiece. When a 100 mm-thick killed steel is welded, for example, the micro-discharge occurs 1-5 times within 10 minutes and the flash-over discharge occurs about once in 20 minutes. The vacuum in this instance is 1×10 -3 Torr near the aperture bored on the exterior wall of the vacuum chamber for welding, 1×10 -2 Torr near the workpiece and 10 -5 ˜10 -6 Torr inside the vacuum chamber for an electron beam gun. In this case, the pressure difference between the portion near the aperture of the vacuum chamber for welding and the vacuum chamber for an electron beam gun reaches as large as 10 2 -10 3 Torr so that the gas and metal molecules are apt to be sucked into the vacuum chamber for an electron beam gun. In consequence, the molecules emitted from the surface of the workpiece enter the vacuum chamber for an electron beam gun and lower instantaneously the vauum near the anode and cathode down to 10 -3 -10 -4 Torr, thereby causing the discharge phenomena. Because of these discharge phenomena, it has been difficult in the conventional apparatus to weld, cut or bore a workpiece of a thickness of 100 mm or more by means of the electron beams.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a suitable method of treating a thick workpiece with electron beams and apparatus therefor.
It is another object of the present invention to provide a method of treating a workpiece with electron beams which is free from the occurrence of discharge phenomena in the electron beam generator during treatment, and apparatus for said method.
It is still another object of the present invention to provide an apparatus for treating a workpiece with electron beams which makes it easy to adjust the axis of the electron beams.
It is one of the characterizing features of the present invention that the distance between the electron gun and the surface of the workpiece is made greater than the mean free path of the gas molecules and metal vapor molecules that are generated during treatment.
The discharge near the anode and cathode forming the electron beam gun occurs because the gas molecules and metal vapor molecules generated from the workpiece during treatment reach the electron beam gun. The molecules that are emitted from the surface of the workpiece with kinetic energy can travel in the space only by their free path. If the workpiece is spaced apart from the electron beam gun by a distance greater than the mean free path of the gas molecules and metal vapor molecules during treatment, therefore, the number of molecules capable of reaching the electron beam gun becomes smaller and hence, the discharge phenomena can be checked.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing an embodiment of the present invention;
FIG. 2 is a sectional view taken along line II--II of FIG. 1;
FIG. 3 is a sectional view taken along line III-- III of FIG. 1;
FIG. 4 is a diagram showing the relationship between the number of times of discharge D and the distance M between the electron beam gun and the workpiece; and
FIG. 5 is a diagram showing the relationship between the thickness T that piercing-welding can attain and the distance M between the electron beam gun and the workpiece.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a sealed vacuum chamber for welding 10 has a front wall 14 provided with an aperture 12. The vacuum chamber 10 is shaped into a rectangular parallelopiped having a length of 6.5 m, a width of 6.5 m and a height of 3.5 m, for example, and is constantly kept at a high vacuum of 1×10 -4 Torr by means of a vacuum pump 16. In order to movably support a workpiece 18 to be welded inside the vacuum chamber 10, a work table 20 is disposed in the chamber.
A vacuum chamber 22 is disposed to oppose the aperture 12 of the vacuum chamber 10 and is connected air-tight to the vacuum chamber 10. An electron beam gun 26 consists of a tungsten ribbon type filament 28, a grid or cathode 30 and an anode 34 equipped with an aperture 32. These members are fixed inside the vacuum chamber 22 via insulators 36 and 38 and are electrically connected to a power source not shown. The vacuum chamber 22 is divided by the anode 34 into chambers 39 and 40 whereby the chamber 39 furnished with the filament 28 is constantly kept at a high vacuum of 1×10 -5 ˜1×10 -6 Torr by means of a vacuum pump 41.
A focusing coil 42 and a deflecting coil 43 are disposed on the downstream side of the anode 34 inside the vacuum chamber 22. A coil bobbin 44 is fixed onto the inner circumference of the vacuum chamber 22 and supports the focusing coil 42 and the deflecting coil 43. When the filament 28 is heated, electrons are emitted from the grid or cathode 30. The electron beams are irradiated into the vacuum chamber 10 through the aperture 32 of the anode, the focusing coil 42, the deflecting coil 43 and the aperture 12 of the vacuum chamber 10 as shown in the drawing, and the beam intensity is so selected as to sufficiently pierce and fuse the workpiece.
A focusing coil 48 and a deflecting coil 50 are arranged to oppose the workpiece placed inside the vacuum chamber 10. A coil bobbin 52 is equipped with screw coupling members 54 and 56 and supports the focusing coil 48 and the deflecting coil 50 and permits them to move vertically inside the vacuum chamber 10. A support 58, which is supported movably in the horizontal direction inside the vacuum chamber 10, is equipped with a screw 62 and bearings 64, 66 that are rotated by a motor 60. When the motor 60 is energized by the power source not shown to rotate the screw 62, the coupling members 54 and 56 screw-coupled to the screw 62 are caused to move up or down.
At the upper portion of the vacuum chamber 10 are disposed a screw 68 extending in the horizontal direction, a motor 70 for rotating this screw 68 and bearings 72, 74. Screw coupling members 76, 78 fixed to the abovementioned support 58 are brought into screw engagement with this screw 68 and are supported movably in the horizontal direction inside the vacuum chamber 10. When the motor 70 is energized by the power source not shown thereby to rotate the screw 68, the members 76, 78 coupled to the screw 68 move rightwardly or leftwardly. The moving direction of the support 58 is in conformity with the axis of the electron beam 46.
An electron beam guide 80 of the bellows-like form is interposed between the focusing coil 48 and the deflecting coil 43. As illustrated in FIG. 2, a beam path 82, and exhaust apertures 84, 86, 88 and 90 are defined on this electron beam guide 80. This arrangement prevents the diffusion, into the electron beam path, of the molecules of gas and metal vapor that are generated upon irradiation of the electron beam onto the workpiece. The molecules 92 inside the electron beam guide 80 are discharged into the vacuum chamber 10 through the exhaust apertures 84, 86, 88, 90 as shown in FIG. 1.
In FIG. 1, when the filament 28, the cathode 30, the anode 34, the focusing coils 42, 48 and the deflecting coils 43, 50 are altogether connected to the power source, the electron beam 46 emitted from the electron beam gun 26 passes horizontally through the focusing coil 42, the deflecting coil 43, the electron beam guide 80 of the bellows-like form, the focusing coil 48 and through the deflecting coil 50 and is irradiated upon the workpiece 18. If the distance M between the anode 34 and the workpiece 18 becomes great, the electron beam 46 expands but is again focused by the focusing coil 48 that is disposed in the proximity of the workpiece. The focusing coil 48 and the deflecting coil 50 are moved in the vertical direction so as to bring the axis of the electron beam 46 emitted from the electron beam gun 26 into conformity with the axes of the focusing coil 48 and deflecting coil 50. This correction is made by controlling the operation of the motor 60.
The distance M between the anode 34 and the workpiece is controlled by controlling the operation of the motor 70. The rear wall of the vacuum chamber 10 and the anode 34 are selected sufficiently great in order to make the distance M greater than the mean free path of the molecules of the gas and metal vapor generated during the welding such as hydrogen and oxygen molecules. In this embodiment, the distance M is at least 1.85 m.
When the workpiece is a 100 mm-thick carbon steel and the distance between the focusing coil 40 and the workpiece 18 is 2.5 m in FIG. 1, the vacuum is 1×10 -4 Torr at point A in the vacuum chamber 10, 1×10 -5 ˜1×10 -6 Torr at point B in the vacuum chamber 39, 1×10 -2 Torr at point C in front of the workpiece 18 and 1×10 -4 Torr at point D close to the aperture 12, respectively. In other words, it is possible to maintain the vacuum of at least 1×10 -4 Torr near the aperture 12 during welding.
As a result, the micro-discharge generated by the electron beam gun 26 is less than once in 60 minutes and the flash-over discharge is not at all observed. This is because the distance M between the workpiece 18 and the anode 34 is so large that the metal vapor and gas molecules generated at the weld zone are evacuated outside by the vacuum pump 16, thereby reducing their quantity sucked into the vacuum chamber 39 for the electron beam gun through the aperture 32 of the anode 34.
FIG. 4 illustrates the relationship between the number of times of occurrence of the micro-discharge and the distance M between the anode 34 and the workpiece 18. As can be seen, the number of times of occurrence of the micro-discharge decreases drastically when the distance M exceeds 1.85 m. This is because the mean free path of the metal vapor and gas molecules during welding is about 1.85 m and when the distance M becomes smaller than this mean free path, the metal vapor molecules and gas molecules are allowed to enter the vacuum chamber for the electron beam gun 39 in greater quantities.
FIG. 5 is a diagram useful for explaining the effect of the focusing coil 48 of FIG. 1 wherein the relationship between the thickness T of the workpiece that can be pierce-welded and the distance M between the anode 34 and the workpiece 18 is shown, without coil 48. The focusing property of the focusing coil 42 for the electron beam 46 decreases with the increase in the distance M whereby scattering of the beam becomes greater and the weldable thickness of the workpiece becomes smaller. In the case of the embodiment of FIG. 1, the focusing coil 48 is placed immediately before the workpiece 18 so that the electron beam is again focused. When the workpiece is thick, therefore, welding can be practised even if the distance M is made greater than 1.85 m, thereby preventing the discharge phenomena.
In the embodiment shown in FIG. 1, both focusing coil 48 and deflecting coil 50 are shown disposed inside the vacuum chamber 10. However, they may be disposed inside the vacuum chamber 22 by increasing the length of the chamber 22. In such a case, the size of the vacuum chamber 10 can be reduced.
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A vacuum chamber for welding in which to place a workpiece is hermetically connected to a vacuum chamber for an electron beam gun in which to place an electron beam gun, and the former is kept at a vacuum of 1×10 -4 Torr while the latter, at a vacuum of 1×10 -6 Torr. The distance between the electron beam gun and the surface of the workpiece is made greater than the mean free path of gas molecules and metal vapor molecules generated in treating, e.g., 1.85 m. Two focusing coils are arranged to prevent the expansion of the electron beams.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention in general relates to photography and in particular to camera apparatus having a built-in, close-up lens arrangement.
2. Description of the Prior Art
Photographic cameras of the type having exposure control systems that automatically operate to provide the correct amount of exposure delivered to a film under both natural and artificially created lighting conditions are well-known in the prior art. Under natural lighting conditions such cameras generally operate to provide proper exposure control over a predetermined range of scene brightnesses and under artificially created lighting conditions, such as those created by a built-in strobe or the like, operate to provide proper exposure over a predetermined range of subject distances related to the focus range of the camera objective taking lens system.
In cameras having fixed focus objective taking lens systems, the nearest distance at which properly exposed and sharply focused pictures can be obtained is determined by the near focus of the objective lens system even though proper exposure can generally be provided by the camera exposure control system for subjects located closer to the camera than the near focus of the camera objective taking lens system.
It is therefore a primary object of the present invention to provide a built-in, close-up lens arrangement for use with a camera having an automatic exposure control system to extend the near subject distances at which correctly exposed, properly focused pictures can be obtained.
It is another object of the present invention to provide a built-in, close-up lens arrangement for use with a camera of the type having an automatic exposure control system and a built-in foldable type electronic strobe such as that shown and described in considerable detail in U.S. Pat. No. 4,231,645 issued on Nov. 4, 1980 to Carl W. Davis et al. and entitled "Camera with Telescoping Dual Actuators". In this patent, a folding electronic strobe unit is mounted on a camera housing for movement between an erect operative position and a folded storage location.
The built-in, close-up lens arrangement of the present invention as described hereafter is particularly suitable for use with the type of camera structure disclosed in the Davis et al. patent and operates, inter alia, to automatically return a close-up lens to a storage location in response to folding the type of electronic strobe of Davis et al. into its storage location.
An example of a prior art camera having an optical lens system for automatically changing the focal distance of the objective lens in response to movement of an artificial lighting device between an operative and an inoperative position is shown and described in U.S. Pat. No. 3,598,031 issued to Donald M. Harvey on August 10, 1971 and entitled "Photographic Camera With Means For Varying A Focus Adjustment To Photograph An Artificially Illuminated Subject". Harvey, however, apparently provides no option for changing the focus of the lens and would not be suitable for use with a camera of the Davis et al. type. It is therefore another object of the present invention to provide a built-in, close-up lens arrangement of the type that can be optionally used to change the near focus of a camera having a built-in foldable artificial lighting device.
Other objects of the invention will in part be obvious and will in part appear hereinafter. The invention accordingly comprises the apparatus possessing the construction, combination of elements, and arrangement of parts which are exemplified in the following detailed disclosure.
SUMMARY OF THE INVENTION
This invention in general relates to photography and in particular to photographic camera apparatus having a built-in, close-up lens arrangement.
The photographic camera apparatus of the invention comprises a camera housing including means for facilitating the mounting of film in a plane for photoexposure and for defining a light path along which scene light can travel to the film mounting plane.
Also included is an objective taking lens mounted within the camera housing in registration with the light path and structured for directing scene light onto film located in the camera film mounting plane.
The camera apparatus of the invention includes a foldable flash unit that is mounted on the camera housing for movement between an operative erect position and a folded storage position.
Also provided in the invention is a supplementary lens structured for use with the objective taking lens so that the two in combination can focus on objects closer than would otherwise be possible with the objective taking lens acting alone.
The invention also includes means for mounting the supplementary lens for movement between a storage location in which the supplementary lens is not registered with the objective taking lens and an operative location in which the supplementary lens is in optical registration with the objective taking lens. The mounting means is structured so that the supplementary lens can be manually moved from its storage location to its operative location and thereafter either can be manually released, or released in response to the movement of the flash unit into its folded position, to automatically return to its storage location.
In a preferred embodiment the mounting means of the invention includes a thin, elongated block having a generally rectangular, elongated recess in one side thereof and an aperture in one end of the recess. The block and the camera housing have complementary structure for mounting the block with the camera housing such that the aperture of the block is in optical registration with the camera objective taking lens when the block is mounted with the camera housing to permit scene light to travel through the objective taking lens. The preferred mounting means also includes a lens carrier adapted to receive the supplementary lens and is structured for slidable movement within the block recess between a first position corresponding to the storage location of the supplementary lens and a second position corresponding to the operative location of the supplementary lens. The lens carrier also includes a lever which is adapted to extend to the exterior of the camera.
Also included in the preferred mounting means are means for biasing the lens carrier into its first position. The block, the lens carrier, and the biasing means are further structured to cooperate with one another to provide a detent arrangement by which the lens carrier automatically is captured in its second position as the lens carrier is moved from its first position toward its second position by pushing on the lens carrier lever and to release the lens carrier from its second position so that it automatically moves back to its first position under the influence of the biasing means in response to pushing on the lever either by hand or by contact with the flash unit upon movement of the flash unit into its storage position.
DESCRIPTION OF THE DRAWINGS
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation together with other objects and advantages thereof will be best understood from the following description of the illustrated embodiment when read in connection with the accompanying drawings wherein like numbers have been employed in the different figures to denote the same parts and wherein:
FIG. 1 is a left front perspective view of a camera embodying the present invention;
FIG. 2 is an enlarged right rear perspective view of part of the camera of FIG. 1;
FIG. 3 is a view similar to FIG. 2 except showing part of the invention positioned differently than in FIG. 2;
FIG. 4 is a sectional view taken generally along line 4--4 in FIG. 3; and
FIG. 5 is a sectional view taken generally along line 5--5 in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a close-up lens arrangement that is particularly suitable for use with a camera of the type having an automatic exposure control system and a foldable artificial lighting device. In its preferred embodiment, the present invention is shown incorporated in a virtually fully automatic type camera which utilizes self-processable type film and which is designated generally at 10 in FIG. 1.
As best seen in FIG. 1, the camera 10 includes an electronic flash unit 12, preferably of the quench type, mounted on a rigid body 14 for movement between an erect operative position, as illustrated in FIG. 1, and a folded inoperative position which is not illustrated. The rigid camera body 14 includes a generally prismatic shaped major housing 16, a generally L-shaped front housing 18, and a generally rectangularly-shaped film loading door 20 which collectively define its outward appearance and serve to house and protect its interior components. The aforementioned housings, 16 and 18, and the film loading door 20 are all preferably molded of an opaque plastic to preclude unwanted light from entering the camera interior.
The camera L-shaped housing 18 is defined, at least in part, by a plurality of camera housing walls including a forwardly facing wall 19 and an apron wall 21 extending forwardly from a bottom portion of the wall 19 in cooperation therewith to define a camera housing recess. The flash unit 12 has a housing that is defined, at least in part, by a plurality of flash unit housing wall exterior surfaces including an illumination source face surface 13 and an adjacent rearwardly extending bottom wall surface 15. A source of illumination, such as a flash output window 17 is mounted in the flash unit housing so that its light output is directed outwardly from the electronic flash unit 12 toward a scene. Well-known means including a pair of pivots 11 (only one shown) are provided for coupling the flash housing to the camera housing 14 for movement relative thereto between the operative erect position shown in FIG. 1 and its folded storage position (not shown) wherein a major portion of the flash housing fits into the camera housing recess previously defined. The flash housing and camera housing are configured such that the flash unit housing bottom wall surface 15 is substantially flush with the camera forwardly facing wall 19 when the flash unit 12 is folded. For a more detailed decription of the flash unit folding arrangement, reference may be had to U.S. patent application Ser. No. 054,598 filed in the name of Bruce K. Johnson on July 3, 1979 and entitled "Camera With Folding Flash Unit", now U.S. Pat. No. 4,268,146.
Formed in the base of the prismatic housing 16 is a well-known film cassette receiving chamber generally designated at 23. The chamber 23 is adapted to releasably hold a film cassette such as that designated at 22. The cassette 22 comprises a generally rectangular parallelepiped housing 25 which has an upwardly facing wall 27 having a generally rectangular aperture 29 therein. Mounted in registration with and biased toward the aperture 29 is a stacked array of integral type self-processable film units generally designated at 26. Each of the film units 26 has a given film speed requiring a predetermined exposure which is provided by the camera 10 in a manner to be described. Underneath the stacked array of film units 26 is a flat, thin battery 24 which is electrically coupled in a well-known manner to power the various electrical systems of the camera 10. An example of such a film cassette is described in considerable detail in U.S. Pat No. 3,872,487 issued to Nicholas Gold on Mar. 18, 1975 and entitled "Photographic Film Assemblage and Apparatus" and of such film units in U.S. Pat. Nos. 3,415,644; 3,594,165; and 3,761,268.
Formed in the vertical forwardly facing wall 19 of the L-shaped housing 18 are a number of apertures, designated at 32, 34, and 36, and an elongated slot 38. Mounted in registration with the aperture 32 is a close-up lens module 30 which includes an opening generally designated at 31. An objective taking lens 40 having an optical axis, OA, is optically registered behind the close-up lens module opening 31 and is positioned forwardly of an aperture formed in an opaque exposure chamber (not shown) that is positioned in a well-known manner inside the prismatic shaped housing 16 and also has a prismatic shape generally complementary to the interior shape of the housing 16. The objective taking lens 40 is of the fixed focus type and is optically structured in a well-known manner to have a depth of field from 4 ft. to infinity.
Located within the exposure chamber is a trapezoidal-shaped mirror (not shown) that is arranged at a predetermined angle with respect to the optical axis, OA, and the film plane to provide a folded light path of predetermined length therebetween along which image forming scene rays from the objective taking lens 40 travel to the film within the cassette 22 during a camera exposure cycle. The exposure chamber is of the type which is described in considerable detail in U.S. Pat. No. 4,057,815 issued to Bruce K. Johnson on Nov. 8, 1977 and entitled "Anti-Flare Structure for Photographic Optical System". It will be recognized by those skilled in the art that, with this type optical arrangement, the objective taking lens 40 and the peripheral edges of the film cassette aperture 29 cooperate to define the field of view of the camera 10, the field of view defining the subject matter that will be recorded during photoexposure.
Mounted in registration with the aperture 34 is a negative lens 42 which forms part of a reversed Galilean viewfinder that is structured in a well-known manner to have a field of view that is substantially coextensive with that of the camera 10 to facilitate aiming the camera 10 in order to frame the subject matter to be recorded in a picture.
The aperture 36, which is located just beneath the viewfinder entrance aperture 34, is provided for the purpose of admitting light to a radiometer (not shown) which forms a part of the automatic exposure control system of the camera 10.
Within the elongated slot 38 (FIG. 1) there is mounted a sliding member 39 having a button 41 thereon. The sliding member 39 is adapted for engagement with a light attenuating member (not shown) which operates in a well-known manner to permit a photographer to make minor adjustments in exposure.
Exposure of the film units 26 is regulated in a well-known manner through the use of an automatic exposure control system (not shown) of the type that is more fully described in U.S. patent application Ser. No. 074,993 filed on Sept. 13, 1979 in the name of Bruce K. Johnson et al. and entitled "Camera with Proportional Fill Flash Quench Strobe". The exposure control system described in the above-referenced U.S. Patent Application utilizes the output signal of the camera radiometer to control the firing of the electronic flash 12 so as to automatically provide a proportional fill flash under conditions where the natural or ambient scene lighting is of high intensity and may also control the firing of the electronic flash 12 under conditions of negligible ambient scene light intensity wherein the proportion of the exposure attributable to the artificial scene light provided by the electronic flash 12 automatically increases in correspondence with decreases in the ambient scene light intensity.
The exposure control system of the camera 10 is capable of regulating exposure under both ambient and artificial lighting conditions or combinations of both to provide proper exposure of the film units 26 at subject distances closer than the near focus (4 ft.) of the objective taking lens 40. The close-up lens module 30, in a manner to be described, provides a photographer with the option of taking pictures of subjects closer than the near focus of the objective taking lens 40.
Referring now to FIG. 2, there is shown the close-up lens module 30 of the invention disposed within the elongated aperture 32 that is formed in the forwardly facing wall 19 of the camera L-shaped housing member 18. The close-up lens module 30 comprises a thin, rectangularly-shaped, elongated block 45 that is dimensioned to fit snugly into the aperture 32. For purposes of connecting the close-up lens module 30 to the L-shaped camera housing member 18, the block 45 is provided with a tab 74 that fits into a recess 37 located in a rim 35 that surrounds the peripheral edges of the aperture 32. At the opposite end of the block 45 there is provided a snap-type lug fastener 54 that extends rearwardly from the block 45 and engages the upper surface of the rim 35 (FIG. 4). In this manner the close-up lens module 30 is provided with snap-type connectors which permit the close-up lens module 30 to be easily assembled with the camera housing structure.
Located in the bottom section of the block 45 is an elongated recessed edge surface 63 which, in combination with an edge portion of the peripheral rim of the aperture 32, defines a slot 64 (see FIGS. 1 and 5) through which extends a tab 59 connecting to a button 60 for purposes which will be explained hereinafter.
As shown in FIG. 3, the block 45 includes a recessed surface 49 that is partially surrounded by an upwardly standing peripheral wall 43 having a cap portion 44 with an aperture 46 therein extending across the surface 49 in spaced apart parallel relation thereto. The cap portion 44 overlies a beveled serrated apertures 47 located in the front surface of the block 45 as best shown in FIG. 4 to define the opening 31 along the camera optical path. In this manner, there is provided on the left side of the block 45 a cavity 61 (see FIG. 4) adapted to receive therein a lens carrier 48 that is adapted in a well-known manner to receive a supplementary lens 50. The lens carrier 48 is structured for slidable movement on the block recess surface 49 between a first position as illustrated in FIG. 2 and a second position as illustrated in FIG. 3.
The supplementary lens 50 is optically structured in a well-known manner to, in combination with the objective taking lens 40, provide the camera with the ability to focus on objects whose distances are between 2-4 feet away from the camera 10 when the supplementary lens 50 via its carrier 48 is moved into its second position. When in its second position, the lens carrier 48 automatically aligns the supplementary lens 50 along the optical axis, OA, of the objective lens 40 as shown in FIG. 3 to perform this function.
One end of a spring 62 attaches to an upwardly extending boss 52 located on the lens carrier 48 and the opposite end of the spring 62 attaches to the upwardly standing lug snap connector 54. The spring geometry and rate are chosen so that the spring 62 provides a means for continuously biasing the lens carrier 48 into its first position as illustrated in FIG. 2.
Lens carrier 48 additionally includes a downwardly extending pawl 56 which rides in a slot 68 that is slightly recessed below the level of the surface 49. The end of the elongated slot 68 terminates in a triangularly-shaped notched out recess 67 (see FIG. 4) for receiving the trailing end of the pawl 56.
To move the lens carrier 48 from its first to its second position, a lever is provided on the lens carrier 48. The lever comprises a tab section 59 (see FIG. 5) that is perpendicular to the main bearing surface of the lens carrier 48 and extends through the slot 64 to terminate as the button 60 (FIGS. 1 and 5).
Located above the slot 64 (see FIG. 1 or FIG. 5) is an elongated recessed area 66 that is spaced rearwardly from the forwardly facing surface of the L-shaped housing wall 19. In moving the lens carrier 48 to its second position, a photographer simply pushes on the button 60 (see FIG. 1) to exert a force to the right. This causes the rear surface of the button 60 to slide along the forward surface of the recessed area 66 until the pawl member 56 drops into the recess 67 provided therefor. When the pawl 56 drops into the recess 67, the lens carrier 48 is automatically captured in its second position and the photographer may remove his finger from the button 60. Also, when the pawl 56 drops into the recess 67, the button 60 also moves toward the front of the camera 10 by a distance generally equal to the depth of the recess 67. The depth of the recess 67 and the pawl trailing end are dimensioned so that the button 60 protrudes beyond the L-shaped housing forwardly facing wall 19 when the lens carrier 48 is in its second position.
The lens carrier 48 can be released from its second position in one of two different ways. A photographer can push on the button 60 in a direction perpendicular to the direction in which the lens carrier 48 traveled in moving from its first to its second position. This action disengages the pawl 56 from the recess 67 thereby permitting the lens carrier 48 to be automatically moved back into its first position under the influence of the spring 62. Movement of the lens carrier 48 from its second position to its first position is stopped when the trailing end of the pawl 56 strikes up against the back wall of the elongated slot 68 (FIG. 4).
The other way in which the lens carrier 48 can be caused to be released from its second position is by folding the electronic flash unit 12 into its storage location as previously described. Folding of the electronic flash unit 12 into its storage location causes the housing surface 15 thereof to strike the button 60 to drive the button 60 towards the rear of the camera 10. When the button 60 is driven in this manner, the pawl 56 as before is disengaged from the recess 67 and the lens carrier 48 automatically returns to its first position in the manner previously described.
It will be appreciated by those skilled in the art that the pushing force on the button 60 to move the lens carrier 48 into its second position in alignment with the objective taking lens 40 in combination with the force exerted on the lens carrier 48 by the spring 62 as this is done creates a moment or couple acting on the lens carrier 48. This couple tends to cause the pawl 56 to press against the slot 68 as the lens carrier 48 travels from its first to its second position. This action enhances the reliability of the detent capturing arrangement for retaining the lens carrier 48 in its second position because the trailing end of the pawl 56 is biased towards the recess 67 and will automatically drop into the recess 67 when sufficiently clear of the edge of the recess 67. To enhance this action, there is also provided an upwardly standing tab section 72 that is located on the capping block portion 44. The tab section 72 is provided so that the boss 52 strikes it as the lens carrier 48 is moved toward its second position. This creates an interference causing another couple effect to occur on the lens carrier 48. This other coupling effect also tends to rotate the trailing end of the pawl 56 into the recess 67.
The lens carrier 48 is also provided with an elongated flag member 76 which extends through a hole 80 located in the upper left-hand corner of the block 40 as best shown in FIG. 3. In line with the hole 80 is another hole 78 that is located in a cone-like structure 79 which, in part, defines the viewfinder aperture 34. Movement of the lens carrier 48 causes the flag 76 to extend through first the hole 80 and then through the hole 78 to provide a visual indication or signal in the viewfinder of the camera 10 to alert a photographer that the supplementary lens 50 is in its operative location.
Both the elongated block 45 and the lens carrier 48 are preferably integrally molded of a suitable plastic material so that there are only two major parts to assemble. In the case of the lens carrier 48, the plastic material preferably is an optical plastic so that the supplementary lens 50 can easily be molded as part of the overall structure of the lens carrier 48 through the use of suitable optically polished mold inserts in the tool for fabricating the lens carrier 48.
Certain changes may be made in the above-described embodiment without departing from the scope of the invention and those skilled in the art may make still other changes according to the teachings of the disclosure. Therefore, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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Camera apparatus of the type having an objective taking lens and an electronic flash movable between an erect operative position and a folded storage position is provided with a built-in, close-up lens arrangement for extending the focus range of the objective lens thus enabling a user to take pictures at nearer distances than would otherwise be possible using the camera objective lens alone. The close-up lens arrangement is structured for manual movement between a first position in which a close-up lens is in a storage location and a second position in which the close-up lens is captured and optically registered with the camera objective lens. The close-up lens can be released either manually or in response to movement of the electronic flash into its storage position. Upon release, the close-up lens automatically returns to its storage location.
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This application is a continuation of application Ser. No. 458,218 filed Dec. 28, 1989, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to automatic washing machines and is concerned more particularly with an automatic clothes washing machine having means for indicating the level of additive fluid in a multi-load reservoir thereof within the wash cycle.
2. Discussion of the Prior Art
In the loading of an automatic washing machine, clothes generally are deposited through an access door into an open end of a perforated spin tub which is rotatably supported in a stationary drain tub within a cabinet. The washing machine may be cycled through a sequence of operations including a presoaking operation followed by a first liquid extraction, a washing operation followed by a second liquid extraction, a rinsing operation followed by a third liquid extraction, and a spin drying operation. For any of these operations, an additive fluid may be injected into the wash load to enhance the results of the associated operation.
Consequently, there has been developed in the prior art a number of additive dispensing means having respective housings disposed for holding additive liquids until released for a particular operation of the wash cycle. Some of these prior art dispensing means have respective housings located in accessible portions of the cabinets, such as mounted on the terminal end portion of an agitator post extending axially in the spin tub, for example. Generally, a predetermined quantity of additive liquid, such as soap, for example is poured into a housing of the described type; and the access door is closed prior to operating the washing machine. Thus, the level of additive liquid in a housing mounted in an accessible portion of the cabinet is not viewable directly while the washing machine is operating.
Alternatively, some of these prior art dispensing means have respective housings which are located in inaccessible portions of the cabinets, such as under a control panel on the cabinet, for example. Generally, a housing of the inaccessibly located type communicates through a connective conduit means with an inlet opening in a more accessible portion of the cabinet. Thus, an alternative prior art dispensing means of the described type may be supplied with additive liquid by pouring the additive liquid into the inlet opening and permitting it to run through the connective conduit means into the housing. Since the resulting level of additive liquid in the housing is not readily observable, this alternative prior art sensing means may include a fluid level sensing means in the housing connected with a fluid level indicator on an external portion of the cabinet, such as in the control panel, for example.
However, the fluid level sensing means and the connected fluid level indicator generally provide a complex and expensive solution to the problem of determining the level of additive liquid in the housing of an additive dispensing means. Moreover, the fluid level indicator may be designed and mounted in a manner which is difficult to read at a glance, especially in a poorly illuminated environment, such as in a basement area, for example. Furthermore, the fluid level sensing means connected to an external fluid level indicator does not provide a direct view of the liquid level in a housing of an additive dispensing means, particularly when the washing machine is operating.
SUMMARY OF THE INVENTION
These and other disadvantages of the prior art are overcome by this invention providing a clothes washing machine with a cabinet having therein an additive fluid dispensing system including a reservoir of additive liquid with a transparent portion aligned with a vertically elongated window in a readily accessible defining wall of the cabinet. The transparent portion of the reservoir is disposed in communication with the additive liquid therein such that the level of additive liquid in the transparent portion is an indication of the level of additive liquid in the reservoir. The reservoir comprises a liquid-tight housing having a capacity for holding therein a multi-load quantity of additive liquid, such as soap, for example, whereby a plurality of successive wash loads may be supplied with respective injections of additive liquid without refilling the housing.
The housing may be provided with a size and shape for fitting in a portion of the cabinet suitable for locating an elongated transparent portion of the housing closely adjacent the vertically elongated window in the readily accessible defining wall of the cabinet. Thus, the housing may be vertically elongated and provided with a generally triangular cross-section for fitting in an elongated corner portion of the cabinet where a side wall of the housing extends along a portion of a front wall of the cabinet having the vertically elongated window therein. The window is longitudinally coextensive with a portion of the housing side wall having protruding therefrom a transparent tubular member which is longitudinally coextensive with the interior of the housing and communicates with the additive liquid in the vertically elongated housing. Accordingly, the level of additive liquid in the tubular member may be observed readily through the vertically elongated window in the front wall of the cabinet even while the washing machine is operating. Furthermore, since the housing is vertically elongated small changes in the level of additive liquid in the housing are more readily noticeable through the window in the front wall of the cabinet, which is closest to the observer. Moreover, the housing may be filled through a filler opening in a portion of a top wall of the cabinet overlying the housing, which is close to the front wall. As a result, the filler opening is readily accessible for pouring additive liquid therein; and any spillage is easily cleaned up.
Also, a light radiating means may be disposed adjacent the transparent portion of the housing for illuminating the additive liquid therein so that the level of the additive liquid may be observed at a glance even in poorly illuminated area. Moreover, the transparent portion of the housing may be provided with guaging means for measuring the quantity of additive liquid in the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of this invention, reference is made in the following detailed description to the accompanying drawings wherein:
FIG. 1 is an isometric view, partly in section, of a clothes washing machine embodying the invention;
FIG. 2 is an enlarged fragmentary view of a portion of the washing machine shown in FIG. 1 and having therein the nozzle of this invention;
FIG. 3 is an enlarged schematic sectional view of the nozzle shown in FIG. 2 while directing a stream of additive liquid into the spin tub;
FIG. 4 is an enlarged schematic sectional view of the nozzle shown in FIG. 2 while directing excess droplets of additive liquid away from the spin tub;
FIG. 5 is a fragmentary isometric view of the washing machine shown in FIG. 1 during operation of the invention; and
FIG. 6 is a schematic view of an alternative means for powering the additive liquid dispensing system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings wherein like characters of reference designate like parts, there is shown in FIG. 1 an automatic clothes washing machine 10 of the vertical axis rotatable type having an upright cabinet 12 made of suitable metallic material, such as stainless steel sheet metal, for example. The cabinet 12 may be provided with a generally hexahedral configuration and a substantially rectangular cross-section. Cabinet 12 may include a base end wall 14, opposing side walls 15 and 16, respectively, a rear wall 17 and an opposing front wall 18. Also, the cabinet 12 is provided with a top or access end wall 20 having therein a generally rectangular recess 22 which includes four corner portions 23, 24, 25 and 26, respectively. The respective corner portions 23-26 aid in defining a circular clothes receiving opening 28 centrally disposed in the recess 22, and in supporting a hinged door 30 in a closed position within the recess 22. Door 30 may be moved pivotally to a fully open position when access to the clothes receiving opening 28 is required, such as when depositing clothes (not shown) in the clothes receiving opening 28 or when removing a wash load (not shown) from the machine 10, for example.
As shown more clearly in FIG. 2, the clothes receiving opening 28 is defined by an inner peripheral portion of access end wall 20 in recess 22 being curved axially inward of cabinet 12. This inner peripheral portion of access end wall 20 is encircled by a spaced lip 32 of an annular cowling 34 which is made of molded plastic material, such as a polycarbonate material, for example. The inner periphery of lip 32 defines a cowling opening 36 which has a diameter larger than the diameter of clothes receiving opening 28. Lip 32 has an outer peripheral portion which is integrally joined to a small diameter end of a frusto-conical element 38 of the cowling 34. Frusto-conical element 38 has a large diameter end portion integrally joined to an inner periphery of an annular channel element 40 of cowling 34. From its inner periphery, channel element 40 slopes radially at a divergent angle with the plane of access end wall 20, and terminates at its outer periphery in an integral flange element 42. The flange element 42 extends axially and comprises the outer peripheral portion of cowling 34.
As shown more clearly in FIGS. 3 and 4, there is disposed in a lower end portion of flange element 42 an axially extending groove 44 wherein a circular rim portion of a stationary drain tub 46 is snugly received. Drain tub 46 is of the conventional type made of rigid material, such as stainless steel, for example. The circular rim portion of drain tub 46 defines an open end thereof disposed in a plane adjacent wall 20 and supports in cantilever fashion the annular cowling 34 which extends radially inward from the rim portion of drain tub 46. Also, the circular rim portion of drain tub 46 terminates an axially extending, imperforated wall thereof which is spaced radially outward of an axially extending, perforated wall of a spin tub 48.
The spin tub 48 is of the conventional type supported for axial rotation within the drain tub 46 and made of suitable material, such as porcellainized stainless steel, for example. Extending axially within the spin tub 48 is a conventional agitator post 49 which is disposed for rotation with the spin tub 48. Agitator post 49 has a distal end disposed adjacent an open end of the spin tub 48, which is defined by a bifurcated rim portion thereof. Pressed into the bifurcated rim portion of spin tub 48 is a dimpled under portion of a conventional spin tub collar 50 which may be perforated similar to the axially extending wall of spin tub 48. Collar 50 is made of suitable plastic material, such as a polycarbonate material, for example, and extends in cantilever fashion radially inward from the bifurcated rim portion of spin tub 48. The collar 50 has an inner periphery defining a collar opening 52 which has a diameter larger than the diameter of cowling opening 36 and is generally aligned therewith. Thus, when clothes (not shown) are deposited in the clothes receiving opening 28, they pass through the aligned cowling opening 36 and collar opening 52 to land in the spin tub 48 for processing by the machine 10.
The frusto-conical element 38 has extended through a portion thereof adjacent the front wall 18 of cabinet 12 a target aperture 54 through which a portion of the collar opening 52 may be viewed. Encircling the target aperture 54 is an outer surface portion of frusto-conical element 38 having attached thereto one end of a cylindrical nozzle 56 which is made of molded plastic material, such as a polycarbonate material, for example. The nozzle 56 extends in cantilever fashion outwardly from the frusto-conical element 38 and is supported in spaced relationship with the channel element 40 of cowling 34. Nozzle 56 comprises a drain tube component 58 having eccentrically disposed therein a longitudinally extending delivery tube component 60 with an outer diameter substantially smaller than the inner diameter of drain tube component 58. The drain tube component 58 has an open spout end which is attached, as by bonding with epoxy adhesive, for example, to a surface portion of frusto-conical element 38 encircling target aperture 54. Also, the drain tube component 58 has an opposing drain end portion which is open and has extended longitudinally therein the smaller diameter delivery tube component 60.
The delivery tube component 60 is disposed longitudinally within the drain tube component 58 and is attached, as by bonding with epoxy adhesive, for example, to an inner surface portion of the drain tube component 58. As a result, the delivery tube component 60 is eccentrically disposed with respect to the axial centerline of drain tube component 58. Delivery tube component 60 has a spout end portion which is conically shaped and is recessed axially within the spout end portion of drain tube component 58. The spout end portion of delivery tube component 60 has extended through a sloped wall portion thereof aligned with target aperture 54 an outlet orifice 62 which is disposed for directing a stream of additive liquid through the target aperture 54. Delivery tube component 60 has an opposing input end portion extended longitudinally out of the drain end portion of the drain tube component 58 and connected hydraulically to an adjacent end portion of a flexible hose 64. The hose 64 is made of suitable material, such as polyethylene, for example, and is connected to the input portion of delivery tube component 60 in a conventional liquid-tight manner, such as by use of an encircling hose clamp 65, for example.
The flexible hose 64 extends downwardly within cabinet 12 and along the front wall 18 thereof to an end portion of hose 64 which is connected hydraulically to an output port of an additive pump 66 in a conventional liquid-tight manner. Pump 66 may be of the rotary vane type which is rotatably coupled to an additive motor 68, such as a pump and an alternating current motor combination sold by Sandek Charger Services of National Charger Service Center in Alexandria, Va., for example. The vane type pump 66 comprises a central hub having extending radially therefrom a circular array of angularly spaced vanes which are made of suitably rigid material, such as steel, for example. Pump 66 is supported by the motor 68 which is attached by suitable means to a lower plate-like end of an elongated reservoir housing 70. Preferably, the housing 70 is provided with a generally triangular cross-section for fitting conveniently in an elongated corner portion of cabinet 12 defined by a juncture of front and side walls, 18 and 16, respectively, of the cabinet. Housing 70 may be made as a single integral unit from soap resistant material, such as molded plastic material, for example, and has a hollow interior connected hydraulically through a flexible hose 71 to an input port of the pump 66. The housing 70 has a volumetric capacity for containing a multi-load quantity of liquid soap 72, such as one gallon or fifteen cups, for example, whereby successive loads of washing may be processed by the machine 10 over an extended period of time, such as one month, for example, without requiring refilling of the housing 70.
Adjacent the front wall of cabinet 12, the housing 70 has a side surface from which protrudes a colinear length of clear plastic tubing 74 having a generally rectangular cross-section. The tubing 74 is sealed to the adjacent side surface of housing 70 and communicates with the interior of housing 70 all along the length of tubing 74. Consequently, there is disposed in tubing 74 a column of the liquid soap 72 which indicates the level reached by the quantity of liquid soap 72 in housing 70. Disposed in the front wall 18 of cabinet 12 and aligned with the tubing 74 is a window 76 made of transparent material, such as clear plastic material, for example, whereby the level of soap 72 in housing 70 may be ascertained from externally of machine 10.
Also, the side of tubing 74 adjacent window 76 may be provided with a colinear series of uniformly spaced graduations 73 which correspond to respective cups of liquid soap 72 in the housing 70. Thus, the graduations 73 provide means for readily determining the total quantity of liquid soap 72 remaining in the housing 72. Moreover, the upper end surface of tubing 74 may have secured thereto in a conventional manner a light radiating means 75 which is connected electrically through a conductor cable 87 to a source of electrical power (not shown), such as a conventional alternating current source utilized for operating the washing machine 10, for example. The light radiating means 75 may comprise an inverted electrical socket (not shown) having therein an electrical lamp (not shown) which is disposed for directing light longitudinally down into the tubing 74. As a first alternative, the light radiating means 75 may comprise one or more light emitting diodes disposed to direct light down into the tubing 74. As a second alternative, the light radiating means 75 may comprise a tubular fluorescent light extending longitudinally parallel with the tubing 74. Furthermore, the opposing longitudinal sides of tubing 74 may be silvered to reflect light back onto the liquid soap 72 in tubing 74. Accordingly, the light radiating means 75 functions to illuminate the level of liquid soap 72 in tubing 74 so that the quantity of soap 72 remaining in housing 70 may be readily ascertained even in poorly illuminated environments.
The housing 70 includes an upper plate-like end which is attached by suitable means, such as right-angled plate 77 and screws 79, for example, to the side wall 16 of cabinet 12. Protruding from the upper end of housing 70 is a vent tube 78 which communicates with the interior of housing 70 for permitting egress and ingress of air as the level of liquid soap 72 increases and decreases, respectively, within housing 70. Also, the upper end of housing 70 has protruding therefrom a filler tube 80 which communicates with the interior of housing 70 and is connected hydraulically to one end portion of a filler hose 82. The filler hose 82 extends from the filler tube 80 upwardly within cabinet 12 and has its other end portion connected in a liquid-tight manner to a filler port 84 (FIG. 2). Filler port 84 is disposed in corner portion 23 of access end wall 20 within recess 22, and is provided with a protective cover 86 which is hinged. Thus, the cover 86 may be moved pivotally to a fully open position for pouring liquid soap 72 through the filler port 80 and filler hose 82 into the reservoir housing 70. Then, the cover 86 may be moved pivotally to a fully closed position where it may remain for the extended period of time, such as one month, for example, required to exhaust the contents of reservoir housing 70.
The additive motor 68 is connected through an electrical cable 88 to a soap dispensing control means comprised of a rotatable knob 90 protruding from a control panel 92 which extends upwardly from a marginal portion of access end wall 20 adjacent rear wall 17 of cabinet 12. Knob 90 may be maintained at a zero rotational position and pressed axially inward toward panel 92 for electrically energizing motor 68 and activating pump 66 as long as the knob 90 is pressed inwardly toward panel 92. Alternatively, the knob 90 may be rotated, such as ninety degrees from the zero rotational positions, for example, to select a predetermined quantity of additive liquid soap 72, such as one-quarter of a cup, for example. Then, the knob 90 may be pressed inwardly toward panel 92 and released to energize motor 68 and activate pump 66 for a predetermined length of time. In either instance, when the pump 66 is activated, liquid soap 72 is drawn from the reservoir housing 70 through hose 71 and forced through the hose 64 to the delivery tube component 60 of nozzle 56.
Consequently, as shown in FIG. 3, the pumped liquid soap 72 emerges from the outlet orifice 62 as a jet stream 94 which passes through the target aperture 54. As a result, the jet stream 94 of liquid soap is directed through the opening 52 of collar 50 and enters the spin tub 48. As shown in FIG. 5, a cup 95 may be held in the path of the jet stream 94 to determine if the quantity of liquid soap 72 being directed into spin tub 48 corresponds to the quantity of liquid soap 72 selected by adjustment of knob 90. Also, the liquid soap, thus obtained, may be examined regarding its quality and concentration for producing the desired effect on the wash water in spin tub 48. Preferably, the jet stream 94 entering spin tub 48 impinges on the agitator post 49 so that the liquid soap 72 in jet stream 94 will flow slowly down the post 48 and mix gradually with the wash water in spin tub 48. The stream 94 of liquid soap may be directed into spin tub 48 when wash water 93 is entering from drain tub 46 in the conventional manner and beginning to rise in the spin tub 48. Alternatively, the stream 94 of liquid soap may be directed into spin tub 48 when the wash water 93 has reached, or nearly reached, the required level in spin tub 48 for processing a wash load comprising items of clothing, such as 97 and 99, for examples, which have been passed through the clothes receiving opening 28 and are immersed in the wash water 93.
As shown in FIG. 4, when the motor 68 is de-energized and the pump 66 de-activated, the jet stream 94 no longer emerges from the outlet orifice 62. However, droplets 96 of liquid soap continue to accumulate at the outlet orifice 62 and fall into the drain tube component 58 of nozzle 56. Due to the slope of drain tube component 58, the droplets 96 run along the drain tube component 58 toward the drain end thereof which is adjacent the flange element 42 of cowling 34. As a result, the droplets 96 run out of the open drain end of drain tube component 58 and fall onto the underlying channel element 40 of cowling 34. Since the channel element 40 has a slope similar to the slope of drain tube component 58, the droplets 96 run radially downward of the channel element 40 to the junction thereof with the flange element 42 of cowling 34. Extended through a marginal portion of channel element 40 adjacent the flange element 42 is a plurality of arcuately spaced drain holes 98. Consequently, the drain holes 98 communicate with the radial space between the axially extending, imperforated wall of drain tub 46 and the axially extending perforated wall of spin tub 48. Accordingly, the droplets 96 pass through one or more of the drain holes 98 and fall into the wash water in the portion of drain tub 46 outside of the spin tub 48. Thus, the droplets 96 eventually mix with the portion of the wash water passing through the perforated wall of spin tub 48 and entering the spin tub 48.
Referring again to FIG. 1, the control panel 92 having protruding therefrom soap dispenser control knob 90 similarly may be provided with a water level control knob 100, a water temperature control knob 102, and a mode selector knob 104. The respective knobs 100, 102 and 104 electrically control the automatic operation of a plurality of components within cabinet 12 which are not shown since they do not affect the operation of the disclosed soap dispenser system. However, the mode selector knob 104 may be rotated to a position requiring the machine 10 to pass automatically through a pre-soaking operation prior to commencing a washing operation where injection of the liquid soap 72 into spin tub 48 is desired. Therefore, in order to retain automatic operation of the machine 10, it may be considered advantageous to incorporate electrical control of the soap dispenser system into the electrical control circuitry operated by the mode selector knob 104. Then, when the pre-soaking and subsequent water extraction operations are completed, the soap dispenser system will be activated simultaneously with the machine 10 commencing a washing operation. Thus, the disclosed soap dispenser system may be activated by manually pressing the knob 90 inwardly toward panel 92 or by automatically energizing the soap dispenser system electrically from the circuitry controlled via movement of the mode selector knob 104.
As shown in FIG. 6, the pump 66 instead of being coupled to the alternating current motor 68 shown in FIG. 1 may be coupled to a comparatively smaller direct current motor 106 which delivers an equivalent amount of power, such as thirty watts, for example, for forcing the liquid soap 72 through the outlet orifice 62. The direct current motor 106 may be especially designed for operating efficiently the pump 66 during the relatively short duty cycles, such as thirty seconds, for example, and life expectancy, such as forty hours, for example, expected of the motor. Direct current motors of this type may be found in battery powered tools, such as cordless drills and screwdrivers, for examples, which have similar torque requirements.
Pump 66 preferably is of the constant displacement type, such as a vane type having rigid vanes, for example, which forcefully expels liquid soap 72 from the nozzle 56 at a uniform rate. The direct current motor 106 is connected electrically to a control means comprising a conventional type of electrical timer circuit 108 and a dispenser amount selector unit 110. The selector unit 110 functions through the electrical timer circuit 108 to determine the length of time the motor 106 is energized thereby metering the amount of liquid soap 62 expelled from the nozzle 56. The electrical timer circuit 108, which generally includes integrated circuit devices (not shown) is energized, along with the direct current motor 68, from an electrically connected battery 112.
From the foregoing, it will be apparent that all of the objectives have been achieved by the structures and methods described herein. It also will be apparent, however, that various changes may be made by those skilled in the art without departing from the spirit of the invention subject matter, as expressed in the appended claims. It is to be understood, therefore, that all matter shown and described herein is to be interpreted as illustrative and not in a limiting sense.
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A clothes washing machine including a cabinet having therein a spin tub rotatably disposed within a stationary drain tub, and an additive liquid dispensing system comprised of a multi-load reservoir of additive liquid connected hydraulically through a pump to a liquid ejector nozzle. The reservoir comprises a liquid-tight housing which is vertically elongated and has a triangular cross-sectional shape for fitting into an elongated corner portion of the cabinet adjacent a front defining wall thereof. A side of the housing adjacent the front defining wall has a vertically elongated transparent portion disposed coextensively in alignment with a vertically elongated window in the front defining wall of the cabinet. The transparent portion of the housing may comprise a vertically extending tubular member disposed in communication with additive liquid in the housing such that the level of liquid in the tubular member is an indication of the level of liquid in the housing. A light radiating means may be disposed adjacent the tubular member which may have wall portions coated with light reflective material for illuminating the liquid in the tubular member. Also, a wall portion of the tubular member may be provided with graduations for measuring the amount of liquid in the housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a speaker assembly which may be taken apart in order that a higher capacity or smaller capacity speaker cone may be used without the necessity of replacing the base and disassembling speaker housing and cabinet.
2. Description of the Prior Art
Prior art speaker assemblies generally include a one-piece speaker base and cone unit. Speakers are generally mounted in a cabinet and provided with suitable acoustical members such as reflectors, sound absorbers and sound directors and the like which are arranged in such a fashion that in the event it is desirable to change a speaker unit, the entire cabinet, speaker arrangement must be replaced. This disclosure provides a two-piece speaker unit wherein speaker includes a base which may be securely mounted in a cabinet, and, a cone which is removably attached to the base. Thus, when it is desirable to increase or reduce the capacity of the speaker, all is necessary is that the cone be removed from the base and the new cone element inserted.
SUMMARY OF THE INVENTION
As is well known, any stress system is only as good as the speakers which are used. Frequently, audiophiles will attempt to upgrade a sound system by the addition of better quality speakers. The cost of such upgrading is oftentimes prohibitive because entire speaker units and cabinets must be replaced. Occasionally, speaker cones which are paper, are damaged in handling or damaged by vandals, small children or the passage of time and use.
This disclosure relates to a two-piece speaker arrangement wherein a permanently attached speaker base has a cone unit removably attached thereto. In the event it is desirable to replace or change the speaker capacity, the detachable cone may be easily removed from the base.
In operation, the base and cone units are provided with cooperating threaded portions to allow the cone to be screwed into the base. Similarly, the base and cone units may include a so-called bayonet-type arrangement whereby a finger fits into a suitably-sized vertical slot and horizontal groove and may be easily attached and/or removed from the base unit.
A biasing spring placed between the base and cone insures that the two units remain in an assembled, secure fit after the initial assembly. Further, a spring-biased contact is centrally located in the base unit and cooperates with a suitably placed contact in the cone unit to complete the electrical connection between the contact and the voice coil.
Thus, it is an object of this invention to provide a speaker assembly for the use in radios, televisions, stereos and the like in which the capacity of the speaker may be altered by simply removing a detachable speaker cone and replacing with a different sized speaker cone unit.
Another object of this disclosure is to provide a speaker assembly having a cone unit that may be threaded onto a permanently mounted base unit and easily removed in the event it is desirable to change the capacity of the speaker or to replace a damaged speaker.
A further object of this disclosure is to provide a two-piece speaker assembly which may be easily taken apart and which includes spring biasing means urging the cone and base units into a secured, locked configuration when they are assembled.
Yet another object of this invention is to provide a speaker having a cone unit and a base unit and being interconnected by a bayonet-type of assembly wherein horizontally extending fingers cooperate with vertical slots and horizontally disposed grooves to align and lock the base and cone together as a single unit.
These and other objects of the invention will become apparent to those having ordinary skill in the art with reference to the following description, drawings and appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, elevantional view showing a two-piece speaker arrangement;
FIG. 2 is a sectional view of the assembled speaker elements; and
FIG. 3 is a view taken generally along the lines 3--3 of FIG. 1.
DESCRIPTION
Referring now to the drawings and in particular to FIG. 1, there is shown a cone unit 10 which is attachable to a rigidly mounted base unit 12. Cone unit 10 provides a paper diaphragm 11 which is attached at its periphery to frame 13 and attached at the rear base of its central portion to a coil carrier 15. Coil carrier 15 is a cylindrical member having a bottom attached to diaphragm 11. Base 12 includes a mounting flange 14 in which a number of openings are generally provided for fastening the base 12 into a speaker cabinet or speaker support such as the underside of an automobile dashboard. The central portion of the base 12 includes a housing 16 which is a circular member surrounding a centrally disposed cavity 18. As shown in FIGS. 1 and 2, the cavity 18 may include suitably sized internal threads 20, 21 or may include a bayonet-type of horizontal groove 22 and vertical slot arrangement designated 22a. In FIGS. 1 and 2 the threaded-type connection is shown on the left and the bayonet-type connection is shown on the right. Either arrangement may be used alone. It is not contemplated that both arrangements be used together.
The circular housing 16 is of a relatively large diameter because the threads or bayonet-type connection is more effective and easily attached when the connecting or mating portions are spaced apart as far as possible. With such spacing, dimensional variations in the mating parts produce only a minimum amount of misalignment.
As with any speaker arrangement, it is necessary that an electrical impulse be provided to the speaker and thus speaker wire 24 provides this impulse. Both a ground and electrical impulse are carried by conductor 24; however, the ground lead is not extended to voice coil 38 since one end of coil 38 is grounded on cone unit 10. A terminal 26 is electrically connected with the conducting portion of wire 24 and is raised above the base or mounting flange 14 by a biasing spring 28. As shown in FIG. 1, the mounting flange 14 is grounded at 30 by direct attachment to one wire of conductor 24. Thus, when the cone unit 10 and base 12 are attached, the ground is transferred from the base to the cone unit 10.
The cone unit 10 is provided with a so-called carrier 34 which provides a rigid member for mounting speaker elements. Carrier 34 includes a first annular cutout 17 which receives base 12 and an annular cutout 36 which provides an open end extending toward coil carrier 15 and provides a receptacle to receive the voice coil 38. Coil 38 is wound onto coil carrier 15 and includes a number of windings of insulated, thin, wire which carry electrical impulses. One end of the voice coil 38 is grounded to the carrier 34 and thus when the cone 10 and base 12 are connected by means of the threads or the bayonet-type connection, a ground is provided to complete the electrical circuit for the speaker. The second end of the voice coil 38 extends through the carrier 34 and through the insulator 42 and is connected with a terminal member 43. For illustrative purposes the lead 40 is shown extending through the body of the carrier 34; however, it is well understood that any other type of convenient path could be used for connecting the one end of the voice coil 38 with its associated terminal 43.
A permanent magnet 46 surrounds the outer periphery of the carrier 34. Carrier 34 is a non-metallic or magnetically permeable member having a very low reluctance or interference with the paths of magnet lines of flux. Carrier 34 may be made of a permeable, soft iron which will hold magnet 46 in position yet not interfere with magnet interaction between magnet 46 and voice coil 38. Thus, a magnet circuit extends from magnet 46, through the adjacent part of carrier 34 and into the voice coil 36. When electrical impulses are flowing through coil 36 the coil becomes magnetized and will move up or down depending on the polarity (north or south) of the applied electrical impulse. Such movement of the coil also moves the attached coil carrier 15 and moves or vibrates the diaphragm 11 to produce an audible sound.
As shown in FIG. 1, a biasing spring 48 fits within cavity 18 and is compressed into the mounting flange 14 when the cone unit 10 is attached as shown in FIG. 2. When spring 48 is compressed it provides an upward force which provides the interconnected cone 10 and base 12 with a biasing force which tends to lock these two members securely in place. Thus, when the cone unit is screwed into the base or when the fingers 23 are inserted into their vertical slots 22a and horizontal bayonet-type grooves 22, spring 48 locks these two members securely into position and prevents the two members from inadvertently vibrating apart when in use or during transport.
Thus, it is shown by the foregoing that the two-piece speaker arrangement provided herein allows a multitude of speaker cones to be used with a single base 12. In the event it is desired to move the cone unit 10, it is simply unscrewed from the base, or, if the groove and finger arrangement 22, 23 is used, the cone is pushed toward the base 12 and then rotated slightly to clear the locking portion of the slot 22 and permit the base 12 to be removed from the cone 10.
The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto, except insofar as the appended claims are so limited, as those who are skilled in the art and have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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A two-piece speaker assembly has a speaker base for permanent attachment to a cabinet and a detachable cone unit that may be removably attached to the base and replaced by a larger or smaller capacity speaker as desired. The separable base and cone units are threaded or provided with a bayonet-type of interlocking arrangement and biased with a spring to maintain a locked connection. Also, an electrical connection between the base and speaker cone is provided by a suitably-sized, contact-type of spring-biased terminals.
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RELATED APPLICATIONS
[0001] The present application is related to U.S. Provisional Patent Application, Ser. No. 61/022,776 filed on Jan. 22, 2008, and U.S. Provisional Patent Application, Ser. No. 61/022,501 filed on Jan. 21, 2008, which are incorporated herein by reference and to which priority is claimed pursuant to 35 USC 119.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the invention
[0003] The invention relates to the field of endovascular OCT device incorporated in the context of an intracranial endovascular access device for intravascular imaging.
[0004] 2. Description of the Prior Art
[0005] Optical coherence tomography (OCT) is a technology that permits high resolution in vivo imaging. Imaging is carried out at near histology resolution thus yielding clinically relevant information without the need for surgical biopsy. OCT has been used in vivo to image coronary artery disease. The in vivo clinical use of OCT has never been reported to study cerebral vasculature. To study cerebral, coronary, and other vasculature in the body such as in the kidneys, arms and legs as well as other organs OCT technology needs to be incorporated into an endovascular device that has all the necessary mechanical, physical and biological properties for proper device delivery and application.
[0006] The problem of obtaining in vivo blood vessel microstructure was previously studied using intravascular ultrasound (IVUS). OCT study has been previously reported in the coronary arteries, but never in the intracranial or other blood vessels outside the heart. The main disadvantage of IVUS is low resolution imaging. IVUS has not been used for in vivo imaging of intracranial blood vessels.
[0007] However, in order to obtain near histological resolution of which OCT is capable, it is necessary first to have some kind of OCT probe which can be used in endovascular applications, including intracranial applications, which can reproducibly and reliably deliver images having OCT quality resolution, which in turn requires stability at microscopic scales in the scanning mechanism and design of the OCT probe.
BRIEF SUMMARY OF THE INVENTION
[0008] OCT is an imaging technique analogous to ultrasound except that IR or NIR light is used instead of sound. The optical beam is focused into the tissue and the reflection or echo time delay of the light which is scattered or reflected from internal microstructure in the tissue at different depths and resolved by interferometry. The image is obtained by performing repeated axial measurements at different transverse positions in the vessels as the optical beam is scanned across the tissue. The result is a two or three dimensional map of the reflectance from the internal morphology of the tissues and cells. Axial resolution of less than 5 microns can be obtained using relatively inexpensive and portable equipment, which is ideally suited for incorporation into catheters and endoscopes, which allow for optical biopsies at near histological levels without incision in a noninvasive manner.
[0009] The illustrated embodiment of the invention is an endovascular OCT probe included in an endovascular access device for intravascular imaging including a longitudinal lumen defined in the endovascular access device, a hollow coil wire defining an axial lumen therein, a single mode optical fiber for transmitting light, the fiber being disposed in the axial lumen of the hollow coil wire so that translation and rotation of the hollow coil wire carrying the optical fiber within the endovascular access device is stabilized for scanning endovascular tissue; and an optic element for directing light from and into the optical fiber at a distal tip of the optical fiber.
[0010] The endovascular access device has a proximal end and further comprises a FC/APC or FC/PC single mode fiber adaptor assembled thereto.
[0011] The endovascular access probe has a distal end which is used for imaging tissue, and where the optic element includes a GRIN lens and prism disposed on the distal end of the optical fiber to direct light in a beam perpendicular to the longitudinal axis of the fiber, and a glass ferrule encasing the GRIN lens and prism to protect the optic element and distal tip of the optical fiber from mechanical damage.
[0012] The endovascular OCT probe further includes a hollow steel tube disposed within the axial lumen of the hollow coil wire within which tube the optical fiber is disposed, the hollow steel tube being provided in at least a proximal of the probe whereby torsional stiffness of the OCT probe is increased to increase rotational and translational scanning stability of the OCT probe.
[0013] The endovascular OCT probe further comprises a fiber rotator and a linear stage transducer separately coupled to a proximal end of the OCT probe for provide for independently controlled rotational scanning and translational scanning of images.
[0014] The endovascular OCT probe further comprises an OCT interferometer and computer coupled thereto for generating images from the returned light from the optical fiber of the probe.
[0015] The endovascular OCT probe includes an annular space between the lumen of the endovascular access device and the hollow coil wire to allow for controlled flushing through a distal end of the OCT probe effective to flush a space between the optic element and tissue being scanned.
[0016] The endovascular OCT probe further comprises a hollow steel tube disposed within the axial lumen of the hollow coil wire within which tube the optical fiber is disposed, the hollow steel tube being provided only in a proximal portion of the probe whereby torsional stiffness of the OCT probe is increased to increase rotational and translational scanning stability of the OCT probe, and a second more distal hollow coil wire of smaller diameter than the proximal hollow coil, the second distal smaller coil wire including the optical fiber extending from the proximal coil wire and terminating in the optic element, the proximal hollow coil wire being characterized by greater stiffness than the distal hollow coil wire.
[0017] The endovascular OCT probe further comprises an external OCT system and electric motors coupled to the optical fiber and controlled by the external OCT system, wherein the OCT probe is separately rotated by a fiber rotator and/or linearly translated by a linear stage which are powered by the electric motors controlled by the external OCT system to generate a reproducible image with spatial resolution of at least 5 microns.
[0018] The proximal hollow coil wire is comprised of an outer coil made by removing the inner core of a larger diameter guide wire, and the distal hollow coil wire is comprised of a smaller coil made by removing the inner core of a smaller diameter guide wire.
[0019] The illustrated embodiment of the invention further includes an endovascular OCT probe for intravascular imaging comprising a microcatheter with a longitudinal lumen defined therein, a plurality of hollow coil wires coupled longitudinally to each other to collectively define a longitudinal lumen through the plurality of hollow coil wires, the plurality of hollow coil wires having a maximum stiffness and diameter at a proximal end of the plurality of hollow coil wires and sequencing monotonically with smaller diameters and less stiffness for each of the hollow coil wires until reaching a minimum stiffness and diameter at a distal end of the plurality of hollow coil wires, an optical fiber for transmitting light being disposed in the longitudinal lumen so that translation and rotation of the hollow coil wire carrying the optical fiber within the endovascular access device is stabilized for scanning endovascular tissue, and an optic element for directing light from and into the optical fiber at a distal tip of the optical fiber.
[0020] The illustrated embodiment also includes a method using a stable scanning endovascular OCT probe comprising the steps of endovascularly rotationally optically scanning tissue and/or endovascularly translationally optically scanning tissue with a stability able to achieve at least 5 micron resolution using the OCT probe in an intracranial or extracranial application, where endovascularly rotationally optically scanning tissue is performed in a torsionally reinforced endovascular OCT probe, and endovascularly translationally optically scanning tissue is performed in a longitudinally reinforced endovascular OCT probe.
[0021] The intracranial applications include assessment and evaluation of cerebrovascular diseases including but not restricted to atherosclerosis, fibromuscular dysplasia, inflammatory diseases of blood vessels, genetic, chromosomal, developmental, degenerative, and acquired abnormalities such as aneurysms, arteriovenous malformations, dissections, amyloid deposition, blood vessel ruptures and tears, evaluation of therapeutic manipulations such as aneurysm coiling, angioplasty, stent placement, AVM embolizations, tumor embolizations, assessment of therapeutic/healing response to surgical and medical treatments or prognostication of medical conditions involving blood vessels.
[0022] The extracranial applications are the same as intracranial applications but are carried out in blood vessels supplying blood to other organs such as the heart, liver, kidney, extremities, lungs, gastrointestinal tract including cerebral aneurysms by imaging the quantity and quality of fibrous connective tissue including collagen and elastin fibers within the aneurysm all to predict risk of rupture of cerebral aneurysms, or by imaging neo-endothelization across the neck of aneurysms treated with coils to document the extent of post-treatment aneurysm healing.
[0023] The method further comprises the step of flushing a bolus of 20 cc of normal saline into an endovascular space of interest through an endovascular catheter of appropriate size that is placed two to three centimeters proximal to the imaging field to flush away luminal blood, which otherwise obstructs the path of light during scanning.
[0024] The step of endovascularly rotationally optically scanning tissue and/or endovascularly translationally optically scanning tissue with a stability able to achieve at least 8 micron resolution using the OCT probe in an intracranial or extracranial application is solely motor controlled.
[0025] The step of endovascularly rotationally optically scanning tissue and/or endovascularly translationally optically scanning tissue with a stability able to achieve at least 5 micron resolution using the OCT probe in an intracranial or extracranial application is separately controlled and separately transduced rotation and translation of the OCT probe.
[0026] The step of endovascularly rotationally optically scanning tissue is performed in a torsionally reinforced endovascular OCT probe, and endovascularly translationally optically scanning tissue is performed in a longitudinally reinforced endovascular OCT probe comprised of a longitudinal lumen defined in an endovascular access device, a hollow coil wire defining an axial lumen therein, a single mode optical fiber for transmitting light, the fiber being disposed in the axial lumen of the hollow coil wire so that translation and rotation of the hollow coil wire carrying the optical fiber within the endovascular access device is stabilized for scanning endovascular tissue, and an optic element for directing light from and into the optical fiber at a distal tip of the optical fiber.
[0027] The step of endovascularly rotationally optically scanning tissue is performed in a torsionally reinforced endovascular OCT probe having an optical fiber disposed in the lumen of a hollow coil wire and an optic element fixed to a distal end of the optical fiber.
[0028] The step of endovascularly translationally optically scanning tissue is performed in a longitudinally reinforced endovascular OCT probe having an optical fiber disposed in the lumen of a thin solid hollow steel tube and an optic element fixed to a distal end of the optical fiber, the steel tube being disposed with a hollow coil wire.
[0029] 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. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a side cross-sectional diagram of a first embodiment of the invention.
[0031] FIG. 2 is a side view of another embodiment of an OCT probe of the invention.
[0032] FIG. 3 is a side view of still another embodiment of an OCT probe of the invention.
[0033] FIG. 4 is a diagrammatic view of a rotator and linear stage transducer used to scan the OCT probe.
[0034] FIG. 5 is a diagram of an OCT interferometric system.
[0035] FIG. 6 is a side cross-sectional diagram of one application of the invention to image aneurysm necks occluded by GDC coils.
[0036] FIG. 7 is a photograph of the first purely translational scan of a human intracranial internal carotid artery wall taken with a probe of the invention.
[0037] FIG. 8 is a photograph of the first purely rotational scan of a human intracranial internal carotid artery wall and stent taken with a probe of the invention.
[0038] FIG. 9 is a side view of yet another embodiment of an OCT probe of the invention.
[0039] The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The illustrated embodiment of the invention is an endovascular OCT device incorporated onto the framework of an intracranial endovascular access device for intravascular imaging. This construct is obtained by removing the solid core of an intracranial access wire while retaining the outer coiled shell. A single mode optical fiber is inserted into the hollow coil wire. In the proximal end that remains outside the body a FC/APC or FC/PC single mode fiber adaptor is assembled. In the distal end which is used for imaging tissue, a gradient-index (GRIN) lens and prism are glued together to focus and guide the light into a beam perpendicular to the fiber's longitudinal axis. A glass ferrule with strong medical glue inside protects the tip from mechanical damage. This construct confers the OCT device with adequate mechanical, biological, radiological, and optical properties necessary for in vivo endovascular imaging in patients. FC/PC and FC/APC connectors are most commonly found in high-end single mode fiber telecommunications systems. The term “FC” is a fiber connector designated by NTT. “PC” and “APC” describe the kind of polish applied to the connector end face. PC stands for physical contact. A PC connector has a polished convex end face. SPC and UPC are “super” polished and “ultra” polished with better back reflection specification than PC. APC stands for an angled physical contact. An APC connector has a polished end face angled at 8 degrees.
[0041] The purpose of the invention is to obtain high-resolution images of blood vessel wall to guide therapeutic decision-making and medical care of patients. OCT is analogous to ultrasound except that imaging is performed with light instead of acoustic waves. OCT measures light reflected from tissue structures. OCT is an imaging technique capable of performing high-resolution (3 to 8 microns), cross-sectional imaging. OCT enables real-time, in situ visualization of tissue microstructure without the need to excise and process the specimen as required for conventional biopsy and histopathology. Consequently, OCT is a powerful method to image biological tissue in-vivo at high resolution. OCT relies on scanning a region of interest to create images. Scanning requires rotational and translational movement which is accomplished by delivery of mechanical forces to the scanning tip of an OCT optical fiber. Consequently a safe, reliable, endovascular device is necessary for mechanical translation and rotation, as well as for delivery of light.
[0042] The main advantage of OCT over IVUS is its high-resolution imaging. The typical resolution using IVUS is 100 microns, while using OCT is 3 to 8 microns. Thus the resolution and quality of images obtained using OCT is dramatically superior to IVUS. While OCT has been used for coronary artery imaging, previous endovascular OCT devices have not had the physical and biological properties which allowed them to be deployed intracranially with fine precision and control. The disclosed endovascular device accomplishes this with the established safety profile of an intracranial access wire. The structural design and construct our endovascular device uniquely allows intracranial endovascular imaging as well as imaging of extracranial vasculature.
[0043] Proposed uses for the illustrated embodiment of the invention can be divided into intracranial and extracranial applications. Intracranial applications include assessment and evaluation of all cerebrovascular diseases including (but not restricted to) atherosclerosis, fibromuscular dysplasia, inflammatory diseases of blood vessels, genetic, chromosomal, developmental, degenerative, and acquired abnormalities such as aneurysms, arteriovenous malformations, dissections, amyloid deposition, blood vessel ruptures and tears, etc, as well as evaluation of therapeutic manipulations such as aneurysm coiling, angioplasty, stent placement, AVM embolizations, tumor embolizations etc. In addition the device can be used for assessment of therapeutic/healing response to surgical and medical treatments as well as prognostication of medical conditions involving blood vessels.
[0044] Extracranial applications are the same as intracranial applications but are carried out in blood vessels supplying blood to other organs such as the heart, liver, kidney, extremities, lungs, gastrointestinal tract etc. Two particular uses of great potential are related to cerebral aneurysms. Firstly, by imaging the quantity and quality of fibrous connective tissue including collagen and elastin fibers within the aneurysm wall, the device can be used to predict risk of rupture of cerebral aneurysms. Secondly, by imaging neo-endothelization across the neck of aneurysms treated with coils this device can document the extent of post-treatment aneurysm healing.
[0045] The device is introduced endovascularly from a peripheral blood vessel such as the femoral or brachial artery or vein through an endovascular access sheath 16 as shown in FIG. 1 . The device is then passed to its desired location using standard endovascular techniques. Proper positioning of the device adjacent to a region of interest is confirmed using X-ray fluoroscopy. When in desired position the device is rotated, linearly translated, or both through predetermined distances using rotary and linear motors placed outside the body. Concurrently, a bolus flush 18 of 20 cc of normal saline is carried out into the lumen at the region of interest, through an endovascular catheter of appropriate size that is placed two to three centimeters proximal to the imaging field. The saline bolus flushes away luminal blood, which otherwise obstructs the path of light. By a combination of rotary and linear movements three dimensional high-resolution images of blood vessel microstructure can be obtained.
[0046] FIG. 1 shows one embodiment for an OCT fiber 10 . The OCT fiber 10 is concentrically disposed inside a transparent plastic microcatheter 12 . The saline flushes the blood out of the micro catheter 12 . OCT fiber 10 rotates and moves linearly telescopes down and up the microcatheter 12 . Light from OCT fiber 10 penetrates the transparent microcatheter 12 and reaches the blood vessel wall. The microcatheter 12 allows better translation or linear motion to the tip 14 of the endovascular OCT fiber 10 . This embodiment is ideal for imaging proximal portions of blood vessels near an endovascular access site.
[0047] FIG. 2 shows the design of endovascular OCT device as a whole apart from microcatheter 12 . The core of a conventional guidewire is removed and a single mode optical fiber 10 is inserted into the hollow coil wire 20 . In the illustrated embodiment guidewires in two sizes of interest have been investigated. One has a 0.018 inch outer diameter and is ideal for intracranial and coronary vessel imaging by virtue of its small size, while the other has a 0.036 inch outer diameter and is better suited for other vascular sites. In the proximal end, a FC/APC or FC/PC single mode fiber adaptor 22 is assembled. In the distal end, GRIN lens and prism 24 are glued together to direct the light perpendicular to the fiber axis. A glass ferrule 26 is attached with strong medical glue to protect the tip 14 from mechanical damage. This embodiment is better suited for imaging distal vasculature such as cerebral or coronary vasculature.
[0048] FIG. 3 shows another embodiment of the endovascular OCT device. In this embodiment a thin steel hollow tube 28 is telescopically disposed over the fiber 10 to increase axial stiffness. This embodiment enables better transfer of rotational torque from the proximal end to the distal tip. Thus, it is to be understood that tube 28 may assume any torsionally stiff element, including but not limited to braided cylinders of metal or stiff polymeric fibers.
[0049] FIG. 4 shows the connection or coupling between OCT probe 30 and the external OCT system. The OCT probe 30 is separately rotated and linearly manipulated by a fiber rotator 32 and linear stage 34 , both of which are powered by electric motors that cause mechanical transduction. The combined helix scan mode of OCT probe 30 when both rotator 32 and linear stage 34 are active realizes three dimensional image acquisition. The static optical fiber 36 of FIG. 5 couples the light into OCT probe 30 by the fiber rotator 32 .
[0050] FIG. 5 shows the schematic diagram of the high speed, high resolution Fourier domain OCT system 38 which reconstructs vessel structure image. 80% of the incident power from swept light source 39 is coupled into sample arm 40 while 20% is feed into reference arm 42 by a 1×2 fiber coupler 44 . The reference power directed toward mirror 41 is attenuated by an adjustable neutral density attenuator 46 for maximum sensitivity. Two circulators 48 are used in both reference arm 42 and sample arm 40 to redirect the back-reflected light to the second 2×2 fiber coupler 50 (50/50 split ratio) for balanced detection. The time fringe signal collected by a photodetector 52 is digitized with an analog-digital acquisition card or differential amplifier 54 and transferred to a computer 56 for processing.
[0051] FIG. 6 diagrammatically shows an endovascular application of the OCT probe 30 (labeled as OCT fiber). Probe 30 is used to endovascularly scan a region of interest, such as cerebral aneurysm neck in this case which has been occluded by implanted GDC coils 58 . Blood is flushed out using 0.9 normal saline flushes delivered through a microcatheter 12 placed a few centimeters proximal to the region of interest. A larger delivery catheter 16 such as a 6F endocatheter can be used to stabilize the endovascular setup. Linear and rotational scans are obtained using OCT probe pullback and rotation from an external motor (not shown).
[0052] FIGS. 7 and 8 are the first human cerebrovascular OCT images to be recorded, which are made possible from the unique design of our endovascular OCT device. FIG. 7 is the linear scanning OCT image from the cavernous portion of the left Internal carotid artery of a patient. FIG. 8 is a rotational scan obtained from the cavernous portion of the left internal carotid artery of the same patient. Optical shadows of stent struts obtained at the edge of an intracranial stent are can be seen in the images.
[0053] Another embodiment includes an OCT brain probe shown in FIG. 9 which uses a two-stage design. The proximal portion of probe 30 is of larger diameter than the distal end. The proximal portion is comprised of an outer coil 60 , made by removing the inner core of a larger diameter guide wire (0.036 inch), and an inside hollow steel tube 28 . The inside hollow steel tube 28 increases the rigidity of the proximal portion of the entire OCT brain probe 30 , which is helpful for transduction of linear movement to the distal tip 14 . The distal portion is composed of a smaller coil 62 made by removing the inner core of a smaller diameter guide wire (0.018 inch) and the optical tip 14 . The small coil 62 of the distal portion maintains flexibility in the distal portion of the OCT brain probe 30 , which is critical for catheter delivery and guidance inside the brain vessel.
[0054] It can now be appreciated that the disclosed probe 30 includes several novel and advantageous features . The flush can be performed from the inner annular channel of the probe when it is applied to a mono-channel operation as depicted in FIG. 1 . The probe can also be applied in bi-channel operation. In this way, another flushing micro-catheter is applied as depicted in FIG. 6 . Each catheter occupies one channel respectively. In the mechanical aspects of the design, the probe tip 14 is secured by a transparent material ferrule, such as glass as depicted in FIG. 3 . This feature reduces the probe fracture risk greatly. To adapt to a tortuous human vessel, such as cerebral artery, the probe has a two-part body as depicted in FIG. 9 . The proximal portion is relatively large and rigid, while the tip and distal portion is small and soft.
[0055] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following invention and its various embodiments.
[0056] The words used in this specification to describe the invention and its, various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0057] The definitions of the words or elements of the following invention and its various embodiments are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments below or that a single element may be substituted for two or more elements in a claim.
[0058] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0059] The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
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An endovascular OCT probe is included in an endovascular access device for intravascular imaging. The probe includes a hollow coil wire defining an axial lumen of the endovascular access device. A single mode optical fiber for transmitting light is disposed in the axial lumen of the hollow coil wire so that translation and rotation of the hollow coil wire carrying the optical fiber within the endovascular access device is stabilized for scanning endovascular tissue with at least 5 microns resolution. An optic element directs light from and into the optical fiber at a distal tip of the optical fiber and is coupled to or fixed to the distal end of the optical fiber. The optic element and the distal end of the optical fiber is disposed within a glass ferule to protect it from damage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sports facilities.
2. Description of the Related Art
Sports facilities having synthetic surfaces such as artificial turf can better withstand wear and tear than natural grass. The synthetic surfaces currently in use, however, are not particularly suited for different sports nor are they easily configurable for multiple purposes.
BRIEF SUMMARY OF THE INVENTION
In one embodiment, the invention enables people to learn and practise sport, choosing from amongst the most widely practised activities the one that they prefer and is most suitable for their own physical and mental aptitudes.
According to the present invention, tone embodiment provides a multi-purpose sports facility.
In the currently preferred embodiment, the multi-purpose facility according to the invention makes it possible to start from the basic sport of running and evaluate the physical resources, aptitude, and resistance manifested by the individual person (with particular attention paid to young people aged between six and eighteen) to enable him or her to choose the most suitable sports activity from a set of activities comprising, for example, athletics, soccer, volleyball, tennis, basketball, and handball.
A youngster who starts by taking up running is then able to train by practising all the activities on a single multi-purpose facility with learning functions. Subsequently, he is able to specialize in one or more sports activities so as to be able to develop gradually his own capabilities and achieve increasingly satisfactory results.
The multi-purpose facility according to the invention enables the drawing-up of training programmes for the various sports, with the added possibility of it being set out according to different schemes (in particular as regards the choice of the sports), as dictated by the preferences, and the local customs and cultures of different geographical areas. The multi-purpose facility in question can be set up at a low cost so as to make it available (for example, by renting) at contained costs and for the benefit of entities such as schools, local authorities, and sports clubs.
In the configuration according to a preferred embodiment, the sports facility comprises in any case, peripherally, a running track, for example of a fairly short length (typically 200 meters) and/or with a number of lanes, which encloses inside it one or more pitches or courts for practising different sports activities.
In a particularly preferred way, the sports facility in question is obtained using as base structure a synthetic-grass covering comprising a sheet substrate with a plurality of filiform formations extending from the substrate for simulating the grass blade of natural turf, as well as a particulate filling material, or infill, dispersed between the filiform formations so as to keep the filiform formations themselves in a substantially upright condition.
Preserving the same basic structure and modifying parameters such as, for example, the extension of the filiform formations and the nature, density, as well as the thickness of the particulate infill, it is possible to bestow on different areas of the multi-purpose sports facility characteristics that are different according specifically to the various sports activities which are to be carried out thereon, possibly in accordance with the respective national and international sports federations.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The invention will now be described, purely by way of non-limiting example, with reference to the annexed plate of drawings, in which:
FIG. 1 is a general plan view of a multi-purpose sports facility according to one embodiment of the invention.
FIG. 2 is a schematic reproduction, in an ideal vertical cross section, of a portion of the base surface of the sports facility of FIG. 1 .
FIG. 3 is a cross-sectional illustration of FIG. 1 , taken where indicated, of a basketball and volleyball surface having a common substrate and different infill densities and filiform characteristics, according to one illustrated embodiment.
FIG. 4 is a cross-sectional illustration of FIG. 1 , taken where indicated, of a basketball and volleyball surface having a common base structure and different infill grain size, according to one illustrated embodiment.
FIG. 5 is a cross-sectional illustration of FIG. 1 , taken where indicated, of a basketball and volleyball surface having a common base structure and different infill densities, according to one illustrated embodiment.
FIG. 6 is a cross-sectional illustration of FIG. 1 , taken where indicated, of a basketball and volleyball surface having a common substrate and different filiform characteristics, according to one illustrated embodiment.
DETAILED DESCRIPTION OF THE INVENTION
In the attached plate of drawings, the reference number 10 designates as a whole a multi-purpose sports facility comprising, in the example of embodiment illustrated herein:
an athletics track 12 constituted by an annular running track, for example of a fairly short length (typically 200 meters) and/or with a number of lanes (from two, to six, to eight), which is circumscribed by a boundary 14 , here having a generally rectangular shape, which encloses an internal space 16 ; and one or more fields, pitches or courts 18 , 20 , 22 for practising different sports activities made in the space 10 delimited by the running track 12 .
For purpose of illustration, without in any way limiting the scope of the invention, the dimensions of the rectangular boundary 14 may typically be in the region of 100-110 meters in length by 40-50 meters in width, which corresponds to a total surface of approximately 5000 m 2 .
Advantageously, the running track 12 has, along its major sides, one or more rectilinear stretches 120 , 140 , which extend practically throughout the length of the boundary 14 and can be used, for example, for short-distance running (for example 100m) or else for jumping activities (long jumping, pole vaulting, hop-step-and-jump, etc.).
As regards the areas 18 , 20 , 22 , the example of embodiment to which FIG. 1 refers envisages that the area 18 is a football pitch (five-a-side football), having for example dimensions of 40×20 m. The area 20 may be instead a basketball court with typical dimensions in the region of 28×15 m. The area 22 is a volleyball court with typical dimensions in the region of 9×18 m.
Of course, both the number of pitches and courts 18 , 20 , 22 and their arrangement, the dimensions indicated, as well as the nature of the areas in question are intended purely to provide an example and hence in no way limit the sphere of protection of the invention.
In a particularly preferred way, all the various pitches, tracks, etc. 12 , 18 , 20 , 22 illustrated herein (or at least one subset thereof) are obtained using, as base structure, a structure of synthetic-grass covering of the type illustrated in FIG. 2 .
This is a structure comprising a sheet substrate 1 with a plurality of filiform formations 2 extending from the substrate 1 so as to simulate the grass blade of natural turf, and a particulate filling material, or infill, 3 dispersed between the filiform formations 2 so as to keep the filiform formations 2 themselves in a substantially upright condition.
In a particularly preferred way, the particulate infill 3 consists of a substantially homogeneous mass of a granular material chosen in the group consisting of polyolefin-based materials and vinyl polymer-based materials, for example of the type described in EP-A-1 158 099, in the name of Mondo S.p.A., the assignee of the instant application.
Recourse to this structure makes it possible to bestow on the various surfaces 12 , 18 , 20 , 22 biomechanical characteristics differentiated according to the particular specialities that are to be practised on a given pitch or track. This is obtained by modifying the characteristic parameters of the constituent elements of the structure (e.g., the filiform formations 2 and the infill 3 ), as illustrated in FIG. 3 .
According to FIG. 4 , for example, a first parameter is the grain size 3 a , 3 b of the infill 3 . It is therefore possible, for example, to reserve smaller values of grain size 3 a to pitches or tracks for which a higher compactness (i.e., a greater “hardness”) is desired, as in the case of the basketball court, such as the pitch 20 , whilst greater values of grain size 3 b are usually reserved to pitches for which characteristics of greater softness or pliancy are desired, such as the pitch 22 .
As illustrated in FIG. 5 , substantially similar considerations apply as regards the density D 1 , D 2 of the infill 3 . For example, the density D 1 is greater than the density D 2 . The same considerations are valid as regards the apparent density D 1 , D 2 of the infill 3 and as regards its grain size 3 a , 3 b , as well as the amount of dispersed material.
In another embodiment, the infill 3 may consist simply of sand, or of a filling with high hardness, or else, in a particularly preferred way, of a polyolefin-based material or a vinyl polymer-based material. Particularly preferred choices for said material are polyethylene, recycled polyolefin material or else a recycled vinyl polymer.
It will be appreciated that the filling materials can be the same as one another or else different for the various playing surfaces 12 , 18 , 20 , 22 .
As illustrated in FIG. 6 , other parameters on which it is possible to adjust in order to modify selectively the biomechanical characteristics of the various tracks, pitches or courts 12 , 18 , 20 , 22 are, for example, the density (points/m 2 ) and/or the length of the filiform formations 2 , understood as the distance between their proximal ends (designated by 2 a ), which are anchored to the substrate 1 , and their distal ends, which extend upwards.
In a particularly advantageous embodiment of the multi-purpose sports facility, it is envisaged to use, for two or more of the tracks or pitches 12 , 18 , 20 and 22 , a sheet substrate 1 with a plurality of filiform formations 2 extending from the substrate 1 with uniform characteristics. In this case, differentiation of the biomechanical characteristics of the various areas 12 , 18 , 20 , 22 is obtained by primarily adjusting the characteristics of the infill 3 and/or the characteristics of distribution of the material itself on the substrate 1 .
The multi-purpose sports facility described herein presents the further advantage of being suited both as regards convenience of laying, and as regards a possible convenient reconfiguration of the various tracks, pitches or courts (variation in number, position, orientation, and characteristics thereof, also according to requirements of use that can vary in time), as well as regarding a convenient operation of dismantling, with practically complete recycling of the component materials, according to the modalities described, for example, in EP-A-1 319 753.
Advantageous variant embodiments of the structure of covering which can be used for the multi-purpose sports facility according to the invention are described in EP-A-1 375 750, EP-A-1 371 779 and in the European patent application filed under No. 03425369 or else in EP-A-0 874 105 and EP-A-0 913 524.
All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.
Of course, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to what is described and illustrated herein, without thereby departing from the scope of the present invention.
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A multi-purpose sports facility is provided with a common base structure comprising a plurality of areas, each of which constitutes a track, pitch or court for practicing a respective sports activity. The invention enables people to learn and practice sport, choosing from the activities most widely practiced the one that they prefer and is tracks, pitches or courts most suitable for their own physical and mental aptitudes.
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RELATED APPLICATION SECTION
[0001] This application claims benefit of priority to U.S. application No. 60/692,510 filed on Jun. 21, 2005, the teachings of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] End users of electricity, also called industrial, commercial and retail ratepayers by load serving entities (utilities that deliver power to the customers' meter), face unfortunate rate structures. During certain hours, usually the day and especially in the summer, load serving entities charge more per kilowatt hour (kWh) for electricity than at night. Additionally, many have a demand charge that is related to the highest power use during the day in a given month of season (a charge per kW of power where the charge might be $16 per kW even though that amount of power was only used for 15 minutes in a month). Since end users generally use more power and electricity during the day than at night, when rates are lowest, their costs for electricity and power are greater than otherwise would be the case. Further, since cooling demands increase during the day as temperatures rise, especially in the summer when rates are highest, the cost of electricity utilities for end users is substantial.
[0003] To control costs, end users have employed several strategies. One of the most effective has been to increase the efficiency of the equipment that they use. For example, many end users have joined Green Lights, a US EPA program, in which they reduced their lighting energy use on average by 50% by upgrading their lighting systems from magnetic ballasts to modem electronic ballasts. Such projects typically yielded rates of return exceeding 50%. End users have also installed Energy Star equipment that reduces computer and other ‘appliance’ energy use. End users have improved the shells of their buildings by installing more energy-efficient windows and insulation. Efficient air conditioning equipment and variable frequency drives on fans have also reduced both kWh use and kW use. These strategies entail reducing the energy usage, thereby reducing charges for energy and power demand from load serving entities.
[0004] Another solution suggested involves thermal storage of energy in the form of ice or cold water. Taking advantage of low night time rates, these end users would install equipment to store the cold water or ice and then use it for cooling during the daytime.
[0005] Still another solution involves building distributed generation (DG), or an end-user power producing plant, that usually also produce hot water (co-generation or combined heat and power) or hot water and cooling in the summer from thermally driven cooling (so-called tri-generation). However, these installations have their own difficulties. Many end users do not want to take on the responsibility of operating these facilities or installing combustion engines. End-users located in regions of high air pollution may find obtaining the necessary air pollution permits impractical. Finally, distributed generation has its own problems associated with idle facilities during the night and much of the day if the generators are to produce power needed for peak times. Compressed air energy storage (CAES) systems have been suggested as part of integrated DG facilities to ameliorate waste and to improve heat rates, although this proposal fails to address the reluctance or inability of end users to host combustion activities.
[0006] While CAES systems have been a focus of research for decades, few have been successfully demonstrated at a few sites around the world and all have been intimately connected to electrical generating/combustion systems. CAES systems have not found widespread acceptance anywhere in the world, however, despite the intuitive appeal of CAES in potentially reducing the mismatch between the availability of generation and the demand for power throughout the day and throughout the year. Researchers and advocates of CAES systems have failed in their efforts to win acceptance.
[0007] CAES were originally suggested to take advantage of the energy usage differential, as discussed above. In fact, even with the additional economic anomaly that occurs because nuclear power plants and coal plants, which cannot easily be turned on or off during each diurnal cycle, the CAES systems of the prior art have not been built. Since these types of power plants provide a large fraction of the baseload power demand during the day, power production often exceeds demand at night, thereby lowering the price of power during these periods to below the average cost for delivered power. In other words, power plants are run at night in order to be able to be dispatchable during the day, wasting resources and creating unnecessary pollution. Furthermore, since peak demands must be met with electricity dispatched and transmitted and distributed at the time of peak need, transmission and distribution system must be built to accommodate the peak demand, thereby living a large proportion of the Transmission &Distribution (T&D) capital idle much of the rest of the time.
[0008] Small volume compressed air storage combined with flywheels have been suggested as a method of creating a short term, uninterrupted power supply (UPS) for electronics and even of being able to provide limited cooling as air is expanded, but the discussion in the literature is not concerned at all with energy savings or management, with integration into the EMP of facilities but with sustaining high quality power. David Morrison, Editor of Power Electronics Technology stated in his article “Leveraging Thermal and Compressed Air Storage” focuses on the value of a system that uses flywheels and compressed air to provide fast back up power. The producer, Active Power, describes their systems as follows: “How does it work? CleanSource XR stores energy in the form of heat and compressed air. During a utility outage, the compressed air is routed through a thermal storage unit to acquire heat energy. The heated air spins a simple turbine-alternator to produce electric power. Air that exits this small turbine is below room temperature and can be used to cool the protected load. Tanks that store the compressed air become cold during discharge, absorbing heat from the ambient environment and ultimately converting this heat into additional backup power. CleanSource XR also contains a small, continuous-duty flywheel that handles small fluctuations in power and supports the critical load during the brief period required for the air turbine to reach full speed in the case of an extended outage. In a White Paper written by John R Sears from Active Power, Sears makes it clear that the purpose of using CAES with a thermal storage and a flywheel is the opposite of using a CAES system to reduce the inflow of power during peak power, clearly indicating that purpose of the Active Power system is to operate when power would not flow to the end user at all. The UPS hybrid discussed in the prior art seeks to REPLACE power that is suddenly interrupted in the flow, not to DISPLACE power that would have flowed at a high cost.
[0009] In fact, the failure of CAES technology to move forward, given the negative economic impact for society and users, increasing capital costs for providing energy services, increasing operating costs and increasing pollution, illustrates the failure of current CAES technology to address a vital need of the energy system. Despite more than 30 years of financial support from the US Department of Energy, CAES has had virtually no impact for end users. Thus, customers pay significantly more for power during the day, often paying ‘demand charges’ based on the highest kilowatt (kW) use in a month or even year, in additional to kilowatt hour (kWh) charges based on energy use. The invention that we will describe here is based on the concept that the purpose of the CAES system should be to offer end users the opportunity to reduce their energy and power consumption during periods of high prices by withdrawing energy stored in the CAES system on a customer's site. While the system may benefit the grid and its operators that is an incidental benefit of the proposed CAES invention, CAES on the customer side of the meter. The goal of this invention is to reduce END USER power consumption and energy consumption from the grid when it is available but high priced by withdrawing energy from CAES that has been put there when prices are lower.
[0010] It is the premise of the present inventors that the failure of CAES to deliver economic benefits to society or to end users is due to the belief that CAES systems should be built on the “generator side of the meter” and in tandem with combustion processes.
SUMMARY OF THE INVENTION
[0011] This invention relates to development of an Energy Management Program (EMP) for end users to relieve them of high charges for energy and power demand from load serving entities (LSE) with use of compressed air energy storage (CAES) systems that do not need combustion to provide power for peak use on the customer side of the meter, creating a new method of doing business that makes development of CAES systems that are integrated into end user energy management programs (EMP) viable.
[0012] Our invention involves using an on-site CAES system which does not rely upon combustion so that end users can readily take advantage of off peak rates. The on-site CAES system can be integrated into the Energy Management Program (EMP) of the end user and can control and reduce the cost of providing services that require energy. “On-site” is defined to mean installation at the location of the end-user, as compared to the load serving entity. This is also referred to herein as being on the “customer side of the meter.” The onsite CAES would be connected to the grid, where generators would use their power stations to produce high voltage electricity. That electricity would then be transferred through high voltage transmission systems to sub stations closer to users. Step down transformers would then distribute the power to end users, through meters. From that point, the electricity would be supplied to the end user facilities through the various electrical panels that then serve individual circuits within end user facilities.
[0013] On-site CAES, by allowing power to be stored on-site when rates are lowest and used when demand is high, creates efficiency and offering END USERS direct benefits not available from the prior art. In contrast to prior CAES art, which envisioned them as utility investments in infrastructure rather than end user cost control mechanisms, on-site CAES directly advantages the end user and allows integration of the CAES system to the end user energy systems, including the ‘driver of peak power loads’, the cooling or other uses that increase through the day. CAES systems and technology placed on the generation side of the meter, usually close to the power plant, contribute nothing to reducing peak transmission and distribution capital requirements. Placed on-site, CAES can become economically viable by operating with lower priced electricity (usually off peak) for the storage function and also by eliminating the power plant with combustion as is typically called for in the prior art CAES systems. On site CAES without combustion thereby eliminates the negative environmental impact, health and safety issues associated with CAES, and the adverse reaction from management about the task of taking on the complexities and operational costs associated with power plants. Our invention eliminates the inhibitions that have prevented implementation.
[0014] Our invention focuses on using a CAES system on the customer side of the meter without combustion and integrated into the EMP of the facility, so that end users can reduce their costs. The system can be run manually or connected into a building Energy Management System (EMS) that manages the extraction of energy from the CAES to automatically reduce costs. It can be remotely monitored by associates of the end user (headquarter, consultants, suppliers or renters of the CAES system) to assure performance and reduction in energy costs. The system should preferably comprise panels equipped with switchgears that would allow power to flow from the grid into the end user's facilities, from CAES into the end user's facilities, and, optionally, from CAES to the grid. For every kWh extracted from CAES during periods of peak use or high rates, the end user will be able to reduce the power purchased from the grid, with a reduction in the kW or demand charge during the period of peak uses or higher rates. The voltage from CAES preferably would be the same voltage as the end user needs, so that if the power was sold back to the grid it would go through the transformers, if any, before entering the grid.
[0015] The system can additionally, or alternatively, be integrated with equipment that capture and use the cooling capacity of CAES that develops when the compressed air is expanded. In contrast to the prior art CAES systems located on the load serving entities side of the meter, the cooling that results from expansion of compressed air would not be lost. In the present invention, end users in need of cooling, such as during the middle of the day when energy costs and demands are at their peak, will be able to efficiently capture and utilize this cooling capacity. Combining the cooling capacity from the CAES with the power generation results from extracting the compressed air will in a complementary energy management system since this cooling scheme can further decrease the energy and peak power requirements of the end user. That is, since the peak charges for the day usually begin early in the morning, before peak power and energy demands develop due largely to daily usage patterns and air conditioning needs, the extraction of energy from the CAES can be managed so that ‘free cooling’ is generated and, preferably, but not in all cases, can be temporarily stored as cold water or ice (or other coolant) and used at the time of day cooling is required. The CAES system can also be integrated to operate with a system of off peak thermal storage in which cool water or ice is stored using off peak power to develop the stored ‘coolth’. Also a large CAES system could be used to start generating power before peak hours and also create coolth that could be stored for use during the period of peak charges. Thus the invention offers a range of options of creating coolant from purchase of off peak power and then using the coolth to reduce peak demands for electricity and thus reduce power use during periods of higher charges for electricity or power. The ability to store the coolant during periods of peak power charges but before periods of peak power demand will offer end users the opportunity to reduce purchases of power during the peak and to reduce their peak power demand and thus reduce their demand charges. Onsite storage will allow management of the system to reduce the total energy used during peak periods and to also reduce the highest amount of power needed from the grid, or both is reduced during peak use. That is, the CAES can be configured to generate coolant during off peak periods (and stored for use during peak periods) or the CAES can be configured to generate coolant as a by-product of power generation during peak rate periods, but before peak energy and power use occur. Such use of ‘coolth’ could in some situations totally eliminate power consumption during periods of peak rate or high rate use, should such a goal be desired as part of the EMP.
[0016] In taking this approach, financing a CAES system will be much easier since the economics are improved by the projects ‘seeing’ not wholesale generation costs, but the full cost of transmission and distribution costs as experienced in retail rates and for allowing the end user to integrate the CAES system into their EMP. Location on the customer side of the meter also allows direct connection to computerized EMS, allowing for economic improvement and even optimization for end users. Use of CAES on the customer side of the meter allows more than peak shaving, that is, small incremental reductions in peak power use, but potentially even allows the complete elimination of use of power purchases during higher daytime peak prices, not just those closest to the actual peak use of electricity.
[0017] Thus the technical and economic advantages of the invention include:
Reduction in losses associated with ‘round tripping’ the storage and then extraction of the energy CAES systems since the coolth of the system during expansion can be used by end users; Improved power factor because the power is generated near the end user; Potential to integrate cooling capacity from taking energy out of the CAES system in such a way as to decrease costs of capital for the CAES system and the host air conditioning capital and operating budgets, including the potential to optimize such systems; Integration with the Energy Management Program and Energy Management Systems, along with use of remote monitoring by end users for optimizing CAES utilization, including in demand reduction programs offered by utilities or in aggregate purchasing headquarters operations may create with scattered sites used by end users allows major cost savings for end use, including capital costs for equipment, operating costs and costs associated with purchasing power and electricity from various buyers; and Improvements in the ability to finance CAES systems.
Indeed, the CAES systems and technology developed to date have seen few applications because they are large, difficult to finance and reimbursed from the wholesale market. Given the relatively lower prices in that market, the economics of the technology and business models that CAES has been based upon are risky and unattractive.
[0023] The invention provides benefits for the grid system as a whole, including:
The ability to utilize capital that is relatively “idle” (transmission and distribution lines) at night (or at other times of low load); The ability to utilize excess power production at night or other low load times; The ability to utilize the potential for cogeneration of cooling when expansion does take place, thereby decreasing demand; The ability for CAES projects to reduce the need for expensive investments in transmission and distribution and peaking generating capacity.
[0028] Solving these problems could create a strong market potential for CAES and greatly improve the economics, reliability and pollution characteristics of the whole power system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0030] The FIGURE illustrates the invention and includes an onsite compressor air energy storage system that would be placed near customers (consumers) of power and would be capable of providing cooling capacity as the air was expanded.
DETAILED DESCRIPTION OF THE INVENTION
[0031] A description of preferred embodiments of the invention follows.
[0032] Referring to the FIGURE, the CAES system is built on the customer side of the meter 1 (i.e., “on-site”). This system consists of a compressor 2 that compresses a fluid, such as air, into storage container 3 that is, optionally, buried in the ground 4 . The container is capable of withstanding high pressures. An expander 5 expands the compressed air when power is needed, usually during the period of peak power demand as indicated on the clock 6 . The compressor 2 and expander 5 could be the same device or separate devices. The expander is operably connected to a generator 7 , which converts the energy stored as compressed air into electricity. Power is then provided to the customer's facilities, using a generator that is part of the designed system to do so, preferably using low voltage suitable for the host facility 8 . Cooling can also be extracted from the expanding air stream 9 and cools water in the water stream 10 via heat exchanger. The water is either used immediately for cooling or is stored for later use. This displaces the demand for power for air conditioning, especially at peak temperatures and demand.
[0033] The compressor would preferably be one or more toroidal intersecting vane machines such as described in Chomyszak, U.S. Pat. No. 5,233,954, issued Aug. 10, 1993, U.S. application Ser. No. 10/744,230, filed on Dec. 22, 2003, PCT/US2004/042904, filed on Dec. 22, 2004 and Tomcyzk, United States Patent Application Publication 2003/0111040, published Jun. 19, 2003, which are incorporated herein by reference. Other compressors can also be used.
[0034] The toroidal intersecting vane compressor can comprise a supporting structure, a first and second intersecting rotors rotatably mounted in said supporting structure, said first rotor having a plurality of primary vanes positioned in spaced relationship on a radially inner peripheral surface of said first rotor with said radially inner peripheral surface of said first rotor and a radially inner peripheral surface of each of said primary vanes being transversely concave, with spaces between said primary vanes and said inside surface defining a plurality of primary chambers, said second rotor having a plurality of secondary vanes positioned in spaced relationship on a radially outer peripheral surface of said second rotor with said radially outer peripheral surface of said second rotor and a radially outer peripheral surface of each of said secondary vanes being transversely convex, with spaces between said secondary vanes and said inside surface defining a plurality of secondary chambers, with a first axis of rotation of said first rotor and a second axis of rotation of said second rotor arranged so that said axes of rotation do not intersect, said first rotor, said second rotor, primary vanes and secondary vanes being arranged so that said primary vanes and said secondary vanes intersect at only one location during their rotation. Similarly, the toroidal intersecting vane expander is self-synchronizing.
[0035] Preferably, the compression is achieved in multiple stages, although a single stage compression is possible.
[0036] The compression is preferably done with the injection of a fluid that allows isothermal compression or substantially isothermal compression, although this is not necessary. Substantially isothermal compression produces a highly efficient thermodynamic cycle. Examples of fluids that can be used include air. The fluid can be a recycled fluid (where the fluid was used in a prior compression). However, the use of air generally avoids the need to recycle the fluid.
[0037] The compressor is operably linked to at least one power source, such as utility supplied electricity sourced from the utility side of the meter 13 . Alternatively, the power source can be a solar panel. In a particularly preferred embodiment, the power source is not a combustion engine.
[0038] While a single storage containers and compressor and expander can be used, a plurality of storage tanks and compressor, expander in order to assure redundancy, reliability, availability and to avoid demand charges for equipment failure.
[0039] The storage containers can be accessed in series or in parallel, can be the same or different sizes. The containers can optionally be insulated to reduce heat loss or not insulated to facilitate heat loss.
[0040] The compressed fluid (e.g., air) can be stored in an underground void (such as a cave or mine), although it will often be preferable to store in a tank above or preferably below ground. In one embodiment, the tank is mobile (e.g., a truck). The container is preferably designed to withstand a variety of possible pressures. The size of the container and the pressures that it is designed to withstand are related to the energy capacity of the system. Where size of the container is a limiting design factor, the container can be designed to withstand about 150 atmospheres or more.
[0041] The storage container and, optionally, other components of the on-site CAES systems could be buried deep enough to be attack-proof or resistant.
[0042] The compressed fluid is then expanded through an expander. The expander would preferably be one or more toroidal intersecting vane machines such as described in Chomyszak, U.S. Pat. No. 5,233,954, issued Aug. 10, 1993, U.S. application Ser. No. 10/744,230, filed on Dec. 22, 2003, PCT/US2004/042904, filed on Dec. 22, 2004 and Tomcyzk, United States Patent Application Publication 2003/0111040, published Jun. 19, 2003, which are incorporated herein by reference.
[0043] For example, the toroidal intersecting vane expander comprises a supporting structure, a first and second intersecting rotors rotatably mounted in said supporting structure, said first rotor having a plurality of primary vanes positioned in spaced relationship on a radially inner peripheral surface of said first rotor with said radially inner peripheral surface of said first rotor and a radially inner peripheral surface of each of said primary vanes being transversely concave, with spaces between said primary vanes and said inside surface defining a plurality of primary chambers, said second rotor having a plurality of secondary vanes positioned in spaced relationship on a radially outer peripheral surface of said second rotor with said radially outer peripheral surface of said second rotor and a radially outer peripheral surface of each of said secondary vanes being transversely convex, with spaces between said secondary vanes and said inside surface defining a plurality of secondary chambers, with a first axis of rotation of said first rotor and a second axis of rotation of said second rotor arranged so that said axes of rotation do not intersect, said first rotor, said second rotor, primary vanes and secondary vanes being arranged so that said primary vanes and said secondary vanes intersect at only one location during their rotation. Where a TIVM is employed, the compressor and expander can be the same device or devices.
[0044] Like the compression step, the expansion step can, optionally, be isothermal or substantially isothermal. In a particularly preferred embodiment, the expansion step results in a substantial cooling of the compressed fluid. The cooled, or expanded, fluid can be advantageously used for cooling, such as by directing the expanded fluid through a heat exchanger to cool another material (a coolant) which, in turn, is used for cooling, or used directly as a coolant. In this embodiment, the heat exchanger, thus, cools a coolant. The coolant can be a variety of materials and includes water, ice, a refrigerant Whether the coolant is the expanded fluid from the CAES or is a cooled material generated from heat exchange with the expanded fluid from the CAES, the coolant can be used, for example, in an air conditioning system for the end user.
[0045] The coolant can be generated during peak demand for air conditioning or it can be generated in advance and stored. However, since expansion, for the purposes of power generation, is preferably performed during peak demands when air conditioning is also at a peak demand, the coolant generation delivers a “synergistic” impact.
[0046] Generating coolant can also be performed during off peak periods. This embodiment can decrease the size or capacity of the CAES system need to reduce peak power and energy use during peak rate periods. In this embodiment, the coolant can be stored for use later in the day. Such a cool water or ice storage system can be optimized for producing greatest economic advantage or rules of thumb could be used to produce a preferred but sub-optimal configuration that is still better than not using a cooling and/or cooling storage system. The process will require the calculation of the cost of paying higher demand charges and higher electricity charges, the cost of CAES storage systems of different sizes, the costs of plumbing or other means to deliver the coolth to the end user facilities, the cost of building and operating storage systems to store ‘coolth’ created both during the expansion process of extracting energy from the CAES and possibly from other means of cooling in off peak hours such as using the chiller or cooling tower or any number of other means to create stored coolth. These numbers than can be evaluated by options and in some cases optimized by a variety of techniques, including hill climbing, linear or dynamic programming or instead a heuristic approach can be developed which merely seeks to improve costs but does not necessary reach the optimal solution.
[0047] In another embodiment, the cooling step can be via more conventional means, employing the expansion step as the power source to provide power. A variety of cooling approaches can be used, such as chillers, ground source heat pumps, evaporative coolers, cooling towers, or other means.
[0048] In one embodiment, the cooled water can be used in the compression process, creating a closed loop. Preferably a mathematical routine would be used to increase the productivity of the system, preferably but not necessarily an optimizing routine. These other means of cooling can be also incorporated into the decision assisting tools described above. Solar power could also be used to increase the output of the system, with a variety of means to heat the air that would enter the expander, including but not limited to heliostats. The primary storage tank or tanks could be used for the solar heating, including having them above ground. Other sources of additional heating of the air are possible, including waste heat, geothermal and any other source heat available on the site.
[0049] Controls are used to assure high efficiency and safe operation. The controls can consider the need for more stored thermal energy based on prior weather data or on weather data fed to the system, either on site or preferably from a remote location.
[0050] The CAES system is preferably connected to the Energy Management System of the end user, allowing optimal use of the capabilities of CAES to meet the service needs of end users at lower cost, although this is not strictly necessary. Similarly, the CAES system may be remotely monitored and controlled, thus allowing an entity to manage its overall energy use strategy to best meet its service and cost objectives. Since organizations differ in their management strategy, some preferring local facility control, others preferring centralized control, the ability to remotely measure provides a means for the decentralized system to evaluate performance at local cites and for centralized systems to actually make decisions and when logical, integrate the decisions at a variety of sites to reach desired economic goals such as using only so much peak power from all its facilities as part of purchase agreement or a power curtailment agreement with load serving entities. Remote monitoring would use any of a variety of communication paths, including direct phone lines, the internet, radios, cell phones or other telecommunication or physical means. Many organizations have Energy Management Plans (or plans with different names such as Energy Plans or Facility Plans), formal or informal, aimed at reducing their overall costs of purchasing energy utilities. Such plans can embrace a wide variety of options, discussed earlier, from improving lighting to preventive maintenance on equipment to make it run better. The plans can involve deciding who to purchase electricity, power supply, even thermal services such as heating and cooling. Even the simplest end users have an Energy Management Plan, if only to purchase all their needs from the local load serving entities. An energy management system is part of a more sophisticated Energy Management Plan and includes a means to track power or machines use, often with a series of sensors that measure performance at designated points and then transfer this information to a computer system where it can be displayed, used for decision making, transferred to still another location and in some cases archived and stored for later analysis. Energy management systems are also called Building Management Systems, Facility Management Systems, Monitoring, and Monitoring and Control Systems. CAES would be incorporated into these systems by tracking such values as total stored air, realizable power for use during the peak or high cost power/electricity periods, available cooling from expansion, and other important characteristics that would then allow end users to manage the CAES system to reduce costs and provide services desired.
[0051] The CAES system operably links the expander to a generator to supply power, preferably at the voltage needed in the end users facilities without transformers, although transformers or power electronics can be used to assure proper voltage regulation. The power thus produced can be used by the end user to decrease power demand during peak hours.
[0052] The system can be operated by a third party, as in a remote monitoring system, for example, through a contractual arrangement with the end user, although other ownership and contractual relationships are possible, including ownership by generators or load serving entities. Any pricing agreement would be acceptable, but preferably the end user would be given a price below whatever was being offered directly off the grid by the load serving entities and generators. This charge could be contractually arranged to assure regulatory compliance with all state or Federal regulations to avoid becoming a utility, but preferably a system of charges would be developed that reflected the energy and demand charge savings that the customer for the stored power would benefit from. Utilities could also own the onsite CAES system as could the system host or any other owner.
[0053] Arrangements for installation of the CAES could be done without any payment to the host, but preferably the owner of the CAES system would pay the host for the right to build the system. The advantages of this immediate payment to a host would be large. Unfortunately, facility managers operate under poor budgets and often require paybacks of 2 or fewer years to make investments. Many issues compete for their time and attention. Paying the owner for installing the CAES provides a strong incentive to gain the ‘mindshare’ needed to get the attention of the facility manager/owner by creating an immediate positive cash. Preferably coupled with guaranteed lower priced electricity such an approach to developing CAES systems on the customer side of the meter is likely to play a decisive role in this technologies success. The owner could also be the host themselves and purchase CAES systems and associated programs to integrate best to the EMP and the EMS, although sales could also be made with this integration being part of the sales package.
[0054] Additional CAES power could be stored so that the system performed the function of Uninterrupted Power Supply. Preferably additional charges would be created for this function.
[0055] Many variations of an end user service CAES system are possible. One system can be designed to eliminate all daytime (peak) energy use by itself. This would require a CAES system of sufficient size to meet not just the total electricity demand but to meet the peak demand as well. In one embodiment, a system designed with storage of cool water during the early part of the day for use later in the day can be used. The invention also includes a system in which night time electricity or electricity bought at lower rates could be used to fill the thermal storage with ice or water using any of a variety of cooling approaches such as chillers, ground source heat pumps, evaporative coolers, cooling towers, or other means. This would also allow the size of the CAES system to be reduced. By using existing or new capital equipment to store coolth during off peak hours the demand for peak power can be reduced, thereby reducing the size of the CAES that would be needed to reduce or to avoid peak charges. Of course, these described cases are only a small subset of the possible arrangements for an end user, on-site CAES system. Many other combinations and permutations can be created.
[0056] In one business model, utilities could be induced to pay the host or the CAES operator a direct payment for reducing peak demand and/or eliminating transmission/distribution bottlenecks or costs of building additional capital equipment, although this is not always necessary for the successful operation of the system or business, and no payments would certainly be acceptable in some regions.
[0057] The benefits of the stored energy on site accrues to the whole grid and any connected grid, reducing vulnerability of blackouts, brownouts and the need for investment in peak related capital equipment. This is true for any CAES system capable of serving a grid.
[0058] Onsite CAES storage can be critically important in areas serviced by large nuclear or fossil plants, by providing a means to use night time energy more effectively. Preferably a financial arrangement between such generators and CAES owners or operators would be developed. This could be especially true for the new coal gasification systems, whose future depends on improving economics, but could also apply to wind energy, ocean current or thermal energy or any other renewable sources of energy, such that might gain from onsite CAES systems because they produce power when prices are normally low and preferably there would be a financial arrangement with such generators for the CAES onsite owners. This arrangement could be for long term contracts to purchase the power produced when prices where low, thus providing those producers with greater potential revenue and improved ability to finance. In this regard, PCT 04/43504 filed on Dec. 23, 2004 in the name of Eric Ingersoll is incorporated herein by reference. This patent describes the use of a CAES system in conjunction with wind energy, for example.
[0059] Onsite energy stored in CAES could also be sold back to grid; preferably a system of doing so would be worked out to create further energy benefits for the society and the owners and hosts of the onsite CAES project. Thus, in one embodiment, the invention includes a method for monitoring electricity sold.
[0060] Onsite storage is also possible by moving a mobile entity that has a CAES system to a site. This system could supply power, preferably but not necessarily in emergencies, to entities that lost power or suddenly needed power. It could also be used when the grid became irregular or the price of electricity shoot up to enormous proportions. It could also be used to replace distributed generation that is ‘down’ so as to avoid high demand charges. Movable CAES systems providing onsite energy could be especially important in areas of environmental sensitivity where generators were not desirable. Movable systems might include a compressor and expander, a compressor/expander as the TIVM machine provides, or expander alone, with the compression being done at a host site elsewhere.
[0061] While this invention has been particularly shown and described with references to 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 scope of the invention encompassed by the appended claims.
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The invention relates to systems for stored compressed air without use of combustion. The systems can be installed on the customer side of the meter and creates electricity during peak hours after it has been stored in off peak hours. The invention creates a financial incentive for conserving energy costs by building compressed air storage systems which heretofore have seen little application.
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FIELD OF THE INVENTION
The invention covers a procedure for measuring hydrostatic pressure, especially that of ground water.
The invention also includes a ground water measuring device with a data collector, a measured data recorder and an active link between the measured data recorder and the data collector.
BACKGROUND OF THE INVENTION
A very important aspect of hydrological measurement practice is continuous monitoring of the water table, since this is needed for resolving environmental problems caused by manmade developments.
Water occurs naturally in the form of surface water and ground water. In the surface water category are rivers, streams, lakes and oceans. The water level of surface water is normally easily accessible which makes installation of equipment for measuring and recording this level relatively easy.
By contrast boreholes have to be sunk in order to monitor ground water feeds, and these are normally constructed using 2" to 6" pipes. These pipes are normally capped to prevent unauthorised access.
The requirements of a ground water measuring system are very exacting because of local environmental conditions and specifications imposed by measurement network operators. Some of these requirements are listed below.
Total installation inside 2" to 6" pipes
Operating temperature -20° C. to ±60° C.
Resistance to water condensate
Stable long-term measurement accuracy of +1 cm over 10 m measurement run
Independent power supply for at least 1 year
Low acquisition costs
Low operating costs
Nowadays a large number of measurement systems are available for measuring water levels. But in the light of the overall requirements outlined above not all measurement procedures are suitable for measuring ground water in conjunction with electronic data collectors.
Measurement procedures so far invented can basically be placed in two categories, those measuring length and those measuring pressure. Those measuring length include all measurement systems operated by means of floats with angle encoders, acoustical and optical procedures and measurement using conductivity levels. Those measuring pressure include all systems such as pneumatic pressure recording (introduction of air bubbles) and electronic pressure measurement (piezo resistant, capacitative etc.)
For the purposes of ground water measurement the only systems to have proven themselves in practice are measurement of length by means of floats with angle encoders and electronic pressure measurement. There is a DVWK paper, Issue 107: Ground Water Measurement Devices, Bonn, 1994 which provides a current overview of the use of ground water measurement systems.
SUMMARY OF THE INVENTION
Based on a process for measuring hydrostatic pressure, particularly of ground water, as described at the outset of this document, the task performed as the basis of this invention is to implement such a process in a container with a very small diameter compared with general technological standards, and to do so in a manner which is resistant to water condensate, saves a great deal of power, works independently and costs very little to actually produce measurements.
The ground water measurement device outlined above has to operate at the lowest possible diameter independently of any source of energy which is not part of the system and must be designed to resist water condensate and to be energy efficient, whilst being located in a small-diameter pipe, for example 2 inches.
The surprising way of achieving this with the present process is for air to be bubbled into the ground water with the measurement pipe pressure being relayed to an absolute pressure cell and with atmospheric pressure then being applied to the same measuring cell.
This is achieved with the deployment of a ground water measurement device of the above type with a data collector, measured data recorder and an active link between measured data recorder and data collector by means of a piston-driven pump which bubbles air into the water together with an integrated valve function to open and close the measurement pipe while simultaneously controlling pressure in the measurement pipe and atmospheric pressure.
It has not been overlooked that the process of bubbling air into water has been used highly successfully for the measurement of water levels in surface waters. For this the outlet end of an air feeder pipe or tube is fed to a point just below the lowest water level to be measured. Air is fed through the pipe continuously (pressure reducer, quantity controller) to ensure that air bubbles come out of the outlet end of the air feeder pipe. In this way air pressure at the outlet end of the feeder pipe is the same as the pressure of the liquid at this point. Taking the density of the water one is left with a linear connection between the desired water level reading and air pressure in the pipe. Air pressure in the measurement pipe is measured outside the water using a compensation process (sprung bellows, sliding weight) or a reference pressure measurement cell. Recording of the water level is by means of a mechanical marking device or a data collector. A description of this measurement system can be found in the company brochure issued by Messrs Ott Measurement Technology GmbH & Co KG, Ludwigstrasse 16, 87437 Kempten, Compact Pneumatic Level Device R25, 20.502.000.P.D.
In addition measurement systems using the introduction of air bubbles are known through patent descriptions DL-PS 7733 - IPC G 01 c, German Offenlegungsschrift to Rhieische Braunkohlenwerke, P 22 48 315.4-52 and Eastern German (DDR) patent specification WP G 01 F / 198 683 leading to German Patent Number 132278, issued Sep. 13, 1978. However none of these air-fed measurement systems are housed completely in a 2" diameter level-detecting tube, nor can they be operated for a whole year using their own independent power supply (6V, 1.5 Ah). Further distinguishing features are that they all require a continuous feed of air and therefore have to be supplied from a volume of air in a spare tank, involving a considerable requirement for space and/or energy resources.
The considerable quantity of apparatus required on the surface has hitherto ruled out application of the air bubble feeder process to ground water measurement technology, and this has been reinforced by the professional view that continuous energy supply from an outside source was necessary over long periods.
The task outlined above was surprisingly simple to resolve using a combination of a compressor integral to the system (piston-driven pump) and determination of the measurement cell as an absolute pressure cell.
It is particularly appropriate given the small amount of energy available that air does not have to be fed in continuously, but at say fifteen minute intervals.
A particularly appropriate design feature is the small diameter measurement pipe which allows air to blow out into a large volume compared with the size of pipe.
In terms of the equipment fitted the diameter of the air feeder vessel can for example be 20 times as great as the diameter of the measurement pipe itself. This ensures that measurement error can be restricted to a very small degree as the water level rises. This principle derives from a simple physical law according to Boyle-Mariotte, namely: "the product of pressure and volume is constant for an enclosed gas at constant temperature". The piston-driven pump used does not have any connecting links. The piston rod simply operates in a straight line. The piston has a tappet which instantly opens a valve in a certain position, namely the position of maximum pressure. The resulting loss of pressure firstly rapidly cleans the measurement pipe and the air feeder vessel of any remaining water. It also ensures that any condensate residues and any algae that may be present at the air outlet apertures are blown away.
The design allows the pressure drop extremity to be used as a trigger for the motor, say a DC motor, to be reversed and operated the other way.
Conical valves have shown themselves to be particularly appropriate. However the tappet can also be used for the instant dislodging of a cup from its valve seating. The counter-pressure spring is designed only to cut in over the Hook scale. It is tared and is triggered at a pressure of say 2 bar, at which the tappet of the piston hits the valve.
Data collector, piston-driven pump, absolute pressure cell, optical interface can all be inserted along with the power source (battery) into a two-inch pipe and lowered beneath the well cap into a frost-free area. This houses the whole assembly in frost-free ambient conditions. The great advantage of this is that extreme temperatures do not influence the measurement system (which consists of electronic and mechanical devices) in any way.
Unlike other equipment there is in this case no continuous supply of air, which saves on electricity. Since, however, as the water table rises (between measurements) air in the outlet feeder vessel and in the pipe is compressed, the barrier between water and air is displaced. What this means is that as the water table rises, water enters the outlet feeder vessel. The pressure measured thus no longer relates to the air feeder outlets but to the water table level in the outlet feeder vessel. In existing equipment this source of error is remedied by an adequately high continuous supply of air. But power consumption by such equipment is too high as it pumps the requisite quantity of air through the system in order to be able to meet the above requirement, an aspect which the present invention surprisingly solves by means of the volume and/or diameter ratios applied.
Overall the invention covers application of the introduction of air bubbles, a technique which is already well-known in the measurement of surface water, to the measurement of ground water levels, replacing the standard compressor with a connection-free piston-driven pump with a tappet fitted to the piston to operate a valve and with pressure being measured via a source of absolute pressure.
The features of this invention mean that if it is used to measure hydrostatic water pressure by means of measurement pipes sunk into the ground water:
the principle of the introduction of air bubbles can be applied;
a two inch pipe can be used to house the equipment;
reliable operation is assured at outside temperatures of -20° C. to +60° C.;
resistance to water condensate is assured;
stable long-term measurement accuracy is guaranteed of +/-1 cm over 10 m;
a self-contained power supply is provided for at least 1 year, something which has been inconceivable for other existing systems;
compared with other existing systems, the procurement cost of this equipment is up to 50% lower, and operating costs are low.
A simple raising and lowering cable can be used to bring up the mechanical and electronic devices. The way that the outlet feeder vessel is deployed, as described in more detail below, means that it can stay in place.
As described below, measurement accuracy is not affected even if there is zero point drift in the absolute pressure measurement cell.
Design features of this invention allow a lockable cap to be fitted, which can be locked and thus allow the device to be deployed in municipal areas without any risk of contamination, for example through accidental oil spillages.
There follows a more detailed description of one possible implementation of the invention, to be read in conjunction with the enclosed drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a system using the introduction of air bubbles to measure ground water levels as per this invention;
FIG. 2 is a diagram which makes clear the degree of measurement accuracy, and
FIG. 3 shows a schematic view of one possible implementation of the invention, depicted while taking measurements in a ground water measurement pipe.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the outlet feeder vessel 1 located below the lowest water level to be measured. Outlet apertures 2 are located all over the outlet feeder vessel 1 at regular intervals. The outlet feeder vessel 1 is itself linked via a measurement pipe 3 to a piston-driven pump 4.
It is important that the cross-sectional surface area of the outlet feeder vessel 1 is many times greater than the cross-sectional surface area of the measurement pipe 3. The ratio [R] between outlet feeder vessel cross-sectional surface area and measurement pipe cross-sectional surface area should, for example, exceed 400.
The piston-driven pump 4 consists of a piston 9, to which a rod 10 is attached and a cylinder sleeve 5, in which are located two boreholes 6 and 8. At the lower end of the piston 4 there is a valve-type mechanism, consisting of a return spring 11 and a cut-off cone 12. The piston 9 moves up and down on a piston rod 13 having trapezoidal thread thereon, linked to an electric motor 21.
When the piston is fully in the `up` position air enters via borehole 6 into the cylinder block. Pressure inside the cylinder equates exactly with atmospheric pressure. Atmospheric pressure is then measured in this in this position using an absolute pressure measurement cell 14. This absolute pressure measurement cell is connected to borehole 8 and is thus in contact with the atmospheric pressure in the cylinder block.
If the piston 9 is now driven down the enclosed air in the cylinder block is compressed to around 2 bar for example. Once a pressure of around 2 bar has been reached the rod 10 presses down on the cut-off cone 12 and opens the outlet 20. Air rushes into the measurement pipe 3. The pumping action is repeated until any water which has entered the outlet feeder vessel 1 has been forced out. This sudden blast of air in measurement pipe 3 has the additional great advantage of forcing out any water droplets present in measurement pipe 3.
The measured pressure drop, as measured between (from the piston lowest position) the maximum piston pressure and the value of the atmospheric pressure (the piston upmost position) is used for controlling the reversal moment of piston 9.
The time taken by the piston 9 to travel depends on the difference in water level (rise) and the desired measurement interval.
The piston 9 is in its bottom position when pressure in the measurement pipe is measured. Pressure in the measurement pipe 3 is thus relayed to the absolute pressure measurement cell 14.
Measurement of pressure in the measurement pipe and measurement of atmospheric pressure are required, since an absolute pressure measurement detector does not provide for any automatic compensation of atmospheric pressure. The electronic devices used for collection and evaluation of data are used to calculate hydrostatic water pressure.
The chosen configuration, a piston-driven pump with a valve outlet in conjunction with an absolute pressure measurement cell guarantees highly accurate and stable long-term measurement. The configuration is not in any way affected by moisture. A further advantage of the chosen configuration is that even if there is zero point drift of the absolute pressure measurement cell, measurement accuracy is not adversely affected as a result.
FIG. 2 shows what happens in practice. The characteristic line of a pressure measurement cell is in relation to the desired measurement reading (input reading) and the output signal received. This characteristic line is in the form of y=a+bx. When measuring with the help of this configuration po and po+pw are measured. Calculation of hydrostatic water pressure is then performed using the change of volume delta V, ΔV=V2-V1. If the characteristic line is now displaced (displacement of the zero point) the measurement is not adversely affected as a result. The [/ \] V=V21-V1 remains the same.
The pressure measured by pressure detectors is the product of the height of the water column and the density of the water plus the atmospheric pressure exerted on the water. In order to exclude the influence of the air pressure pressure detectors with differential pressure measurement are used in well-known and established equipment. To achieve this, atmospheric pressure is fed via a thin tube to the reverse side of the detector membrane. Moisture which has condensed into droplets inside this tube can hinder the passage of air and thus lead to incorrect measurements.
The readings measured (pressure in the measurement pipe and atmospheric pressure) are relayed to an electronic collection and evaluation device 30. This electronic collection and evaluation device 30 has a display 31 for displaying measurements taken at the site. There is an optical interface (infrared) 25 also connected to the electronic collection and evaluation device which allows data which has been collected to be read out as necessary from the electronic collection and evaluation device storage unit.
FIG. 3 illustrates additional advantages of measurement system 39. For a readout or to change the battery the measurement system has to be removed from the pipe. When this is done the position of the outlet feeder vessel 1 must not be altered. This is achieved by securing the outlet feeder vessel 1 to a thin wire 40 which is attached running upwards to a special securing device 41 beneath the lockable cap 42. Since the measurement system 39 is also connected to the outlet feeder vessel 1 via the measurement pipe 3, the upper section of the measurement tube is in the form of a spiral. This means that when the measurement system is taken out, the measurement pipe 3 can stretch for several meters without altering the position of the outlet feeder vessel 1.
The measurement system itself is also connected to the securing device 41 by means of an elastic cable. This elastic cable prevents any damage occurring to the measurement system from downwards pull.
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The invention covers a procedure for measuring hydrostatic pressure, especially that of ground water, with the particularity that air is bubbled into the ground water, the pressure in the measuring pipe is fed to an absolute pressure cell and atmospheric pressure is then applied to the same measurement cell.
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This application is a continuation, of application Ser. No. 521,263, filed Aug. 8, 1983, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cartridge type gauging head for checking linear dimensions of parts, including a substantially tubular casing, a shaft partially housed in said casing and axially movable with respect to it, a feeler coupled to the shaft for contacting the part to be checked, a guide device for guiding the axial displacement of the shaft with respect to the casing, a position transducer for providing a signal depending on the mutual positions of the shaft and the casing and resilient means for urging the shaft along a measurement direction.
2. Description of the Prior Art
Cartridge heads of the type referred to hereinabove are described in Swiss Pat. No. 594874 and U.S. Pat. No. 3,434,086. In particular, U.S. Pat. No. 3,434,086 discloses a cartridge type head comprising a generally cylindrical metal shell adapted to be closed with a metal cap which may be cemented into place or otherwise affixed. The cap has a neck provided with an axial bore guiding an armature assembly. A bobbin assembly may be cemented in the metal shell or held in place by the cap and a bushing.
It is also known in the art, as disclosed in Italian Pat. No. 906.206, to guide the axial displacements of a shaft or spindle with respect to a casing by means of a bushing including a first portion fixed to the casing, a second portion matched with a small radial clearance to the spindle for axially guiding it and an intermediate portion adapted for preventing the transmission of deformations from the first to the second portion of the bushing.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a cartridge type head that is more robust and reliable and guarantees better accuracy than the known cartridge heads.
This and other objects and advantages are attained by a cartridge head of the type specified at the beginning of the present description wherein, according to the invention, the guide device includes an intermediate portion fixed to the casing, guide elements adapted to guide the axial displacements of the shaft and two connection portions between the intermediate portion and the guide elements, the connection portions being adapted to prevent the transmission of deformations from the intermediate portion to the guide elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now described in detail with reference to the accompanying drawings, given by way of non-limiting example, in which:
FIG. 1 is a partially cross-sectioned longitudinal view showing two semi-finished parts of a cartridge gauging head, after their assemblage;
FIG. 2 is a longitudinal partially cross-sectioned view of a third semi-finished part of the gauging head.
FIG. 3 shows a longitudinal partially cross-sectioned view of a variant of the semi-finished part shown in FIG. 2; and
FIG. 4 is a longitudinal partially cross-sectioned view, with a smaller scale with respect to that of FIGS. 1 to 3, of a gauging head achieved by assembling the semi-finished part shown in FIG. 2 or in FIG. 3 with those of FIG. 1.
DETAILED DESCRIPTION
With reference to FIG. 1, a tubular cylindrical casing 1 defines a first semi-finished part having a longitudinal geometrical axis; a first portion 2 of a position transducer of the differential transformer type, basically comprises electrical windings and forms, together with an electric cable--for power supply and transmission--, a second semi-finished part.
The latter semi-finished part is connected to the first, as shown in FIG. 1, by coupling, by means of a fixed connection, portion 2 of the transducer to the inside wall of casing 1.
The coupling is achieved by using a resin or glue 57, preferably "Araldite" (refer to FIG. 4 too).
In this way, a portion of the inside surface of casing 1, together with a surface of said portion 2 of the transducer, define an upper end chamber 4 housing the wires (not shown in the drawing) contained in cable 3 and an end of the cable.
Chamber 4 is then filled with a resin 58, in this case too preferably "Araldite", that ensures the upper sealing of the gauging head and moreover serves to reliably fix the end of cable 3 so as to preserve it against accidental tears.
Chamber 4 is then closed on top by a protective cap 5 that serves to prevent excessive bendings of cable 3.
In FIG. 2 there is shown a third semi-finished part, basically including an integral member defining a hollow guide device 9 and a shaft or stem 6 passing through the guide device 9 and adapted to cooperate with two guide elements including internal cylindrical surface portions 10 and 11 of the guide device 9.
In fact, between surface portions 10 and 11 and shaft 6 there is a small radial play, ensuring guiding of the axial sliding of shaft 6.
At an end of shaft 6 there is coupled, through a stem 7, a magnetic core 8, that forms the second part of the transducer.
In a through hole 12, transversally formed in shaft 6, there is partially inserted a pin 13, carrying at a free end a small idle wheel 14; a slot 15, longitudinally formed in guide device 9 and being slightly larger than the diameter of idle wheel 14, houses wheel 14, that slides therein while shaft 6 moves with respect to said guide device, so preventing a rotation motion of shaft 6 about its axis i.e. rotation of shaft 6 with respect to guide device 9.
A split toroidal ring 16 is arranged in an appropriate seat 17 of shaft 6, and can abut against an end base surface 18 of guide device 9 for limiting the stroke of shaft 6 in the measurement direction.
This third semi-finished part, shown in FIG. 2, is coupled to the first semi-finished part--consisting in tubular casing 1 (already coupled to portion 2 of the transducer)--by connecting, by means of a fixed connection, guide device 9 to said casing. This connection is achieved by gluing a cylindrical portion 24 of the outside surface of guide device 9 to a limited section of the inside surface of tubular casing 1, as shown in FIG. 4. Preferably, the type of glue or resin 59 used is "Araldite". In order to make the coupling more stable, portion 24 has annular grooves 66 that fill up with part of the glue. Cylindrical portion 24--that, owing to grooves 66 is in actual fact formed by three cylindrical portions--is intermediate with respect to portions 10, 11, to which it is connected by means of other cylindrical portions 25 and 26 of a smaller thickness.
It should be realized that the connection position of guide device 9 with respect to casing 1 defines the amount of prestroke of the gauging head, i.e. the length that the shaft has to pre-travel so that the head, from the rest condition, reaches the measuring condition.
The particular shape of the guide device presents other advantages : any pressures applied on and consequent deformations of the outside surface of tubular casing 1 can be transmitted to guide device 9 in correspondence with portion 24; but they are not transmitted to portions 10 and 11 that directly cooperate with shaft 6, as they are absorbed by connection portions 25 and 26 which are resiliently deformable.
A pressure spring 56, shown in FIG. 4, tends to push shaft 6 in the measurement direction because it has an end abutting against a ring 19 fixed to shaft 6 and another end abutting against a ring 20 fixed to a base of the first portion 2 of the transducer.
The stroke limit of shaft 6 in the opposite direction with respect to the measurement one is reached when the base surface 21 of shaft 9 abuts against ring 20.
An annular seat 22, formed at an end of shaft 6, is adapted for housing an end of a bellows-shaped gasket 60, shown--partially cross-sectioned--in FIG. 4, that ensures the sealing of the gauging head.
A seat 23 for the other end of gasket 60 is partially formed in the guide device 9 and partially limited by a section of the inside surface of tubular casing 1.
Seats 22 and 23 are shaped in such a way that the ends of bellows gasket 60 are subject to compression stresses, and in this way--as described in U.S. Pat. No. 4,386,467--there is ensured safe coupling.
A feeler 61, preferably made of carbide, is fixed to a base of a cylinder-like shaped element 62, that has at its other end a threaded portion 63; portion 63 is fixed to shaft 6 i.e. screwed in a threaded hole 64 formed at the end of shaft 6 that is outside casing 1. Feeler 61, owing to the action of spring 56, is urged, with an appropriate amount of contact force, against the mechanical pieces or parts to be checked so as to detect their deviations with respect to prefixed or nominal linear dimensions.
In FIG. 3 there is shown a semifinished part identical to that of FIG. 2, but featuring a different embodiment of the guide device that enables shaft 6 to slide with respect to tubular casing 1.
This device consists of an integral member or element 50, with a substantially cylindrical shape, adapted for being fixed, by means of glue or resin, to the tubular casing 1 at an intermediate section 51, in all aspects similar to portion 24 shown in FIG. 2. A bushing 52 is placed between element 50 and shaft 6; bushing 52 houses, in appropriate seats formed near its ends, guide elements i.e. balls 53, that can contact element 50 on the one side and shaft 6 on the other, so enabling their relative motion.
In every operating condition of the gauging head, balls 53 are arranged at a considerable axial distance from intermediate section 51. Moreover the sections of element 50 adjacent intermediate section 51 have a reduced thickness with respect to that of section 51. Accordingly the sections of element 50 adjacent intermediate section 51 are resiliently deformable for preventing transmissions of substantial stresses and deformations from casing 1 and intermediate section 51 to balls 53, thus allowing axial sliding of shaft 6 without danger of seizure.
Two caps 54 and 55, coupled to the ends of element 50, limit the axial displacements and prevent outgoing of bushing 52. Furthermore element 54 defines the partial seat 23 for sealing gasket 60.
As shown in FIG. 4, tubular casing 1 houses at its interior the end of gasket 60 located in seat 23 and a longitudinal portion of the gasket; thus gasket 60 is protected, partially or totally, by casing 1.
It is obvious that while the above embodiments have been given by way of illustrative examples, many modifications of constructional detail and design can be made thereto by persons skilled in the art without departing from the scope of the invention. For example, the fixed connections between the casing and the first portion of the transducer and between the guide device and the casing instead of being obtained by means of glue, can be obtained by other means, for example welding or interference-fit.
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A cartridge gauging head for checking linear dimensions of parts comprises a tubular casing, a shaft axially movable with respect to the casing, a feeler fixed at an end of the shaft for contacting the part to be checked, a transducer for providing a signal depending on the mutual positions of the shaft and the casing, and a guide member for guiding the axial displacements of the shaft. The guide member includes an intermediate portion coupled to the casing and two end portions adapted to cooperate with the shaft for guiding it.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 09/017,962, filed Feb. 3, 1998, now abandoned.
This invention relates to filling materials packed or blown into fabric enclosures to form cushions, upholstered cushioning, comforters, and pillow cores.
BACKGROUND OF THE INVENTION
Conventional pillows are usually filled with a cushioning filler material of cotton wadding or batting, feathers, down, sponge rubber, fiber fill or foam. Among these materials, down shows excellent properties in bulkiness, softness, thermal insulation, compression recovery and moisture transmission. Many people, however, are allergic to down, and down may harbor not only allergens, but also insects and bacteria. Down is also cost prohibitive for many applications.
Cotton, compared with down, has inferior bulkiness, softness and thermal insulation. Its compression recovery is not as good as down or some of the synthetic filling materials. When damp, the cotton wads together and does not sufficiently recover to its uncompressed state.
The synthetic materials have advantages over the natural materials, in view of cost, durability and health concerns. Polyester fiber fill is an especially popular filling material. Other synthetic fibers used as fillers include polyethylene, polypropylene, polyamide and aramides. A matrix of straight fibers is pre-fluffed with a picker apparatus to separate the fibers to permit their insertion into a cushion or pillow casing. The fibers are then blown through an injector or plurality of injectors into cavities formed in the casing. With cushion use, fibers tend to bunch up and create pockets which permit the cushion or pillow to “bottom out”. Particularly, it has been found that fibers nest and clump together when blown into larger volume casings or casings with complicated shapes. Thus, in an effort to prevent undue clumping of fibers, larger or more complicated cushions are separated by ticking into several smaller compartments that are filled with the fibers.
To eliminate some of the crushing and clumping associated with straight fiber filling materials, U.S. Pat. No. 3,922,756 proposes forming the fibers into a filamentary spherical body. Spherically intertwined fiber aggregates also are shown in U.S. Pat. Nos. 4,998,309 and 4,794,038.
In lieu of fiber fill, blocks of sponge rubber or foam may be shredded into chunks or particles that are used as filling materials for cushions and pillows. The edges of the shredded foam chunks tend to hook together, which creates regions with more foam and regions with less foam within the cushion core. The foam chunks or particles do not reproduce the cushioning plushness of fiber fill or down.
To address the clumping problems associated with fibers, U.S. Pat. No. 5,061,737 suggests combining fiber fill (1-3 inch long fibers) with shredded polyurethane foam chips (¼ inch blocks) to form a filling material. The fibers are coated or slickened with a silicone finish prior to mixing with the shredded foam. The patent states that the length and diameter of the fibers relative to the size of the foam chips and the limited movement permitted by the slickened fiber surfaces affords adequate cushioning support while still maintaining the cushion shape.
U.S. Pat. No. 4,109,332 proposes using polyurethane foam cut into polygonal shaped rods. The rods have flat planar top, bottom and side surfaces, and preferably have a length and width proportionally greater than the rod thickness (or height). The patent emphasizes the importance of the planar nature of the side areas to prevent the rods from hooking on to one another when used as a filling for cushions.
Other synthetic filling materials include engineered elastomeric spheres, U.S. Pat. Nos. 4,754,511 and 5,608,936, pebbles or beads, U.S. Pat. Nos. 3,608,961 and 3,999,801, or tubular hollow forms.
To date, the prior art has not shown cellular polymer or flexible foam filling materials that can be readily inserted by blowing or other means into the chambers of cushion, upholstery cushion and pillow casings without the need for additional ticking or compartments, that repeatedly recover from compression, that avoid clumping and nesting thereby preventing pockets and “bottoming out”, and that may be made economically as compared to prior filling materials.
SUMMARY OF THE INVENTION
A filling element for a cushion, pillow, or upholstered article is formed from a resilient material, such as flexible, open cell foam, shaped into a bent strand. The strand preferably has a portion along its length that is Z-shaped, V-shaped, C-shaped or S-shaped. The resilient material may be formed to have a combination of these shapes along different portions of the strand length.
In the preferred embodiment, the strand has a distal end, a proximal end and a length measured as the distance between the distal end and the proximal end. The strand has a substantially constant cross-sectional thickness along its length. In all cases, the length of the strand is substantially greater than its nominal cross-sectional thickness. Preferably, the length of the strand is about 5 to 20 times greater than the nominal cross-sectional thickness of the strand. In addition, the individual sections making up the strand length also have a length greater than the nominal cross-sectional thickness of the strand.
The strand is formed with at least one bend along its length. Preferably, the bend is at an angle of between about 15 to about 120 degrees, most preferably about 30 to about 40 degrees.
The filling element may be formed from a strand with a Z-shape. In this case, the strand has generally straight legs or leg sections depending at bent angles from a generally straight center section. The legs terminate at the distal end and proximal end, respectively. These ends have generally planar faces. The planar faces of the distal and proximal ends may be cut at an angle perpendicular to the sidewalls of the legs. Preferably, the planar faces of the ends are cut at an angle other than perpendicular to the sidewalls of the legs, such that the faces each have a cross-sectional areas greater than the nominal cross sectional area of the corresponding leg.
The filling element may be formed from a strand with an S-shape. In such case, the strand has generally curved legs depending at bent angles from a generally curved center section. The legs terminate at the distal end and proximal end, respectively. These ends have generally planar faces. The planar faces of the distal and proximal ends may be cut at an angle perpendicular to the sidewalls of the legs. Preferably, the planar faces of the ends are cut at an angle other than perpendicular to the sidewalls of the legs, such that the faces each have a cross-sectional areas greater than the nominal cross sectional area of the corresponding leg.
The resilient material is a cellular polymer material, preferably flexible, open cell polyether or polyester polyurethane foam. When a polyurethane foam is used, the foam has a density in the range of about 0.6 to about 1.2, preferably about 0.8 to about 1.0 pounds per cubic foot, and an indentation force deflection (IFD) in the range of about 4 to about 15, preferably about 8 to about 12 pounds.
DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic diagram showing a plurality of filling elements of the invention as they are blown into a casing to form a cushion;
FIG. 2 is perspective view of a strip of resilient material prior to cutting to a desired strand length;
FIG. 3 is a perspective view of a piece of resilient material of FIG. 2 cut to a desired strand length to form a filling element according to the invention;
FIG. 4 is a perspective view of a strip of an alternate resilient material prior to cutting to a desired strand length; and
FIG. 5 is a perspective view of a piece of resilient material of FIG. 4 cut to a desired strand length to form a filling element according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Cushions, pillows and upholstered articles may be formed by blowing a filling material, such as polyester fiber fill, into a casing. The preferred method blows the filling elements with a gas stream, such as air. The casing is then sealed or sewn together to form the cushion or cushioning interior of the cushion, pillow or upholstered article. The filling elements of the present invention may be blown into cushion casings using the same blowing apparatus used for fiber fill.
As shown in FIG. 1, the apparatus 10 to fill a casing includes a supply hopper 14 , a blower 16 and an inserting pipe or tube 18 . The filling material 12 , which is a plurality of the filling elements according to the invention, is placed into the supply hopper 14 and blown from the hopper 14 through the pipe 18 and into the casing 20 by blower 16 . If not sewn together after it is filled, the cushion casing may be supplied with a zipper 22 or other fastening means.
A resilient material, such as flexible open cell polyurethane foam, is cut, such as by a rotary cutter, or otherwise formed into a bent strand to form a filling element according to the invention. As shown in FIG. 2, the material may be formed into a long continuous strand 30 having a plurality of generally straight sections interconnected together at their ends to form bent angles alternating upwardly and downwardly.
Individual filling elements are formed by cutting sections from the long strand 30 . Filling element 34 (shown in FIG. 3) is formed by cutting long strand 30 at lines 32 . The filling element 34 has a proximal end 46 and a distal end 48 and a length measured as the distance between the proximal and distal ends.
The Z-shaped filling element 34 has a generally straight center section 36 with generally straight left leg section 38 and generally straight right leg section 40 depending therefrom. The center section 36 and left leg section 38 form a bent angle 42 therebetween. The center section 36 and right leg section 40 form a bent angle 44 therebetween. Preferably, the angles formed between the center section 36 and the leg sections 38 , 40 are in the range of about 15 to 120 degrees, most preferably about 30 to 40 degrees. Although shown to be equivalent in FIG. 3, the angle 42 may be the same as or different from the angle 44 .
The left leg section 38 terminates at a proximal end 46 with a planar face having a rectangular cross section. The right leg section 40 terminates at a distal end 48 with a planar face having a rectangular cross section. As shown in FIG. 2, the cut lines 32 are taken through the strand 30 at points at which two generally straight sections meet at an angle. As a consequence of these cuts, which are at oblique angles relative to the side walls of the generally straight sections, the planar faces at the proximal and distal ends 46 , 48 have cross sectional areas that are greater than the nominal cross sectional area of the corresponding leg sections 38 , 40 . Had the cut lines been taken perpendicular to the sidewalls of a leg section, the planar faces at the proximal and distal ends of the filling element would have had cross sectional areas equivalent or nearly equivalent to the cross sectional area of the corresponding leg sections.
The filling element 34 has a length, as measured from the farthest extended portion of the proximal end 46 to the farthest extended portion of the distal end 48 , in the range of about 1.5 to 7 inches. Preferably, the length of the filling element does not exceed 5 inches. It has also been found that the length should be at least 2 inches for many applications to avoid many of the clumping and nesting problems attributed to shredded foam of the prior art. In the particularly preferred embodiment, the center, left leg and right leg sections are of substantially equal length. A particularly preferred section length is between about 1 to 2 inches, most particularly 1.25 inches.
FIGS. 4 and 5 relate to an alternate embodiment of the invention. FIG. 4 shows a long strand of resilient material 50 having a series of alternating upwardly curved sections and downwardly curved sections. The strand 50 is cut at cut line 52 to form filling element 54 shown in FIG. 5 .
The S-shaped filling element 54 has a center section 56 disposed between a left leg section 58 and right leg section 60 . The place at which the center section 56 meets the left leg section 58 forms a downwardly bent angle 62 . The place at which the center section 56 meets the right leg section 60 forms an upwardly bent angle 64 . The left leg section 58 terminates at proximal end 66 having a planar face, and the right leg section terminates at a distal end 68 having a planar face. The planar faces at the proximal and distal ends 66 , 68 have a generally circular or oval cross section. Depending upon the angle of the cut line 52 in relation to the strand 50 , the planar faces may have a cross-sectional area the same as or greater than that of the nominal cross-sectional area of the corresponding leg sections.
The strands may be formed from any resilient material with generally uniform properties. Cellular polymer materials, such as flexible, open cell polyether or polyester polyurethane foams, are preferred. Other materials include cross-linked polyethylenes, polyolefins, and rebonded or recycled foams.
Cellular polyurethane structures typically are prepared by generating a gas during polymerization of a liquid reaction mixture comprised of a polyester or polyether polyol, a polyisocyanate, a surfactant, catalysts, and one or more blowing agents. The gas causes foaming of the reaction mixture to form the cellular structure.
Polyurethane foams with varying density and hardness may be formed. Hardness is typically measured as IFD (“indentation force deflection”) or CFD (“compression force deflection”). Tensile strength, tear strength, compression set, air permeability, moisture resistance, fatigue resistance, and energy absorbing characteristics may also be varied, as can many other properties. Specific foam characteristics depend upon the selection of the starting materials, the foaming process and conditions, and sometimes on the subsequent processing.
The engineered shaped filling elements according to the invention do not shift or form pockets when used as filling materials in cushion casings. Unlike fiber fill, the filling elements may be blown into a large cushion casing without first segmenting the casing with ticking. The filling elements do not take on a compression set, but rebound after being subjected to loads.
Per unit weight and per unit volume, the filling elements of the invention offer cushioning properties greater than that provided by fiber fill. When cushions filled with equivalent volume amount of fiber fill and cushions filled with the filling elements of the invention are subjected to equivalent dynamic and static loads, the cushions with the filling elements of the invention recover their height more completely and more rapidly than fiber-filled cushions. Load to half height tests and fatigue tests confirm the filling materials of the present invention perform better than the equivalent volume amount of fiber fill.
FATIGUE TEST
Sample 1: Filling element according to FIG. 3 .
Sample 2: Fiber fill (12 denier).
Separate cushions were filled with equivalent volume amounts of each sample material and the cushion height was measured. The cushions were then subjected to a fatigue test in which they were compressed and released through a number of cycles to simulate ordinary household use of a furniture cushion. After the various compression cycles were completed, the cushion height was measured. Those measurements are reported in the Table below:
Sample 1
Sample 2
Initial height
8.750 in.
9.250 in.
After 20,000 cycles
8.000 in.
8.625 in.
After 40,000 cycles
8.000 in.
7.375 in.
After 60,000 cycles
8.000 in.
7.375 in.
After 80,000 cycles
8.000 in.
7.375 in.
After 100,000 cycles
8.000 in.
7.375 in.
% Height retention
91.4%
79.7%
after 100,000 cycles
As demonstrated in the fatigue test, the cushion material of sample 1 showed greater height retention than the prior art fiber fill.
The invention has been illustrated by detailed description and examples of the preferred embodiments. Various changes in form and detail will be within the skill of persons skilled in the art. Therefore, the invention must be measured by the claims and not by the description of the examples or the preferred embodiments.
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A resilient material shaped into a bent strand with a preferred length from 1.5 to 7 inches forms a filling element for cushions, pillows and upholstered articles. The strand may be bent so as to have a Z-shape or an S-shape or a V-shape or a C-shape along a portion of its length. The length of the strand is greater than its nominal cross-sectional thickness. A quantity of filling elements (e.g., the filling material), preferably formed from flexible, open cell polyurethane foam, is inserted or blown into a casing for a cushion, pillow or upholstered article. Following compression, the filling elements rebound substantially to their uncompressed state without clumping together or leaving pockets within the casing.
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BACKGROUND OF THE INVENTION
The present invention relates to an improved feeder apparatus for automatically controlling the tension of a yarn, including an electronic device for detecting possible faults, which can be applied to machines for making fabrics, knitted fabrics and cloth articles, and to textile machines in general.
As is known, in knitting machines and other textile machines there are usually provided several yarn feeders which conventionally comprise two small levers, articulated at different articulation points, which cooperate with corresponding switches.
These switches are independent from one another and and are adapted to disenergize the machine as a yarn is broken, by signalling a possible breakage of the yarn by means of individual light displays.
Also known is that conventional circular knitting machines are supplied with a lot of yarns, the tension of which must be controlled immediately upstream of the yarn inlet to the machine for a proper operation of the latter.
This control is at present performed manually, yarn by yarn, by using mechanical or electronic tension measuring devices, which must be held in a hand of the operator, whereas the operator by his other hand, adjusts the knitted fabric.
Moreover, in prior knitting machines, the operator controlling possible faults of the yarn feeders, must walk about the machine, which may have a diameter up to 2.5 metres, in order to detect the yarn feeder the yarn of which is broken.
This, as it should be apparent, requires a lot of time with a consequent decrease of the textile machine yield.
Moreover, the delays in recovering the proper operation of the machine are further increased by the fact that the individual displays, provided for displaying the yarn breakages, are frequently scarcely visible because of powder and the like, and because of the high lighting usually provided in the textile machine room.
Thus, the operation the textile machine is frequently stopped, with a consequent loss of time by the operator, even if the machine ne is not in a fault condition.
This drawback occurs because possible small impacts, or increases of the tension of the yarns, of very short duration, due, for example, to a badly wound bobbin or between the end of a bobbin and the start of a subsequent bobbin, or, moreover because of dirt accumulating between the yarn braking discs.
Accordingly, the above mentioned temporary variations of the tension of the yarns, cause the related movable mechanical lever to vibrate and the textile machine to stop since the lever undesirably impacts against the corresponding switch.
SUMMARY OF THE INVENTION
Accordingly, the aim of the present invention is to overcome the problems and drawbacks thereinabove mentioned, by providing an improved feeder apparatus which allows a continuous control of the tension of the yarn before supplying said yarn to the textile machine, and which, moreover, comprises an electronic display device for displaying and controlling, in a centralized way, possible faults, which electronic device also includes auto-diagnosis means allowing an operator to easily and quickly repair a feeder which has been detected in a fault condition.
Within the scope of the above mentioned aim, a main object of the present invention is to provide such an improved feeder which is so designed as to greatly facilitate the job of the operator, to provide optimum conditions from the yield standpoint.
Another object of the present invention is to provide such a yarn feeder for textile machines which can feed its yarn without being negatively affected by dirt and the like.
Yet another object of the present invention to provide a yarn feeder which is very reliable and safe in operation and, moreover, is very competitive from a mere economic standpoint.
According to one aspect of the present invention, the above mentioned aim and objects, as well as yet other objects, which will become more apparent hereinafter, are achieved by an improved feeder apparatus for automatically controlling in real time the tension of a textile yarn, said feeder apparatus including an electronic multiple function device, and being provided for application to knitting machines and textile machines in general, characterized in that said feeder apparatus comprises a device applied to a lever for continuously controlling the tension of the yarn, before the inlet of said yarn into said textile machine, and a device for displaying and controlling possible faults of said feeder apparatus, said lever being a swinging lever arranged downstream of a drum and operating for controlling the position of an adjustable movable shield element adapted to intercept light, thermal or electromagnetic radiations; said shield being arranged between a radiation emitting element and a radiation sensing element, in order to chop the amount of radiations received by the sensor which transforms the received radiation amount to an electronic signal proportional to said radiation amount, said signal, which can be suitably amplified, controlling, depending on its amplitude, a display of the yarn tension, depending also on the swinging amplitude of said lever.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the yarn feeder apparatus according to the present invention will become more apparent hereinafter from the following detailed disclosure of a preferred, though not exclusive, embodiment thereof, which is illustrated, by way of an indicative, but not limitative example, in the figures of the accompanying drawings, where:
FIG. 1 is a perspective view of the improved yarn feeder apparatus, for automatically controlling the tension of the yarn, and including a multiple function electronic device for performing a centralized display and control of possible faults, according to the present invention;
FIG. 2 is a front view of that same improved feeder apparatus shown in FIG. 1;
FIG. 3 is a rear view of the improved feeder apparatus shown in FIG. 1;
FIG. 4 i s a side view of the subject feeder apparatus, in a working condition thereof, with the yarn under tension;
FIG. 5 is another side view of the improved feeder apparatus, in a working condition thereof, with the yarn free of tension;
FIG. 6 is a further side view of the improved feeder apparatus, with the yarn in a loose condition;
FIG. 7 is a schematic view of the improved feeder apparatus according to the present invention, in which there is clearly shown a coding card and a further electronic card controlling the tension of the yarn;
FIG. 8 is an electric connection diagram showing the electric connections of the several coding electronic cards connected to the individual yarn feeders, in a knitting machine, and a central control card or board, of the subject electronic device for performing centralized display and control operations of faults, also according to the present invention;
FIG. 9 illustrates a block diagram of a preferred, though not limitative, embodiment of the coding card or board;
FIG. 10 illustrates a further block diagram of the central control card, according to a preferred embodiment thereof;
FIG. 11 illustrates and electric diagram of the device for continuously controlling the tension of the yarn, before supplying said yarn to the textile machine; and
FIG. 12 i s a schematic view, on an enlarged scale, illustrating the principle thereon based the device for continuously controlling the tension of the yarn.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the number references of the figures of the accompanying drawings, the improved feeder apparatus according to the present invention, which has been generally indicated at the reference number 1, comprises a device for continuously controlling the tension of a yarn to be supplied to a textile machine, and an electronic device for displaying and controlling, in a centralized manner, possible faults occurring in said feeder.
Each textile machine will be provided with a plurality of these feeder apparatus.
In this feeder, the yarn 2, supplied by a yarn supply R (not shown) is guided by a first transmission bush element 3, so as to pass through a brake 4 comprising two opposite discs 6, the clamping of which can be adjusted in a known way.
Before deviation by an eye element 8, the yarn will engage a first lever lever 50, adapted to operate in the case of a breakage of the yarn; then, this yarn will be wound in several turns about a drum 10 including a plurality of slots.
This drum is rotatively driven through pulley 12, coaxially rigid with the drum and driven by a toothed belt.
Before supplying to the textile machine M, the yarn 2 passes through a further eye element 14 and on a second bush element 16.
Between these two passages, the yarn rests on the second movable lever 20, responsive to the tension of the yarn, and articulated on the housing 1 at a transversal axis 21.
As is clearly shown in FIG. 4, the lever 20 is provided with a cross-piece 24, bearing on the yarn 2.
This lever 20 i s urged to move in the direction of the arrow F, under the action of a suitable counterweight element, or a blade spring, as it will be disclosed in a more detailed way hereinafter.
FIG. 5 shows the position of the lever 20 in a normal tension condition of the yarn which follows a broken line.
If the yarn is greatly tensioned, as it is shown in FIG. 4, then the path assumed by said yarn, between the bush element 16 and drum 10, will be substantially rectilinear, since the lever 20 is urged to upwardly raise.
On the contrary, if the tension on the yarn is small, then the lever 20 will be arranged in a substantially vertical position, by causing the yarn 2 to assume the configuration shown in FIG. 6.
The principle on which the yarn tension controlling device according to the invention is based is schematically shown in FIG. 12.
In this Figure there are shown, on an enlarged scale, two end positions L and T of the lever 20, which substantially correspond to FIGS. 6 and 4, and respectively related to the loose condition of the yarn and to the very tensioned condition thereof, as well as any intermediate positions N represented by a dashed line, corresponding, for example, to a normally tensioned condition of the yarn (see FIG. 4).
At the articulation point 21, as an extension of the arm of the lever 20, there is provided an arm 30, rigid with said lever, to which there is applied, according to the above mentioned device, a shield, indicated at the reference number 32, either of the fixed or of the adjustable type, adapted to shut off a flow 34 of any suitable type of radiation, for example light, magnetic or thermal radiations, as emitted by an emitter 36 and directed to a radiation sensor 38.
As shown in FIG. 12, at the position L of the lever 20 (as indicated by the continuous line), the shield 32 will fully shut-off the radiation beam 34 directed toward the sensor 38; in the normal position N (as indicated by the dashed line), the shutoff is partial , whereas in the position T (see the line constituted by the small dashes) the shut-off is zero.
To these shut-off conditions, correspond related different values of the electric voltage generated by the sensor 38.
The electric diagram of the first device thereinabove disclosed is shown in FIG. 11.
In this figure, the emitter element 36, supplied by a line 37, will irradiate toward the receiving sensor 38, a flow 34 of radiations which are variably shut-off or intercepted by the shield 32 connected to the arm 30 of the lever 20, depending on the position of the latter.
The voltage available at the output of the sensor 38 will be suitably amplified, if necessary, by an amplifier 45 in order to turn-on a plurality of diode assemblies 50, 51, 52 of different colours, preferably red, green and yellow, in order to signal in a differentiated way, the related strictly dependant degree of tension of the yarn, as shown above, which will depend on the angular position of the lever 20.
More specifically, under a normal tension condition of the yarn, the green LED' s wi 11 be energized, whereas in a great tension condition of the yarn the red LED's will be energized, and in a loose condition of the yarn the yellow LED's will be energized.
The diodes 50, 51 and 52 are assembled on a diode card 40, arranged at any suitable position in the housing of the yarn feeder, or are inserted in said card, as shown in FIG. 4.
The above disclosed electronic device for displaying and controlling in a centralized way possible faults of the yarn feeders, according to the present invention, is provided with a very important feature, i.e. that the switches, indicated at the reference numbers 104 and 106 in FIG. 7, and integrated with the above mentioned levers, are operatively connected to a coding card, generally indicated at the reference number 110.
The latter is connected in parallel to an electric line, overally indicated at the reference number 111, which is of the two-wire type and is connected to a central control card, generally indicated at the reference number 120.
On the line 111 there are parallel connected all the cards 110 which correspond to the dividual yarn feeders (see FIG. 8).
More specifically, the line 111 comprises a wire 111 a which carries the supply current for the cards 110, and a second wire 111b, which carries the signals processed by the several cards 110, both said wires being connected to the control card 120.
Moreover, the individual cards 110 are individually connected to ground.
The central control card 120, in turn, is power supplied through the line 121 and includes an output line 122 in order to stop the operation of the textile machine ne.
Moreover, the cards 120 drive, through a line 123, a display 124 adapted to display, by means of a digital type of display, the yarn feeder which is under a fault condition.
Moreover, at the output of the card 120 there is moreover provided an auxiliary line 125, which is interconnected to an interface 126 for driving a processor 127.
With the disclosed arrangement, the central displaying is performed by introducing, into each yarn feeder, a coding electronic card 110, each of which is responsive to the switching state of the switches 104 and 106 which will signal, through the operation of the levers 20 and 50, the good condition of the yarn or the tension condition thereof.
The control card is so programmed as to make visible, on the display 124, preferably of the three digit type, the number of the switched on or off switch, as well as their locations, for example high for the breakage of the yarn supplied to the accumulating drum and low for a breakage of the yarn at the output of said drum.
Each codifying or coding electronic card is supplied from the first of the two connecting lines with return to ground.
The first line of wire 111a receives and transmits to the central control card the signals of each individual codifying or coding card, as it has been already disclosed.
The control card verifies, sequentially, the conditions of the coding cards, connected to the switches related to the individual yarn feeders.
As a fault occurs, the central control card will display the distinctive number of the first switch, the condition of which has switched, and, simultaneously, it will stop the textile machine, so as to allow the operator to recover the good operation conditions.
Only upon actuating a reset function by the operator, said control card will continue to cyclically and sequentially diagnose another possible malfunction or fault, susceptible to occur at a subsequent position.
In this connection it should be pointed out that the above mentioned reset operation can also be performed automatically, as the operator resets the lever which has been brought to a lowered position.
Under such an event, the control card will continue its search of a possible fault and, if not, then the display will remain in an off condition until another subsequent malfunction is detected.
The central control card 120, as it is clearly shown in FIG. 10, comprises an oscillator 130, which generates a signal having a frequency of 10/20 KHz, and sends i t to a binary counter 132, programmable for 64, 128, 192, 256 pulses in order to fit the knitting machines having a different number of yarn feeders.
The first pulse is used for performing a zeroing operation, and accordingly 63,127, 191 , 255 pulses will be respectively available.
The unit 134 provides a or clearing signal, having a voltage from 0 to 6 volt, and will send these signals to a buffer 136 which will amplitude modulate the signals.
Through the buffer 136 further pass the signals sent by a decimal counter 140.
By means of the absorbing detector 144, as a coding card passes to an alarm condition, because of an operation of a switch, then a great current drain occurs and then the unit 152 will cause the textile machine to stop its operation through the relay 156, will switch on the display 124 and lock the oscillator 130 and counters 132 and 140. The display, as stated, is a three digit display, and it displays the precise number of the yarn feeder where the alarm has been energized, and, moreover, it will also signal if the switch is high or low, that is related to the levers 20 or 50.
A reset pushbutton 150 is moreover provided, which is connected to an unit 152 which will start again, after a locking, the counting system.
A switch 160 actuates a relay 161, which allows the low switches to be inhibited, that is the levers 50.
In this case the textile machine can operate exclusively by pulses.
Each coding card, as is clearly shown in FIG. 9 has an input for the signals or pulses coming from the central control card 120, which signals are supplied to an analogic comparator 173 which will detect the "high" signal (6 V) and will clear the counter 175.
The second analogic comparator 174 will detect the "low" (3 V) signals and will enable the counter 175 counting operation.
The counter 175 will send its output pulses to the digital comparator 176, which controls the switch 106, and to the comparator 177, which control the switch 104, said comparators being connected to a dipswitch 178, to each individual coding card corresponding a different number of the dipswitches.
By way of example, if the dipswitch is set on the number 10, in order to better understand the operation of a coding card, then the counter will start to count.
At the first pulse, the digital comparator (176/177) will receive "1" from the counter 175 and from the dipswitch 178; at the second pulse it will have "2", on a side, and 10, on the other, and so on until it will have 10 on both sides.
Now, the coding card self-recognizes itself and will control if one of the switches 104 or 106 has been energized.
If not, then the counting operation continues.
If, on the contrary, a switch has been actuated, then a comparatively high amplitude signal is generated, which will increase the current drain to about 10/15 mA, and is sent in the same time in which the count was 10, and on the same line of the 3 volt pulses, thereby the alarm is energized.
In order to prevent false al arms from occurring, due, as stated, to momentary vibrations of the yarn, the control card is programmed so as to delay by few milliseconds the actual stopping of the textile machine, so as to overcome, without any stop, several possible transitory faults which do not affect the evenness of the product.
Exclusively if the anomalous tension condition of the yarn continues beyond the set ti me, then the textile machine will be stopped and the related display will be provided on the display device.
It is moreover provided a built-in autodiagnosis system of the control card, so that, if a fault occurs in said control card, then this will be signalled and the textile machine stopped.
Finally, it is provided that the control card, through the interface, can communicate to a computer; the number of occurred interruptions on each switch, so as to provide useful diagnostic data in order to aid the operator to detect the causes of the single repetitive faults, at a given region of the textile machine.
From the above disclosure it should be apparent that the invention fully achieves the intended aim and objects.
In particular the fact is to be pointed out that an electronic device has been provided allows an operator to easily and quickly detect a possible fault yarn feeder.
The invention, as disclosed, is susceptible to several modifications and variations all of which come within the spirit of the inventive idea.
Moreover, all of the details can be replaced by other technically equivalent elements.
In practicing the invention, the used materials, as well as the contingent size and shape can be any according to requirements.
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A feeder apparatus for automatically controlling in real time the tension of a textile yarn, includes a control device for continuously controlling the tension of the textile yarn, before supplying it to a textile machine, the control device controlling a swinging lever arranged downstream of a drum and driving an adjustable movable shield element adapted to intercept a light, thermal or electromagnetic radiation impinging on a sensor which transforms the received radiation into an electronic signal proportional to said radiation and driving a display of the yarn tension.
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This is a continuation of application Ser. No. 07/690,520, filed Apr. 24, 1991, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an overhead door assembly, suitable in particular for use in vehicles such as railroad cars, comprising an overhead door, vertical guide members for guiding the overhead door in the vertical direction, and the horizontal guide members for guiding the overhead door in the horizontal direction, as well as driving means for opening and closing the door.
Such overhead door assemblies are known from practice and are used for example with sheds, garages and the like. An overhead door may consist of a single stiff panel and is then usually referred to by the term up-and-over door. There are also overhead doors known which are built up from a plurality of panels extending horizontally across the entire width of the door and hingedly interconnected. Such articulated doors are referred to by the term sliding door.
The known overhead doors are not satisfactory for use with vehicles such as railroad cars, because the use in railroad cars involve entirely different forces than in stationary uses. Doors of railroad cars may for instance be subject to very strong suction forces, but also to great compressive forces when the end doors of carriages are involved. Under these conditions, the doors should remain closed hermetically and should vibrate as little as possible.
SUMMARY OF THE INVENTION
The object of this invention is to provide an overhead door assembly which is suitable in particular for use in vehicles such as railroad cars. To that end, according to the invention an overhead door assembly of the type described hereinabove is characterized in that the vertical guide means and the driving means cooperate with each other and with the overhead door in such a way that when the overhead door is being closed, it is first brought before the door opening to be closed off. The door is subsequently brought into a position where it closes off the door opening substantially by the vertical guide means through a plugging movement.
BRIEF DESCRIPTION OF THE DRAWINGS
Hereinafter the invention will be further described, by way of example, with reference to the accompanying drawings of one embodiment. In said drawings:
FIG. 1 is a diagrammatic perspective view of an embodiment of a door assembly according to the invention;
FIG. 2 is a diagrammatic vertical section taken on the line II--II of FIG. 1, showing in more detail a part of an embodiment of a door assembly according to the invention;
FIG. 3 is a detail of FIG. 2;
FIG. 4 is a section taken on the line IV--IV of FIG. 3;
FIG. 5 is a diagrammatic side elevational view similar to that of FIG. 2, of an embodiment of a complete door assembly according to the invention;
FIG. 6 shows an embodiment of a manually operated device for a door assembly according to the invention; and
FIG. 7 is a diagram of a variant of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a diagrammatic perspective view of an embodiment of an overhead door assembly according to the invention, comprising an overhead door 1, which in this embodiment is articulated and is built up from panels 2-5. The panels 2-5 extend in the transverse direction of the door and are hingedly interconnected along horizontal hinge lines. Disposed on opposite sides of the door at the level of the hinge lines and adjacent the terminal edges of the bottom and the top panel 5 and 2, respectively, are a plurality of guide wheels. Several guide wheels 6-10 are shown in FIG. 1. By means of the guide wheels the door is guided along corresponding guide rails during opening and closing of the door, as will be described further hereinafter.
FIG. 1 further shows two endless chains or other similar transport members 11, 12, extending rearwardly on opposite sides of the door opening adjacent the top of the door and each having been passed over two chain wheels 13, 14 and 15, 16, respectively. Rope sheaves, or toothed or untoothed pulleys, may be used in place of the chain wheels. For brevity's sake, hereinafter reference will be made to chain wheels and chains, but they will be understood to include all other similar members such as pulleys and belts (which may or may not be toothed) rope sheaves and ropes, etc. The chain wheels are mounted on bearings in a suitable manner, and in the embodiment shown the rear chain wheels are mounted on a common, driven shaft 17. The shaft 17 carries an additional chain wheel 18 which can be driven by a driving unit 20 via a chain 19.
The chains 11, 12 are each connected to the topmost door panel 2 via a connecting arm 21 and 22, respectively. At one end, at 23 and 24, respectively, the connecting arms are hingedly connected with corresponding links of the chains. At the other end, the connecting arms are hingedly connected to the topmost door panel adjacent its top edge at 25 and 26, respectively.
As can be seen from FIG. 1, upon clockwise rotation of the chain wheels, the arms 21, 22 will move the door towards the right. As a result of the guide rails to be described hereinafter the panels will first travel upwards and then horizontally towards the rear.
When the chain wheels rotate counterclockwise, the arms 21, 22 force the topmost panel from the angled position shown in FIG. 1 into a substantially vertical, closed position. As the panel moves to the closed position, the axis of arm 21 will come into alignment with the imaginary line 89 extending between the center of chain wheel 13 and connecting point 23 (FIG. 2). This position of alignment is the dead center position. Upon further movement to the closed position (i.e., upon further counterclockwise rotation of chain wheel 13), the arm 21 moves over the dead center position. There is provided for at least one of the arms a stop member 27 which is arranged in such a way that the arm abuts against the stop member just after the arm is moved over center.
As a result of this so-called over center closing principle, it is impossible for the door to be opened by exerting a force on the door from outside. Further, the door remains in the closed position even when the power for the driving unit is cut off.
In explanation of the over center closing principle, it is further observed that the topmost panel, in the closed position, will bear on the sealing strips (FIG. 2) at the time when the center of the chain wheel is still just out of register with the connecting arm. Upon further rotation, the panel will be pushed against the sealing strips with more force, the strips being compressed in the process, so that the connecting arm is enabled to travel beyond the dead center position and will abut against the stop 27. In that position, the door is completely closed. Any force exerted on the door from outside will only lead to the connecting arm being forced against the stop 27 more tightly.
FIG. 2 is a diagrammatic view of a part of an embodiment of an overhead door assembly according to the invention. In FIG. 2 and the other figures, the same reference numerals as in FIG. 1 are used, insofar as corresponding elements are involved.
FIG. 2 shows a vertical edge of the door opening to be closed off by the overhead door 1. The vertical edge is formed by a doorpost or a suitable, preferably metal, section 30 with a stop surface 31 for the door panels. The stop surface is provided with a pliable sealing strip 32 (see also FIG. 4). The door panels are shown in practically the same position as in FIG. 1, i.e. the door has almost been shut, but it does not yet hermetically seal the door opening.
FIG. 2 diagrammatically shows the guide members for the guide wheels of the overhead door. In addition to guide wheel 10, FIG. 2 further shows a topmost guide wheel 33 and a guide wheel 34 arranged at the level of the hinge line between the lowermost two panels 4 and 5. The path of travel of the guide wheels comprises a horizontal part formed by at least one horizontal guide rail 35. Further a vertical track is provided which is bounded by a rear vertical section 36 and a front vertical section 37, permitting the guide wheels of the overhead door to move between them. The horizontal guide rail 35 adjoins the rear vertical section 36 in this embodiment via a rail 30 curved as a quarter of a circle.
The rear vertical section 36 is connected to a lever 39 by means of an upwardly extending rod 48 or the like. The lever 39 has a fixed pivot 40 and is adapted to be operated by a projection of the top panel 2 or of the connecting arm 21 in such a way that when the overhead door is being closed, the lever 39 pulls the rod upwards. Advantageously, the top roller 33 can be used to operate the lever 39.
It is observed that at the other side of the door preferably a similar construction is used.
As long as the door is not entirely closed yet, the vertical sections 36, 37 are spaced apart sufficiently so that each guide wheel can only be in contact with one of the vertical sections at the same time. This ensures smooth travelling of the wheels and the sections with minimal wear. Nor does any wear of the sealing strips develop because the door is not in contact with the sealing strips during the vertical movement. Both vertical sections are capable of moving towards the stop surface 31 counter to the spring force. The front vertical sections are supported against a fixed point, for example the stop surface 31, by means of a plurality of compression springs, one of which is shown at 40. Further, the front vertical sections are preferably suspended at the top by means of a tension spring 41. Further, for the front vertical sections, stops 42 are provided which bound the range of travel in the direction of the stop surface 31.
Under spring force the rear vertical sections 36 are pulled rearwardly in the direction of stops 43. For that purpose, in the embodiment shown tension springs 44 are employed. Mounted on the rear sections 36 at the level of the stops 43 are wedge-shaped members 45, whose function will be explained hereinafter.
The operation of the overhead door assembly described is as follows. When, starting from the situation shown in FIG. 2, the chain wheel 13 rotates counterclockwise, the connecting arm 21 forces the top panel 2 of the overhead door 1 into a vertical position. The free end of the lever 39 is moved upwards by the topmost guide wheel 33 or another projection of the topmost panel or the connecting arm. Via the rod 48, the lever pulls the rear vertical section 36 upwards, as indicated by arrows 46 in FIG. 2. During this movement, the wedge-shaped members cooperate with the stops 43, so that the rear vertical section is also forced forwards. Via the guide wheels, the door panels and the front vertical sections are thereby forced in the direction of the support surface 31 until the door panels securely bear against the sealing strip 32. In the completely closed position of the overhead door shown in FIG. 3, the front vertical sections abut against the stops 42. The topmost panel of the door is out of reach of the rear vertical section and is directly forced against the sealing strip by the connecting arms 21, 22. Accordingly, when the overhead door according to the invention is closed, it is first brought before the opening to be closed off and subsequently forced in its entirety against the sealing strip by means of a so-called plugging movement so as to effect the definitive closure. Simultaneously, the arms 21 and 22 travel beyond the dead center position so that movement as a result of any forces applied directly to the door itself, is prevented.
FIG. 3 shows a part of FIG. 2, but in FIG. 3 the door is disposed in the definitively closed position. The rear guide rail 36 has been moved entirely upwards and also forwards by the wedge-shaped members 45. The guide wheels of the door have thereby been moved forward too and have forced the front guide rail 37 against the stops 42 counter to the force of the spring or springs 40. The location of the stops has been selected such that in the closed position the door panels themselves are securely pressed against the sealing strips 32 which have been provided around the door opening.
This is shown once more in section in FIG. 4. FIG. 4 further shows in what manner the stops 42 and 43 may be mounted on a common substantially L-shaped section 49. The section shown comprises a first leg 50 mounted on the wall 51 in which the door opening to be closed off is disposed. In this embodiment, the first leg 50 is directed towards the door opening and thus also forms the stop surface 31 on which the sealing strip 32 is mounted.
The other leg 52 extends transversely of the wall 51 and supports the stops 42, 43. In this embodiment, the free edge of the leg 52 in turn is flanged outward and forms a stiffening flange 53.
When opening the door, the chains 11, 12 are driven clockwise, whereby the arms 21, 22 first pass the dead center position again and are subsequently moved rearwardly by the chains, the topmost panel being carried along with them. As a result, the topmost panel tilts rearwardly so that the roller 33 (or another projection of the panel or the arm) releases the lever 39. The rear guide rail is then permitted to move downwards. For that purpose, spring means may be provided which pull and/or force the rear guide rail downwards. In the embodiment shown, the lever 39, however, is provided with a cam 55 which upon the returning movement of the connecting arm is operated by the guide wheel 33 (or another projection) whereby the rod 48, and via the rod 48 the rear guide rail 36, is moved downwards. If so desired, this movement can be supported by spring means again.
When the rear guide rail 36 move downwards, a rearward movement also occurs, under the influence of the springs 44. Then the springs 40 can force the front guide rails 37 rearwardly, whereby the door itself is released from the sealing strips 32 via the guide wheels of the door panels. The door is "unplugged".
Due to the above described downward and rearward movement of the rear guide rails, the connection with the curved rail 38 is reestablished, so that the door may subsequently be pulled up during the continued clockwise drive of the chains 11, 12. During that operation, the door runs clear of the sealing strips again.
In the embodiment shown, the stops 42 and 43 are constructed as rotatable rollers, so that during the up and down movement of the rear guide rail 36 only rolling friction develops. The same applies to the front guide rail, which can be carried along to some extent in vertical direction by the guide wheels of the door when the door is being opened or closed.
For the sake of completeness, FIG. 5 once more shows a door assembly according to the invention, in which the door is shown in the entirely opened position at 60 and in the entirely closed position at 61. In the open position, the door is disposed substantially in horizontal position at the level of the top edge of the door opening. The door is then supported by the horizontal rails 35 via the guide wheels. FIG. 5 further shows at 62 a control box with buttons for opening and closing the door.
In the embodiment shown, the driving means 20 comprise an electric motor 63 which is coupled with a drive chain, belt or rope 19 via a gear box 64.
The electric motor is preferably provided with an automatically operating brake which prevents rotation of the motor when the motor is not excited. It is observed that other drive sources can be used too, such as hydraulic or pneumatic drive units.
The gear box may also be directly coupled to the shaft 17, as shown diagrammatically in FIG. 7. In the embodiment of FIG. 7 the gear box and the driving motor are arranged high and central of the space to be closed off by the door, whereas in the arrangement of FIG. 1 and 5, the driving means are arranged comparatively low against a sidewall of the space to be closed off by the door.
However, in either case a manually operated device is used, which can be employed in emergencies. One example of suitable manually operated device 65 is shown diagrammatically in FIG. 6.
FIG. 6 shows a gear box 67 coupled to the shaft 66 of the driving motor 63, the gear box 67 having a driving shaft 68 on which a crank 69 can be mounted. The crank is slidable upon the driving shaft 68. When the crank is fitted onto the driving shaft as far as possible and is pushed in the direction of the gear box 67, the driving shaft 68 moves rearwardly (to the left in FIG. 6), counter to the spring force exerted by a spring 70. The result is that via a lever assembly 71, 72 the brake of the driving motor is uncoupled. Further, a microswitch 83 is operated by a plate 73 mounted on the shaft 68, the microswitch being capable of disconnecting the power to the motor.
The crank comprises a crank head 77 and a crank arm 78. The crank head comprises a spring brake 79 and is provided with a lug 80 which engages around a pin 81 when the crank is fitted onto the shaft 68. The construction is such that the lug 80 engages the pin 81 before the brake of the driving motor is uncoupled. Accordingly, the spring brake 79 is already active at the moment when the brake of the driving motor is uncoupled via the lever assembly 71, 72.
In the embodiment shown in FIG. 7, the lever assembly coupled to the motor brake is schematically shown at 74. Further, in the embodiment of FIG. 7, not a gear box but a rope, belt or chain transmission 75 between the crank and the motor is used.
FIG. 7 further shows an entrance door 76 within the overhead door 1.
When the panels are of a suitable construction, an overhead door according to the invention is very suitable to serve as a fire-proof door for airtight separation, for example of two compartments of a railroad car, a vessel, a building etc.
It is observed that after the foregoing, various modifications will readily occur to those skilled in the art. Thus, the door might consist of a smaller number of panels than shown, even of a single panel. Also, instead of an electric drive, a different drive can be used. Further, the upward movement of the rod 48 could be converted into a plugging movement of the rear guide rails in a different manner, for example via suitably arranged levers and/or rotating cams. it would also be possible to use a single chain with a connecting arm coupled thereto, mounted facing the middle of the door.
Further, the door assembly according to the invention could be used in a position rotated 90°, with the panels being moved in upright position from one of the sides of a door opening before and into the door opening by one or more chains in horizontal position. These and similar modifications are understood to fall within the scope of the invention.
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An overhead door assembly designed particularly for use with vehicles such as railroad cars is disclosed. The door assembly is made up of an overhead door, vertical guide members for guiding the overhead door in the vertical direction and horizontal guide members for guiding the door in the horizontal direction. A motor is provided for driving the door between an open and a closed position. According to the invention, the door is first guided to a position directly in front of the door opening, but slightly spaced therefrom. The door is then moved horizontally in a plugging movement so as to securely close off the door opening.
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BACKGROUND OF THE INVENTION
The present invention relates to an arrangement pertaining to a working implement having the form, for instance, of a fork-frame structure which is provided with one or more, preferably at least two lifting forks or tines, each of which is suspended on a respective lifting frame in a manner which will enable the lifting forks to be moved laterally.
It is known to move forks that are suspended on a fork arm with the aid of hydraulically operated screw-nut devices, for instance of the kind described in WO-A1-88/00894, or with the aid of double-acting hydraulic piston-cylinder devices. These known devices for lateral movement of the lifting forks are highly-complicated, however, and therewith expensive to provide and also require the provision of a hydraulic power source in order to perform their functions.
This type of working implement requires the provision of devices by means of which the working implement can be coupled automatically to the implement attachment means on the working machine, and also with devices by means of which the working implement can be connected to the machine, which includes automatic hose connections for connecting the working implement hydraulically to the hydraulic system of the working machine, so as to enable hydraulically operated functions incorporated in the working implement to be activated directly from the driving cabin of the working machine. These latter types of automatic couplings are also constructed so as to enable a working implement to be coupled to the machine without the driver needing to leave the driver's cabin or to employ the help of an assistant. Despite this, however, it is found that known coupling devices of this kind do not fulfill the aforesaid conditions and are also encumbered with the troublesome drawback that when connecting and disconnecting the quick-couplings of the hydraulic hoses some hydraulic oil is always spilled onto the ground. Although various methods of preventing this have been proposed in the art, none has been successful to any great extent.
Furthermore, when disconnected, such automatic hose couplings are totally exposed and unprotected and therefore subjected to dust, sand, dirt and the like, which, due to the presence of oil on the disconnected quick-connection halves, readily fastens to the couplings and is liable to destroy the hose couplings totally. As a result of this, a parallel problem is one of providing a well functioning automatic coupling device for a working implement which requires access to an energy source of the working machine in order to carry out its function.
SUMMARY OF THE INVENTION
A prime object of the present invention is to provide a simple arrangement for moving laterally the lifting forks of both tractor-carried lifting-fork implements and fork trucks in order to adjust the spacing between the forks.
A further object of the invention is to provide tractors in particular and also other machines of the kind mentioned in the introduction with an arrangement or device which will enable a working implement in the form of a fork-frame structure which carries lifting forks to be coupled to an implement attachment means carried by arms on a working machine, in a manner such that the motor required for moving the lifting forks is connected automatically to its drive source without the occurrence of oil spillage.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to the accompanying drawings in which:
FIG. 1 illustrates in perspective an exemplifying embodiment of the inventive arrangement in an operational state immediately prior to coupling the working implement to the arm-carried implement attachment means of a working machine;
FIG. 2 is an enlarged view of part of the inventive arrangement shown in FIG. 1;
FIG. 3 illustrates in larger scale an electric contact device forming part of the inventive arrangement;
FIG. 4 is a perspective view in larger scale seen from the rear side of the implement and illustrates a locking means for parallel outward/inward movement of the forks of the implement;
FIGS. 5 and 6 illustrate schematically said parallel inward/outward movement of the forks; and
FIG. 7, finally, is a perspective view of one embodiment of the present invention applied to a fork lift truck.
DETAILED DESCRIPTION
In FIG. 1 the reference numeral 1 identifies generally an implement attachment means which is carried on one end of the operating arm or implement arm of a working machine, not shown in detail in the Figure. The reference numeral 2 identifies a working implement or tool in the form of a fork-frame structure 4 provided with lifting forks 3 and also with attachment means in the form of attachment hooks 5 and two attachment lugs 6 in which holes are provided, the attachment means being adapted to the implement attachment means. The implement attachment means 1 can be manouvered from the machine driving cabin and includes on one side a transversally extending, preferably round carrier rod 7 which is attached to the side members 8 of the attachment means, each side member including two mutually separated plates 9. The spacing between the plates is greater than the thickness of the implement attachment hooks 5. Each of the side-pieces 8 of the instrument attachment means is provided on its lower part with locking holes 10 which accommodate hydraulically or mechanically operable locking pins 11 which function to lock and positionally fixate the attachment lugs 6 on the fork-frame structure to the implement attachment means 1. When coupling the implement 2 to the implement attachment means 1, the rod 7 of the manouverable implement attachment is moved, in a known manner, from beneath into the hooks 5 on the implement and the implement attachment means 1 is then swung around its rod 7, on which the actual implement is now suspended through the intermediary of its hooks 5, in towards the attachment lugs 6 on the implement. With the lugs positioned in line with respective locking holes 10 on the implement attachment means, the movable locking pins 11 are moved to a position in which the lugs 6 are locked to the attachment means 1, whereupon the implement is held immovably hanging from the implement attachment means 1 of the machine.
The fork-frame structure 4 includes a pair of lifting forks 3 which, with the aid of slide hooks 12, are displaceably suspended, in a known manner, on a transverse slide bar 13 included in the fork-frame structure 4. The lifting forks 3 slideably abut one side 14 of the slide bar 13 and are also slideably supported against the lower, transverse bar 15 of the fork-frame structure.
In accordance with the present invention, one and/or the other of the lifting forks 3 is connected to, or capable of being connected to a movement transmission device 16 which functions to move the forks laterally and therewith adjust the spacing between the forks, this spacing being adapted to the size of the object or objects to be handled. In the case of the embodiment illustrated in FIG. 1, both of the lifting forks 3 are connected to a movement transmission device 16.
The movement transmission device 16 of the illustrated embodiments has the form of an endless chain 17 which runs over sprocket wheels 19 mounted on the short sides 18 of the fork-frame structure, of which sprocket wheels at least one is driven, in use. In case only one of the sprocket wheels is driven, the case the other accompanies the movement of the driven wheel. In the case of the FIG. 1 embodiment, the upper part or run 20 of the endless movement transmission device 16 or the chain 17 is connected to one of the lifting forks 3, whereas the lower part or run 21 of the device or chain is connected to the other lifting fork 3, such that when the device 16 is driven in the direction shown by the arrows 22 both of said forks 3 will be moved towards one another, whereas movement of the device 16 in the opposite direction will cause the forks 3 to move apart. The connection between chain and fork may either be a fixed connection, e.g. a bolt connection, or a detachable connection, e.g. an electromagnet connection, thereby enabling one fork 3 to be moved independently of the other. FIGS. 4-6 illustrate a locking means 30 which, in accordance with the present invention, may be operable hydraulically, pneumatically or electrically when concerned with fork-lift trucks, although in principle solely electrical operation is applicable in the case of tractor-carried fork implements. The locking means 30 is mounted on the back of the fork, between the slide bar 13 of the fork-frame structure and the lower transverse frame-beam 15. In the illustrated case, the locking means has the form of a double-acting piston-cylinder device 31 having a two-sided or through-passing piston rod 32 which is provided at each end with a locking plate 33. In the neutral position or non-locking position of the locking means, the locking plates 33 are located between the two parts or runs 20 and 21 of the endless chain, so as to enable the plates to be moved to an upper locking position, as illustrated in FIG. 4, in which they clamp the upper run 20 of the endless chain firmly against an anvil surface or counter-pressure surface 34 on the fork 3 concerned, or to a lower end position in which they clamp the bottom run 21 of the endless chain against a lower anvil surface or counter-pressure surface 35 on the fork concerned.
In the case of the FIG. 4 embodiment, the upper run 20 of the endless chain is also firmly connected to that fork which does not carry the locking means 30 and with the locking means 30 in its upper locking position. Thus in the position in which the upper run 20 of the chain is connected to both of the forks 3, the forks will be moved in parallel, as illustrated in FIG. 5, whereas with the locking means 30 in its lower locking position, in which the bottom run 21 of the chain is connected to that fork 3 which is provided with the locking device, both forks will be moved in towards one another, or away from one another, depending on the direction of chain movement, and thus in the same manner as that described with reference to the FIG. 1 embodiment. Thus, when the locking means 30 is located in its neutral position, the fork 3 which is firmly connected to the chain 17 can-be moved relative to the other fork, which is therewith stationary, so as to also enable the distance between the forks to be changed.
For the purpose of facilitating lateral movement of the forks 3 even when they carry load, rollers 36 are mounted at an angle between the forks 3 and the long sides of the slide beam 13, and also between the forks and the long side of the beam 15 facing towards the forks, as illustrated schematically in FIG. 4.
In the case of the exemplifying embodiments of the invention illustrated in the drawings, the movement transmission device 16 is driven by an electric motor 23 (FIG. 1) the output drive shaft of which carries the driven sprocket wheel 19. Electric current is supplied to the motor through a two-part pin contact or electrical connector, one part 25 of which, e.g. the pin part or outtake part, is connected to the implement attachment means 1, and the other part 26, e.g. the socket or intake part, is connected to the lifting arm 4, such that these two connector parts are brought into contact with one another automatically when applying the lifting frame 4 to the implement attachment means 1. As illustrated in FIG. 2, the pins 27 on the connector plug are spring biased, so that the pins will be held constantly against an electrical contact plate or tab in the connected state of the current supply device, this contact plate being provided in the part referenced 25 in the FIG. 1 embodiment.
A preferred embodiment of an electrical connector device of the present invention is illustrated in FIG. 3. The socket-outlet 25 of this device, i.e. that part of the device which is located on the current supply side, is mounted on the implement attachment means of the tractor and includes a plurality of electrical contact plates 40 which are fixed in mutually spaced relationship in a body 41 made of an electrically insulating material, preferably rubber or some corresponding material, and the intake part 26 of which, i.e. that part of the electrical connector device which is located on the consumer side, is joined to the implement 2 and includes a number of connector pins 42 which correspond in number to the number of the electrical contact plates 40 and which are fixed mutually spaced in a body 43 made of an electrically insulating material, preferably rubber or some corresponding material. The body 43 has formed therein, between respective connector pins 42, a through-passing slot 44 such as to form fingers 45, each of which carries a connector pin 42 and which, due to the nature of the material used, are resilient. By allowing the fingers 45 of the connector pins to be urged rearwardly when coupling together the plug and socket connection 25, 26 and also, optionally, the rubber body 41 carrying the electrical contact plates 40, when the electrical connection is established the electric contact plates 40 and the connecting pins 42 will be held positively in mutual abutment by the rearwardly bent fingers 45 and, when applicable, by the elastic restoring force exerted by the body 41 of the electrical intake part of the connection. By constructing at least the outtake part 25 of the electrical contact device, and preferably also its intake part 26 of rubber or some corresponding material, there is obtained an electrical connector device which is very robust and operationally reliable in the present context.
FIG. 7 illustrates the present invention as applied to a fork-lift truck, the lifting forks or tines 50 of which can be moved with the aid of the endless movement transmission device 16, of the present invention which also in this case has the form of an endless belt 57 driven by a motor 51. When the working implement forms an integral part of the machine, i.e. of the truck in the illustrated case, the motor may be a hydraulic motor or some other suitable motor, such as a pneumatic or electric motor, and is mounted on a carrier plate 54 attached to the upper part 53 of the raisable and lowerable fork-frame structure 52, so as to accompany the frame structure 52 as it moves up and down. In the case of the FIG. 7 embodiment, the motor 51 is connected to one end wheel 19 of the movement transmission device through the intermediary of a chain transmission 55, which includes a chain, a sprocket wheel mounted on the output shaft of the motor 51 and a further sprocket wheel mounted on the same shaft, although when the movement transmission device 16 has the form of an endless chain, the chain can be extended so as to pass from one chain end wheel and over a drive wheel mounted on the output drive-shaft of the motor 51 and back via a guide wheel (not shown) which imparts the intended, illustrated extension to the upper run 20 of the chain.
It will be understood that the present invention is not restricted to the aforedescribed and illustrated embodiments, but that these embodiments can be changed, modified and complemented in many different ways within the scope of the inventive concept defined in the following claims. For instance, the movement transmission device 16 may have the form of a V-belt, a wire, a toothed belt or some corresponding device, since movement of the two lifting forks towards and away from one another does not need the application of large forces. Furthermore, each lifting fork may be mounted on a motor and a movement transmission device, and it may also be convenient to provide each lifting fork with a locking device 30, therewith obviating the need to provide a fixed or stationary connection between the movement transmission device 16 and the one and/or the other fork.
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A working machine is frontally provided with a structure for removably supporting an implement. The implement which is removably supported is a frame which transversely shiftably mounts two forwardly projecting lifting tines. An electrically powered adjusting device mounts the lifting tines to the frame. An electrical cable which provides electrical service from the working machine to the adjusting device includes a two-part connector the parts of which are automatically plugged together and separated as the frame is mounted to and demounted from the working machine. A locking device is provided for mechanically fixing a selected position to which the lifting tines have been adjusted.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Japanese Patent Application No. 2011-218584, filed on Sep. 30, 2011, the entire disclosure of which is incorporated by reference herein.
FIELD
[0002] This application relates to a printing device capable of canceling a print job once registered.
BACKGROUND
[0003] Nowadays, printing systems in which a host device such as a host computer and a printing device such as a printer are connected via a network are used. In such printing systems, the printing device receiving print jobs sent from the host device and executing the printing in sequence often displays on the panel information on the job in the process of printing. Therefore, when multiple print jobs are received, the print job displayed on the panel is job information in the process of printing at the time.
[0004] However, with a high speed printing device such as a page printer, multiple sheets of printing paper are conveyed in the device. For example, at the time of a sheet being about to be ejected, several new sheets have already been fed into the device from the paper feeder and conveyed within the device. If the printing device is paused in such a state, the sheets fed into the device are ejected according to a proper control; however, the device cannot be paused before the sheets are ejected. In other words, if an attempt is made to pause the printing device in the middle of continuous printing, the subsequent sheets fed into the device will jam within the device. Then, the printing device should be paused after the sheets being conveyed within the device are ejected.
[0005] On the other hand, many printing devices are capable of canceling a print job. The function of cancelling a print job is a function to pause the ongoing print job through operation on the operation panel for no further output of sheets, for example, when some wrong print setting is found after the printing starts.
[0006] Here, two panel operations are generally required for cancelling a print job. The first operation is an order to pause the printing device in operation and the second operation is an order to confirm job information and execute the job cancellation. The reason for requiring the two panel operations is that when an attempt is made to pause the aforementioned high-speed printing device at a specific moment, the printing device does not pause immediately and a print job different from the intended print job may be cancelled. Therefore, when the operator cancels a job, he/she confirms the job information after the printing device pauses and operates the panel to cancel the intended print job with no mistake.
[0007] Unexamined Japanese Patent Application Kokai Publication No. 2008-36999 discloses an image forming device determining whether a reserved and registered print job satisfies preset cancelation conditions and executing a job cancelation procedure when the cancelation conditions are satisfied so as to cancel the print job without complicate operations.
[0008] As mentioned above, two operations are conducted on the operation panel for cancelling a print job in the prior art. However, there may be the same print job at the time of the first panel operation and at the time of the second panel operation, for example, depending on the number of pages of print data. Some user who is familiar with the job cancelling operation may conduct the second panel operation without confirming the cancelation target job well. In such a case, a wrong print job may be designated as the cancellation target.
[0009] Furthermore, two panel operations for canceling a job are a burden for the user.
SUMMARY
[0010] Then, an exemplary object of the present invention is to provide a printing device eliminating the need of multiple panel operations in a job cancellation procedure to reduce the user workload and allowing the cancellation target job to be specified with no mistake.
[0011] The printing device according to a first exemplary aspect of the present invention comprises a receiver receiving a print job sent from a host device; a print processor executing printing on at least one or more recording media based on print data included in the print job received by the receiver; a job table registering and storing administrative information of the print job received by the receiver; a controller registering, upon reception of a print job by the receiver, administrative information of the print job received by the receiver in the job table, and ordering the print processor to execute printing based on the registered print job, adding information indicating that the printing is in progress to the administrative information of the print job on which the execution is ordered, inquiring of the print processor whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, and deregistering from the job table the print job registered in the job table if an ejection completion response is made; a job cancellation inputter through which the user inputs a job cancellation order to cancel the printing of a print job in the process of printing; and a job-ID-upon-cancel-operation storage storing the ID of the print job in the process of printing when a printing cancellation order is input from the job cancellation inputter, wherein the controller outputs an order to pause the ongoing printing to the print processor according to the job cancellation order input from the job cancellation inputter; the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller; and the controller compares the ID of the print job registered in the job table as in the process of printing with the ID stored in the job-ID-upon-cancel-operation storage, and cancels the printing of the print job having the print job ID when the ID of the registered print job and the stored ID are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0012] The printing device according to a second exemplary aspect of the present invention comprises a receiver receiving a print job sent from a host device; a print processor executing printing on at least one or more recording media based on print data included in the print job received by the receiver; a job table registering and storing administrative information of the print job received by the receiver; a controller registering, upon reception of a print job by the receiver, administrative information of the print job received by the receiver in the job table, counting and storing the number of the registered print jobs, ordering the print processor to execute printing based on the registered print job, and adding information indicating that the printing is in progress to the administrative information of the print job on which the execution is ordered,
[0013] inquiring of the print processor whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, and deregistering from the job table the print job registered in the job table if an ejection completion response is made; a job cancellation inputter through which a job cancellation order for cancelling the printing of a print job in the process of printing is input; and a number-of-jobs-upon-cancel-operation storage storing the number of print jobs when a printing cancellation order is input from the job cancellation inputter, wherein the controller outputs an order to pause the ongoing printing to the print processor according to the job cancellation order input from the job cancellation inputter; the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller; and
[0014] the controller compares the number of print jobs registered in the job table as in the process of printing with the number stored in the number-of-jobs-upon-cancel-operation storage, and cancels the printing of the print job in the process of printing when the number of registered print jobs and the stored number are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0015] The printing method according to a third exemplary aspect of the present invention is a printing method in a printing device including a receiver receiving a print job sent from a host device; a print processor executing printing on at least one or more recording media based on print data included in the print job received by the receiver; and a job table registering and storing administrative information of the print job received by the receiver, wherein upon reception of a print job by the receiver, administrative information of the print job received by the receiver is registered in the job table, and the print processor is ordered to execute printing based on the registered print job, information indicating that the printing is in progress is added to the administrative information of the print job on which the execution is ordered, the print processor is inquired whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, the print job registered in the job table is deregistered from the job table if an ejection completion response is made, “a job cancellation order for cancelling the printing of a print job in the process of printing” input from a job cancellation inputter is received, the ID of the print job in the process of printing when a printing cancellation order is input from the job cancellation inputter is stored in a job-ID-upon-cancel-operation storage, an order to pause the ongoing printing is output to the print processor according to the job cancellation order input from the job cancellation inputter, the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller, the ID of the print job registered in the job table as in the process of printing is compared with the ID stored in the job-ID-upon-cancel-operation storage, and the printing of the print job having the print job ID is cancelled when the ID of the registered print job and the stored ID are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0016] The printing method according to a fourth exemplary aspect of the present invention is a printing method in a printing device including a receiver receiving a print job sent from a host device; a print processor executing printing on at least one or more recording media based on print data included in the print job received by the receiver; and a job table registering and storing administrative information of the print job received by the receiver, wherein upon reception of a print job by the receiver, administrative information of the print job received by the receiver is registered in the job table, the number of the registered print jobs is counted and stored, the print processor is ordered to execute printing based on the registered print job, information indicating that the printing is in progress is added to the administrative information of the print job on which the execution is ordered, the print processor is inquired whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, the print job registered in the job table is deregistered from the job table if an ejection completion response is made, the administrative information of the next print job registered and stored is updated to in the process of printing, the print processor is ordered to execute the printing of the updated print job, a job cancellation order for cancelling the printing of a print job in the process of printing input from a job cancellation inputter is received, the number of print jobs when there is a printing cancellation order from the job cancellation inputter is stored in a number-of-jobs-upon-cancel-operation storage, an order to pause the ongoing printing is output to the print processor according to the job cancellation order input from the job cancellation inputter, the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller, and the controller compares the number of print jobs registered in the job table as in the process of printing with the number stored in the number-of-jobs-upon-cancel-operation storage, and cancels the printing of the print job in the process of printing when the number of registered print jobs and the stored number are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0017] The non-transitory storage medium according to a fifth exemplary aspect of the present invention is a storage medium storing a program for a computer to realize a printing method of cancelling printing of a print job received from a host device, executing a process to receive a print job sent from the host device by mean of a receiver; a process to make print on at least one or more recording media based on print data included in the print job received by the receiver; a process to register, upon reception of a print job by the receiver, administrative information of the print job received by the receiver in a job table, and order the print processor to execute printing based on the registered print job, and add information on the printing being in progress to the administrative information of the print job on which the execution is ordered; a process to inquire of the print processor whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, deregister from the job table the print job registered in the job table if an ejection completion response is made, update the administrative information of the next print job registered and stored to in the process of printing, and order the print processor to execute the printing of the updated print job; a process to receive a job cancellation order for cancelling the printing of a print job in the process of printing input from a job cancellation inputter; and a process to store the ID of the print job in the process of printing when there is a printing cancellation order from the job cancellation inputter in a job-ID-upon-cancel-operation storage, and allowing the computer to further execute a process in which an order to pause the ongoing printing is output to the print processor according to the job cancellation order input from the job cancellation inputter; the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller; and the ID of the print job registered in the job table as in the process of printing is compared with the ID stored in the job-ID-upon-cancel-operation storage, and the printing of the print job having the print job ID is cancelled when the ID of the registered print job and the stored ID are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0018] The non-transitory storage medium according to a sixth exemplary aspect of the present invention is a storage medium storing a program for a computer to realize a printing method of cancelling printing of a print job received from a host device, executing a process to receive a print job sent from the host device by means of a receiver; a process to make print on at least one or more recording media based on print data included in the print job received by the receiver; a process to register, upon reception of a print job by the receiver, administrative information of the print job received by the receiver in a job table, count the number of the registered print jobs, order execution of printing, and add information on the printing being in progress to the administrative information of the print job on which the execution is ordered; a process to inquire of the print processor whether ejection of a recording medium corresponding to the print job on which the execution of printing is ordered from the print processor is completed, deregister from the job table the print job registered in the job table if an ejection completion response is made, update the administrative information of the next print job registered and stored to in the process of printing, and order the print processor to execute the printing of the updated print job; a process to receive a job cancellation order for cancelling the printing of a print job in the process of printing from a job cancellation inputter; and a process to store the number of print jobs when there is a printing cancellation order from the job cancellation inputter in a number-of-jobs-upon-cancel-operation storage, and allowing the computer to further execute a process in which an order to pause the ongoing printing is output to the print processor according to the job cancellation order input from the job cancellation inputter; the print processor completes the ordered pause of printing and makes a response indicating the completion of pause of printing to the controller; and the number of print jobs registered in the job table as in the process of printing is compared with the number stored in the number-of-jobs-upon-cancel-operation storage, and the printing of the print job in the process of printing is cancelled when the number of registered print jobs and the stored number are equal in spite of time difference between the time the job cancellation inputter received the job cancellation order and the time the print processor received the response indicating the completion of pause of printing.
[0019] The present invention stores information on the job ID upon cancel operation when a job cancellation order is made, makes comparison with the job ID upon cancel operation in executing print job cancellation, and if they match, executes the job cancellation without further operation on the operation button, whereby job cancellation is executed without complicate operation. Furthermore, the present invention stores information on the number of jobs upon cancel operation, makes comparison with the number of print jobs upon execution of cancellation, and if they match, executes the job cancellation without further operation on the operation button, whereby job cancellation is executed without complicate operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A more complete understanding of this application can be obtained when the following detailed description is considered in conjunction with the following drawings, in which:
[0021] FIG. 1 is an illustration showing the basic system configuration of the embodiment;
[0022] FIG. 2 is an illustration showing the job table structure;
[0023] FIG. 3 is an illustration showing the conceptual relationship between the print queue state and print queue table;
[0024] FIG. 4 is an illustration showing the print queue table structure;
[0025] FIG. 5 is an illustration showing the data structure on the number of created print queues, writing position, and reading positions in the initial state;
[0026] FIG. 6 is an illustration showing an exemplary job table storing specific data;
[0027] FIG. 7 is an illustration showing an exemplary print queue table storing specific data;
[0028] FIG. 8 is an illustration showing the data structure on the number of created print queues, writing position, and reading positions;
[0029] FIG. 9 is a flowchart for explaining the processing of the reception part upon regular printing;
[0030] FIG. 10 is a flowchart for explaining the processing of the control part upon regular printing;
[0031] FIG. 11 is a flowchart for explaining the processing of the RIP part upon regular printing;
[0032] FIG. 12 is a flowchart for explaining the processing of the transfer part upon regular printing;
[0033] FIG. 13 is a flowchart for explaining the processing of the paper ejection part upon regular printing;
[0034] FIG. 14 is a flowchart of the control part for explaining the printing process including job cancellation;
[0035] FIG. 15 is a flowchart of the control part for explaining the printing process including job cancellation;
[0036] FIG. 16 is a flowchart of the RIP part for explaining the printing process including job cancellation;
[0037] FIG. 17 is a flowchart of the RIP part for explaining the printing process including job cancellation;
[0038] FIG. 18 is a flowchart of the transfer part for explaining the printing process including job cancellation;
[0039] FIG. 19 is a flowchart of the paper ejection part for explaining the printing process including job cancellation;
[0040] FIG. 20 is a flowchart for explaining the processing of the display operation control part;
[0041] FIG. 21 is an illustration showing the system configuration of Embodiment 1;
[0042] FIG. 22 is a flowchart for explaining the processing of the control part in Embodiment 1;
[0043] FIG. 23 is a flowchart for explaining the processing of the control part in Embodiment 1;
[0044] FIG. 24 is a flowchart for explaining the processing of the display operation control part in Embodiment 1;
[0045] FIG. 25A is an illustration showing an exemplary regular display upon job cancellation;
[0046] FIG. 25B is an illustration showing an exemplary irregular display upon job cancellation;
[0047] FIG. 26 is an illustration showing the system configuration of Embodiment 2;
[0048] FIG. 27 is a flowchart for explaining the processing of the control part in Embodiment 2;
[0049] FIG. 28 is a flowchart for explaining the processing of the control part in Embodiment 2; and
[0050] FIG. 29 is a flowchart for explaining the processing of the control part in Embodiment 3.
DETAILED DESCRIPTION
[0051] Embodiments of the present invention will be described hereafter with reference to the drawings.
[0052] FIG. 1 is an illustration showing the basic system of this embodiment. In the figure, a printer 1 is connected to a host device 2 such as a personal computer (PC) via a network such as a LAN (local area network). The printer 1 is composed of a reception part 3 , a control part 4 , a RIP part 5 , a transfer part 6 , a printer engine (print processor) 7 , a paper ejection part (print processor) 8 , a reception buffer 9 , a job table 10 , a display operation control part 11 , a display panel 12 , and an operation button (job cancellation inputter) 13 . The RIP (raster image processor) part 5 command-analyzes and converts print data to image data, and in doing so, creates and stores a print queue in a print queue table 14 . The image data command-analyzed and created by the RIP part 5 are expanded in a not-shown image memory.
[0053] The host device 2 converts the print data created according to the application to print data (PDL (page description language) data) by means of the printer driver and sends them to the printer 1 . The reception part 3 of the printer 1 receives the print data supplied from the host device 2 and notifies the control part 4 of information such as the job ID, document name, total number of print sheets included in the print data. Here, the print data further include information such as color/monochrome printing and double sided/single sided printing in addition to the above information. Furthermore, the reception part 3 writes the received print data in the reception buffer 9 in sequence.
[0054] Receiving the notice from the reception part 3 , the control part 4 stores the above information in the job table 10 . FIG. 2 is an illustration showing the structure of the job table 10 . The job table 10 consists of storage areas “job ID,” “document name,” “total number of print sheets,” “remaining number of print sheets,” “reception buffer address,” and “job status” under each record number. Information on the job ID, document name, and total number of print sheets is stored in the corresponding storage areas.
[0055] Here, the storage area “job ID” stores, for example, an identification code given to each print job, the storage area “document name” stores information on the document name of the job ID, and the storage area “total number of print sheets” stores the total number of pages of the print data. Furthermore, the storage area “remaining number of print sheets” stores the remaining number of print sheets calculated by subtracting the number of sheets ejected from the total number of print sheets of the corresponding print data.
[0056] Furthermore, the storage area “reception buffer address” stores information on the address in the reception buffer 9 where the corresponding print data are stored. Furthermore, the storage area “job status” stores the job status of the corresponding print job; the job status to be stored can be, for example, “receiving,” “printing,” or “in RIP (image data conversion in progress).”
[0057] Here, in the initial state of the job table 10 , as shown in FIG. 2 , the storage areas “job ID” are all reset to “empty,” the storage areas “document name” are all reset to “none,” the storage areas “total number of print sheets” are all reset to “0,” the storage areas “remaining number of print sheets” are all reset to “4,” the storage areas “reception buffer address” are all reset to “0,” and the storage areas “job status” are all reset to “none.”
[0058] Receiving a reception start signal from the reception part 3 , the control part 4 searches the job table 10 in sequence from the record number 1 and writes information of the job ID, document name, and total number of print sheets of the print data in the storage areas of the first record number of which the storage area “job ID” is “empty.”
[0059] The RIP part 5 reads the print data from the reception buffer 9 according to instruction from the control part 4 , and command-analyzes and converts them to image data. The image data converted by the RIP part 5 are expanded in a not-shown image memory. Furthermore, the print queue created concurrently is stored in the print queue table 14 . FIG. 3 is a conceptual illustration of the print queue table 14 and FIG. 4 is an illustration showing the data structure of the print queue table 14 .
[0060] The print queue table 14 consists of storage areas “job ID,” “current page number,” “image memory address,” “drawing state,” and “job cancelation information” under each record number.
[0061] The storage area “job ID” stores, for example, an identification code given to each print job as described above. Furthermore, the storage area “current page number” stores the page number in the process of RIP processing among the corresponding print data. Furthermore, the storage area “image memory address” stores information on the address of the image area where the image data of the corresponding page is expanded.
[0062] Furthermore, the storage area “drawing state” stores the progress of drawing processing on the corresponding print data, such as “drawing” and “drawing completed.” Furthermore, the storage area “job cancelation information” stores information indicating that job cancellation is ordered.
[0063] Here, as shown in FIG. 4 , in the initial state of the print queue table 14 , the storage areas “job ID” are all reset to “empty,” the storage areas “current page number” and “image memory address” are all reset to “0,” and the storage areas “drawing state” and “job cancellation information” are all reset to “none.”
[0064] Therefore, in the initial state, as shown in FIG. 5 , the number of print queues created is “0,” the new print queue writing position is “1” (the record number 1), the print queue reading position for transfer is also “1” (the record number 1), and the print queue reading position for paper ejection is also “1” (the record number 1).
[0065] Here, the transfer part 6 reads image data from the image memory and transfers the image data to the printer engine 7 . The printer engine 7 outputs image data to a storage medium (for example, paper) based on the image data transferred from the transfer part 6 . Furthermore, the paper ejection part 8 ejects the paper on which print is made by the printer engine 7 onto a not-shown paper tray and notifies the control part 4 that the paper is ejected.
[0066] Specific processing/operation with the above configuration will be described hereafter.
[0067] It is assumed in explaining the processing/operation of this embodiment that the job table 10 already has the information shown in FIG. 6 stored. For example, the storage areas under the record number 1 store print job information of which the “job ID” is “J0004,” “document name” is “Price List,” and “total number of print sheets” is “9” (nine sheets). The “job status” of this print job is currently “printing.” The conversion to image data by the RIP part 5 has already been completed and the “remaining number of print sheets” is “7” (seven sheets).
[0068] Furthermore, the storage areas under the record number 2 store print job information of which the “job ID” is “J0005,” “document name” is “Layout Diagram,” and “total number of print sheets” is “1” (one sheet). The “job status” of this print job is also “printing.” The conversion to image data by the RIP part 5 has already been completed and the “remaining number of print sheets” is “1” (one sheet); no printout has been made.
[0069] On the other hand, the storage areas under the record number 3 store print job information of which the “job ID” is “J0006,” “document name” is “Meeting Material,” and “total number of print sheets” is “14” (14 sheets). The “job status” of this print job is “in RIP.” The conversion to image data by the RIP part 5 has started and the print data remains in the reception buffer 9 . More specifically, the print data are stored in the reception buffer 9 from the start address “0x8000A064” stored in the “reception buffer address.”
[0070] Furthermore, the storage areas under the record number 4 store print job information of which the “job ID” is “J0007,” “document name” is “Budget Proposal,” and “total number of print sheets” is“5” (five sheets). The “job status” of this print job is “receiving”; the reception by the reception part 3 is in progress. More specifically, the print data are being stored in the reception buffer 9 from the start address “0x8000CB18” stored in the “reception buffer address.”
[0071] Here, at the time of starting the processing of this embodiment, the other record (the record number 5) in the job table 10 is in the initial state.
[0072] Like the above job table 10 , it is assumed that the print queue table 14 already has the data shown in FIG. 7 stored. For example, the storage areas under the record number 1 store information on the page 9 (the “current page number” is “9”) of which the “Job ID” is “J0004.” The image data of the page 9 has been drawn from the information in the “drawing state,” and expanded in an image memory from the start address “0x8081012C” from the information in the “image memory address.”
[0073] Furthermore, for example, the storage areas under the record number 2 store information on the page 1 (the “current page number” is “1”) of which the “Job ID” is “J0005,” which is completely drawn from the information in the “drawing state,” and expanded in an image memory from the start address “0x80C10140” from the information in the “image memory address.”
[0074] Furthermore, for example, the storage areas under the record numbers 3 to 7 store information on the pages 1 to 5 (the “current page number” is “1,” “2,” . . . , and “5”) of which the “Job ID” is “J0006.” The pages 1 to 4 are completely drawn and the page 5 is currently in drawing from the information in the “drawing state.” They are expanded in an image memory from the start address “0x81010154” from the information in the “image memory address.”
[0075] Here, the storage areas under the record numbers 8 and 9 are not used. The storage areas under the record number 10 store information on the page 8 (the “current page number” is “8”) of which the “job ID” is “J0004,” which is completely drawn from the information in the “drawing state” and expanded in an image memory from the start address “0x80400118” from the information in the “image memory address.”
[0076] Therefore, in the above state of the print queue table 14 , as shown in FIG. 8 , the number of print queues used is “8,” the next writing position is “7” (the record number 7), the next reading position for transfer is “1” (the record number 1), and the next reading position for paper ejection is “10” (the record number 10).
[0077] First, the regular printing procedure with no job cancellation order when the job table 10 and print queue table 14 are in the above-described states will be described. FIG. 9 is a flowchart for explaining the processing/operation of the reception part 3 . FIG. 10 is a flowchart for explaining the processing/operation of the control part 4 . FIG. 11 is a flowchart for explaining the processing/operation of the RIP part 5 . FIG. 12 is a flowchart for explaining the processing/operation of the transfer part 6 . FIG. 13 is a flowchart for explaining the processing/operation of the paper ejection part 8 .
[0078] First, the reception part 3 determines whether print data are received from the host device 2 connected to the network (Step (abbreviated to S, hereafter) 1 ) according to the flowchart shown in FIG. 9 . The reception part 3 waits until print data are received (NO in S 1 ). Receiving print data (YES in S 1 ), the reception part 3 extracts job information included in the print data (S 2 ). This process is a process to extract information such as the aforementioned job ID, document name, and total number of print sheets included in the received print data.
[0079] Then, the reception part 3 notifies the control part 4 of print data reception start (S 3 ). In other words, the reception part 3 outputs a reception start notice for obtaining approval for reception start to the control part 4 and waits for a reception start approval response from the control part 4 (S 4 ).
[0080] Receiving the reception start notice from the reception part 3 , the control part 4 starts the procedure according to the flowchart shown in FIG. 10 and first determines whether there is a notice from an external source (S 5 ). In this case, receiving the reception start notice (YES in S 5 ), the control part 4 makes reservation in the reception buffer 9 (S 6 ) and conducts registration in the job table 10 (S 7 ). In other words, the control part 4 reserves a storage area for the print data in the reception buffer 9 and registers the job information extracted from the print data in the job table 10 .
[0081] Subsequently, the control part 4 makes a reception start approval response to the reception part 3 (S 8 ). Receiving the reception start approval response from the control part 4 (YES in S 4 ), the reception part 3 starts receiving print data and stores the input print data in the reception buffer 9 in sequence (S 9 ).
[0082] After making a reception start approval response to the reception part 3 , the control part 4 determines whether the RIP processing is available (S 10 ). This determination is made with reference to the storage area “job status” in the job table 10 shown in FIG. 6 . For example, in the case of information “in RIP” being stored under the record number 3, no RIP processing is conducted on new print data (NO in S 10 ). On the other hand, in the case of the information “in RIP” not being stored in the storage area “job status” under any record number, the control part 4 updates the job table 10 (S 11 ) and notifies the RIP part 5 to start RIP processing (S 12 ). In such a case, the information “in RIP” is stored in the storage area “job status” under the record number on which the RPI processing starts.
[0083] Notified from the control part 4 to start RIP processing (YES in S 13 ), the RIP part 5 sets the “current page” to 1 (S 14 ) and determines whether there are any unprocessed RIP data (S 15 ) according to the flowchart shown in FIG. 11 . More specifically, the RIP part 5 determines whether there are any unread data (unprocessed RIP data). Here, if there are no unprocessed RIP data (NO in S 15 ), the RIP part 5 notifies the control part 4 that the RIP processing is completed (S 16 ). On the other hand, if there are any unprocessed RIP data (YES in S 15 ), the RIP part 5 reserves a print queue (S 17 ).
[0084] In the example shown in FIG. 6 , the print job stored under the record number 4 is in the process of receiving. Then, a print queue is reserved, an image memory is also reserved (S 18 ), the print queue table 14 is updated (S 19 ), the print data are read from the reception buffer 9 , and the RIP processing starts (S 20 ). Then, it is determined whether image data for one page are completed (S 21 ). If image data for one page are not completed (NO in S 21 ), the RIP processing is repeated (S 20 and S 21 ).
[0085] Subsequently, if image data for one page are completed (YES in S 21 ), the print queue table 14 is updated (S 22 ) and the “current page” is incremented (+1) (S 23 ). Then, it is determined whether there are any unprocessed RIP data (S 15 ). It there are any unprocessed RIP data (YES in S 15 ), the above processing (S 17 to S 23 ) is repeated. If there is no print data left in the reception buffer 9 (NO in S 15 ), the control part 4 is notified that the RIP processing is completed (S 16 ).
[0086] Receiving the RIP processing completion notice from the RIP part 5 (YES in S 5 ), the control part 4 releases the reception buffer 9 (S 24 ) and updates the job table 10 (S 25 ).
[0087] For example, in the example shown in FIG. 6 , receiving the notice of completion of RIP processing on the “job ID” of “J0006” under the record number 3, the control part 4 releases the storage area in the reception buffer 9 where the print data of the print job are stored and updates the “job status” to “printing.” Furthermore, receiving the notice of completion of RIP processing on the “job ID” of “J0007” under the record number 4, the control part 4 releases the storage area in the reception buffer 9 where the print data of the print job are stored and updates the “job status” to “in RIP” and to “printing” in turn.
[0088] Then, it is determined whether there is any print job in the process of receiving (S 26 ). If there is any print job in the process of receiving (YES in S 26 ), the job table 10 is updated (S 27 ) and the RIP part 5 is notified to start RIP processing (S 28 ). For example, in the example shown in FIG. 6 , as new print data are entered from the host device 2 and new print job information is entered in the available areas under the record number 5, the new print job information is written in the job table 10 and the RIP part 5 is notified to start RIP processing.
[0089] As print information is created in the print queue table 14 and one or more print queues are created (YES in S 29 ), the transfer part 6 makes reference to the storage area “drawing state” in the print queue table shown in FIG. 7 and determines whether it is “drawing completed” (S 30 ) according to the flowchart shown in FIG. 12 . For example, in the example shown in FIG. 7 , the storage area “drawing state” under the record numbers 1 to 6 is “drawing completed” (YES in S 30 ); then, the print queue table 14 is updated so that the corresponding storage area “drawing state” is updated to “transfer” (S 31 ). Then, the image data expanded in a not-shown image memory are transferred to the printer engine 7 (S 32 ), and the printer engine 7 makes printout on paper based on the image data.
[0090] Subsequently, the transfer part 6 releases the image memory in which the corresponding image data are expanded (S 33 ), updates the print queue table (S 34 ), and updates the print queue state (S 35 ).
[0091] On the other hand, as print information is created in the print queue table 14 and one or more print queues are created (YES in S 36 ), the paper ejection part 8 makes reference to the storage area “drawing state” in the print queue table shown in FIG. 7 and determines whether it is set to “transfer” (S 37 ) according to the flowchart shown in FIG. 13 . For example, as the transfer part 6 starts transfer and there is a print queue having the storage area “drawing state” set to “transfer” (YES in S 37 ), the paper ejection part 8 waits for a print paper ejection notice from the printer engine 7 (S 38 ). Subsequently, as the printer engine 7 completes printout on paper and a print paper ejection notice is issued (YES in S 38 ), the print queue table 14 is updated (S 39 ), the print queue state is updated (S 40 ), and the control part 4 is notified that the paper ejection is completed (S 41 ).
[0092] Receiving the paper ejection completion notice from the paper ejection part 8 (YES in S 5 ), the control part 4 calculates the remaining number of sheets (S 42 ). This process is a process to calculate the remaining number of print sheets of the corresponding print job.
[0093] The data in the “remaining number of print sheets” shown in FIG. 6 are decremented (−1) and the corresponding storage area “remaining number of print sheets” is updated (S 43 ). For example, for the print data having the “job ID” of “J0004” shown in FIG. 6 , the current data in the storage area “remaining number of print sheets” are decremented by 1 so as to update to “6” from a current value “7.”
[0094] Subsequently, it is determined whether the remaining number of sheets is 0 as a result of the above processing (S 44 ). If the corresponding storage area “remaining number of print sheets” is “0” (YES in S 44 ), the print job of the corresponding recording number is deleted (S 45 ). For example, as the print data having the “job ID” of “J0004” shown in FIG. 6 are further transferred and the data in the storage area “remaining number of print sheets” become “0,” the data of the print job of the record number 1 are deleted.
[0095] The regular printing procedure is described above. The printing procedure in which a job cancelation order is made will be described hereafter.
[0096] FIGS. 14 and 15 are flowcharts for explaining the processing/operation of the control part 4 . FIGS. 16 and 17 are flowcharts for explaining the processing/operation of the RIP part 5 . FIG. 18 is a flowchart for explaining the processing/operation of the transfer part 6 . FIG. 19 is a flowchart for explaining the processing/operation of the paper ejection part 8 . FIG. 20 is a flowchart for explaining the processing/operation of the display operation control part 11 .
[0097] Here, it is assumed again that the job table 10 has the print job information shown in FIG. 6 stored and the print queue table 14 has the print queue shown in FIG. 7 created.
[0098] As described above, the reception part 3 waits for reception of print data from the host device 2 connected to the network, extracts job information included in the print data upon receiving the print data, notifies the control part 4 of reception start, and waits for reception start approval from the control part 4 .
[0099] Receiving the reception start notice from the reception part 3 , the control part 4 first determines whether there is a notice from an external source (Step (abbreviated to ST, hereafter) 1 ) according to the flowchart shown in FIG. 14 . Here, receiving the reception start notice, the control part 4 make reservation in the reception buffer 9 (ST 2 ) and conducts registration in the job table 10 (ST 3 ) as described above. In other words, the control part 4 reserves a storage area for the print data in the reception buffer 9 and registers the job information extracted from the print data in the job table 10 .
[0100] Subsequently, the control part 4 makes a reception start approval response to the reception part 3 (ST 4 ). Receiving the reception start approval response from the control part 4 , the reception part 3 stores the print data in the reception buffer 9 in sequence.
[0101] After making a reception start approval response to the reception part 3 , the control part 4 determines whether RIP processing is available (ST 5 ). This determination is made with reference to the storage area “job status” in the job table 10 shown in FIG. 6 as described above. For example, in the case of information “in RIP” being stored under the record number 3, no RIP processing is conducted on new print data (NO in ST 5 ). On the other hand, in the case of the information “in RIP” not being stored in the storage area “job status” under any record number, the control part 4 updates the job table 10 (ST 6 ) and notifies the RIP part 5 to start RIP processing (ST 7 ).
[0102] The RIP part 5 determines whether there is a RIP pause notice from the control part 4 (C in the flowchart shown in FIG. 16 and ST 8 in the flowchart shown in FIG. 17 ). If there is a RIP pause notice (YES in ST 8 ), the RIP part 5 pauses the RIP processing and notifies the control part 4 that the RIP pause is completed (ST 9 ). The RIP pause notice is a notice output from the control part 4 when a job cancellation order described above is issued. The RIP part 5 pauses the ongoing RIP processing, conducts a series of processing described later (ST 10 to ST 12 ), and waits for a RIP unpause notice from the control part 4 (ST 13 ).
[0103] Therefore, unless there is a RIP pause notice (unless a job cancellation order is issued), a RIP processing start notice from the control part 4 is waited (NO in ST 8 , ST 14 ), and if a RIP processing start notice is issued (YES in ST 14 ), the “current page” is set to 1 (ST 15 ) and it is determined whether there are unprocessed RIP data (ST 16 ) as described above. Here, if there are unprocessed RIP data (YES in ST 16 ), it is confirmed again that there is no RIP pause notice (job cancellation order) (NO in ST 8 ), the print queue table 14 is reserved (ST 17 ), and the area of the image memory for expansion is reserved (ST 18 ).
[0104] Subsequently, it is determined whether to unpause the RIP (ST 19 ). If there is no RIP unpause (YES in ST 19 ), the storage area “job cancellation information” of the print queue table 14 is set to “none” (is maintained “none”) (ST 20 ), the print data are read from the reception buffer 9 , and the same RIP processing as described above is conducted (ST 21 to ST 25 ). Subsequently, after all unprocessed RIP data are converted to image data (NO in ST 16 ), the control part 4 is notified that the RIP processing is completed (ST 26 ).
[0105] On the other hand, receiving the RIP processing completion notice from the RIP part 5 (YES in ST 1 ), the control part 4 releases the reception buffer 9 (ST 27 ) and updates the job table 10 (ST 28 ) as described above. Subsequently, the control part 4 determines whether there is a print job in the process of receiving (ST 29 ). If there is a print job in the process of receiving (YES in ST 29 ), the control part 4 updates the job table 10 (ST 30 ) and notifies the RIP part 5 to start RIP processing (ST 31 ).
[0106] The transfer part 6 determines whether there is a printing pause notice from the control part 4 (ST 32 ). If there is a printing pause notice (YES in ST 32 ), the transfer part 6 pauses the printing, notifies the control part 4 that the printing pause is completed (ST 33 ), and waits for a printing unpause notice from the control part 4 (ST 34 ). This printing pause notice is also a notice sent from the control part 4 when a job cancellation order described later is issued. If there is no printing pause notice, as described above, printing information is created in the print queue table 14 and if one or more print queues are created (YES in ST 35 ), it is confirmed again that there is no printing pause notice from the control part 4 (NO in ST 36 ) and the storage area “drawing state” shown in FIG. 7 is referred to determine whether it is set to the “drawing completed” (ST 39 ), which is followed by the same processing as described above (ST 40 to ST 45 ).
[0107] The paper ejection part 8 determines whether a paper ejection completion response request is made by the control part 4 (ST 46 ). If a paper ejection completion response request is made (YES in ST 46 ), the paper ejection part 8 makes a paper ejection completion response to the control part 4 (ST 47 ). This paper ejection completion response request is made when a job cancellation order described later is issued. If no paper ejection completion response request is made, as described above, print information is created in the print queue table 14 and if one or more print queues are created (YES in ST 48 ), it is confirmed again that no paper ejection completion response request is made by the control part 4 (NO in ST 49 ), and the storage area “drawing state” shown in FIG. 7 is referred to determine whether it is set to “transfer” (ST 51 ). Then, it is confirmed whether the storage area “job cancellation information” is not set to “execution” (ST 52 ).
[0108] Then, as described above, a print paper ejection notice from the printer engine 7 is waited (ST 53 ). If there is a print paper ejection notice (YES in ST 53 ), the print queue table 14 is updated (ST 54 ), the print queue state is updated (ST 55 ), and the control part 4 is notified that the paper ejection is completed (ST 56 ) as described above.
[0109] Receiving the paper ejection completion notice from the paper ejection part 8 (YES in ST 1 ), the control part 4 calculates the remaining number of sheets (ST 57 ), updates the job table 10 (ST 58 ), and determines whether the remaining number of print sheets is 0 (ST 59 ) as described above. Then, if the storage area “remaining number of print sheets” is “0” (YES in ST 59 ), the control part 4 deletes the print job of the corresponding record number (ST 60 ).
[0110] On the other hand, if the user operates on the operation button (job cancellation inputter) 13 to issue a job cancellation order during the above processing, an operation signal is sent to the display operation control part 11 .
[0111] FIG. 20 is a flowchart for explaining the processing of the display operation control part 11 . First, the display operation control part 11 determines whether there is a printer pause operation (Step (abbreviated to STP in FIG. 20 , hereafter) 1 ). In other words, the display operation control part 11 receives an operation signal based on operation on the operation button (job cancellation inputter) 13 , acknowledges a job cancellation order, and determines that there is a printer pause operation (YES in STP 1 ). Then, the display operation control part 11 notifies the control part 4 to pause the printer based on the determination (STP 2 ).
[0112] Receiving the printer pause notice (YES in ST 1 ), the control part 4 determines whether the number of print jobs is 1 or greater (ST 61 ). If the number of print jobs is not 1 or greater (NO in ST 61 ), in other words if the number of print jobs is “0,” there is no point of job cancellation and the control part 4 notifies the display operation control part 11 that the job cancellation is invalid (ST 62 ). The display operation control part 11 displays invalidity of the job cancellation based on the notification from the control part 4 (STP 5 ).
[0113] On the other hand, if the number of print jobs is one or greater (YES in ST 61 ), the control part 4 notifies the RIP part 5 to pause the RIP processing, notifies the transfer part 6 to pause the printing, and requires a paper ejection completion response from the paper ejection part 8 (ST 63 ).
[0114] Receiving the notice (YES in ST 8 ), the RIP part 5 pauses the ongoing RIP processing and notifies the control part 4 that the RIP pause is completed (ST 9 ) as described above. Subsequently, the RIP part 5 waits for a RIP unpause notice from the control part 4 (ST 13 ).
[0115] Furthermore, receiving the printing pause notice from control part 4 (YES in ST 32 or YES in ST 36 ), the transfer part 6 pauses the image data transfer and notifies the control part 4 that the printing pause is completed (ST 33 or ST 37 ). Subsequently, the transfer part 6 waits for a printing unpause notice from the control part 4 (ST 34 or ST 38 ).
[0116] Furthermore, receiving the paper ejection completion response request from the control part 4 (YES in ST 46 or YES in ST 49 ), the paper ejection part 8 confirms the print paper ejected and makes a paper ejection completion response to the control part 4 (ST 47 or ST 50 ).
[0117] Receiving the above RIP pause completion response from the RIP part 5 , printing pause completion response from the transfer part 6 , and paper ejection completion response from the paper ejection part 8 (YES in ST 64 ), the control part 4 determines again whether the number of print jobs is one or greater (ST 65 ). If the number of print jobs is one or greater (YES in ST 65 ), the control part 4 updates the job table 10 (ST 66 ), and notifies the display operation control part 11 that the job cancellation is valid (ST 67 ). Here, it is determined again whether the number of print jobs is one or greater because the print job to be cancelled may be completed while the RIP part 5 executes the RIP pause procedure or the transfer part 6 executes the printing pause procedure.
[0118] Notified from the control part 4 that the job cancellation is valid, the display operation control part 11 displays the job information on the display panel 12 (STP 4 ), and waits for an order for or against execution of the job cancellation (STP 6 ). In this case, the display operation control part 11 displays information of the document name of the print job under the record number 1 that is in the process of printing on the display panel 12 , and waits for an order to execute the job cancellation or an order to nullify the job cancellation from the user.
[0119] Subsequently, if the operation button 13 is operated and an order to execute the job cancellation is issued (YES in STP 6 ), the display operation control part 11 notifies the control part 4 to execute the job cancellation (STP 7 ). On the other hand, if an order to nullify the job cancellation is issued (NO in STP 6 ), the display operation control part 11 notifies the control part 4 of nullify the job cancellation (STP 8 ).
[0120] Notified from the display operation control part 11 to execute the job cancellation (YES in ST 68 ), the control part 4 notifies the RIP part 5 to update the print queue (ST 69 ). Receiving the print queue update notice (ST 10 ), the RIP part 5 updates the print queue table 14 (ST 11 ).
[0121] Subsequently, the RIP part 5 notifies the control part 4 that the print queue update is completed (ST 12 ). Receiving the print queue update completion notice (YES in ST 70 ), the control part 4 further updates the job table 10 (ST 71 ). For example, the control part 4 clears the information under the record number 1 of the print job of the document name “Price List” of the “J0004” and moves up the record numbers one by one.
[0122] Then, it is determined whether the “job status” under the record number 1 in the job table 10 is “in RIP” (ST 72 ). In this case, the print job information updated in the above processing is stored in the storage areas under the record number 1. If the “job status” of the print job stored under the record number 1 is in RIP (YES in ST 72 ), the RIP part 5 is notified to unpause the RIP (ST 73 ) and the transfer part 6 is notified to unpause the printing (STP 74 ).
[0123] On the other hand, if the “job status” under the record number 1 is not in RIP (NO in ST 72 ), the job table 10 is searched (S 75 ). If there is any print job of which the “job status” is in RIP (YES in ST 76 ), the RIP part 5 is notified to unpause the RIP (ST 77 ) and the transfer part 6 is notified to unpause the printing (ST 74 ).
[0124] With the above processing, the RIP processing and image data transfer of the print job under the record number 1 after the job cancellation procedure are conducted. In this case, the RIP part 5 updates the print queue table 14 based on the RIP unpause notice (YES in ST 19 ), and sets the storage area “job cancellation information” of the corresponding print job to execution (ST 22 ).
[0125] On the other hand, for the print job to be cancelled, the transfer part 6 releases the image data in the image memory (ST 43 ) without transferring the image data of the print job from the image memory (YES in ST 41 ).
[0126] Furthermore, for the print job to be cancelled, the paper ejection part 8 notifies the control part 4 that the paper ejection is completed (ST 54 to ST 56 ) without waiting for a print paper ejection notice from the printer engine 7 (YES in ST 52 ).
[0127] The above processing is the basic processing to execute job cancellation. Embodiment 1 of this embodiment will be described hereafter.
[0128] FIG. 21 is an illustration showing the system configuration of this embodiment, which is basically the same as the system configuration described with reference to FIG. 1 except that a job-ID-upon-cancel-operation storage 15 is added. In other words, the printer 1 is connected to the host device 2 via a network such as a LAN, and composed of the reception part 3 , control part 4 , RIP part 5 , transfer part 6 , printer engine 7 , paper ejection part 8 , reception buffer 9 , job table 10 , display operation control part 11 , display panel 12 , operation button 13 , print queue table 14 , and job-ID-upon-cancel-operation storage 15 . The job-ID-upon-cancel-operation storage 15 stores information on the print job ID when the operation button 13 is operated for (operation for) job cancellation. Details will be given hereafter.
[0129] FIGS. 22 and 23 are flowcharts for explaining the processing/operation of the control part 4 . FIG. 24 is a flowchart for explaining the processing/operation of the display operation control part 11 . Here, the flowchart shown in FIG. 22 is the above-described flowchart shown in FIG. 14 plus the processing of this embodiment, the flowchart shown in FIG. 23 is the above-described flowchart shown in FIG. 15 plus the processing of this embodiment, and the flowchart shown in FIG. 24 is the above-described flowchart shown in FIG. 20 plus the processing of this embodiment. Therefore, the processes in FIGS. 22 , 23 , and 24 that are the same as those in the corresponding figure are referred to by the same reference numbers and their explanation will be omitted.
[0130] As described above, as the operation button 13 is operated and an operation signal is entered into the display operation control part 11 , the display operation control part 11 acknowledges a job cancellation order based on the operation signal from the operation button 13 and notifies the control part 4 to pause the printer (YES in STP 1 , STP 2 ).
[0131] Notified from the display operation control part 11 to pause the printer (YES in ST 1 ), the control part 4 determines whether the number of print jobs is one or greater (ST 61 ) and if the number of print jobs is one or greater (YES in ST 61 ), notifies the RIP part 5 to pause the RIP processing, notifies the transfer part 6 to pause the printing, and requests a paper ejection completion response from the paper ejection part 8 (ST 63 ) as described above. Furthermore, in this embodiment, the control part 4 stores information on the print job ID of which the printing is in progress in the job-ID-upon-cancel-operation storage 15 (ST 63 - 1 ). For example, if the print job ID of which the printing is in progress at the time is “J0004” (the document name “Price List”) shown in FIG. 6 , the control part 4 stores the print job ID “J0004” in the job-ID-upon-cancel-operation storage 15 . Furthermore, if the print job ID of which the printing is in progress is “J0005” (the document name “Layout Diagram”), the control part 4 stores the print job ID “J0005” in the job-ID-upon-cancel-operation storage 15 .
[0132] On the other hand, receiving the RIP pause notice, the RIP part 5 immediately notifies the control part 4 that the RIP pause is completed if there is no ongoing RIP processing. On the other hand, the RIP part 5 completes the ongoing RIP processing for a page and notifies the control part 4 that the RIP pause is completed if there is any ongoing RIP processing. Subsequently, the RIP part 5 waits for a RIP unpause notice from the control part 4 .
[0133] Furthermore, notified from the control part 4 to pause the printing, the transfer part 6 pauses the image data transfer if there is no ongoing transfer, or completes the ongoing image data transfer if there is any ongoing transfer, and notifies the control part 4 that the printing pause is completed. Subsequently, the transfer part 6 waits for a printing unpause notice from the control part 4 .
[0134] Furthermore, receiving a paper ejection completion response request from the control part 4 , the paper ejection part 8 makes a paper ejection completion response to the control part 4 when the paper ejection part 8 is not currently in wait for print paper ejection from the printer engine. On the other hand, the paper ejection part 8 makes a paper ejection completion response to the control part 4 after waiting for a print paper ejection notice from the printer engine for all queues of which the drawing state is “transfer” in the print queue when the paper ejection part 8 is currently in wait for print paper ejection.
[0135] Receiving the RIP pause completion response from the RIP part 5 , printing pause completion response from the transfer part 6 , and paper ejection completion response from the paper ejection part 8 (YES in ST 64 ), the control part 4 determines again whether the number of print jobs is one or greater (ST 65 ). If the number of print jobs is one or greater (YES in ST 65 ), the control part 4 updates the job table 10 (ST 65 ), and determines whether the current print job ID is equal to the print job ID stored in the job-ID-upon-cancel-operation storage 15 (ST 67 - 1 ). Here, if the print job IDs are equal (YES in ST 67 - 1 ), the control part 4 notifies the display operation control part 11 that the job IDs are equal and the job cancellation is valid (ST 67 - 2 ). On the other hand, if the job IDs are not equal (NO in ST 67 - 1 ), the control part 4 notifies that the job cancellation is valid but the job IDs are not equal (ST 67 - 3 ).
[0136] The display operation control part 11 waits for the above notice from the control part 4 (STP 3 ). Receiving the notice from the control part 4 (YES in STP 3 ), the display operation control part 11 displays invalidity of the job cancellation if the job cancellation is invalid (STP 5 ).
[0137] On the other hand, receiving the notice that the print job IDs are equal and the job cancellation is valid from the control part 4 , the display operation control part 11 conducts regular job information display (STP 4 - 1 ) and waits for an order for or against execution of the job cancellation (STP- 6 ).
[0138] FIG. 25A shows an example of the above display, displaying information on the job ID and document name on which the job cancellation order is issued. For example, in the example of the figure, information on the print job “J0004” (the document name “Price List”) is displayed and “x cancel (reset)” is also displayed. Seeing this display, the user can easily confirm that the print job to be cancelled is the print job specified. Therefore, the user who saw the display presses a button “double-circle” to execute the print job (YES in STP 6 , STP 7 ) or presses a button “x” to cancel the print job (YES in STP 6 , STP 8 ).
[0139] On the other hand, in the case of being notified from the control part 4 that the job cancellation is valid butnd the job ID stored in the job-ID-upon-cancel-operation storage 15 is not equal to the current job ID, the display operation control part 11 conducts irregular job information display on the display panel 12 (STP 4 - 2 ) and waits for an order for or against execution of the job cancellation (STP 6 ).
[0140] FIG. 25B shows an exemplary display of the above case, displaying the job ID and document name on which the job cancellation order is issued and a message to call attention. For example, in the example of FIG. 25B , information on the print job having the job ID “J0004” and the document name “Price List” is displayed, “x cancel (rest)” is also displayed, and “[ATTENSION] Please confirm the job to cancel” is displayed. Seeing the display, the user can easily recognize from the display that the print job to be cancelled is not the print job specified. Then, the user who saw the display presses the button “x” if he/she wants to cancel the print job (YES in STP 6 , STP 8 )
[0141] The above-described processing can prevent, for example, the user who is familiar with the job cancellation operation from conducting the second panel operation without checking the job to be cancelled well.
[0142] The above-described display shown in FIG. 25B is a display for announcing that the print job to be canceled does not match. Other than the above-described display, for example, display blinking or different in color can be used. Furthermore, display in boldface or in different font or the above-described display with attention-calling sound can be used.
[0143] Embodiment 2 of the present invention will be described hereafter.
[0144] FIG. 26 is an illustration showing the system configuration of this embodiment, which is basically the same as the system described with reference to FIG. 1 except that a number-of-jobs-upon-cancel-operation storage 16 shown in the figure is added. In other words, the printer 1 of this embodiment is also connected to the host device 2 via a network such as a LAN, and composed of the reception part 3 , control part 4 , RIP part 5 , transfer part 6 , printer engine 7 , paper ejection part 8 , reception buffer 9 , job table 10 , display operation control part 11 , display panel 12 , operation button 13 , print queue table 14 , and number-of-jobs-upon-cancel-operation storage 16 . The number-of-jobs-upon-cancel-operation storage 16 used in this embodiment stores the number of print jobs stored in the job table 10 when the user operates the operation button 13 .
[0145] FIGS. 27 and 28 are flowcharts for explaining the processing of this embodiment, explaining the processing of the control part 4 . Here, the flowchart shown in FIG. 27 is the above-described flowchart shown in FIG. 14 plus the processing of this embodiment and the flowchart shown in FIG. 28 is the above-described flowchart shown in FIG. 15 plus the processing of this embodiment. Therefore, the processes in FIGS. 27 and 28 that are the same as those in the corresponding figure are referred to by the same reference numbers and their explanation will be omitted.
[0146] As described above, as the operation button 13 is operated and an operation signal is entered into the display operation control part 11 , the display operation control part 11 acknowledges a job cancellation order based on the operation signal from the operation button 13 and notifies the control part 4 to pause the printer.
[0147] Notified from the display operation control part 11 to pause the printer (YES in ST 1 ), the control part 4 determines whether the number of print jobs is one or greater (ST 61 ), and if the number of print jobs is one or greater (YES in ST 61 ), notifies the RIP part 5 to pause the RIP processing, notifies the transfer part 6 to pause the printing, and requests a paper ejection completion response from the paper ejection part 8 (ST 63 ) as described above. Furthermore, in this embodiment, the control part 4 stores information on the number of print jobs of which the processing is currently in progress in the number-of-jobs-upon-cancel-operation storage 16 (S 63 - 2 ).
[0148] On the other hand, receiving the RIP pause notice, the RIP part 5 immediately notifies the control part 4 that the RIP pause is completed if there is no ongoing RIP processing. On the other hand, the RIP part 5 completes the ongoing RIP processing for a page and notifies the control part 4 that the RIP pause is completed if there is any ongoing RIP processing. Subsequently, the RIP part 5 waits for a RIP unpause notice from the control part 4 .
[0149] Furthermore, notified from the control part 4 to pause the printing, the transfer part 6 pauses the image data transfer if there is no ongoing transfer, or completes the ongoing image data transfer if there is any ongoing transfer, and notifies the control part 4 that the printing pause is completed. Subsequently, the transfer part 6 waits for a printing unpause notice from the control part 4 . Furthermore, receiving the paper ejection completion response request from control part 4 , the paper ejection part 8 executes the necessary processing and makes a paper ejection completion response to the control part 4 .
[0150] On the other hand, receiving the RIP pause completion response from the RIP part 5 , printing pause completion response from the transfer part 6 , and paper ejection completion response from the paper ejection part 8 (YES in ST 64 ), the control part 4 determines again whether the number of print jobs is one or greater (ST 65 ). If the number of print jobs is one or greater (YES in ST 65 ), the control part 4 updates the job table 10 (ST 66 ), and determines whether there is a record of which the job ID is not empty (ST 67 - 4 ). Here, if the determination (ST 67 - 4 ) results in YES, the control part 4 further determines whether the number of jobs stored in the number-of-jobs-upon-cancel-operation storage 16 is 1 (ST 67 - 5 ).
[0151] Here, if the number of print jobs stored in the number-of-jobs-upon-cancel-operation storage 16 is 1 (YES in ST 67 - 5 ), execution of the job cancellation is immediately determined without executing the above-described processing (ST 67 and/or ST 68 ). In other words, if the number of current print jobs is 1 and the number of jobs stored in the number-of-jobs-upon-cancel-operation storage 16 is 1, the number of print jobs does not change and the job cancellation is executed without further operation by the user.
[0152] With the above processing, the user does not need to operate the operation button 13 again and the target job information can be cancelled with one operation.
[0153] Embodiment 3 of the present invention will be described hereafter.
[0154] This embodiment utilizes the same system configuration as in the above-described FIG. 21 . Therefore, the printer 1 of this embodiment is also connected to the host device 2 via a network such as a LAN, and composed of the reception part 3 , control part 4 , RIP part 5 , transfer part 6 , printer engine 7 , paper ejection part 8 , reception buffer 9 , job table 10 , display operation control part 11 , display panel 12 , operation button 13 , print queue table 14 , and job-ID-upon-cancel-operation storage 15 .
[0155] FIG. 29 is a flowchart for explaining the processing/operation of the control part 4 in this embodiment. Here, the flowchart shown in FIG. 29 is the above-described flowchart shown in FIG. 15 plus the processing of this embodiment. Therefore, the processes in FIG. 29 that are the same as those in the corresponding figure are referred to by the same reference numbers and their explanation will be omitted.
[0156] As described above, as the operation button 13 is operated and an operation signal is entered into the display operation control part 11 , the display operation control part 11 acknowledges a job cancellation order based on the operation signal from the operation button 13 and notifies the control part 4 to pause the printer. Subsequently, the display operation control part 11 waits for confirmation notice from the control part 4 .
[0157] If the number of print jobs is one or greater, the control part 4 notifies the RIP part 5 to pause the RIP processing, notifies the transfer part 6 to pause the printing, and requests a paper ejection completion response from the paper ejection part 8 as described above. Furthermore, in this embodiment, the control part 4 stores information on the job ID of which the printing is currently in progress in the job-ID-upon-cancel-operation storage 15 .
[0158] On the other hand, receiving the RIP pause notice, the RIP part 5 immediately notifies the control part 4 that the RIP pause is completed if there is no ongoing RIP processing. On the other hand, the RIP part 5 completes the ongoing RIP processing for a page and notifies the control part 4 that the RIP pause is completed if there is any ongoing RIP processing. Subsequently, the RIP part 5 waits for a RIP unpause notice from the control part 4 .
[0159] Furthermore, notified from the control part 4 to pause the printing, the transfer part 6 pauses the image data transfer if there is no ongoing transfer, or completes the ongoing image data transfer if there is any ongoing transfer, and notifies the control part 4 that the printing pause is completed. Subsequently, the transfer part 6 waits for a printing unpause notice from the control part 4 . Furthermore, receiving the paper ejection response request from control part 4 , the paper ejection part 8 executes the necessary processing and makes a paper ejection completion response to the control part 4 .
[0160] On the other hand, receiving the RIP pause completion response from the RIP part 5 , printing pause completion response from the transfer part 6 , and paper ejection completion response from paper ejection part 8 , the control part 4 determines again whether the number of print jobs is one or greater. If the number of print jobs is one or greater, the control part 4 updates the job table 10 (ST 66 ), and determines whether the print job ID stored in the job-ID-upon-cancel-operation storage 15 and current print job ID are equal (ST 67 - 6 ). Here, if the determination (ST 67 - 7 ) results in YES, the control part 4 immediately determines execution of the job cancellation without executing the above-described processing (ST 67 and/or ST 68 ). In other words, the current print job ID and the print job ID stored in the job-ID-upon-cancel-operation storage 15 are equal, the print job to be cancelled does not change, and the job cancellation is executed without further operation by the user.
[0161] With the above processing, the user does not need to operate the operation button 13 again and the target job information can be cancelled with one operation.
[0162] The procedures shown in the flowcharts in the embodiments of the present invention are applicable to various devices by writing them on a storage medium such as a magnetic disc, optical disc, and semiconductor memory as recording control programs that can be realized by a computer. Alternatively, they are applicable to various devices through communication media transfer. The same efficacy as in the case of using the device of the embodiments can be obtained by storing the procedures described in the embodiments on a desired storage medium and executing the recording control programs on another computer or the like. Here, the computer is not confined to a computer installed in the device described in the embodiments and can be any computer capable of reading the recording control programs stored on a storage medium and comprising an operation device such as a CPU executing control operation according to the read recording control programs.
[0163] Several embodiments of the present invention are described above. These embodiments are given by way of example and do not confine the scope of the invention. These novel embodiments can be realized in many different modes and various elimination, replacement, and change can be made without departing from the gist of the invention. These embodiments and their modification fall within the scope and gist of the invention and within the invention set forth in the scope of claims and the scope equivalent thereto.
[0164] Having described and illustrated the principles of this application by reference to one (or more) preferred embodiment(s), it should be apparent that the preferred embodiments may be modified in arrangement and detail without departing from the principles disclosed herein and that it is intended that the application be construed as including all such modifications and variations insofar as they come within the spirit and scope of the subject matter disclosed herein.
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The printing device is a printing device having a reception part receiving print data, a print job information storage storing print job information of the print data, an image data conversion part concerting the print data to image data, a print queue generation part generating print queue information administrating the print data on the basis of page upon conversion from the print data to image data, a print job ID storage storing the print job ID at the time of an order when job cancellation is ordered, and a control part comparing the print job ID stored in the print job ID storage with the print job ID at the time of execution in execution of job cancellation and cancelling the print job ID when the print job IDs are equal. The printing device allows job cancellation to be specified without multiple panel operations in ordering job cancellation order.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to continuous batch pyrolysis systems for continuous recovery of carbon, hydrocarbons and other materials from waste vehicle tires.
[0002] Waste vehicle tires are a major environmental problem. Waste tires in the past have often been discarded in disposal and landfill sites. Sites for storage or land fill of waste tires, however, are becoming less available. Many existing sites for waste tires are reaching capacity with an estimated 3 billion waste tires discarded in sites in the United States. New sites are difficult to open because of increasingly stringent government regulations and public concerns about the environment. Most states now have laws prohibiting the dumping of waste tires in disposal sites.
[0003] Tire sites are not only unsightly but they present a risk of being set on fire. When tire sites are set on fire, the burning of tires is environmentally harmful since tire combustion produces dangerous substances such as sulfur-containing acids and other pollutants. The water and air pollution from fighting fires at tire dumps is very hazardous to the environment.
[0004] In order to avoid the problems of tire disposal sites, a number of tire recycling programs have been tried. Tire recycling programs have included tire shredding, crumbing, direct tire recycling, tire incineration and tires used as fill. None of these recycling programs has proved to be commercially and environmentally satisfactory. Tire pulverizing is a process that grinds up tires into smaller pieces for use in road surfacing, on athletic fields, paddocks and other uses. Tire shredding or crumbing has had limited success and is not expected to make significant reductions in the national waste tire inventory. The direct recycling of tires reclaims some tires still having useable tread and recaps some tire so that they can be used again as tires. Only a small percentage of tires can be safely recapped for reuse. In some cases, tires are cut into parts to be used as soles for shoes, for loading-docks or other bumpers, for floor mats and for other products. The percentage of tires used in this manner is small. Tire incineration burns tires as a fuel source for co-generation and other energy needs, but incineration has not proven to be efficient and environmentally satisfactory for producing energy. Tire incineration plants are expensive to construct because of the environmental problems associated with emissions from burning rubber. A significant number of cement plants burn tires along with coal. However, emissions from these plants often generate local opposition and controversy and the cost of reducing pollution renders the burning as economically questionable. The use of disposed tires as fill material has proven to be of questionable value due to the fire hazards and resulting air and water pollution resulting when fires do occur.
[0005] Pyrolysis has the potential for being the most economical and environmentally best process for recycling of waste tires. In order to achieve that potential, however, the pyrolysis systems must be carefully designed and controlled to maximize the quality and the quantity of the pyrolysis products produced. The pyrolysis products are determined by and derived from the many different components of waste tires. In order to understand the economics of tire recycling, it is important to consider the composition of tires.
[0006] Tires are made of vulcanized cross-linked polymer chains (rubber) and various reinforcing materials. The most commonly used rubber matrix is the co-polymer styrene-butadiene rubber (SBR) or a blend of natural rubber and SBR. In addition to the rubber compound, tires contain:
[0007] Reinforcing fillers: Carbon black, used to strengthen the rubber and aid abrasion resistance.
[0008] Reinforcing fibers: Textile or steel fibers, usually in the form of cords, provide the reinforcing tensile strength to tires.
[0009] Extenders: Petroleum oils, used to control viscosity, reduce internal friction during processing, and improve low temperature flexibility in the vulcanized product.
[0010] Vulcanizing agents: Organo-sulfur compounds, used to act as the catalyst to accelerate the vulcanization process; and Zinc oxide and stearic acid, used to activate the curing (cross-linking) system and to preserve cured properties.
[0011] In one typical example and in addition to steel or other reinforcing fibers, the following components by weights are found, in one typical example, in tires SBR 62%, carbon black 31%, extender oil 2%, zinc oxide 2%, stearic acid 1%, sulfur 1% and accelerator 1%.
[0012] In order to recover products from tires, pyrolysis applies high temperatures to thermally decompose the tires. Pyrolysis causes the thermal decomposition of tires in an inert atmosphere to form low molecular weight products. Tire pyrolysis produces liquids, gases and solids and the three principal products from tire pyrolysis are gas, oil, and char. The gas and oil comprise about a half of the pyrolysis products by weight and they have energy contents similar to those of conventional fuels. Char is a fine particulate solid composed of carbon black, ash, and other inorganic materials, such as zinc oxide, and silicates.
[0013] In batch pyrolysis systems, tires are introduced into a large oven-like reactor for gasification in the absence of oxygen. The lysing occurs at temperatures between 450 and 600° C. or more. The pyrolysis process yields a volatile gas, known as pyrolysis gas, which in addition to water vapor also contains hydrogen, carbon monoxide, carbon dioxide, paraffins, olefins and other hydrocarbons and cooling of the pyrolysis gas yields pyrolysis oil products and pyrolysis gas products. Various products are produced from the solid char that remains in the reactor after pyrolysis is completed such as pigments, semi-reinforcing fillers and activated filtration material. The pyrolysis products obtained from tires consists approximately of 20% oil, 25% gas, 15% steel and other solid materials, together with approximately 40% carbon.
[0014] Pyrolysis oil resembles diesel or light fuel oil, with the difference that pyrolysis oil has a relatively high content of sulphur and aromatic hydrocarbons. The high content of sulphur and of other impurities is reduced, for example, by scrubbing, and the hydrocarbon compounds can be separated into different fractions by staged condensation. The temperatures at which oils condense out from the pyrolysis gas differ depending on the density of the oil, but in general the heavier oil fractions condense out at temperatures around 350° C., the medium heavy oils at temperatures between 100 and 350° C. and the light oils at temperatures under 100° C. The oil fractions which have condensed out are stored in collection tanks as recovered oil products, while the remaining non-condensed pyrolysis gas is used, in part, as fuel for the pyrolysis process and, in part, as recovered products of the pyrolysis process.
[0015] The char from the pyrolysis process is further refined to form, for example, products such as pigments, semi-reinforcing fillers and activated filtration material. In order to refine the carbon, the pyrolysis processing includes, among other things, raising the temperature to between 800 and 900° C. in order to totally remove from the char any traces of volatile hydrocarbons. The heating is followed by reduction of the temperature and in some embodiments by steam treatment. Further processing can include milling, magnetic removal of iron and steel, classifying and pelletizing.
[0016] Techniques for the recovery of carbon black and hydrocarbons from waste tires by pyrolysis are described in U.S. Pat. No. 6,271,427. In the U.S. Pat. No. 6,271,427 Patent, a method is described which improves control of the pyrolysis process and which makes it possible to recycle significant components such as carbon black and condensed oils from discarded tires in a more efficient way and with a higher quality. The method controls the pyrolysis process based on a predetermined schedule using parameters set depending on the raw materials which are used and depending on which final products are desired. The method places tire waste material for batch-wise processing in a pyrolysis reactor and recycled pyrolysis gas is fed into the reactor to heat the tire waste material. The composition and relative amount of the pyrolysis gas which is produced is measured and the measurements are used to control and regulate the process.
[0017] The economic feasibility of tire pyrolysis is strongly affected by the value of the recovered pyrolysis products. Pyrolysis products have historically yielded poor returns as the prices obtained for the recovered pyrolysis products have failed to fully justify pyrolysis process costs. Although more than 30 major pyrolysis projects have been proposed in the past few years, none are believed to have been commercially successful in the United States.
[0018] The economic feasibility of tire pyrolysis involves several critical factors including quality of the recovered pyrolysis products, capacity of the pyrolysis systems, throughput over time of the pyrolysis systems and environmental acceptability of the pyrolysis system operations. Further factors relating to economic feasibility are the governmentally sponsored incentives such as tire “tipping” fees paid for each recycled tire and CO 2 or other credits for environmentally favorable processes.
[0019] Although attempts at continuous pyrolysis processes have been made in order to increase the throughput over time of the pyrolysis systems, such continuous pyrolysis processes have not been able to produce pyrolysis products of sufficient quality to be able to achieve economic feasibility. Continuous pyrolysis processes tend to suffer from air leaks that introduce oxygen into the pyrolysis chamber and hence reduce the quality of the pyrolysis products. By contrast, batch pyrolysis processes can be made more oxygen free and hence produce higher quality pyrolysis products. However, batch pyrolysis processes have been more difficult to scale to larger sizes in order to increase the throughput over time of the batch pyrolysis systems.
[0020] In order to achieve the potential benefits of pyrolysis for waste tire processing, there is a need for improved pyrolysis systems that increase the quality and value of the pyrolysis products while enhancing the efficiency and throughput of the pyrolysis systems.
SUMMARY OF THE INVENTION
[0021] The present invention is a scaleable pyrolysis system for batch processing of waste vehicle tires and other waste to provide pyrolysis products. The core pyrolysis system includes one or more batch reactors, heating units, solids processing units, gas/liquid processing units and control units. In operation, the solids processing units introduce waste tires, or other waste materials, into the reactor and, after pyrolysis processing, the solids processing units extract the solid residue from the reactor. During the pyrolysis processing, the gas/liquid processing units process the pyrolysis gases to extract pyrolysis gas and oil products. A pyrolysis control operates to insure that the sequence of heating and cooling during the pyrolysis processing is optimized for production of pyrolysis products both as to quality and throughput. The reactor design is such that the temperature gradients internal to the reactor are controlled by preferential channeling of heat to provide pyrolysis products that are of high quality, and hence commercially advantageous, while facilitating high throughput.
[0022] In particular embodiments of the present invention, the reactor has a design such that heat transfer to the waste material within the reactor is efficient and controlled. In particular embodiments, a plurality of heat conductors are distributed internal to the reactor chamber in order to facilitate rapid heat transfer internal to the reactor. In one particular embodiment, the internal heat conductors are arrayed as horizontal heat conductors. In another particular embodiment, the internal heat conductors are arrayed as vertical heat conductors.
[0023] In order to increase the capacity and throughput of the pyrolysis system, multiple core pyrolysis systems are replicated in a pyrolysis array. In a simple array, each core pyrolysis system is the same and is replicate one or more times. In more complex arrays, different parts of the liquid/gas units of the core pyrolysis system are scaled and shared among reactors. In all of the pyrolysis systems, the control unit sequences the temperatures in the reactor to optimize the generation of pyrolysis products.
[0024] The foregoing and other objects, features and advantages of the invention will be apparent from the following detailed description in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 depicts a schematic block diagram of a single reactor batch pyrolysis system.
[0026] FIG. 2 depicts a pyrolysis system array formed of multiple ones of the batch pyrolysis systems of FIG. 1 .
[0027] FIG. 3 depicts a pyrolysis system having a reactor with multiple heat entry ports for distributing heat with improved distribution external to the reactor pyrolysis chamber.
[0028] FIG. 4 depicts a pyrolysis system having a reactor with multiple heat entry ports and multiple exhaust ports for distributing heat with improved distribution external to the pyrolysis chamber.
[0029] FIG. 5 depicts a closed pyrolysis system having a reactor with vertical heat conductors for injecting heated pyrolysis gas internal to the reactor chamber for distributing heat with improved distribution internal to the reactor pyrolysis chamber.
[0030] FIG. 6 depicts a pyrolysis system having a reactor with vertically looped heat conductors for distributing heat within the reactor chamber and with an external fire box for distributing heat with improved distribution both internal and external to the reactor pyrolysis chamber.
[0031] FIG. 7 depicts a pyrolysis system having a reactor with horizontal heat conductors for distributing heat through the reactor pyrolysis chamber with improved heat distribution external to the reactor pyrolysis chamber.
[0032] FIG. 8 depicts a pyrolysis system having a reactor with vertical heat conductors for distributing heat through the reactor pyrolysis chamber with improved heat distribution external to the reactor pyrolysis chamber.
[0033] FIG. 9 typical vertical heat conductors for the pyrolysis system of FIG. 8 .
[0034] FIG. 10 depicts a pyrolysis system having a reactor with vertical heat conductors with multiple controlled heat feeds to the vertical conductors and the reactor fire box.
[0035] FIG. 11 depicts a top view of the pyrolysis system of FIG. 10 with the cover removed to expose a view of the vertical conductors.
[0036] FIG. 12 depicts a pyrolysis system having a reactor with fluted side walls for improving heat distribution external to the reactor pyrolysis chamber.
[0037] FIG. 13 depicts a sectional view near the bottom of the pyrolysis chamber of the pyrolysis system of FIG. 12
[0038] FIG. 14 depicts a view of a section of the fluted side wall of the pyrolysis system of FIG. 12 .
[0039] FIG. 15 depicts a top view of the pyrolysis system reactor of FIG. 12 .
[0040] FIG. 16 depicts a sectional/perspective view of a pyrolysis system having a reactor with vertical heat conductors extending from the bottom of the pyrolysis chamber, through the internal portion of the chamber and exiting through the side walls of the chamber.
DETAILED DESCRIPTION
[0041] FIG. 1 , a schematic block diagram of the batch pyrolysis system 10 is shown. The batch pyrolysis system 1 0 includes the solid processing units 1 , the reactor 2 , the heating units 3 , the gas/liquid units 4 and the control unit 5 .
[0042] In FIG. 1 , the solid processing units 1 include the supply unit 1 - 2 and the residue unit 1 - 3 . The supply unit 1 - 2 functions to introduce waste tires or other supply material into the reactor 2 . The waste tires can be either in the form of whole tires or cut tires. Typically, tires are washed and cleaned in a washing machine in supply unit 1 - 2 to remove foreign matter such as dirt, oil, sand or other undesirable material. The cleaning is done with heated water or steam generated by fuel or heat available from the pyrolysis system 10 . The cleaning process also typical functions to preheat the waste tires prior to placement in the reactor 2 - 2 . The waste tires are placed into the reactor 2 in either a whole or cut condition. When cut, the cutting can be into large pieces, such as halves, quarters or eights, or can be shredded into much smaller pieces. The size of the whole or cut pieces of waste tires placed into the reactor 2 affects the rate of heat transfer into the tires during the pyrolysis processing. Accordingly, the whole and cut condition of the waste tires is a variable that is supplied to the control unit 5 in order to allow the control unit 5 to properly adjust the pyrolysis process as a function of the material supplied for pyrolysis. Heat transfer is a function of the density of the waste material. The reactor is of a size such that 100 loose tires are accommodated, 180 to 200 baled tires, 200 to 300 cut tires and 400 shredded tires. The more tires the higher the density and hence the longer the pyrolysis period. While waste tires are a significant environmental problem, other waste materials may be processed by pyrolysis. For example, plastics and organic materials, frequently called “automobile fluff” remaining after the shredding of automobiles at automobile disposal sites provide a large amount of waste material. Similarly, hospital waste is produced in large volumes and is readily processed by pyrolysis.
[0043] In one embodiment, a tire baler is used to compress and bind bales of up to about 20 tires which are then loaded into the retort chamber 2 - 2 . Between about 180 and 270 tires are placed in the retort chamber 2 - 2 per batch cycle, but this range may vary depending on the size of the tires and the size of chamber 2 - 2 .
[0044] In one embodiment, the waste tires are cut into segments of approximately 15 cm by approximately 5 cm. The cutting step typically does not separate the reinforcing material of the tire from the other material. The cut segments thus form fragments of tires connected by reinforcing material but which generally can be considered bulk material.
[0045] The cleaning of the waste tires is important, among other reasons, to ensure that the pyrolysis char to be formed has a low content of ash. The washing water typically has a temperature of about 40° C. Another reason for the washing is to remove ice and snow in cold climates since any water will lead to the formation of steam and an uncontrolled increase of pressure in the pyrolysis chamber. In order to further ensure that moisture does not enter the pyrolysis chamber, the supply unit 1 - 2 dries the waste tires or fragments after washing. The drying is suitably carried out in a drying chamber with circulating drying air having a temperature of about 120° C.
[0046] In FIG. 1 , the residue unit 1 - 3 functions to extract the solid residue remaining in the reactor after the heating and cooling of the pyrolysis processing is complete. Typically a vacuum system is used to remove the char and other residue. After removal of the residue, the residue is further processed to separate the carbon and other fine material from the steel and other large material. I
[0047] n FIG. 1 , the reactor 2 has a retort chamber 2 - 2 for receiving the waste tire or other material prior to pyrolysis processing. The chamber 2 - 2 is surrounded by a heating chamber 2 - 1 that includes means for heating the retort chamber 2 - 2 from room temperature up to 1000° C. or more. The chamber 2 - 2 includes insulating walls necessary for safety and heating efficiency. Since the pyrolysis reactor 2 is designed for batch processing, the reactor chamber 2 - 2 typically includes a covered opening (se FIG. 3 ) which is opened when the reactor 2 is cool for inserting waste tires from supply unit 1 - 2 , is closed during pyrolysis processing when the temperature is cycled up and then down and is reopened to remove the residue into residue unit 1 - 2 when the reactor is cool.
[0048] The heating unit 3 provides heat to the reactor 2 . The source of the heat is burner 3 - 1 which burns fuel of any type, but in particular burns fuel recovered by the gas/liquid unit 4 . The heated and combusted gases from burner 3 - 1 are injected into the reactor heating chamber 2 - 1 to heat the reactor pyrolysis chamber 2 - 1 and from there are exhausted to exhaust 2 - 4 . In some embodiments the heated and combusted gases from burner 3 - 1 are input to a heat exchanger 3 - 2 . The heat exchanger 3 - 2 receives and heats gases from the gas input unit 4 - 4 of gas/liquid unit 4 that are then input directly to the reactor pyrolysis chamber 2 - 2 . In some embodiments, when a heat exchanger is employed, the heated and combusted gases from burner 3 - 1 may all be used to transfer heat in the heat exchanger 3 - 2 and then exhausted directly with out being input to reactor 2 . The heated pyrolysis gases from the pyrolysis chamber 2 - 2 are vented through pipes 2 - 6 to the gas/liquid unit 4 .
[0049] In FIG. 1 , the gas/liquid unit 4 includes a condenser unit 4 - 1 that receives the pyrolysis gas through pipe 2 - 6 connected from the reactor chamber 2 - 2 . The condenser unit 4 - 1 cools the pyrolysis gas to extract condensed liquid into the condensed liquid unit 4 - 2 . The condenser unit 4 - 1 typically includes a water-cooled pre-condenser, a water-cooled heat exchanger, and a water-cooled main condenser. Water cooled in a water cooling tower is circulated by water pumps through the different water-cooled components of the condenser unit 4 . The water is circulated by the pumps from the cooling tower through the main condenser, through the heat exchanger and finally through the pre-condenser and then back to the pumps.
[0050] Typically, the main condenser in the condenser unit 4 - 1 is multi-staged for cracking the pyrolysis gas at different temperatures. For example, the first stage cools the pyrolysis gas to produce heavier oil fractions at temperatures near 350° C. The second stage cools the pyrolysis gas to produce medium heavy oils at temperatures between 100 and 350° C. The Third stage cools the pyrolysis gas to produce light oils at temperatures under 100° C.
[0051] The oil fractions of different weights which are condensed out are indicated as W 1 through W 3 in the condenser unit 4 - 1 . The oils of different weights are stored by the condensed liquid unit 4 - 2 in collection tanks as recovered oil products. The remaining non-condensed pyrolysis gas is input from the condenser unit 4 - 1 to the uncondensed gas unit 4 - 3 which extracts gas products that are stored in suitable tanks. Additionally, part of the uncondensed gas is supplied to the gas input unit 4 - 4 for use in the pyrolysis process. Another part of the uncondensed gas is supplied to the burner 3 - 1 for heat generation through combustion.
[0052] The batch process in one embodiment of the FIG. 1 pyrolysis system runs for an eight-hour batch cycle including approximately 4 hours heating and 4 hours cooling. During the batch cycle, pyrolysis of the tires takes place in a closed system. After the tires are loaded and the reactor chamber 2 - 2 is sealed, the pyrolysis period begins under control of the control unit 5 . First, air within the reactor chamber 2 - 2 is evacuated during an initial purging with nitrogen gas from the gas input unit 4 - 4 . The inert atmosphere of nitrogen gas is used to prevent combustion from occurring in chamber 2 - 2 . The pressure inside the reactor chamber 2 - 2 is slightly above atmospheric pressure (+0.5 psi). In one embodiment, the reactor chamber 2 - 2 is housed in the heating chamber 2 - 1 which is in the form of a furnace above four burners constituting the burner 3 - 1 of the heating unit 3 . The burners are capable of initially burning diesel fuel, if necessary for start up, and then burn uncondensed gas or oil from the pyrolysis process.
[0053] As the batch of waste tires is heated the pyrolyzing tires emit pyrolysis gas. The pyrolysis gas passes into the condenser unit 4 - 1 typically formed of three-stage, water-cooled condensation vessels where oil condenses out from the pyrolysis gas. After the condenser unit 4 - 1 , the remaining gases pass to the uncondensed gas unit 4 - 3 . The uncondensed gas unit 4 - 3 typically includes a wet scrubber to clean the gas before it is piped to the gas burner unit 3 - 1 to fuel the pyrolysis process.
[0054] The heating cycle continues until the internal reactor chamber 2 - 2 reaches a temperature of about 880° C. (1600° F.). Thereafter the reactor chamber 2 - 2 is allowed to begin the cooling cycle. As the reactor chamber 2 - 2 is cooling, it is once again purged with nitrogen gas from the gas input unit 4 - 4 and the gas that is released to the exhaust 2 - 4 . Finally, the reactor chamber 2 - 2 is opened and the remaining carbon and steel are removed, separated, and placed in containers for further post pyrolysis processing.
[0055] A key feature of the pyrolysis process is that it is not labor-intensive, and it can be fully automated once the tires have been loaded into the reactor chamber 2 - 2 . The system design relies heavily on automation under control of control unit 5 ensuring a high degree of safety and quality control.
[0056] A series of sensors, thermocouples, interlocks, and mechanical devices allow the pyrolysis system to operate safely within precisely controlled and timed temperatures and pressures. If any problems occur within the process, the pyrolysis unit will automatically shut down in a safe manner. The pyrolysis system of FIG. 1 automatically shuts down in a safe condition in case of a power failure. In the case of a malfunction, the control unit identifies the source of the problem.
[0057] The pyrolysis system 10 of FIG. 1 is intended to operate 24 hrs/7 days for 365 days per year. Assuming an average of 180 tires per batch run, 3 runs per day, 365 days per year, the pyrolysis system 10 processes (recycles) 197,100 tires annually. Based on operational records, it is estimated that after recycling 197,100 tires, 3,942,000 pounds of tires (assuming average tire weight is 20 lbs per tire) will be completely recycled within a year. This recycling rate produces 394 tons of gas (20% of recovered products), 552 tons of oil (28% of recovered products), 256 tons of steel (13% of recovered products), and 769 tons of char (carbon black) (39% of recovered products).
[0058] The recovered oil products include 2.5A, 2.5B and 2.5C oil. Pyrolysis oil is similar in composition to light heating oil with slightly higher sulfur content than diesel fuel; 0.5% sulfur for diesel and 1.5% sulfur for pyrolysis oil. While the molecular structure of pyrolysis oil is similar to that of light heating oil, the caloric content is closer to that of diesel fuel. The bulk of the pyrolysis oil is typically sold to local fuel oil suppliers that blend the pyrolysis oil with heating oil to produce a lower-sulfur, blended fuel oil.
[0059] Approximately one-third to one-half of the recovered combustible methane/hydrogen gases are consumed by combustion in the burner 3 - 1 during the pyrolytic heating process. As the sensor on the pyrolysis gas vapor transfer line from the retort indicates the presence of sufficient combustible gases to fire the burners, the initial oil burners are shut down and the gas burners are ignited. The combustible gases pass through a wet scrubber and a water vapor trap in the uncondensed gas unit 4 - 3 prior to use. Although a flare stack is provided in the system of FIG. 1 , it is not normally used since gases are combusted and therefore consumed during the heating process in the burner 3 - 1 of the heating unit 3 . To the extent that excess gas is available and not need ed for the burner 3 - 1 , the gas is used for co-generation or other energy needs.
[0060] The recovered char or carbon black is readily sold. The primary market is to tire manufacturers as a semi-reinforcing additive to rubber. Extensive tests of industrial carbon produced using the batch pyrolysis process categorize the char as “semi-reinforcing black filler.” Secondary markets include the plastics industry, activated carbon, carbon filtration media, pigments and inks. Further processing of the carbon into small sizes greatly enhances the commercial value.
[0061] The recovered steel is sold for recycling. The steel consists primarily of ASTM 1080 quality metal and is readily marketable.
[0062] The unburned scrubbed gas and the excess heat produced by the retort heating and cooling processes can be marketed as a function of the location of the pyrolysis system. The excess heat is marketable directly when the pyrolysis system is located in or adjacent to an area where local users require a supply of heat for heating or cooling buildings or for other energy uses.
[0063] CO 2 -rich air from the pyrolysis system is provided together with heat to support greenhouse operations. This option is dependent upon local conditions favorable to the greenhouse operation, such as the availability of sufficient nearby land and certain climatic conditions.
[0064] The excess gas, oil and other sources of energy available from the pyrolysis system are used for the direct or co-generation of electricity when there is a local market for electrical power. For such uses, the pyrolysis system is preferably located at a site reasonably close the electrical power grid.
[0065] Since the batch processing occurs in the absence of oxygen and at very high temperatures, tire pyrolysis produces very little waste. Historically, hazardous air pollutants (HAPs) have been the largest environmental concern with continuous process (as distinguished from batch process) tire pyrolysis plants. These emissions are eliminated with the batch process since the off-gases are scrubbed and used as a heating fuel source. Post-process nitrogen purged gases are passed through a liquid scrubber and then flared. Test data indicates only trace concentrations of several polycyclic aromatic hydrocarbons (PARs), in negligible quantities, are emitted.
[0066] The largest sources of air emissions are associated with the fuel for burner 3 - 1 . The burner 3 - 1 is initially fueled with heating oil, if necessary and later with methane/hydrogen gas derived from the pyrolysis process. Air emissions from burning oil and methane have been calculated on the quantities of fuel (oil and gas) consumed during the recycling of 197,100 tires. According to the calculations, the combustion of methane produced 94 lbs of NO2 per year under the operating parameters (1,290,000 BTUs produced per day for 365 days per year and 0.2 lbs of NO 2 released per million BTUs produced). Emissions from the oil burner for the 365-day operational period were calculated to be 0.79 tons PM10, 13.00 tons SO x , 7.88 tons NO x , 4.33 tons CO and 0.39 tons of volatile organic compounds (VOCs).
[0067] Other emissions such as metals, radionuclides, vinyl chloride, fluorides, sulfuric acid mist, hydrogen sulfide, total reduced sulfur (TRS), or reduced sulfur compounds have been shown to be negligible or nonexistent.
[0068] Since pyrolysis occurs in an oxygen-free atmosphere, very little ash is produced. Ash stays mixed with the char remaining in the retort after pyrolysis is complete.
[0069] Incomplete pyrolyzed materials are avoided or if present are reprocessed until fully pyrolyzed. Control unit 5 monitors the retort temperature to prevent incompletely pyrolyzed materials from forming during pyrolysis.
[0070] A scrubber of the type manufactured by the Duall Division scrubs the gases produced by the pyrolytic process prior to their use as fuel. The scrubber wastewater is diluted and discharged to a sanitary system. The scrubber wastewater contains some PAHs and is slightly acidic, but is not a hazardous waste per federal and state guidelines.
[0071] FIG. 1 , the pyrolysis system 10 include numerous temperature (T) sensors, gas chromatography sensors (C) and flow sensors (F) for monitoring and providing data for controlling the pyrolysis process. These sensors are generally everywhere present in the system and the typically locations are shown with one or more of the letters “T”, “C” or “F” in a circle. These sensors are typically connected to the control unit 5 and provide information to assist in control of the pyrolysis process. Additionally, each of the units in FIG. 1 receives control instructions from the control unit 5 and provides status and other information to control unit 5 .
[0072] In FIG. 2 , a pyrolysis system array 11 includes eight batch pyrolysis systems 10 of the FIG. 1 type including the pyrolysis systems 10 1 , 10 2 , . . . , 10 8 . The batch pyrolysis systems include the solid processing units 1 1 , 1 2 , . . . , 1 8 , include the reactors 2 1 , 2 2 , . . . , 2 8 , include the heating units 3 1 , 3 2 , . . . , 3 8 , include the gas/liquid units 4 1 , 4 2 , . . . , 4 8 and the control unit 5 having the control units 5 1 , 5 2 , . . . , 5 8 all associated with the pyrolysis systems 10 1 , 10 2 , . . . , 10 8 , respectively.
[0073] FIG. 2 , each of the pyrolysis systems 10 includes numerous temperature (T) sensors, gas chromatography sensors (C) and flow sensors (F) for monitoring and providing data for controlling the pyrolysis process in each of the separate reactors 2 . As indicated in connection with FIG. 1 , these sensors are generally everywhere present in the system and are connected to the control unit 5 and provide information to assist in control of the pyrolysis processes. Additionally, each of the units, as in FIG. 1 , receives control instructions from the control unit 5 and provides status and other information to control unit 5 .
[0074] In FIG. 2 , each of the reactors 2 , including the reactors 2 1 , 2 2 , . . . , 2 8 separately completes a batch pyrolysis processing cycles. While separate heating units 3 and gas/liquid units 4 may be use in the array, economies of scale are provided when the reactors share parts of the heating and gas/liquid units. In one example, gas/liquid units 4 1 and 4 5 are replaced with a single gas/liquid unit 4 15 and gas/liquid units 4 2 and 4 6 are replaced with a single gas/liquid unit 4 26 . Such combinations are by way of example, as any combination of the gas/liquid units and/or the heating units is possible.
[0075] In FIG. 2 , the control unit 5 control unit operates to sequence the pyrolysis systems 10 so that one or more of the batch pyrolysis reactors 2 is operating in a pyrolysis period whereby the array 11 is in continuous pyrolysis operation.
[0076] In FIG. 3 , the pyrolysis system 10 includes a reactor 2 with multiple heat entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 for distributing heat with improved distribution to the reactor 2 and the waste material 31 . The waste material is shown, by way of example, as non-baled tires 31 2 - 15 . Each of the ports entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 opens into the fire chamber 2 - 1 that surrounds the pyrolysis chamber 2 - 2 for applying the heat from the heat unit 3 more uniformly around the pyrolysis chamber 2 - 2 . The implementation of the heat distribution in the entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 . The entry ports 3 - 3 2 and 3 - 3 3 in FIG. 3 are about half way up the walls of reactor 2 . Various forms of the FIG. 3 embodiment are employed. For example, a separate burner is placed at each of the port openings into fire chamber 2 - 1 or alternatively, a centralized heater is used with blower distribution into entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 . The pyrolysis gas is vented through the ports 2 - 7 and pipe 2 - 6 to the gas/liquid unit 4 . The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. The exhaust 2 - 4 is ported through the side wall of reactor 2 from the chamber 2 - 1 . If desired the pyrolysis chamber 2 - 2 may be formed by a stainless steel or other high temperature-resistant material and can be formed as a removable element for ease of loading tires and removing residue.
[0077] FIG. 4 depicts a pyrolysis system having a reactor with multiple heat entry ports and multiple exhaust ports for distributing heat with improved distribution to the reactor. In FIG. 4 , the pyrolysis system 10 includes a reactor 2 with multiple heat entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 for distributing heat with improved distribution to the reactor 2 . Each of the ports entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 opens into the fire chamber 2 - 1 that surrounds the pyrolysis chamber 2 - 2 for applying the heat from the heat unit 3 more uniformly around the pyrolysis chamber 2 - 2 . The implementation of the heat distribution in the entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 . The entry ports 3 - 3 2 and 3 - 3 3 in FIG. 4 are near the top of the walls of reactor 2 through openings 2 - 8 1 and 2 - 8 2 . Various forms of the FIG. 4 embodiment are employed. For example, a separate burner is placed at each of the port openings into fire chamber 2 - 1 or alternatively, a centralized heater is used with blower or other distribution into entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 . In order to control the heat flow in the combustion chamber 2 - 1 , the control units 18 - 1 , 18 - 2 and 18 - 3 are provided, in some embodiments, for connection at the ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 , respectively. The pyrolysis gas is vented through the port 2 - 7 and pipe 2 - 6 to the gas/liquid unit 4 . The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. The exhaust 2 - 4 is ported through the side wall of reactor 2 from the combustion chamber 2 - 1 . If desired, the pyrolysis chamber 2 - 2 may be formed by a stainless steel or other high temperature-resistant material and can be formed as a removable element for ease of loading tires and removing residue.
[0078] FIG. 5 , the pyrolysis system 10 includes a reactor 2 with vertical heat conductors 2 - 9 for injecting heated pyrolysis gas internal to the reactor chamber 2 - 2 . In FIG. 5 , the pyrolysis system includes a single heat entry port 3 - 5 for distributing heated gas with improved distribution into the pyrolysis chamber 2 - 2 through the heat conductors 2 - 9 . The entry port 3 - 5 receives the heated gas from the heat exchanger 3 - 2 that in return receives selected portions of the pyrolysis gas from the gas/liquid unit 4 . The heat conductors 2 - 9 open into and receive gas from the heated gas in the chamber 2 - 9 1 . The chamber 2 - 9 1 is formed on the outside by an airtight wall 2 - 9 2 that functions to prevent the pyrolysis gas from penetrating the insulating core 2 - 15 . The conductors 2 - 9 have openings at the top that inject the heated gas directly into the pyrolysis chamber 2 - 2 . The injected pyrolysis gas heats the tires which in turn causes additional pyrolysis gas to be generated. The injected and generated pyrolysis gas is vented through the port 2 - 7 and piped to the gas/liquid unit 4 through pipe 2 - 6 for further processing. The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. In some embodiments, the pyrolysis chamber 2 - 2 and or the outer chamber 2 - 9 1 may be formed by a stainless steel or other high temperature-resistant material and can be formed so as to be a removable element for ease of loading tires and removing residue.
[0079] In FIG. 6 , the pyrolysis system 10 includes a reactor 2 with vertical heat conductors 2 - 9 for injecting heated pyrolysis gas internal to the reactor chamber 2 - 2 . In FIG. 5 , the pyrolysis system includes a pyrolysis heat entry port 3 - 5 for distributing heated gas with improved distribution into the pyrolysis chamber 2 - 2 through the heat conductors 2 - 9 . The entry port 3 - 5 receives the heated gas from the heat exchanger 3 - 2 that in return receives selected portions of the pyrolysis gas from the gas/liquid unit 4 . The heat conductors 2 - 9 open into and receive gas from the heated gas in the chamber 2 - 9 1 . The chamber 2 - 9 1 is formed on the outside by an airtight wall 2 - 9 2 that functions to prevent the pyrolysis gas from penetrating into the combustion chamber 2 - 1 . The conductors 2 - 9 have openings at the top that inject the heated gas directly into the pyrolysis chamber 2 - 2 . The reactor 2 combustion chamber 2 - 1 receives combusted gases from a burner in heat unit 3 through the port 3 - 3 . The combustion gases encircle the pyrolysis chamber 2 - 2 and are vented through the port 2 - 16 and the exhaust 2 - 4 . The combusted gases from port 3 - 3 and the injected pyrolysis gases from port 3 - 5 heat the tires in the pyrolysis chamber and this heating causes additional pyrolysis gas to be generated. The injected and generated pyrolysis gas is vented through the port 2 - 7 and pipe 2 - 6 to the gas/liquid unit 4 for further processing. The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. In some embodiments, the pyrolysis chamber 2 - 2 and or the outer chamber 2 - 91 may be formed by a stainless steel or other high temperature-resistant material and can be formed so as to be a removable element for ease of loading tires and removing residue.
[0080] In FIG. 7 , the pyrolysis system 10 has a reactor 2 with horizontal heat conductors 2 - 11 formed of pipes opening through the sidewalls of chamber 2 - 2 for distributing heat within the reactor chamber 2 - 2 . In FIG. 7 , the horizontal heat conductors 2 - 11 extend through the reactor chamber 2 - 2 and receive and carry heated gas from and to the heated combustion chamber 2 - 1 . In FIG. 7 , the reactor 2 includes multiple heat entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 for distributing the heat from hot combustion gases heat to the reactor 2 and the pyrolysis chamber 2 - 2 through the heat conductors 2 - 11 . The entry ports, such as ports 3 - 32 and 3 - 33 , are typically aligned with one or more opening ends of the heat conductors 2 - 11 to help force combustion gases through the conductors 2 - 11 and hence heat the internal parts of the chamber 2 - 2 . Various forms of the FIG. 7 embodiment are employed. For example, a separate burner is placed at each of the port openings into fire chamber 2 - 1 or alternatively, a centralized heater is used with blower or other distribution into entry ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 . In order to control the heat flow in the combustion chamber 2 - 1 , the control units 18 - 1 , 18 - 2 and 18 - 3 are provided, in some embodiments, for connection at the ports 3 - 3 1 , 3 - 3 2 and 3 - 3 3 , respectively. The pyrolysis gas generated by the tires is vented through the port 2 - 7 and the pipe 2 - 6 to the gas/liquid unit 4 for further processing. The reactor 2 includes a cover (not shown) which is removable for providing access to the pyrolysis chamber 2 - 2 . In some embodiments, the pyrolysis chamber 2 - 2 may be formed by a stainless steel or other high temperature-resistant material and can be formed so as to be a removable element for ease of loading tires and removing residue.
[0081] In FIG. 8 , the pyrolysis system 10 includes a reactor 2 with vertically looped heat conductors 2 - 10 in the form of pipes for circulating heated gas from the heat unit 3 through the conductors 2 - 10 to the combustion chamber 2 - 1 and from there to the exhaust port 2 - 16 . In FIG. 8 , the reactor 2 has multiple heat entry ports 3 - 3 1 , 3 - 3 2 , 3 - 3 3 and 3 - 3 4 for distributing heat into the combustion chamber 2 - 1 . The heat from the combustion gases in chamber 2 - 1 and the heat conductors 2 - 10 heats the pyrolysis chamber 2 - 2 .The heat conductors 2 - 10 open at both ends relative to the combustion chamber 2 - 1 but are airtight with respect to the pyrolysis chamber 2 - 2 so that no combustion gas is introduced into the into pyrolysis chamber 2 - 2 . The pyrolysis gas generated by the tires is vented through the pipes 2 - 6 1 and 2 - 6 2 to the gas/liquid unit 4 for further processing. The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. In some embodiments, the pyrolysis chamber 2 - 2 may be formed by a stainless steel or other high temperature-resistant material and can be formed so as to be a removable element for ease of loading tires and removing residue.
[0082] In FIG. 9 , typical ones 2 - 10 1 and 2 - 10 2 of the vertical heat conductors 2 - 10 of the pyrolysis system of FIG. 8 are shown. The conductors 2 - 10 1 and 2 - 10 2 include temperature sensors 9 1 and 9 2 , respectively, for measuring the temperature internal to the pyrolysis chamber 2 - 2 of the reactor of FIG. 8 . The temperature sensors 9 1 and 9 2 , are at different heights so that temperatures at different heights in the pyrolysis chamber 2 - 2 of the reactor of FIG. 8 are obtained. For thermocouple sensors, the wire shields 10 1 and 10 2 are welded or otherwise fastened to the conductors 2 - 10 1 and 2 - 10 2 , respectively.
[0083] In FIG. 10 , the pyrolysis system 10 includes a reactor 2 with vertically looped heat conductors 2 - 10 in the form of pipes for circulating heated gas from the heat unit 3 through the conductors 2 - 10 to the combustion chamber 2 - 1 and from there to the exhaust port 2 - 16 . The reactor 2 has multiple heat entry ports 3 - 3 1 , 3 - 3 2 , 3 - 3 3 , 3 - 3 4 and 3 - 3 6 for distributing combustion gases in the combustion chamber 2 - 1 and, with conductors 2 - 10 , through the pyrolysis chamber 2 - 2 . The heat from the combustion gases in chamber 2 - 1 and the heat conductors 2 - 10 heats the pyrolysis chamber 2 - 2 .The heat conductors 2 - 10 open at both ends relative to the combustion chamber 2 - 1 but are airtight with respect to the pyrolysis chamber 2 - 2 so that no combustion gas is introduced into the into pyrolysis chamber 2 - 2 . The pyrolysis gas generated by the tires is vented through the pipes 2 - 6 1 and 2 - 6 2 to the gas/liquid unit 4 for further processing. The reactor 2 includes a cover 2 - 12 which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached by bolts of which bolts 2 - 13 are typical. In some embodiments, the pyrolysis chamber 2 - 2 may be formed by a stainless steel or other high temperature-resistant material and can be formed so as to be a removable element for ease of loading tires and removing residue. FIG. 10 depicts a cross sectional view, along section line 10 - 10 of the FIG. 11 view, of the pyrolysis system 10 and has vertical conductors 2 - 1 0 similar to those in the system of FIG. 8 each including an up leg and a down leg connected by a looped leg at the top. In FIG. 10 , the vertical conductor up legs 2 - 10 3U and 2 - 10 4U and the two down legs 2 - 10 5D and 2 - 10 6D are shown. The conductor legs 2 - 10 3U and 2 - 10 4U receive heated combustion gas from heat unit 3 through controls 18 - 3 and 18 - 4 at the entry ports 3 - 3 3 and 3 - 3 4 and the heated gases flow upwardly from the bottom toward the top of pyrolysis chamber 2 - 2 . The conductor down leg 2 - 10 5D receives heated combustion gases from another one of the vertical conductors 2 - 10 , as indicated more particularly in FIG. 11 , and heated gases flow downwardly from the top toward the bottom of pyrolysis chamber 2 - 2 . The conductor up leg 2 - 10 6D receives heated combustion gases from another one of the vertical conductors 2 - 10 , as indicated more particularly in FIG. 11 , and heated gases flow upwardly from the bottom toward the top of pyrolysis chamber 2 - 2 .
[0084] In FIG. 11 , a top view of the pyrolysis system of FIG. 10 is shown with the cover 2 - 12 removed to expose a view of the tops of the vertical conductors 2 - 10 . The heated gases from the heat unit 3 connect through control 18 - 3 to port 3 - 3 3 to the vertical conductor up leg 2 - 10 3U . The vertical conductor up leg 2 - 10 3U is the beginning of the chain of connected loop conductors 2 - 10 3 , 2 - 10 7 , 2 - 10 8 and 2 - 10 9 . The conductor 2 - 10 9 vents into the combustion chamber 2 - 1 . The heated gases from the heat unit 3 connect through control 18 - 4 to port 3 - 3 4 to the vertical conductor up leg 2 - 10 4U . The vertical conductor up leg 2 - 10 4U is the beginning of the chain of the four most centered connected vertical conductors terminating in the downward leg 2 - 10 5D that vents into the combustion chamber 2 - 1 . The heated gases from the heat unit 3 connect through control 18 - 7 to port 3 - 3 7 to the vertical conductor up leg of the loop conductor 2 - 10 10 . The vertical conductor up leg for loop conductor 2 - 10 10 is the beginning of the chain of connected loop conductors 2 - 10 10 , 2 - 10 6 , 2 - 10 11 and 2 - 10 12 . The loop conductor 2 - 10 12 has a down leg which vents into the combustion chamber 2 - 1 . While the embodiment of FIG. 10 and FIG. 11 has the pairs of legs in the conductors 2 - 10 arrayed in two concentric circles, other numbers of circles and other arrays can be employed in order to provide preferential heat flow internal to the pyrolysis chamber 2 - 2 . For example, three concentric rings or rows and columns of pairs of conductors can be employed.
[0085] Typically, several or all of the loop conductors 2 - 10 of FIG. 10 and FIG. 11 have temperature sensors as described for example in connection with FIG. 9 so that as the pyrolysis period is progressing, the temperature of the tire waste material is continuously measured. If any particular region is sensed to have a temperature variance relative to the other regions, the gas distribution through operation of the controls 18 is modified to correct any unwanted variance. The controls are effective both during heating and cooling periods. During cooling periods, the heat unit 3 typically circulates room temperature or cooler air through the combustion chamber and out through the exhaust 2 - 4 .
[0086] In FIG. 12 , the pyrolysis system 10 includes a reactor 2 (with the cover not shown) with combustion gas heat entry ports from burners 3 - 1 1 and 3 - 1 2 . The FIG. 12 pyrolysis system has a fluted side wall 14 for improving heat distribution in the pyrolysis chamber 2 - 2 by improving heat distribution in the combustion chamber 2 - 1 . The combustion gases encircle the pyrolysis chamber 2 - 2 in the combustion chamber 2 - 1 , are directed upwardly by fluted wall 14 and are vented through the port 2 - 16 . The combusted gases heat the tires in the pyrolysis chamber 2 - 2 . While fluted walls are effective to direct the combustion gases from the bottom toward the top, groves and other forms of contoured walls may be employed to channel heat up and around the pyrolysis chamber.
[0087] FIG. 13 depicts a sectional view near the bottom of the pyrolysis chamber of the pyrolysis system of FIG. 12 depicting the burner jets directed at an angle to increase the rotational motion of the combustion gas in the reactor fire box with improved heat distribution external to the reactor pyrolysis chamber. In FIG. 13 , the burner jets 3 - 4 1 and 3 - 4 2 are directed at an angle toward the side walls rather than directly toward the center of the reactor to increase the rotational motion of the combustion gas in the reactor combustion chamber 2 - 1 . The angle of the blown combustion gases (or cooling gases) into the chamber 2 - 1 helps the fluted wall 14 to receive and direct the gases up toward the vent 2 - 16 as shown in more detail in FIG. 14 .
[0088] FIG. 14 depicts a view of a section of the fluted side wall of the pyrolysis system of FIG. 12 . The wall of chamber 2 - 2 includes raised flutes 14 , including flutes 14 - 1 , 14 - 2 , 14 - 3 , 14 - 4 and 14 - 5 . The flutes 14 receive the combustion gases 30 and direct them toward the top of the reactor.
[0089] FIG. 15 depicts a top view of the pyrolysis system of FIG. 10 and is labeled to indicate the flutes labeled in FIG. 14 .
[0090] FIG. 16 depicts a sectional/perspective view of a pyrolysis system having a reactor 2 with vertical heat conductors 2 - 14 extending from the bottom of the pyrolysis chamber 2 - 2 , through the internal region of the chamber 2 - 1 and exiting through the side wall of the chamber 2 - 2 to the combustion chamber 2 - 1 . The vertical heat conductors 2 - 14 are in the form of pipes for circulating heated gas from the heat unit 3 through the conductors 2 - 14 to the combustion chamber 2 - 1 and from there to the exhaust port 2 - 16 . Some of the conductors 2 - 14 extend from the bottom of the pyrolysis chamber 2 - 2 and exit near the top into the combustion chamber 2 - 1 while others of the conductors 2 - 14 extend from the bottom of the pyrolysis chamber 2 - 2 and exit the side wall about one third the way up from the bottom into the combustion chamber 2 - 1 . The different heights of the heat conductors 2 - 14 helps accommodate changes that occur to the waste material in the pyrolysis chamber during pyrolysis. At the beginning of the pyrolysis period, waste tires or other waste material fills to near the top of the pyrolysis chamber 2 - 2 . At this time, the heat conductors that exit near the top are effective and heat flow can be preferentially channeled to them. However, when the pyrolysis period is well along, the waste material shrinks so that only approximately the bottom one third of the pyrolysis chamber is filled with a residue. At this time, the heat conductors that exit near the one third height of the pyrolysis chamber are effective and heat flow can be preferentially channeled to them. Accordingly, the preferential channeling during the heating portion of the pyrolysis period is different than during the cooling portion of the pyrolysis period. In FIG. 16 , the reactor 2 has multiple heat entry ports 3 - 3 , for example one for each of the conductors 2 - 14 and one at the base for the combustion chamber 2 - 1 , for distributing heat into the combustion chamber 2 - 1 . The entry ports 3 - 3 each include a control 18 for regulating the flow to each of the different ports. The controls 18 in some embodiments are dynamic and are adjusted under commands from a control unit (not shown, but like control unit 5 in FIG. 1 ) running under computer control and in other embodiments are manually changed mechanical configurations for adjusting flow. While a control 18 has been shown separately for each conductor 2 - 14 , controls can be grouped for two or more conductors or may be eliminated entirely. The heat from the combustion gases in chamber 2 - 1 and the heat conductors 2 - 14 heats the pyrolysis chamber 2 - 2 .The heat conductors 2 - 14 open at the top end relative to the combustion chamber 2 - 1 but are airtight with respect to the pyrolysis chamber 2 - 2 so that no combustion gas is introduced into the into pyrolysis chamber 2 - 2 . The pyrolysis gas generated by the tires is vented through the pipe 2 - 6 to the gas/liquid unit 4 for further processing. The reactor 2 includes a cover (not shown) which is removable for providing access to the pyrolysis chamber 2 - 2 and when closed is bolted or otherwise firmly attached.
[0091] In FIG. 16 , only a single circle of heat conductors 2 - 14 are shown. However, as described in connection with FIG. 11 two or more circles and other configurations of heat conductors are fully contemplated.
[0092] The invention has been shown and described with reference to a number of different embodiments. Common among the embodiments is preferentially channeling the heat to and from the waste material. The preferential channeling occurs both external and internal to the pyrolysis chamber. In the embodiments of FIG. 3 and FIG. 4 , for example, the heat is preferential channeled external to the pyrolysis chamber 2 - 2 through multiple input ports to the combustion chamber 2 - 1 . By insertion of heat through the multiple ports not only at the bottom but higher on the sides up from the bottom, the pyrolysis chamber is more uniformly heated and thereby improves the heat transfer in the waste material in the pyrolysis chamber 2 - 2 .
[0093] In the embodiment of FIG. 5 and FIG. 6 , the preferential channeling is accomplished internal to the pyrolysis chamber 2 - 2 by means of vertical heat conductors 2 - 9 . The vertical heat conductors 2 - 9 are distributed through and in contact with the tire waste material in the pyrolysis chamber 2 - 2 . The heat transfer in the waste material is greatly enhanced both for heating and cooling. Additionally in FIG. 6 , channeling is also to the outside of the pyrolysis chamber 2 - 2 with the ability to balance between internal and external channeling by controlling the balance of the flow between external port 3 - 3 and internal port 3 - 5 .
[0094] In the embodiments of FIG. 7 , FIG. 8 , FIG. 10 and FIG. 16 , the preferential channeling is accomplished internal to the pyrolysis chamber 2 - 2 by means of heat conductors 2 - 11 , 2 - 10 , 2 - 10 and 2 - 14 , respectively, together with the controls 18 when present.
[0095] In the embodiment of FIG. 12 , the preferential channeling is accomplished external to the pyrolysis chamber 2 - 2 by means of angular burners and/or fluted side walls.
[0096] 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 various changes in form and details may be made therein without departing from the scope of the invention.
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Disclosed is a scaleable pyrolysis system for batch processing of waste vehicle tires and other waste to provide pyrolysis products. The core pyrolysis system includes one or more batch reactors, heating units, solids processing units, gas/liquid processing units and control units. In operation, the temperature gradients internal to the reactor are controlled by preferential channeling of heat to provide pyrolysis products that are of high quality, and hence commercially advantageous, while facilitating high throughput.
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BACKGROUND OF THE INVENTION
The present invention relates to an electrical push button switch and more particularly it relates to a push button switch for electronic timepieces having a conductive elastomeric spring.
In the development of electronic watches, utilizing semiconductor integrated circuitry and digital readout devices, such as liquid crystal or light emitting diode displays, the need arose for suitable switching devices by which such watches could be adjusted to display the correct hours, minutes, seconds, date, etc. For some electronic watches, particularly those employing light emitting diode display units, a further switching mechanism was required to activate the display unit momentarily each time that a display of the current time is desired.
Typically, electronic watch circuits are contained in a watch case having an air tight cover, and it is not uncommon that such watches be waterproof and even hermetically sealed. In such watches one prior art approach to the switching requirements, as disclosed in the U.S. Pat. to Bergey, No. 3,782,102, was to employ tiny permanent magnets in a push button device contained on the outside of the watch case. These magnets were positioned so that when the push button was depressed the magnetic field of the permanent magnet in the push button passed through the non-magnetic watch case and attracted a magnetic armature within the sealed watch movement, thereby accomplishing switching. The disadvantages of such a complicated switching device became readily apparent. For one thing, a relatively large number of parts were required for proper functioning of the switch. Also, the watch could not be exposed to magnetic fields since the magnetism of the permanent magnet could likely be altered. Also, two springs were required in order for such a magnetic switch to function: an external spring for biasing the push button outwardly from the watch case and an inward spring for biasing the armature in a position normally away from the position it would be in as a result of the magnetic pull of the push button magnet. Finally, such magnetic switch devices were not only expensive and complicated, but they required precise alignment of the magnet and the armature. The limitations and disadvantages of such switch devices are overcome by the present invention.
Other watch case mounted control switches of the prior art utilized metal parts with very close tolerances, and were press fitted into the watch case. These switches normally utilized a minimum of four separate parts, all of which moved upon one another during any switching operation. The relatively large number of parts as well as the requirement for close tolerances in such switches resulted in relatively high costs. This drawback is likewise overcome by the present invention.
It is therefore one object of the present invention to provide a push button switch for electronic watches that is simple to fabricate and use, and which manifests a long life by having fewer moving parts and thus may be manufactured at substantially lower costs than prior art switches.
Another object of the present invention is to provide a push button switch for electronic watches which is waterproof and which affords a switching function without sacrifice of an air tight seal of the interior chamber of an electronic watch.
Yet another object of the present invention is to provide a push button switch for electronic watches having a moving contact biased by a conductive elastomeric material and adapted to contact an internal metallized switch pad on a printed circuit substrate comprising the electronic circuitry of the watch without need of other fixed or moving parts.
BRIEF SUMMARY OF THE INVENTION
The aforesaid objects are accomplished by a push button switch according to the present invention which advantageously utilizes a conductive elastomeric material such as silver filled silicone rubber. The elastomer is supported by the watch case within a port therein at a location adjacent to a rigid switch contact which may be a metallized portion of a printed circuit substrate of the electronic watch movement within the watch case. The elastomeric material extends through the watch case wall to a point adjacent to the fixed contact, but not touching it. In one embodiment, a rigid pin forming a push button is placed axially into the elastomeric material but not all the way therethrough. When the pin is pressed toward the center of the watch case, the elastomeric material is deformed into a contact engagement with the metallic contact of the printed circuit substrate. In another embodiment the elastomer serves to spring load a movable metal pin serving as both push button and movable contact. As the elastomeric material is conductive, an electrical circuit is completed between the watch case and the printed circuit board upon pressing the pin, thereby electrically controlling watch functions such as time set and display of time. When the pin is released, the elastomeric material returns to its original undeformed position and the switch is thereby restored to its normally open position.
Other objects, advantages and features of the invention will become apparent from the following detailed description of embodiments presented in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged view in front elevation of an electronic watch having a liquid crystal display and embodying the switch of the present invention with the switch devices shown in hidden view. The watch band is broken away to save space.
FIG. 2 is a view in rear elevation and partial section of the watch of FIG. 1 with the back watch cover removed to show the switch of the present invention and the printed circuit substrate forming a part thereof.
FIG. 3 is a side view in elevation of a portion of the watch of FIG. 1 taken along line 3-3.
FIG. 4 is an enlarged view in front elevation and section of a push button switch embodying the principles of the present invention shown in its normally open position and shown in its closed position in phantom.
FIG. 5 is an enlarged view in front elevation and section of an alternate embodiment of a switch employing the principles of the present invention and which is shown in open position.
FIG. 6 is an enlarged view in front elevation and section of a still further embodiment of a switch employing the principles of the present invention and which is shown in open position.
FIG. 7 is an enlarged view in front elevation of the watch of FIG. 1 in which the switches are joined together by a common push button.
FIG. 8 is a view in rear elevation of the watch of FIG. 7 with the back cover removed.
FIG. 9 is an enlarged view in front elevation and section of a portion of the watch of FIG. 7 showing the switches joined by the common push button.
FIG. 10 is a side view in elevation of a portion of the watch of FIG. 7 taken along line 10--10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
WIth reference to the drawings, FIG. 1 shows an electronic watch 10 having a metallic or conductive watch case 12, a face plate 14 and a liquid crystal digital display 16 within the face plate 14. A push button time set switch 20 extends outwardly from the watch case 12. In FIG. 2, the interior of the electronic digital watch is shown in a somewhat diagrammatic format with a printed circuit substrate 22 shown connected to a power cell 24. Adjacent to the push button time set switch 20 are two metallized switch contact pads 26, being a portion of the printed circuit substrate 22. One such pad may be employed to set the hours display and the other pad 26 may be utilized to set the minutes display. Should both push button set switches 20 be depressed thereof so that contact is made with both pads 26, the internal circuitry 27 of the printed circuit substrate 22 may be arranged so that a time holding function obtains.
Turning now to the details of one preferred embodiment of the switch, FIG. 4 shows a switch of the present invention mounted within the sidewall of the watch case 12. A conductive elastomeric material, such as silver filled silicone rubber, forms the moving contact member 28 of the switch 20. A non resilient pin 30, typically made of a plastic or metallic material, is embedded axially in the elastomeric member 28. The switch is closed by pressing the pin 30 toward the watch case 12 whereupon the pin deforms and stretches the elastomeric contact member 28 into a contacting engagement with the metallized contact 26 as shown in phantom in FIG. 4. The engagement of the contact surface 32 with the metallized contact 26 continues so long as the pin 30 is pressed. When the pin 30 is released, the elastomeric contact member 28 returns to its original unflexed position and the electrical conduction path between the case 12 and the metallized pad 26 is broken. The elastomeric contact member 28 may be bonded by a conductive adhesive or molded to the sidewall 34 of the watch case 12, or an alternative engagement may be achieved by utilization of an annular ring 35 in the elastomeric contact 28 which mates with a corresponding groove 36 in the sidewall 34 of the case 12. One or more such ring and groove combinations may be employed to achieve the necessary engagement of the elastomer to the sidewall of the case.
An alternate preferred embodiment of the present invention is shown in FIG. 5. In this preferred embodiment, a conductive elastomeric sleeve 38 is bonded to the sidewall 34 of the case 12 by a suitable conductive adhesive material 40. Seated within this elastomeric sleeve 38 is a conductive metallic pin 42 having a push button end 44 and a contact end 46. When pressure is applied to the push button end 44 the conductive elastomeric sleeve enables the contact end 46 of the pin 42 to engage electrically the metallized contact 26 thereby completing an electrical circuit between the frame 12 and the contact 26. Removal of pressure from the push button end 44 returns the contact end 46 to an unflexed spaced away position relative to the contact 26.
A further alternate embodiment of the invention is shown in FIG. 6. Here, a metal sleeve 48 is press-fitted against the sidewall 34 of the case 12 to achieve a firm and secure mechanical as well as an electrical connection thereto. The sleeve 48 has an inner end portion extending beyond the sidewall 34 within the case 12 and may be swayed into an annular flange 49 as shown in FIG. 6 and then continuously welded to the case 12. A metal pin 50 having a push button outer end 52 is moveably mounted axially within the sleeve by a flexible conductive elastomeric ring 54. Preferably the switch is formed by having the metal pin 50 positioned within the sleeve 48 and then transfer molding the elastomeric ring 54 around the pin 50 and within the sleeve 48 to form a single unitized switch contact member which may be easily and readily mounted within the case 12 to form a waterproof push button switch in combination with the printed circuit contact 26.
A single push button assembly 60 is shown in FIGS. 7-10. It has been found that a single push button bar 62 greatly simplifies time setting operations, and as can be seen in FIGS. 7-10, such a bar may be advantageously used with the switches of the present invention.
In the embodiment shown in FIGS. 7-10 two adjacently spaced apart switches 64 and 66 are joined together by the bar 62. Each switch may comprise the switch of FIG. 4 as described herein with the modification that the pin portions 68 and 70 aand the push button bar 62 may be formed as a single injection molded structure of non resilient material such as plastic. In addition, a molded conductive elastomeric member 72 is mounted in the sidewall of the watch case 12a and is adapted to receive the pin portions 68 and 70 which are embedded therein. The switch 64 may be closed by pressing a portion 74 of the bar 62 adjacent to pin 68 thereby causing the elastomeric member 72 to deform and electrically engage a metallized contact 26a in the manner previously described. Similarly, the switch 66 may be closed by pressing a portion 76 of the bar 62 adjacent to pin 70 thereby deforming the elastomeric member 72 into electrical contact with a contact 26b. Both switches 64, 66 may be closed simultaneously by pressing a middle portion 78 of the bar 62.
Three time set functions in the watch 10 may be achieved by the assembly 60. One switch 64 may be connected to advance the "minutes" display when closed, whereas the other switch 66 may be used to advance the "hours" display. Or, when both switches are depressed, the circuitry of the substrate 22a may be configured so that the entire time display is held to enable the actual time to catch up with the indicated display. Of course, when neither switch 64 or 66 is closed, the watch 10 would calculate and display time in its normal operating mode.
Silver filled silicone rubber is the preferred conductive elastomeric material for use in the present invention. Other materials such as polyurethane, plasticized vinyl, neoprene and butyl rubber may also be used. Where a low resistance contact is desired or requisite for proper circuit operation, powdered silver is the preferred filler within the elastomeric material. Where a higher resistance may be employed without degradation of circuit function, carbon may be successfully used as the filler materials. Silver plated copper powder, nickel, tin, zinc, gold and other conductive oxides in combinations of these may be employed.
The metallized switch contact 26 contained within the printed circuit substrate 22 of the electronic digital watch 10 may be a suitable conductor such as an alloy of beryllium and copper.
To those skilled in the art to which this invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the invention. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting.
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A push button switch for setting the time display of electronic timepieces utilizes a conductive elastomeric material such as silver filled silicone rubber as a conductive spring in its moving contact. The elastomer biased contact may be seated in a port in the watch frame and bonded thereto to make the frame waterproof. Momentary electrical contact is secured by pressing the moving contact against a metal contact portion of the printed circuit time keeping substrate within the watch frame. The watch frame is electrically connected to ground in the electronic watch circuit.
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BACKGROUND OF THE INVENTION
The invention relates to a method of transferring a piece of cloth from a pair of spreader clamps to a conveyor via a transverse boom, wherein the piece of cloth is first suspended and straightened between the spreader clamps, then supplied to the transverse boom and subsequently delivered from the transverse boom to the conveyor.
This technique relates to the operation of laundry apparatuses, wherein a large amount of moist pieces of cloth are to be straightened individually and supplied to a conveyor that transfers the pieces of cloth to eg a rotary ironer.
Such known handling of laundry will appear from eg PCT/DK2007/000228.
The known technique is associated with the drawback that the fore edge of the clothing, ie the edge that sits foremost on the conveyor, seen in the direction of conveyance thereof, will curve downwards between the spreader clamps even if they are in an extreme position, due to the own weight of the clothing and its water content pulling the clothing downwards. By the known technique, this undesired curve on the fore edge is transferred to the clothing when it is situated on the conveyor and transferred to the rotary ironer, and the most significant drawback of this manifests itself when the clothing is folded following the ironing in which case the end result will have a sloppy or unprofessional appearance.
It is the object of the invention to provide a method for straightening the fore edge of the piece of cloth to the effect that the fore edge will be completely straight when the piece of cloth has been supplied to the conveyer.
SUMMARY OF THE INVENTION
This object is obtained by an alignment of the fore edge of the piece of cloth being performed, seen in the direction of conveyance of the conveyor, following initiation of the delivery from the clamps to the transverse boom, but before it has been supplied to the conveyor.
The alignment can be provided in two different ways, on the one hand by time-controlling the mutually movable parts and, on the other, by a change of shape of some of the mutually movable parts. The preferred embodiments of the invention are exercised either by the transverse boom being moved in the direction of said direction of conveyance during the period of time when the clothing is delivered from the spreader clamps to the transverse boom, or by the transverse boom being provided with a supporting area; and that the shape of that area is changed after the piece of cloth has been supplied to the transverse boom, but before it is supplied to the conveyor. The transverse boom can be configured in one piece or may be divided into sections, eg three or more.
The invention also comprises a first apparatus for exercising the method and comprising a conveyor and comprising a pair of spreader clamps for receiving a pair of adjacent corners of a piece of cloth and for spreading the piece of cloth and for supplying it onto a transverse boom that extends transversally to the direction of conveyance of the conveyor and is shiftable in the latter direction.
The apparatus is characterised in that the apparatus comprises a control unit which is configured for controlling, on the one hand, the spreading movement of the spreader clamps and, on the other, the shifting of the transverse boom in the direction of the direction of conveyance of the conveyor in concordance with a pattern of movement which is stored in the control unit. The pattern of movement may have all degrees of complexity—from a simple linear course to a complex movement that depends on time, a number of sensors for detecting the shape of the clothing as well as on further parameters, if any.
The invention also comprises another apparatus of the kind just related which is, according to the invention, characterised in that the transverse boom comprises an alignment profile that extends essentially in parallel with a movement path for the spreader clamps a distance lower than the spreader clamps, which alignment profile comprises a form-changeable support area for a rim area of the piece of cloth and comprises means for temporarily retaining the piece of cloth.
The means according to the latter apparatus may be combined with the means in the first apparatus for obtaining a completely straight fore edge of the piece of cloth.
It is noted that the undesired downwardly curving part of the piece of cloth known from the prior art is very difficult to calculate in advance, it depending on the elasticity and weight of the clothing and the amount of water absorbed by the clothing. Therefore, in some cases, it will not be possible to accurately calculate in advance the mutual time-control of the machine parts or the shape-change of the alignment profile; rather one would operate with a number of fixed settings that an operator can choose from. In practice, a series of typically largely identical pieces of cloth will be run, and, in the course of a fairly small number of test runs, the method and the apparatus according to the invention will be adjusted to achieve a completely straight fore edge. However, the invention also encompasses that means may be provided for detecting the shape of the fore edge and for setting the time control and/or the form change of said machine parts in such a way as to dynamically compensate for the unintended, downwardly curving part of the piece of cloth.
The transverse boom has means for retaining the piece of cloth. Those means may be mechanical, but typically they are vacuum means which is why the transverse boom will also be designated a vacuum boom.
According to one embodiment, the vacuum boom is flexible transversally to its own plane, which may be accomplished eg by curving the central part of the boom upwards, whereby the major and freely suspended part of the piece of cloth is lifted to compensate for the downwardly directed curve. Alternatively, the central part of the boom is curved downwards before the piece of cloth is delivered from the clamps. When the central part is subsequently curved back to its resting position, the fore edge of the piece of cloth becomes aligned.
According to another embodiment, the vacuum boom is shape-changeable in its own plane, which, according to one embodiment, can be accomplished by the boom being divided into two or more sections that are connected to each other by means of hinges and are carried and controlled by mechanisms configured therefor.
The more water absorbed by the clothing, the heavier it is, and the deeper is the curve formed when suspended between the spreader clamps. It is therefore an advantage to be able to adjust the form-changeability, and hence, according to one embodiment, detector means may be provided for detecting the shape of the edge of the piece of cloth before—during—and/or after it is transferred from the spreader clamps to the boom.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in further detail in the description that follows of a number of embodiments, reference being made to the drawing, wherein
FIGS. 1-3 illustrate the prior art,
FIGS. 4 and 5 show a first embodiment of the apparatus according to the invention;
FIGS. 6A and 6B show details of the embodiment shown in FIGS. 4 and 5 ;
FIGS. 7 and 8 show an alternative embodiment of the invention; while
FIGS. 9-13 show further examples of embodiments according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-3 show the essential parts of a known apparatus to which the invention is related. By 1 is shown a conveyor belt that runs around a number of rollers of which the roller 2 is seen. The function of the apparatus is to deliver a laundry item 3 to the conveyor belt 1 , and, according to the prior art, it is accomplished by means of a pair of spreader clamps 4 , 5 that are journalled on a machine part 6 to the effect that the clamps 4 , 5 can be moved along the machine part 6 essentially transversally to the direction of conveyance of the conveyor belt 1 , see the arrow in FIG. 1 . The spreader clamps 4 , 5 can be closed and opened (open position in FIG. 2 ), and the apparatus can be configured such that the spreader clamps 4 , 5 receive a piece of cloth either automatically or manually. When the piece of cloth 3 is extended between the clamps 4 , 5 as is shown in FIG. 1 , the fore edge 7 of the piece of cloth will curve downwards due to the own weight of the clothing and the weight of the amount of water contained in the clothing. By the prior art, the piece of cloth is transferred from the position shown in FIG. 1 to the position shown in FIG. 2 , where the piece of cloth 3 is supplied to a vacuum boom 8 . Then the spreader clamps are opened as shown in FIG. 2 and moved completely to one side to the effect that they release the piece of cloth completely. The undesired downwardly curving shape of the fore edge 7 is thus maintained when the piece of cloth has been handed over to the vacuum boom 8 .
The above explanation of the downwardly curving fore edge 7 of the piece of cloth is slightly simplified in relation to FIGS. 1-3 . In reality, the highest load due to the weight of the clothing will occur between the tips of the spreader clamps, which is, however, difficult to illustrate. By the clamps in FIG. 1 being forcefully influenced to move away from each other, the fore edge 7 can straightened almost simultaneously with the clothing between the tips of the clamps still curving downwards, and this will cause the fore edge 7 to still curve when the clothing has been deposited onto the conveyor belt. It will also be understood that the position of the clamps relative to the horizontal is of consequence. The above detailed explanation is most relevant in the context of horizontal clamps, while the explanation given in relation to FIGS. 1-3 suffices when the clamps point vertically downwards.
Therefore, the present invention generally speaks of the shape of the fore edge of the piece of cloth, albeit the problem concerns the complete piece of cloth that is situated between the clamps and in particular between the tips of the clamps.
FIG. 3 will show (for the sake of clarity the spreader clamps are not shown) that the vacuum boom 8 is moved rearwards, see the shown arrows, by which the piece of cloth is deposited onto the belt 1 , the vacuum in the vacuum boom 8 being relieved at some point. Therefore, the prior art entails that the curved shape of the fore edge 7 still exists when the piece of cloth 3 is advanced by means of the conveyor belt 1 , typically to a rotary ironer. Therefore, the fully ironed clothing will also have that inexpedient shape, and the major drawback manifests itself later, when the clothing is folded in an automated process. The curved edges will reveal an unfinished and unprofessional laundry result.
FIGS. 4 and 5 show a first embodiment of an apparatus according to the invention where, instead of the vacuum boom 8 described above, a transverse boom 9 is provided which is provided with a pair of support areas in the shape of perforated sheets 10 , 11 . The perforated sheets 10 , 11 are pivotally journalled at their respective outer ends, and actuator means are provided that are configured to shift the ends of the perforated sheets 10 , 11 that face towards each other as will be explained in further detail in the context of FIGS. 6A and B. The fore edge 7 of the piece of cloth 3 has the same inexpedient shape in FIG. 4 as was shown in FIG. 2 , but the perforated sheets 10 , 11 being, according to the invention, able to turn to the position shown in FIG. 5 , the fore edge 7 can be aligned to be completely straight. When, at a later stage, the transverse boom 9 is moved back in the same manner as described in the context of FIG. 3 , the piece of cloth 3 will be supplied onto the conveyor belt 1 with a straight fore edge 7 or an approximately straight fore edge. The final shape will depend on how many sections of perforated sheets are provided and how they are controlled relative to each other; see the embodiments described at a later stage. First, in the context of FIGS. 6A and 6B , a number of details of the embodiment shown in FIGS. 4 and 5 will be explained.
FIG. 6A shows the transverse boom 9 , and more specifically that end where the perforated sheet is journalled, which is shown by L. The opposite end of the same perforated plate 10 will appear from FIG. 6B which also shows a drive mechanism for moving the perforated plate 10 back and forth. The drive mechanism comprises a pneumatic cylinder 12 that drives an actuator arm 13 connected to the perforated sheet 10 via a free clearance in the transverse boom 9 . FIG. 6 further shows a detector 14 configured for receiving light from a light source 15 which is situated between the perforated plates 10 and 11 . The location is configured such that the detector 14 is able to receive light from the light emitter 15 when the clothing is situated on the perforated sheets 10 , 11 as shown in FIG. 4 . In that case, propellant air is supplied to the cylinder 12 to the effect that the perforated sheets 10 , 11 are moved to the position shown in FIG. 5 where the fore edge 7 is straightened, and where the clothing precisely blocks the light beam from the light emitter 15 to the detector 14 . It will be understood that the perforated sheet 11 can be driven by a separate cylinder identical to the cylinder 12 ; or that the cylinder 12 can also be configured to operate both perforated sheets.
Another apparatus for exercising the invention is shown in FIGS. 7 and 8 , wherein the same perforated sheet 8 can be used as is shown in FIGS. 1-3 . By the embodiment shown in FIGS. 7 and 8 , the fore edge 7 is aligned by the vacuum boom 8 being moved rearwards (see the arrow) simultaneously with the clothing being deployed (see the arrows) on the vacuum boom 8 by means of the clamps 4 , 5 . By the piece of cloth 3 being deployed gradually towards the vacuum boom 8 , while simultaneously the latter is conveyed backwards, the fore edge 7 could end up with a completely rectilinear course which is shown in FIG. 8 without the vacuum boom having to be modified from a technical point of view. In practice, the described pattern of movement requires a control unit in which a control program is stored that defines the mutual patterns of movement of the movable parts. Such control programs may comprise everything from a simple linear pattern of movement to complex patterns of movement that depend on one or more detectors and/or manual adjustment options on the apparatus.
It will be understood that the mutually shifting in time of parts in accordance with the embodiment shown in FIGS. 7 and 8 can be combined with the machine parts described in the context of FIGS. 4 and 5 , and to further describe the many options that are entailed by the invention, FIGS. 9-13 show further embodiments of the invention.
By the embodiment shown in FIG. 9 , a vacuum boom is provided which is divided into three sections 16 , 17 , 18 . As will appear from FIG. 10 , the section 17 is configured for being movable in the direction of the arrow relative to sections 16 and 18 . Section 17 may alternatively be configured to be movable as shown by the arrow in FIG. 11 for straightening the curve of the fore edge 7 of the piece of cloth 3 . It will be understood that the sections 16 - 18 shown in FIGS. 10 and 11 are—apart from being movable relative to each other—also configured for being moved in unison in order for them to deliver the piece of cloth 3 to the conveyor belt 1 as is shown and explained in the context of FIG. 3 .
FIGS. 12 and 13 show a further embodiment where vacuum sections 19 , 20 are configured to be movable relative to each other as is shown by the arrows in FIG. 13 . It will readily be understood that it is possible to thereby rectify the disadvantageous shape of the fore edge 7 . It will also be understood that the more sections are provided, the straighter a correction can be made. An ideal scenario is when a perforated sheet is used that can be curved evenly with a view to an even straightening of the downward curve of the fore edge 7 of the piece of cloth 3 . It will also be understood that the other embodiments shown in FIGS. 7-13 and others can be supplemented with one or more detectors, see the detector 14 , 15 in FIG. 6B . Thereby it is possible to emit control signals to an electronic control circuit which is configured for controlling the mutual movement of the described machine parts.
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The invention concerns a method and corresponding apparatus of transferring a piece of cloth ( 3 ) from a pair of spreader clamps ( 4,5 ) to a conveyor ( 1 ) via a transverse boom, where the piece of cloth is first suspended and straightened between the spreader clamps, then delivered to the transverse boom ( 8,9 ), and subsequently delivered from the transverse boom to the conveyor. Apart from that, a straightening of the fore edge of the piece of cloth is performed, seen in the direction of conveyance of the conveyor, after its delivery from the clamps to the transverse boom has been initiated, but before it is delivered to the conveyor.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
FEDERAL SPONSORSHIP
[0002] Not Applicable.
BACKGROUND
[0003] A variety of machines in which clothes may be hung and processed in a single unit have been proposed. There are a series of patents that require the use of solvents for dry cleaning garments, for example U.S. Pat. No. 2,845,786, issued to E. L. Chrisman on Aug. 5, 1958; U.S. Pat. No. 3,166,923 issued to Zacks on Jan. 26, 1965; and U.S. Pat. No. 2,741,113, issued to Norkus on Apr. 10, 1056. The use of solvents, especially in the home, can create health and safety issues.
[0004] There are additional patents that claim a machine in which the clothes are “finished” only. These patents are directed toward de-wrinkling and smoothing the clothes, typically by using steam. However, these machines do not clean the clothes, these machines are used after the clothes are already clean. Some examples of these devices are seen in U.S. Pat. No. 3,707,855 issued to Buckley on Jan. 2, 1973; U.S. Pat. No. 4,391,602 issued to Stichnoth et al. on Jul. 5, 1983; U.S. Pat. No. 3,739,496 issued to Buckly et al. on Jun. 19, 1973; U.S. Pat. No. 3,732,628 issued to Bleven et al. on May 15, 1973; and U.S. Pat. No. 4,761,305 issued to Ochiai on Aug. 2, 1988. U.S. Pat. No. 6,189,346 issued to Chen et al. on Feb. 20, 2001 discloses a clothes treating apparatus that uses a “conditioning mist” as an alternative to dry-cleaning clothes. This patent does not provide for washing clothes with water or rinsing the clothes.
[0005] In addition, some patents claim machines that only dry clothes, and do not wash or finish the clothes: for example U.S. Pat. No. 3,257,739 issued to Wentz on Jun. 28, 1966; and U.S. Pat. No. 3,102,796 issued to Erickson on Sep. 3, 1963.
[0006] U.S. Pat. No. 3,114,919 issued to Kenreich on Dec. 24, 1963 discloses a machine that can wash and dry using conventional laundry soap, however, this apparatus can only wash one shirt, or the like, and one pair of pants, or the like, at a time. In addition, this patent discloses an apparatus that has fixed outlets for dispensing wash and rinse water. This patent, like U.S. Pat. No. 3,664,159 issued to Mazza on May 23, 1972, utilizes a shaking of the garments to remove dirt and debris from the garments. However, shaking the garments can cause the garments to fall during the washing cycle, and can impart wrinkles to the garments. In addition, these patents teach that the wash water is applied from the top and bottom of the clothing, and not along the length of the clothing.
[0007] Finally, U.S. Pat. No. 3,672,188 issued to Geschka et al. on Jun. 27, 1972 discloses an apparatus that uses conventional laundry soap water, and hot air to wash and dry clothes. However, in this patent the soap and water are applied to the garments from top and bottom nozzles. Likewise, in U.S. Pat. No. 3,868,835 issued to Todd-Reeve on Mar. 4, 1975, the water and soap are applied from nozzles located near the top and bottom of the apparatus. In neither of these apparatuses is the soap and water applied over the entire length of the garments.
SUMMARY OF THE INVENTION
[0008] The invention is generally designed to wash and dry garments or other items in a single machine. The invention is for use in residences or in hotel rooms, hospitals, laundromates, and other commercial applications. In a conventional clothes washing machine it is best to transfer the clothes soon after they are washed to the dryer in order to prevent wrinkling. In addition, it is even more important to rapidly remove dried clothes from the dryer shortly after completion of the drying process to further prevent wrinkling. When using the invention, there is no need to rapidly move clothes from the washing machine to the dryer, or to rapidly remove clothes from the dryer. The clothes are washed and dried on hangers in a single machine. Once the cycle is complete, the clothes may remain in the invention indefinitely, until ready to be worn, suspended from the hangers.
[0009] The device is used by placing garments on conventional hangers, and hanging the garments on bar within the machine cabinet. The inventor prefers to use plastic hangers, however any hanger that will support the garments without imparting stains to the wet garments may be used. A manifold supplies wash water, rinse water and finally hot air to the clothes. The manifold contains a series of arms, with one arm between each garment. The arms contain nozzles directed downward and toward the garments. The manifold, arms, and nozzles contain a dual internal system of pipes. One set of internal pipes allows wash water and rinse water to be directed toward the clothes. The other set of internal pipes allows hot air to be directed toward the clothes.
[0010] During operation, the wash water containing soap travels up the first set of internal pipes in the manifold, through the arms, out the nozzles, and onto the clothes. The entire manifold traverses up and down the length of the hanging clothes, spraying the clothes with soapy water.
[0011] After the wash cycle is complete, rinse water travels through the same first set of internal pipes in the manifold, and arms, and out the same nozzle. The manifold again traverses up and down the length of the hanging clothes, spraying the clothes with rinse water.
[0012] In the drying cycle hot or cool air travels through the second set of internal pipes in the manifold, through the arms, and out a separate set of nozzles and toward the clothes. The hot air may exit the apparatus through vents, or may be re-circulated through a compressor. The compressor will remove the moisture from the hot air and direct the hot toward the garments.
[0013] The duration of the washing cycle, rinse cycle, and drying cycle is controlled through a control panel.
[0014] When the clothes washing and drying cycle is complete the clothes may remain in the machine until such time as is convenient to remove the clothes.
BRIEF DESCRIPTION OF THE DRAWING
[0015] [0015]FIG. 1 is a perspective view, and shows the device from the front with the door open, and a cut-away section to see inside the sub-cabinet.
[0016] [0016]FIG. 2 is a plan view of the manifold.
[0017] [0017]FIG. 2 a is cross-sectional view of the manifold.
[0018] [0018]FIG. 2 b shows a partial sectional view of the area indicated in FIG. 2.
[0019] [0019]FIG. 3 is a perspective view without a cut-away.
DESCRIPTION OF THE INVENTION
[0020] Apparatus 10 comprises a cabinet 12 with front wall 12 a , rear wall 12 b , two side walls 12 c and 12 d , and a top and bottom wall 12 e and 12 f . In the preferred embodiment said walls of cabinet 12 are insulated. Apparatus 10 , like conventional washers and dryers, is connected to a water supply by hose 16 , to an electrical supply by conductors 18 , and to a drain by hose 20 .
[0021] Bottom wall 12 f contains drain 14 . Drain 14 is connected to drain hose 20 , and drains cabinet 12 . Cabinet 12 , which is sealed against the escape of water, is provided with a door 22 through which clothing to be processed can be inserted. In the preferred embodiment door 22 is transparent, and the garments may be viewed during the operating cycle. Alternatively, door 22 may be opaque and insulated. Door 22 is attached to cabinet 12 with one or more conventional hinges 6 . Door 22 is closed and watertight during operation of the device. Door 22 may, but does not have to, extend the entire length of the front wall 12 a of cabinet 12 .
[0022] Cabinet 12 is adjacent to sub-cabinet 24 . Sub-cabinet 24 contains the mechanism by means of which the operating cycle of apparatus 10 is automatically carried out. The operating cycle may include any variation or combination of pre-washing, washing, rinsing and drying. For means of illustration only, and not as a limitation, the device control mechanism could allow the consumer to set the device for heavy or light washing; set the water temperature; add bleach, fabric softeners, or other laundry additives; set one or more rinse cycles; set a initial delay of the start of the washing cycle to allow for the action of spot-removers; set a delay of the start of the washing cycle to accommodate the convenience of the user; set a pre-wash cycle; and set varying drying temperatures and times. The various washing and drying requirements are set via control panel 28 . The electricity for running control panel 28 , and all other parts of the device, is supplied through conductor 18 .
[0023] The device requires the use of a control panel 28 to effectuate the different washing and drying needs of the user. Said control panel 28 includes a timer, a means for setting or programming the various washing and drying cycles, a means for dispensing laundry detergent, bleach, fabric softener, or other laundry additives, and a means for regulating the washing, rinsing, and dying times.
[0024] The clothes-receiving portion of cabinet 12 has, at its upper end, a hanging bar 30 . Hanging bar 30 is suspended horizontally and parallel to walls 12 a and 12 b . Hanging bar 30 has one or more hanger spacers 32 . Clothes, towels, sheets or other items to be laundered are placed on a conventional, non-rusting, hanger. The hanger is inserted onto hanging bar 30 , and held at regularly spaced intervals by hanger spacers 32 .
[0025] Manifold 40 is comprised of a plurality of arms 42 . The arms 42 are in a single plane, and are parallel to each other, and perpendicular to hanging bar 30 . The arms extend between hanger-mounted garments 26 . The first arm in the parallel plane is 42 a , and the last arm in the parallel plane is 42 z.
[0026] Inside manifold 40 are two sets of internal pipes. One set is the liquid-carrying pipes 46 . The other set is the air-carrying pipes 47 . The liquid-carrying pipes 46 and air-carrying pipes 47 may be a separate set of internal pipes inside manifold 40 . Alternatively, as shown in FIG. 2 b , the manifold 40 , liquid-carrying pipes 46 , and air-carrying pipes 47 may be manufactured as a single unit with a divider 55 separating the air in the air-carrying pipes 47 from the water in the water-carrying pipes 46 .
[0027] Water enters sub-cabinet 24 through water supply hose 16 . Laundry detergent or other laundry additives may be added to the water, as requested by the user. For example, and for purposes of illustration and not limitation, laundry detergent may be added to the water. The water/detergent mixture then travels into manifold 40 and arms 42 through liquid-supply hose 48 , and into manifold 40 . Once inside manifold 40 , the water/detergent mixture travels through liquid-carrying pipes 46 . The water/detergent mixture exits arms 42 through liquid-exits 44 and sprays the hanger-mounted garments 26 . Liquid-exits 44 may be either nozzles or holes. The inventor currently prefers to use nozzles for liquid-exits 44 . Manifold 40 moves up and down the length of the hanger-mounted garments 26 spraying both sides of garments 26 with the water/detergent mixture. The water/detergent mixture will run off the garments 26 , down to bottom wall 12 f , through drain 14 , and out drain nose 20 . In the preferred embodiment bottom wall 12 f will be sloped in such a manner that drain 14 is at the lowest point in bottom wall 12 f , causing the water to run out drain 14 , and exit the device through drain hose 20 .
[0028] The drying cycle may be started after completion of the washing cycle. In the drying cycle warm or cool air is forced from subcabinet 24 to manifold 40 via air-supply hose 49 , and then into manifold 40 . Once inside manifold 40 , the air travels through air-carrying pipes 47 and out air-exits 45 . Air-exits 45 may be either nozzles or holes. The inventor currently prefers to use holes for air-exits 45 . Manifold 40 again moves up and down the length of hanger-mounted garments 26 blowing air on both sides of garments 26 , and thereby drying the garments 26 .
[0029] In the preferred embodiment, each arm 42 has a plurality of liquid-exits 44 and air-exits 45 . Arm 42 a has a plurality of exits 44 a and 45 a on only the side facing toward garment 26 , and arm 42 z has a plurality of exits 44 z and 45 z on only the side facing toward garment 26 . The remainder of arms 42 have a plurality of exits 44 and 45 on both sides of each arm 42 so that hanger-mounted garments 26 may be sprayed from both sides.
[0030] Liquid-exits 44 and air-exits 45 are placed on arms 42 so that the liquid or air exits arms 42 in a downward direction. The shape of the arms may be any shape that allows the liquid- and air-exits to point downward. The inventor currently prefers to have the cross-sectional shape of the arms be an isosceles triangle with the two equal sides of the triangle facing downward, and to place the liquid- and air-exits on the two downward facing sides of the triangle. The downward angle of the liquid or air may be any angle necessary to prevent garments 26 from tangling and twisting, and to help smooth garments 26 . The inventor currently prefers to use a downward angle of between 40 degrees and 60 degrees on liquid-exits 44 and air-exits 45 .
[0031] There are no specific requirements regarding placement of liquid-exits 44 and air-exits 45 relative to each other. That is, liquid-exits 44 and air-exits 45 may be placed in a horizontal line, may be placed with either on top of the other, or may be placed in any arrangement that allows liquid to exits the liquid-exits 44 , and allows air to exit air-exits 45 .
[0032] Manifold 40 has one or more unthreaded guide holes 51 . Apparatus 10 contains one or more guide post 50 . In the preferred embodiment, the number of unthreaded guide holes 51 is equal to the number to guide posts 50 . Guide post 50 is a smooth post that runs in a vertical direction parallel to rear wall 12 b . Guide post 50 is inserted through unthreaded hole 51 in manifold 40 , and manifold 40 may freely move along the length of guide post 50 .
[0033] Manifold 40 has one or more threaded screw holes 53 . Apparatus 10 contains one or more screw posts 52 . In the preferred embodiment, the number of threaded screw holes 53 is equal to the number of screw posts 52 . Screw post 52 is a threaded post runs in a vertical direction parallel to rear wall 12 b . Screw post 52 and threaded screw hole 53 are threaded so that the threaded screw post 52 will turn inside threaded screw hole 53 and, in turning, move manifold 40 either up or down.
[0034] Screw post 52 is moveably attached to motor 54 . Motor 54 will turn screw post 52 in an alternating clockwise and counter-clockwise direction, thereby moving manifold 40 up and down screw post 52 . Motor 54 may be programmed via control panel 28 so that screw post 54 turns in one direction for varying lengths of time. The length of time that screw post 54 turns in any one direction is directly correlated to the length that the manifold travels in any one direction. Thus, screw post 54 may turn for such a length of time that manifold 40 travels only part of the height of cabinet 12 , or the entire length of cabinet 12 . Control panel 28 may also provide a means for setting or programming the speed of the upward/downward motion, as well as the distance manifold 40 travels in the upward/downward plane.
[0035] Manifold 40 will continue to spray garments 26 for the length of time as set by the user. After the wash cycle is completed, the rinse cycle will begin. In the rinse cycle, water alone travels through liquid-supply hose 48 to manifold 40 and into arms 42 through liquid-supplying pipes 46 . The water exits arms 42 through liquid-exits 44 , and sprays the garments 26 with rinse water. The rinse water exits the device through drain 14 and drain hose 20 .
[0036] The drying cycle will begin at the time requested by the user after the rinse cycle is complete. The inventor currently prefers to allow a length of time for passive dripping of water from the clothes before beginning the drying cycle. However, the drying cycle may be set to begin at any time, even immediately after completion of the rinse cycle. Ambient air will be drawn into sub-cabinet 24 through air-intake hose 61 . If requested by the user, the air will be heated. The air will travel through air-supply hose 49 to manifold 40 and then into arms 42 through air-carrying pipes 48 . The air exits through air-exits 45 . Manifold 40 moves up and down the length of the garments 26 spraying air onto the garments. The heated air may exit cabinet 12 passively through vent 60 . Alternatively, the heated air may be removed from cabinet 12 and processed through condenser 62 , removing the moisture from the air. The treated air will then be returned to recirculate in cabinet 12
[0037] In the preferred embodiment the apparatus will indicate the end of the washing and drying cycle by a light or suitable alarm.
[0038] Although not required, in the preferred embodiment one or more racks 70 may be attached to bottom wall 12 f . The rack 70 extends horizontally near the bottom of the cabinet 12 . Socks or other small items may be placed on the rack 70 and treated as described above.
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A device for washing and drying garments or other items in a single unit. The garments or other items are placed in the device on conventional plastic hangers leaving space in between each item. A manifold with arms extends between the items. The manifold moves up and down so that the arms move up and down the length of the items to be treated. The arms have one set of pipes that spray wash water, rinse water and other washing liquids on the items. The arms have another set of pipes that carry air to the items, drying the items. After the cycle is complete the clothes or other items may be left in the device until needed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage entry of PCT/CN2011/001578 filed Sep. 16, 2011, which claims priority to Chinese Patent Application No. 201110210344.1, filed on Jul. 26, 2011, said applications are expressly incorporated herein in their entirety.
TECHNICAL FIELD
[0002] This invention relates to an amphiphilic macromolecule and uses thereof, and this amphiphilic macromolecule is applicable to oilfield drilling, well cementing, fracturing, crude oil gathering and transporting, sewage treating, sludge treating and papermaking, and it can be used as intensified oil producing agent and oil displacing agent, heavy oil viscosity reducer, fracturing fluid, clay stabilizer, sewage treating agent, retention aid and drainage aid and strengthening agent for papermaking.
BACKGROUND OF THE INVENTION
[0003] The main function of the polymer used for tertiary oil recovery is believed to increase solution viscosity and decrease water permeability in oil layer, so as to decrease mobility ratio and adjust water injection profile, and thus to enhance oil recovery by increasing the conformance factor. The solution viscosity and stability of the viscosity are important indicators for determining polymer displacement characteristics, and also are the key problem for determining recovery effect. With the continuous increase of oilfield comprehensive water content, it becomes increasingly difficult to extract oil and keep stable production, thus the requirements on the polymer used for tertiary oil recovery also increase constantly.
[0004] Heavy oil recovery is a common problem worldwide. The heavy oil has characteristics of high viscosity, high gum asphaltene content or high wax content; heavy oil gathers up about 70% sulfur and 90% nitrogen of the crude oil, the light component which accounts for about 70% of the total heavy oil is the convertible section by using the current technology, but it is still difficult to convert it efficiently. The heavy component which accounts for about 20% of the total heavy oil is difficult to be converted directly by using conventional technology. The rest of the heaviest is 10% of bottom residue of the heavy oil, which is rich in over 70% of metals and over 40% of sulfur and nitrogen, it can't be converted effectively into light product. The heavy oil does not easily flow in the formation, wellbore and oil pipeline. Furthermore, since the oil-water mobility ratio is big, heavy oil can easily cause many problems such as rapid water breakthrough, high water content of produced fluid, and easy formation sand production. The process for heavy oil recovery can be mainly divided into recovery of liquid flooding (e.g., hot water flooding, steam huff and puff, steam flood and so on) and recovery of yield enhancement (e.g., horizontal well, compositing branched well, electric heating and etc). A chemical viscosity reducer can disperse and emulsify the heavy oil effectively, reduce the viscosity of the heavy oil remarkably and decrease the flow resistance of heavy oil in the formation and wellbore, which is significantly important for reducing energy consumption in the process of recovery, decreasing discharging pollution and enhancing heavy oil recovery.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In the following context of this invention, unless otherwise defined, the same variable group, and molecular and structural formula have the same definitions.
[0006] The instant invention relates to an amphiphilic macromolecule, this amphiphilic macromolecule has repeating units as described below: a structural unit A for adjusting molecular weight, molecular weight distribution and charge characteristics, a highly sterically hindered structural unit B and an amphiphilic structural unit C.
[0007] In an embodiment, the structural unit A for adjusting molecular weight, molecular weight distribution and charge characteristics comprises (meth)acrylamide monomer unit A 1 and/or (meth)acrylic monomer unit A 2 . Preferably, the structural unit A includes (meth)acrylamide monomer unit A 1 and/or (meth)acrylic monomer unit A 2 simultaneously. In the art, the molecular weight of the amphiphilic macromolecule may be selected as needed, preferably, this molecular weight may be selected between 1000000-20000000.
[0008] Preferably, the (meth)acrylamide monomer unit A 1 has a structure of formula (1):
[0000]
[0009] In formula (1), R 1 is H or a methyl group; R 2 and R 3 are independently selected from the group consisting of H and a C 1 -C 3 alkyl group; R 2 and R 3 are preferably H.
[0010] Preferably, the (meth)acrylic monomer unit A 2 is (meth)acrylic acid and/or (meth)acrylate. Preferably the (meth)acrylate is sodium methacrylate.
[0011] Preferably, the molar percentage of (meth)acrylamide monomer unit A 1 in the entire amphiphilic macromolecule repeating units is 70-99 mol %; preferably 70-90 mol %, more preferably 72.85-78 mol %.
[0012] Preferably, the molar percentage of (meth)acrylic monomer unit A 2 in the entire amphiphilic polymer repeat units is 1-30 mol %; preferably 1-25 mol %, and more preferably 20-25 mol %.
[0013] In another embodiment, the structural unit A for the regulation of molecular weight, molecular weight distribution and charge characteristics has a structure of formula (2):
[0000]
[0014] wherein, R 1 is H or a methyl group; R 2 and R 3 are independently selected from the group consisting of H and a C 1 -C 3 alkyl group; R 2 and R 3 are preferably H; R 4 is selected from H or a methyl group; Gr is —OH or —O − Na + ; m and n represent the molar percentages of the structural units in the entire amphiphilic macromolecule repeating units, and m is 70-99 mol %, preferably 70-90 mol %, more preferably 72.85-78 mol %; n is 1-30 mol %, preferably 1-25 mol %, more preferably 20-25 mol %.
[0015] In another embodiment, in formula (2), R 1 -R 3 are preferably H, and Gr is preferably —O − Na + .
[0016] In another embodiment, the highly sterically hindered structural unit B contains at least a structure G, wherein the structure G is a cyclic hydrocarbon structure formed on the basis of two adjacent carbon atoms in the main chain, or is selected from a structure of formula (3), and the highly sterically hindered structural unit B optionally contains a structure of formula (4):
[0000]
[0017] In formula (3), R 5 is H or a methyl group; preferably H; R 6 is a radical selected from the group consisting of the structures of formulas (5) and (6).
[0000]
[0018] In formula (5), a is an integer from 1 to 11; preferably 1-7;
[0019] In formula (4), R 7 is H or a methyl group; R 8 is selected from the group consisting of —NHPhOH, —OCH 2 Ph, —OPhOH, —OPhCOOH and salts thereof, —NHC(CH 3 ) 2 CH 2 SO 3 H and salts thereof, —OC(CH 3 ) 2 (CH 2 ) b CH 3 , —NHC(CH 3 ) 2 (CH 2 ) c CH 3 , —OC(CH 3 ) 2 CH 2 C(CH 3 ) 2 (CH 2 ) d CH 3 , —NHC(CH 3 ) 2 CH 2 C(CH 3 ) 2 (CH 2 ) e CH 3 , —O(CH 2 ) f N + (CH 3 ) 2 CH 2 PhX − ,
[0000]
[0020] wherein b and c are respectively integers from 0 to 21, preferably from 1 to 11; d and e are respectively integers from 0 to 17, preferably from 1 to 7; f is an integer from 2 to 8, preferably from 2 to 4; and X − is CP or Br − .
[0021] Preferably, the highly sterically hindered structural unit B comprises a structure G and a structure of formula (4).
[0022] In another embodiment, the cyclic hydrocarbon structure formed on the basis of two adjacent carbon atoms in the main chain is selected from the group consisting of:
[0000]
[0023] Preferably, the molar percentage of structure G of the highly sterically hindered structural unit B in the entire amphiphilic macromolecule repeating units is 0.02-2 mol %; preferably 0.02-1.0 mol %, more preferably 0.05-0.5 mol %.
[0024] Preferably, the molar percentage of the structure of formula (4) of the highly sterically hindered structural unit B in the entire amphiphilic macromolecule repeating units is 0.05-5 mol %; preferably 0.1-2.5 mol %, more preferably 0.1-1.0 mol %.
[0025] In another embodiment, the highly sterically hindered structural unit B has a structure of formula (7):
[0000]
[0026] In formula (7), the definition on G is as described above, preferably the structure of formula (3),
[0000]
[0000] the definitions on R 7 and R 8 are as described in formula (4). x and y represent the molar percentages of the structure units in the entire amphiphilic macromolecule repeating units, and x is 0.02-2 mol %, preferably 0.02-1.0 mol %, more preferably 0.05-0.5 mol %; y is 0.05-5 mol %, preferably 0.1-2.5 mol %, and more preferably 0.1-1.0 mol %.
[0027] In another embodiment, the amphiphilic structural unit C has a structure of formula (8):
[0000]
[0028] In formula (8), R 9 is H or a methyl group; R 10 is —N + (CH 3 ) 2 (CH 2 ) ξ CH 3 X − , —N + ((CH 2 ) σ CH 3 ) 3 X − or —N + (CH 3 )((CH 2 ) τ CH 3 ) 2 X − ; ξ is an integer from 3 to 21; σ is an integer from 2 to 9; τ is an integer from 3 to 15; X − is Cl − or Br − . Preferably, ξ is from 3 to 17, σ is from 2 to 5, τ is from 3 to 11.
[0029] Preferably, the molar percentage of amphiphilic structural unit C in the entire amphiphilic macromolecule repeating units is 0.05-10 mol %; preferably 0.1-5.0 mol %, more preferably 0.5-1.8 mol %.
[0030] In another embodiment, the amphiphilic macromolecule has a structure of formula (9):
[0000]
[0031] In formula (9), the definitions on R 4 , m and n are as described in formula (2); the definitions on R 7 , R 8 , G, x and y are as described in formula (7); the definitions on R 9 and R 10 are as described in formula (8); z represents the molar percentage of this structural unit in the entire amphiphilic macromolecule repeat units, and z is 0.05-10 mol %, preferably 0.1-5.0 mol %, more preferably 0.5-1.8 mol %.
[0032] Specifically, this present invention provides a high molecular compound having a structure of formulas (I)-(X):
[0000]
[0033] The molecular weight of the amphiphilic macromolecule described above is between 1000000 and 20000000; preferably between 3000000 and 13000000.
[0034] The measurement of the molecular weight M is as follows: The intrinsic viscosity [η] is measured by Ubbelohde viscometer as known in the art, then the obtained intrinsic viscosity [η] value is used in the following equation to obtain the desired molecular weight M:
[0000] M= 802[η] 1.25
[0035] The amphiphilic macromolecule according to this present invention can be prepared by known methods in the art, for example, by polymerizing the structural unit for adjusting molecular weight, molecular weight distribution and charge characteristics, the highly sterically hindered structural unit and the amphiphilic structural unit in the presence of an initiator. The polymerization process can be any type well known in the art, such as, suspension polymerization, emulsion polymerization, solution polymerization, precipitation polymerization, and etc.
[0036] A typical preparation method is as follows: the above monomers are each dispersed or dissolved in an aqueous system under stirring, the monomer mixture is polymerized by the aid of an initiator under nitrogen atmosphere to form the amphiphilic macromolecule. The so far existing relevant technologies for preparing an amphiphilic macromolecule can all be used to prepare the amphiphilic macromolecule of this invention.
[0037] All the monomers for preparing the amphiphilic macromolecule can be commercially available, or can be prepared on the basis of prior art technology directly, and some monomers' synthesis are described in details in specific examples.
DESCRIPTION OF FIGURES
[0038] FIG. 1 depicts the relationship of viscosity vs. concentration of the amphiphilic macromolecules obtained from examples 1-5 of the invention in saline having a degree of mineralization of 3×10 4 mg/L at a temperature of 85° C.
[0039] FIG. 2 depicts the relationship of viscosity vs. temperature of the amphiphilic macromolecules obtained from the examples 1-5 of the invention in saline having a degree of mineralization of 3×10 4 mg/L at the concentration of 1750 mg/L.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present invention is further illustrated below by combining specific examples; however, this invention is not limited to the following examples.
Example 1
[0041] This example synthesized the amphiphilic macromolecule of formula (I):
[0000]
[0042] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0043] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 75%, 23%, 0.15%, 0.65%, 1.2% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 9, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 28° C.; after 5 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 1160×10 4 .
Example 2
[0044] This example synthesized the amphiphilic macromolecule of formula (II).
[0000]
[0045] The synthesis route of the monomer
[0000]
[0000] was as follows:
[0000]
[0046] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0047] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 75%, 24%, 0.15%, 0.1%, 0.75% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 8, then nitrogen gas was introduced in for 40 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 25° C.; after 5.5 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 730×10 4 .
Example 3
[0048] This example synthesized the amphiphilic macromolecule of formula (III):
[0000]
[0049] The synthesis route of the monomer
[0000]
[0000] was as follows:
[0000]
[0050] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0051] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 77%, 21%, 0.25%, 0.25%, 1.5% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 9, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 23° C.; after 5 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 720×10 4 .
Example 4
[0052] This example synthesized the amphiphilic macromolecule of formula (IV):
[0000]
[0000] The synthesis route of the monomer
[0000]
[0000] was as follows:
[0000]
[0053] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0054] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 75%, 23%, 0.05%, 0.15%, 1.8% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 9, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 28° C.; after 5 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 460×10 4 .
Example 5
[0055] This example synthesized the amphiphilic macromolecule of formula (V):
[0000]
[0056] The synthesis route of the monomer
[0000]
[0000] was as follows
[0000]
[0057] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0058] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 78%, 20%, 0.2%, 1%, 0.8% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 10, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 25° C.; after 6 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 580×10 4 .
Example 6
[0059] This example synthesized the amphiphilic macromolecule of formula (VI):
[0000]
[0060] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0061] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 73%, 24%, 0.5%, 1%, 1.5% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 8, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 55° C.; after 3 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 770×10 4 .
Example 7
[0062] This example synthesized the amphiphilic macromolecule of formula (VII):
[0000]
[0063] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0064] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 77%, 22%, 0.25%, 0.25%, 0.5% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 9, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 55° C.; after 2 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 920×10 4 .
Example 8
[0065] This example synthesized the amphiphilic macromolecule of formula (VIII):
[0000]
[0066] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0067] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 72.85%, 25%, 0.15%, 1%, 1% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 10, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 55° C.; after 3 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 430×10 4 .
Example 9
[0068] This example synthesized the amphiphilic macromolecule of formula (IX):
[0000]
[0069] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0070] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 75%, 23%, 0.25%, 0.25%, 1.5% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 8, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 50° C.; after 2.5 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 690×10 4 .
Example 10
[0071] This example synthesized the amphiphilic macromolecule of formula (X):
[0000]
[0072] The synthesis of the amphiphilic macromolecule of this example was as follows:
[0073] Firstly, water, accounting for ¾ of the total weight of the reaction system, was charged into a reactor, then various monomers, totally accounting for ¼ of the total weight of the reaction system, were charged into the reactor as well, and the molar percentages m, n, x, y, z for each repeating units were 75%, 23%, 0.25%, 0.25%, 1.5% in succession. The mixture was stirred until complete dissolution, and a pH adjusting agent was then added in to adjust the reaction solution to have a pH value of about 8, then nitrogen gas was introduced in for 30 minutes to remove oxygen contained therein. An initiator was added into the reactor under the protection of nitrogen gas, and nitrogen gas was further continued for 10 minutes, then the reactor was sealed. The reaction was conducted at a temperature of 50° C.; after 4 hours, the reaction was ended with a complete conversion. After the drying of the obtained product, powdered amphiphilic macromolecule was obtained. The molecular weight of the amphiphilic macromolecule was 830×10 4 .
Measurement Examples
Measurement Example 1
[0074] Saline having a mineralization degree of 3×10 4 mg/L was used to prepare amphiphilic macromolecule solutions with different concentrations, and the relationship between the concentration, temperature and the viscosity of the solution was determined. The results were shown in FIG. 1 and FIG. 2 .
[0075] The figures showed that the amphiphilic macromolecule solutions of examples 1-5 still have favorable viscosifying capacity under the condition of high temperature and high degree of mineralization. The highly sterically hindered unit in the amphiphilic macromolecule reduced the rotational degree of freedom in the main chain and increased the rigidity of the macromolecule chain, which made the macromolecule chain difficult to curl and tend to stretch out, thus enlarging the hydrodynamic radius of the macromolecule; in the meantime, the amphiphilic structural unit associated each other to form the microdomain by intramolecular- or intermolecular-interaction, thus enhancing the viscosifying capacity of the solution remarkably under the conditions of high temperature and high salinity.
Measurement Example 2
[0076] Testing method: Under a testing temperature of 25° C., 25 ml electric dehydration crude oil samples from three types of oilfields were added in a 50 ml test tube with a plug, then 25 ml aqueous solutions of amphiphilic macromolecule with different concentrations formulated with distilled water were added in. The plug of the test tube was tightened, then the test tube was shaken manually or by using an oscillating box for 80-100 times in horizontal direction, and the shaking amplitude should be greater than 20 cm. After sufficient mixing, the plug of the test tube was loosed. Viscosity reduction rate for crude oil was calculated according to the following equation:
[0000]
Viscosity
reduction
rate
(
%
)
=
viscosity
of
crude
oil
sample
-
viscosity
after
mixing
viscosity
of
crude
oil
sample
×
100
[0000]
TABLE 1
Experimental results of the heavy oil viscosity reduction of the amphiphilic macromolecule
obtained from the example 6 to example 10 (oil-water ratio 1:1, 25)
oil-water volume ratio
(1:1)
oil
viscosity
oil
viscosity
oil
viscosity
test temperature
sample
reduction
sample
reduction
sample
reduction
(25° C.)
1
rate(%)
2
rate(%)
3
rate(%)
initial viscosity (mPa · s)
1650
—
5100
—
16000
—
Example 6
400 mg/L
730
55.76
1750
65.69
7100
55.63
600 mg/L
470
71.52
1250
75.49
3250
79.69
800 mg/L
330
80.00
950
81.37
1850
88.44
1000 mg/L
295
82.12
820
83.92
1500
90.63
1200 mg/L
270
83.64
675
86.76
1225
92.34
Example 7
400 mg/L
780
52.73
1800
64.71
7700
51.88
600 mg/L
590
64.24
1350
73.53
4200
73.75
800 mg/L
460
72.12
1100
78.43
2850
82.19
1000 mg/L
340
79.39
880
82.75
1900
88.13
1200 mg/L
300
81.82
790
84.51
1500
90.63
Example 8
400 mg/L
820
50.30
1475
71.08
5650
64.69
600 mg/L
590
64.24
1200
76.47
3950
75.31
800 mg/L
450
72.73
850
83.33
2600
83.75
1000 mg/L
375
77.27
670
86.86
1450
90.94
1200 mg/L
330
80.00
620
87.84
1290
91.94
Example 9
400 mg/L
780
52.73
1450
71.57
5800
63.75
600 mg/L
450
72.73
1150
77.45
4100
74.38
800 mg/L
360
78.18
850
83.33
2500
84.38
1000 mg/L
280
83.03
680
86.67
1570
90.19
1200 mg/L
260
84.24
620
87.84
1390
91.31
Example 10
400 mg/L
710
56.97
1450
71.57
5270
67.06
600 mg/L
500
69.70
1050
79.41
3100
80.63
800 mg/L
410
75.15
830
83.73
1890
88.19
1000 mg/L
320
80.61
675
86.76
1200
92.50
1200 mg/L
270
83.64
650
87.25
950
94.06
[0077] Table 1 showed that the amphiphilic macromolecules of examples 6-10 had good effects for viscosity reduction as to all three oil samples. With the increase of the concentration of the amphiphilic macromolecule solution, the viscosity reduction rate increased. And, when the concentration of the amphiphilic macromolecule solution was the same, the viscosity reduction rate increased with the enhancing of the viscosity of the oil sample. It was believed that the amphiphilic macromolecule could reduce the viscosity of the crude oil remarkably via a synergetic effect between the highly sterically hindered structural unit and the amphiphilic structural unit, which could emulsify and disperse the crude oil effectively.
INDUSTRIAL APPLICATION
[0078] The amphiphilic macromolecule of this invention can be used in oilfield drilling, well cementing, fracturing, crude oil gathering and transporting, sewage treating, sludge treating and papermaking, and it can be used as intensified oil producing agent and oil displacing agent, heavy oil viscosity reducer, fracturing fluid, clay stabilizer, sewage treating agent, retention aid and drainage aid and strengthening agent for papermaking.
[0079] The amphiphilic macromolecule of this invention is especially suitable for crude oil exploitation, for instance, it can be used as an intensified oil displacement polymer and a viscosity reducer for heavy oil. When it is used as an oil displacement agent, it has remarkable viscosifying effect even under the condition of high temperature and high salinity, and can thus enhance the crude oil recovery. When it is used as a viscosity reducer for heavy oil, it can remarkably reduce the viscosity of the heavy oil and decrease the flow resistance thereof in the formation and wellbore by emulsifying and dispersing the heavy oil effectively.
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Amphiphilic macromolecules having structural units to adjust molecular weight and molecular weight distribution and charging property effects, high stereo-hindrance structural units, and having amphiphilic structural units. The Amphiphilic macromolecules are suitable for fields such as oil field well drilling, well cementation fracturing, oil gathering and transfer, sewage treatment, sludge treatment and papermaking, etc., and can be used as an oil-displacing agent for enhanced oil production, a heavy oil viscosity reducer, a fracturing fluid, a clay stabilizing agent, a sewage treatment agent, a papermaking retention and drainage aid or a reinforcing agent, etc.
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This application is an application filed under 35 U.S.C. Sec. 371 as a national stage of international application PCT/EP01/06208, which was filed May 31, 2001.
TECHNICAL FIELD
The invention relates to an adapter for a hand-operated dispensing device for a fluid that is/can be placed under pressure in a container in the substantially upright position thereof and in the substantially reversed or upside-down position.
BACKGROUND OF THE INVENTION
Dispensing devices in the form of hand-operated pumps for containers for fluids or dispensing valves for containers for fluids subjected to the pressure of propellant gas are known, which are assigned an auxiliary valve to let in fluid from a container which adopts an oblique or substantially reversed or upside-down position. In these conventional devices, the auxiliary valve consists of a ball valve which is assigned to the pump housing or valve housing of the dispensing device in question. The ball valve is mounted to be freely and reciprocally movable parallel to the axis between an open position and a closed position. It is exclusively subjected to gravity, so that the ball valve adopts its final position more or less quickly—or not at all—as a function of the oblique position of the container and of the viscosity of the liquid therein. This results, inter alia, in a nonuniform dispensing of the fluid in the container as a consequence of a differing admixing of air and is perceived by the consumer as disadvantageous. This disadvantage is particularly noticeable in the case of cosmetic or pharmaceutical products, where the consumer relies on dispensing a particular quantity of the product when actuating such dispenser packs.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to propose an adapter which can be optionally used in conjunction with conventional hand-operated pumps or dispensing valves on containers subjected to the pressure of propellant gas and, furthermore, can also be used in any position of a container differing from the normal, upright position thereof, such as an upside-down or oblique position of the container, which guarantees a consistently uniform quantity of fluid. Any dispensing device designed exclusively for actuation and functioning in the upright position of the container will be capable of being employed, by use of the adapter according to the invention, for actuation and dispensing of the liquid from the container in the reversed or upside-down position of the container.
What is achieved by the adapter according to the invention is that any dispensing device created for dispensing fluid in the normal, upright position of a container can, by attachment of the adapter to the lower end of the housing of the dispensing device in question, be converted into and used as a universally usable dispensing device which, in any desired position of the container, always and reliably dispenses a consistently uniform quantity of discharged fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in detail below with reference to the diagrammatic drawings of a plurality of examples of embodiment, in which:
FIG. 1 shows an embodiment of an adapter according to the invention in conjunction with a conventional, hand-operated pump in a central longitudinal section;
FIG. 2 shows a modified embodiment of an adapter in conjunction with the hand pump shown in FIG. 1 , in a central longitudinal section;
FIG. 3 shows a modification of the adapter in FIG. 2 on a larger scale, with the pump largely broken away;
FIG. 4 shows a further modification of the adapter in FIG. 3 , in a central longitudinal section on a larger scale;
FIG. 5 shows a further modification of the adapter in FIG. 3 , in a central longitudinal section on a larger scale;
FIG. 6 shows a further modification of the adapter in FIG. 3 , in a central longitudinal section on a larger scale;
FIG. 7 shows a further embodiment of an adapter according to the invention, in a central longitudinal section;
FIG. 8 shows a further embodiment of an adapter according to the invention, which is integrally molded with a housing of the dispensing device, in a central longitudinal section;
FIG. 9 shows a modification of the adapter in FIG. 8 , in a central longitudinal section;
FIG. 10 shows a non-return valve of the adapter in FIG. 9 , in a view rotated through 90°, on a larger scale;
FIG. 11 shows a modification of the adapter in FIG. 8 , in a central longitudinal section;
FIG. 12 shows a modification of the adapter in FIG. 8 , in a central longitudinal section; and
FIG. 13 shows a modification of the adapter in FIG. 8 , in a central longitudinal section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an adapter 20 for a hand-operated pump 120 as a dispensing device for a fluid which is, or can be, subjected to pressure in a container (not shown) in the substantially upright position thereof and in the substantially reversed or upside-down position thereof. The dispensing device 22 comprises a housing 148 , which, as is known per se and therefore not shown is sealingly secured on an aperture at the upper end of the container. The housing 148 is provided with a base 26 , at whose lower end a connecting nipple 130 is disposed. A passage channel 348 , extends through the base 26 and connecting nipple 130 and, for the passage of the fluid in the substantially perpendicular position of the container, is in connection with an ascending pipe 32 extending into the fluid in the container.
A tubular, substantially cylindrical adapter housing 34 contains a linking channel 36 between the ascending pipe 32 and the passage channel 30 of the housing 148 of the dispensing device 22 . The adapter housing 34 has an upper end 38 and a lower end 40 , which respectively form a connecting pipe 42 for the connecting nipple 130 and an ascending pipe nipple 44 for the ascending pipe 32 . A plurality of inlets 46 for the fluid are provided in the wall of the adapter housing 34 , which are disposed at equal circumferential angular intervals at mid-height of the adapter housing 34 . These inlets 46 permit the passage of fluid from the container in the substantially reversed position of the container, as is explained in detail below.
In the embodiments of the adapter 20 according to the invention shown in FIGS. 1 to 7 , an inlet valve 48 is inserted into the adapter housing 34 as an independent or separate component to be non-displaceable axially.
The inlet valve 48 is provided within the adapter housing 34 for the approximately simultaneous closure of the inlets 46 in the approximately upright position of the container, but for the approximately simultaneous clearance of the inlets 46 in the event of a pressure difference acting on the fluid in the container in the substantially reversed position of the container.
A non-return valve 50 is disposed within a valve chamber 52 of the adapter housing 34 to be freely movable axially between two end positions, the upper end position being defined by a non-return valve seat 54 extending transversely through the adapter housing 34 and the lower position by a supporting device 56 in the upright position of the container, on which supporting device 56 the non-return valve 50 adopts a throttle position for the fluid, leaving throttle ports 58 free.
The valve chamber 52 has a diameter which is greater in size than the diameter of the non-return valve 50 , in order to form bypass flow channels 60 for the fluid in the upright position of the container.
The inlet valve 48 is produced from a flexibly elastic material, such as silicone or polyethylene, and consists of a valve sleeve 62 with a sleeve base 64 and is supported within the adapter housing 34 at a distance below the inlets 46 by the supporting device 56 . The inlets 46 consist of a plurality of inlet ports 66 provided at the same height and at the same circumferential angular intervals in the cylindrical wall of the adapter housing 34 . The inlet ports 66 are sealed, in the upright position of the container, by the valve sleeve 62 but, in the event of a pressure in the adapter housing 34 lower than that prevailing in the container, are opened by a radially inward-directed bulging of the valve sleeve 62 .
The supporting device 56 consists of at least three supporting ribs 70 , which are disposed at equal circumferential angular intervals and extend radially inwards from the interior wall of the valve chamber 52 and upwards from the lower end 40 of the adapter housing 34 and end at a distance below the inlet ports 66 . The valve sleeve 62 is supported by its sleeve base 64 on the upper end faces of the supporting ribs 70 . The supporting ribs 70 simultaneously serve to guide the coaxially movable non-return valve 50 in the valve chamber 52 . Intervening spaces, which are disposed in the circumferential direction of the interior wall of the adapter housing 34 between the supporting ribs 70 , form the bypass flow channels 60 through which the fluid can flow past the non-return valve 50 toward the dispensing device 22 .
The lower end 40 of the adapter housing 34 forms a tapered longitudinal section 74 , whose lower end forms the ascending pipe nipple 44 of smaller diameter. The supporting ribs 70 extend into the tapered longitudinal section 74 , and project radially inward, in order to form the throttle seat for the non-return valve 50 . As a result, on the first pump stroke in the upright position of the container, the air contained in the housing 148 can be forced past the non-return valve 50 through the throttle seat thereof into the container. The support ribs 70 adopt a distance from one another, diametrally relative to the valve chamber 52 , which corresponds to the clear diameter of the ascending pipe nipple 44 and is smaller in size than the diameter of the non-return valve ( 50 ), in order to form bearing ribs 57 for the non-return valve 50 .
The ascending pipe 32 has an upper end 72 which is chamfered at an angle of 90° from its center to both sides in the manner of a gabled roof. This shape of the end 72 of the ascending pipe offers the possibility of dispensing with the support device 56 for the non-return valve 50 and, instead, supporting the spherical non-return valve 50 only on the gable-like end 72 of the ascending pipe 72 , because in this case also throttle ports for the discharge of product residues when the pump 120 is placed under pressure exist to the side of the two mutually opposite tips of the end 72 of the ascending pipe.
Although the adapter according to the invention, as stated initially, can be used with any desired pressure or pump system, the mode of operation of the adapter will be explained below with reference to the metering pump shown in FIGS. 1 and 2 , which is known per se.
FIGS. 1 and 2 show a metering pump 120 as a dispensing device. The pump is fixed in a closure cap 122 , which comprises suitable means, for example a helical thread 124 , for fixing the cap together with the pump 120 disposed therein on the open top of a conventional container.
The container (not visible below the pump 120 ) is filled with a fluid product. The fluid product is aspirated into the pump 120 through the connecting nipple 130 , which is connected to the underside of the pump 120 . The adapter 20 , as already described above, is fixed by its upper, tubular end 38 to the connecting nipple 130 and receives in its lower ascending pipe nipple 44 the upper end of the ascending pipe 32 , which extends as far as the bottom of the container. The lower end of the ascending pipe 32 is therefore normally dipped into the fluid, when an associated container is in the general upright position.
The closure cap 122 has a generally cylindrical hollow wall 131 , an interior cylindrical aperture 132 being formed above and separate from the helical thread 124 by an annular flange 134 which projects inward. Within the aperture 132 is located a holder 138 , which comprises an exterior wall 140 , which at its lower end forms an outward-projecting annular flange 142 . The annular flange 142 is fixedly disposed and sealed relative to the top of the container aperture. The holder 138 serves to secure the pump 120 in the cap 122 . To this end, the pump housing 148 is provided with an upper flange 150 , which protrudes outward. The flange 150 has a radially inward-projecting shoulder on the exterior wall 140 of the holder 138 . The holder 138 , in order to secure the pump housing 148 , can easily be secured on the pump housing 148 by means of a snap seating and be connected thereto.
The pump housing 148 comprises a substantially cylindrical pump chamber 180 , which is open at the upper end and into which a cylindrical inner sleeve 172 of the holder 138 engages. The inner sleeve 172 is disposed coaxially with the exterior wall 140 of the holder 138 and connected to the latter at the upper end by an annular end wall 164 . The inner sleeve 172 ends in a tapered lower end 173 within the pump chamber 180 .
The flange 150 at the upper end of the pump housing 148 is provided with a vertical groove 162 , which is shown in the right-hand halves of FIGS. 1 and 2 . The groove 162 forms an air outlet slit between the pump housing 148 and the exterior wall 140 of the holder 138 and interacts with certain venting channels in the holder 138 . In particular, the upper, annular end wall 164 forms a circumferential groove 168 at the top of the container 138 . The groove 168 is linked to the top of the groove 162 , as is shown in the right-hand halves of FIGS. 1 and 2 . The groove 168 is linked, in a position offset by 180° relative to the groove 162 , to a radial groove 170 (FIG. 2 ), which is provided in the bottom of the upper end wall 164 of the holder 138 . The groove 170 extends inward beyond the wall of the pump housing 148 .
The cylindrical inner sleeve 172 of the holder 138 is connected to a plurality of ribs 174 , which are disposed to be distributed at a distance from one another over the circumference and project outward. The vertical exterior surfaces of the ribs 174 rest on the interior wall of the pump housing 148 and serve for the coaxial orientation of the holder 138 and of the pump housing 148 .
The entire circumference of the upper interior edge of the pump housing 148 is conically widened, in order to form an annular channel 171 around the holder 138 at the upper ends of the ribs 174 . The intervening spaces between the ribs 174 link an annular space 170 below the ribs 174 at the lower end of the cylindrical inner sleeve 172 of the holder 138 to the annular channel 171 , which extends around the upper ends of the ribs 174 . This provides a venting channel, which extends out from the interior of the pump housing 148 through the radial groove 170 , around the circumferential groove 168 , out through the groove 162 over the shoulder 156 and then downward between the cylindrical exterior wall 140 of the holder 138 and of the pump housing 148 into the inner head space of the container above the fluid. This venting channel, together with other components of the pump, permits atmospheric air to penetrate into the container, as is described below.
A pump piston 182 is so disposed that it can be sealingly and reciprocally moved within the pump chamber 180 . The pump piston 182 is provided with a hollow cylindrical shank 186 , which extends upward and projects outward from the pump chamber 180 through the holder 138 via the cap 122 . The cylindrical piston shank 186 is adapted to an actuating and dispensing head or button 190 , which is provided with a dispensing aperture 192 , which is linked to the upper end of the piston shank 186 via a radial outlet channel 194 . An axial outlet channel 198 extends upward through the pump piston 182 and the shank 186 thereof and links the outlet channels 194 within the actuating head 190 to the pump chamber 180 .
The outside of the piston shank 186 is tapered toward the upper end, so that its diameter increases with increasing height above the holder 138 . The lower end of the pump piston 182 forms a sealing surface, concave toward the base 26 (FIG. 2 ), for the lateral surfaces of the lower end of the inner sleeve 172 of the holder 138 in order to rest thereon and provide a seal when the pump piston 182 is disposed in the fully raised position of rest as shown in FIGS. 1 and 2 . If however, the pump piston 182 is partially or substantially fully depressed, the concave sealing surface 202 of the pump piston 182 moves away from the lower end of the interior wall 172 of the holder 138 .
As a consequence thereof, ambient air can penetrate into the container in order to top up the volume of the dispensed content and maintain the atmospheric air pressure within the container. When this occurs, ambient air flows into the cap aperture 132 and also under the actuating head 190 .
When the piston shank 186 is disposed in its lowered position, the air flows through an annular gap 123 ( FIG. 2 ) past the cylindrical inner sleeve 172 of the holder 138 and of the pump housing 148 . The air then flows through the radial groove 170 and the circumferential groove 168 . Here it is distributed in other directions, around the circumference of the holder 138 through approximately 180°, where it then flows through the groove 162 of the pump housing 148 . The air then flows between the holder 138 and the pump housing 148 and downward into the container.
Fluid is fed via the connecting nipple 130 and a suction channel 348 to the pump chamber 180 through a fixed feed line, which in the preferred embodiment shown consists of a cylindrical tubular feed part 220 , which projects from the base of the pump housing 148 into the pump chamber 180 and inside the latter and has an open upper end.
A second differential piston is made up of two parts, specifically a valve body 250 and a sealing sleeve 290 (FIG. 2 ). The valve body 250 is axially oriented above the stationary, tubular feed part 220 and also disposed in a manner such that it is movable with the pump piston 182 and relative thereto above the tubular feed part 220 . The pump piston 182 encloses an enlarged bore, the upper end of which leads into the outlet channel 198 of smaller diameter at a point which is formed by an annular valve seat 258 . The valve body 250 is molded onto the upper end of a valve cone, which rests firmly against the annular valve seat 258 in the pump piston 182 , in order to prevent fluid from flowing out from the pump chamber 180 through the outlet channel 198 .
The lower end of the valve body 250 is configured as a valve head 270 . The valve head 270 has an upper piston surface which is provided with four ribs 274 , which extend outward at equal circumferential angles and project from the upper piston surface. The piston surface of the valve head 270 is placed under the pressure of the fluid in the pump chamber 180 , as is described in detail below.
The underside of the valve head 270 is provided with an annular groove of trapezoidal cross section and represents an integral part of an inlet valve. To this end, the outer lateral wall of the annular groove forms a valve surface 280 , which is conically widened downward and outward to seal the upper conical contact surface 318 of a sealing sleeve 290 , which is linked to the valve body 250 in a manner such that it is capable of limited axial adjustment. The valve surface 280 and the conical contact surface 318 form an essentially identical acute-angled aperture with the central longitudinal axis 0 — 0 of the pump in the downward direction. The inner lateral wall of the annular groove is formed by a cylindrical guide pin 330 .
The sealing sleeve 290 is provided, on its side facing the container, with a substantially cylindrical piston shell 302 . The upper end of the sealing sleeve 290 has an inner annular flange 310 , whose underside forms a shoulder 311 , which rests on the upper end of a helical compression spring 340 when the pump piston 182 is disposed in its upper, inactive position. In this inactive position, the inlet valve (channel 154 ) is open. The annular flange 310 can be adjusted axially out of this inactive position into a working position in which the inlet valve is closed. The annular flange 310 extends with its shoulder 311 and its upper front side at right angles to the pump axis 0 — 0 and axially into an annular groove 279 of the valve head 270 .
As a result of the lower stop for the sealing sleeve 290 , formed by the upper end of the helical compression spring 340 , a free space is created, which permits a limited axial movement between the valve body 250 and the sealing sleeve 290 . This relative mobility of the sealing sleeve 290 is provided here in a manner such that the contact surface of the sealing sleeve 290 rests on the inner valve surface 280 of the outer edge of the valve head 270 in one end position of the range of relative movement of the sealing sleeve 290 , so that the inlet valve formed by said parts is closed. The circumstances in which this relative movement from one end position to the other end position takes place are described in detail below.
The piston shell 302 of the sealing sleeve 290 is provided with guide ribs 350 which project outward and are disposed at a distance apart over the circumference, and by means of which the sealing sleeve 290 is displaceable along the interior wall of-the pump chamber 180 , in order to maintain the axial orientation of the sealing sleeve 290 within the pump chamber 180 and relative to the tubular feed part 220 .
The lower end of the sealing sleeve 290 is so formed that it can be telescopically deformed downward in a sealing manner in firm contact along the outside of the stationary tubular feed part 220 . To this end, the lower end of the sealing sleeve 290 is provided with an annular beading 360 , which projects inward to rest on the outside of the tubular feed part 220 when the movable sealing sleeve 290 moves downward, as is explained below.
According to FIG. 1 , the spring 340 is disposed with its lower end within the pump chamber 180 at the base and within the tubular feed part 220 and engages around a lower guide pin 346 , which is disposed coaxially with the main axis of the pump and protrudes upward from the base of the housing. The guide pin 346 is an integral part of the pump housing 148 and, with its inlet channel 348 , links the adapter 20 to the tubular feed part 220 . It is apparent that the spring 340 normally prestresses the valve body 250 together with the pump piston 182 resting thereon into a fully raised position, when the pump is in its inactive position of rest.
The valve head 270 is provided on the circumference outwardly and downwardly resembling a fruston with a plurality of ribs (not shown), which are disposed at a distance apart from one another over the circumference and extend downward along the interior wall of the pump housing 148 and assist the axial guidance of the valve body 250 .
The sealing sleeve 290 follows this movement for a short time, while the annular flange 310 is supported by its shoulder 311 on the restoring spring 340 . If, however, the lower free end of the sealing sleeve 290 encounters the tubular feed part 220 , the movement of the sealing sleeve 290 is briefly interrupted. However, the upper end of the sealing sleeve 290 , briefly halted at the tubular feed part 220 , is rapidly reached by the valve head 270 , so that both parts adopt the closed position. From this moment on, the valve head 270 carries the sealing sleeve 290 downward with it, so that the sealing sleeve 290 slides telescopically and sealingly over the tubular feed part 220 . The friction deriving therefrom contributes to a relative pressure of the inner flange 310 on the annular groove, so that the linking channel 154 between the contact surface 318 of the sealing sleeve 290 and the valve surface 280 of the valve head 270 is closed or sealed. From this moment onward, which additionally begins immediately after the start of operation of the pump, the pump chamber 180 is completely closed. The depression of the pump piston 182 now causes an increase of the pressure in the pump chamber 180 .
It must be emphasized, however, that this behavior is greatly dependent on the choice of that point at which the inner flange 310 is supported on the valve body 250 . Specifically, while the pressure P in the pump chamber continues to increase, an axial, outward-oriented force is added to the abovementioned friction between the sealing sleeve 290 and the guide pin 346 . If “s” is the cross-sectional region of the ribbed groove that extends from the inside of the pump shell 302 of the sealing sleeve 290 to the interior wall of the pump chamber 180 , the force obtained is the product of “s” and “P”. Even if “P” is enlarged only slightly, the force by far exceeds the friction of the sealing sleeve 290 on the tubular feed part 220 and is therefore critical for the firm closure of the linking channel 154 . If this linking channel 154 is located at a distance from the main axis 0 — 0 of the metering pump such that an angular range having the cross section “S” for the fluid under pressure “P” is accessible between the bearing surface of the sealing sleeve 290 on the valve body 150 and the interior wall of the pump cylinder 143 , an axial force “SP” develops which is oriented toward the container and which counteracts the force “sP” and tends to force back the sealing sleeve 290 and open the linking channel 154 . It is therefore necessary to ensure in all circumstances that “S” is less “s”. While the pump chamber 180 is placed under pressure, the closing of the linking channel 154 is better the smaller “S” is relative to “s”. The embodiment shown in the figure is an optimum where “S” equals 0. In this phase of the placing of the pump under pressure, therefore, all actions take place in a manner as if the sealing sleeve 290 and the valve body 250 were inseparably linked to one another. The fluid enclosed in the pump chamber 180 is then dispensed as with conventional pumps.
However, this analogy no longer applies to the subsequent working phases of the pump. As soon as the force “F” is no longer being applied, the restoring spring 340 forces back the valve body 250 . The valve body 250 moves away from the sealing sleeve 290 , which as a consequence of the friction on the tubular feed part 220 is held stationary. The sealing sleeve 290 therefore moves out of the closed position into the open position. The linking channel 154 between the valve head 270 and the annular flange 310 of the sealing sleeve 290 is open and therefore provides a link between the container and the pump chamber 180 via the intervening spaces or grooves which are disposed between the guide ribs 350 . The restoring spring 340 , on which the inner shoulder 311 of the annular flange 310 rests, now carries the valve body 250 with it at the same time as the sealing sleeve 290 . This results in an increase in volume in the pump chamber 180 . As the linking channel 154 is open, fluid is let into the pump chamber 180 . The linking channel 154 makes it possible to fill the pump chamber 180 to an extent whereby the volume of the pump chamber 180 increases. If, therefore, the metering pump 120 has completely returned to its initial position or position of rest and the link between the free lower end of the sealing sleeve 290 and the upper end of the tubular feed part 220 is restored, fluid is no longer aspirated through the tubular feed part 220 . Theoretically, therefore, the link would become superfluous. That, however, would mean that a gas-tight contact between the tubular feed part 220 and the end of the sealing sleeve 290 would have to be maintained constantly, and its quality would inevitably deteriorate to the detriment of the plastic flow of the plastic components.
When the metering pump is actuated, the linking channel 154 therefore closes approximately at the same time as the link 146 is interrupted. However, when the pump piston 182 moves upward, the linking channel 154 opens before the link is restored. A significantly lower vacuum therefore occurs in the pump chamber 180 . It follows that only a little air, if any at all, can penetrate, even when the seal of the pump piston 182 relative to the pump cylinder 143 should no longer be particularly tight. In particular, the pump piston 182 in this case needs only a single sealing lip 214 . This single sealing lip 214 is directed toward the container, so that, during dispensing of the fluid, the pressure prevailing in the pump chamber 180 continues to increase the sealing effect. Dispensing with one of the two sealing lips reduces the friction of the pump piston 182 of the pump cylinder 143 by half. The spring 340 need not therefore be as powerful as previously, in order to move the pump piston 182 and the valve body 250 back upward again. The operative who compresses the restoring spring 340 during the downward movement of the pump piston 182 therefore needs to apply a lesser force F, which is in a more favorable ratio to the force exerted by the finger of a child. All these advantages are achieved with one additional part, specifically the sealing sleeve 290 , which represents a special part. This improves the quality of spraying, which ensures the dispensing of a uniform metered volume independently of the age of the metering pump. The two fitted-together parts 250 and 290 of the differential piston therefore interact via the restoring spring 340 and permit the aspiration of the fluid during the actuation of the metering pump. The pump chamber 180 is then filled with air, which is generally the case when the metering pump is operated for the first time, the pressure in the pump chamber 180 not increasing to such an extent, as a result of the downward movement of the movable parts 182 , 250 , 290 within the pump housing 148 , that the outlet valve 258 , 262 could be opened. During the output movement of conventional pistons, therefore, the vacuum in the pump chamber 180 necessary for the access of fluid is not present. This disadvantage is eliminated by the fact that the linking channel 154 between the pump chamber 180 and the container opens immediately on commencement of the upward movement of the pump piston 182 . As a consequence thereof, air can again be distributed, but on this occasion in the opposite direction. In this manner, air flows from the pump chamber 180 into the container. In the course of the further upward movement of the pump piston 182 a vacuum is simply produced by the increase in the volume in the pump chamber 180 which, as desired, aspirates fluid into the pump chamber 180 and fills the latter with fluid.
The procedure for placing under vacuum, then, is the same as in the case of the pump 120 described previously. On first operation of the pump 120 , air is forced out from the pump, while the product is aspirated on the return stroke.
In the approximately upright position of the pump 120 , with the adapter 20 in FIGS. 1 and 2 , the product is aspirated through the ascending pipe 32 during the return stroke. The product flows around the non-return valve 50 and fills the pump chamber 180 . When this occurs, the inlet or sleeve valve 48 remains closed. During the pumping stroke, some of the product, which is not located in the pump chamber 180 , is forced downward through the adapter 20 past the non-return valve 50 through the ascending pipe 32 , because the non-return valve 50 is kept from reaching its closing position by the V-shape of the end of the ascending pipe or ribs on the adapter 20 and retained in what is referred to as its throttling position.
In the upside-down position of the pump 120 with the adapter 20 , not shown in the figures, the non-return valve 50 drops onto its throttling or ball seat and seals the non-return valve seat 54 during the return stroke. As a result of this sealing, a vacuum is produced in the pump chamber 180 , as a result of which the flexible inlet valve 48 bulges inward and, as a consequence thereof, is opened. As a result, the product is aspirated into the pump 120 through the inlets 46 in the adapter 20 and past the inlet valve 48 . When the filling operation has ended, the inlet valve 48 closes and the product can be dispensed, as usual, from the pump camber 180 .
FIG. 2 shows a second embodiment of an adapter 20 a , which in turn is attached to the same pump 120 as in FIG. 1 . In the adapter 20 a , a sleeve-shaped inlet valve 48 a is provided in the region of its sleeve base 64 a with an annular sealing flange 66 a , which rests sealingly on a smoothly cylindrical longitudinal section 67 a of the interior wall of the adapter housing 34 a and is supported on the upper end faces of supporting ribs 70 a at a distance below the lower end of the connecting nipple 130 a of the housing 148 a of the pump 120 a.
A valve sleeve 62 a of thin wall thickness consists here, again, of elastically flexible material and engages with its upper end into the connecting nipple 130 a of the pump housing 148 a . The valve sleeve 62 a normally rests sealingly, over a short length, on an interior wall 76 a of the lower end of the connecting nipple 130 a of the adapter housing 34 a , in a manner such that, in the event of a reduced pressure within the adapter housing 34 a , the wall of the valve sleeve 62 a is caused to bulge inward by the inflowing fluid under the effect of the pressure difference and permits the entry of the fluid into the adapter housing 34 a.
The inlet consists of at least one inlet slit, the inlet in the embodiment shown in FIG. 2 consisting of three inlet slits 46 a , which are disposed at equal circumferential angles in the interior wall of a connecting pipe 42 a and extend between the connecting nipple 130 a of the pump housing 148 a and the upper connecting pipe 42 a of the adapter housing 34 a beyond the lower end of the connecting nipple 130 a into the interior of the adapter housing 34 a.
An upper edge of the connecting pipe 42 a of the adapter housing 34 a , which is secured on the outside of the connecting nipple 130 a of the housing 148 a of the dispensing device 22 a , is cut out to form, in each case, an inlet port 47 a for the respectively associated inlet slit 46 a.
The inlet slits 46 a extend downward beyond a lower edge of the connecting nipple 130 a of the housing 148 a and end at a distance above the sealing flange 66 a of the inlet valve 48 a , in order to form outlet ports 49 a for each of the inlet slits 46 a . These outlet ports 49 a lie at a distance from and opposite to the outside of the valve sleeve 62 a of the inlet valve 48 a , protruding from the outside of the sleeve base 64 a of the inlet valve 48 a.
Throttle ports 58 a in the base of the adapter housing 34 a , on which the spherical non-return valve 50 a lies in the upright position of the container, are provided with at least three bypass flow channels 60 a.
It can be seen that the adapter 20 a in FIG. 2 has a shorter overall length and a smaller dead volume in the adapter housing 34 a.
FIG. 3 shows an adapter 20 b whose connecting pipe 42 b is widened in diameter and provided with a greater wall thickness. A plurality of inlet slits 46 b , extending parallel to the axis and disposed at equal circumferential angular intervals, are limited in the circumferential direction by longitudinal ribs 47 b on the interior wall of the connecting pipe 42 b . In addition, the longitudinal ribs 47 b are each provided, at a distance below their lower ends of equal height, with a stop shoulder 43 b , on which stop shoulders 43 b the lower end face of a connecting nipple 130 b of a pump 120 b forming the dispensing device rests.
In the embodiment of an adapter 20 c in FIG. 4 , a flexible valve sleeve 62 c of the inlet or sleeve valve 48 c extends over substantially its entire length into a connecting nipple 130 c of a pump housing 148 c and normally lies sealingly only with the outside of its upper free end 35 c on an interior wall 36 c of the connecting nipple 130 c.
Below this abovementioned sealing region between inlet valve 48 c and connecting nipple 130 c , the interior wall of the connecting nipple 130 c is widened at 45 c in order to facilitate the installation of the inlet valve 48 c and the lifting away of the upper end 35 c of the inlet valve 48 c from the interior wall of the connecting nipple 130 c . Inlet slits 46 c extend between the connecting pipe 42 c of the adapter housing 34 c and the connecting nipple 130 c of the housing 148 c of the dispensing device 120 c.
The adapter housing 34 c is provided above a valve chamber 52 c with an inner annular shoulder 33 c on which an annular flange 74 c of the inlet valve 48 c is supported. The clear diameter of the annular shoulder 33 c approximately corresponds to the clear diameter of the connecting nipple 130 c of the pump housing 148 c . At least three stops 38 c are molded on the top of the annular shoulder 33 c , are disposed at equal circumferential angular intervals, rest on the lower end face of the connecting nipple 130 c and form radially inward-extending passage channels 37 c for the fluid product that are flush with the inlet slits 46 c and make a transition into the annular space between connecting nipple 130 c and valve sleeve 62 c.
In this arrangement, a longitudinal section of the adapter housing 34 c extends below the annular shoulder 33 c and forms a smoothly cylindrical interior wall of the valve chamber 52 c for a non-return valve 50 c . Here again, the diameter of the valve chamber 52 c is substantially greater than the diameter of the spherical non-return valve 50 c , so that good flow around the non-return valve 50 c is achieved.
The longitudinal ribs 49 c separate the inlet slits 46 c in the circumferential direction of the interior wall of the upper end, forming the connecting pipe 42 c , of the adapter housing 34 c . The stops 38 c are disposed at an equal axial height at a distance above the inner annular shoulder 33 c of the adapter housing 34 c.
It is further apparent from FIG. 4 that the upper end, protruding into the valve chamber 52 c , of an ascending pipe 32 c projects with its gable-shaped tip 76 c above the height of bearing webs 77 c out into the valve chamber 52 c , so that the spherical non-return valve 50 c exposes a relatively large through-flow cross section. It can also be seen that the overall height of the adapter 20 c is exceptionally small, because of the connecting pipe 42 c engages over approximately its full length over the connecting nipple 130 c and, in addition, the inlet valve 48 c engages almost completely over the connecting nipple 130 c . Because of this compact arrangement of said parts, stable mounting of the adapter housing 34 c and of the ascending pipe 32 c in an ascending pipe nipple 40 c of the adapter 20 c is guaranteed.
FIG. 5 shows a modified embodiment of an inlet valve 48 d , whose non-return valve seat 54 d exhibits a 45° angle for optimum sealing by a spherical non-return valve 50 d . A sleeve base 64 d is provided with a radially outward-projecting sealing flange 74 d , which is mounted sealingly on an inner annular shoulder 37 d of an adapter housing 34 d . The top of the sealing flange 74 d is provided with four ribs 75 d disposed at equal circumferential angles, these extending as far as the outer circumference of the sealing flange 74 d and serving as a stop for the lower end of a connecting nipple 130 d . The interior wall of a connecting pipe 42 d of the adapter housing 34 d is provided with three axial inlet slits 46 d disposed at equal circumferential angular intervals and guided in a U-shape around the connecting nipple 130 d , as is apparent on the left-hand side of FIG. 5 .
In FIG. 5 , as in FIG. 4 , the inlet slits 46 d of U-shaped cross section also ensure that the upper end of the valve sleeve 62 d , which exclusively rests sealingly on the interior wall of the connecting nipple 130 d , can easily be lifted off from the interior wall of the connecting nipple 130 d and opened in the event of a pressure difference between the two sides of this sealing region.
Above the base of a valve chamber 52 d , four ribs 51 d are provided at equal circumferential angular distances and ensure that, in the event of an ascending pipe 32 d not being completely inserted into the ascending pipe nipple 40 d , the spherical non-return valve 50 d does not block off the adapter housing 34 d in the event of a pump stroke in the upright position of the pump 120 d.
FIG. 6 shows a modified embodiment of an adapter 20 e according to the invention, wherein, at a distance above a passage aperture 80 e in the base of a valve chamber 52 e for a spherical non-return valve 50 e , a baffle plate 82 e is disposed at an axial distance above the passage aperture 80 e . The free front end 83 e of the baffle plate 82 e extends from the interior wall of the valve chamber 52 e at a distance above the passage aperture 80 e and ends at a distance in front of the diametrally opposite side. The baffle plate 82 e masks the passage aperture 80 e , in a manner such that the fluid flow from an ascending pipe 32 e is deflected against the interior wall of the valve chamber 52 e and the flow can pass around the spherical non-return valve 50 e , so that it remains open during the suction stroke of the pump 120 e or when the dispensing valve of a pressure container is open.
FIG. 7 shows a modified embodiment of an adapter 20 f and of an inlet valve 48 f , whose lower edge 67 f is configured as an annular sealing flange 66 f and comprises an increasingly small wall thickness toward its outer edge. The inlet valve 48 f consists, as in all cases described, of elastically flexible material, such as silicone or PE, and is again configured above the sealing flange 66 f as a valve sleeve 62 f which is inserted by its upper end into a connecting nipple 130 f of a pump house 148 f . The upper end of the valve sleeve 62 f is provided on its circumference with ribs 45 f that form passage channels 30 f , which provide a link between the pump housing 148 f and the interior of the container.
The adapter 20 f has an adapter housing 34 f , which contains a widened sealing flange chamber 90 f and is therefore produced in two parts. The sleeve-shaped inlet valve 48 f is provided at its lower end with the sealing flange 66 f , whose diameter is substantially greater than that of the upper valve sleeve 62 f , whose lower end is formed by the sealing flange 66 f . A base 92 f of this sealing flange chamber 90 f is provided with a plurality of inlet ports 97 f for the fluid, disposed at equal circumferential intervals, which are normally sealed by the sealing flange 66 f , which is increasingly thin and therefore more flexible toward its outer edge, the flange in the sealing flange chamber 90 f resting sealingly on the inlet ports 97 f . In the upside-down position of the device, the sealing flange 66 f is lifted away from the inlet ports 72 f during a suction stroke of the pump 120 f , so that the fluid product can be aspirated from the container into the pump housing 148 f . A baffle plate 82 f is likewise disposed in a valve chamber 52 f for a spherical non-return valve 50 f . By contrast with the embodiment shown in FIGS. 6 and 7 , the baffle plate may also be round in shape and disposed coaxially with and at a distance above a passage aperture 80 f in the base of the valve chamber 52 f , at least three thin webs linking the baffle plate to the base, of annular shoulder shape, of the valve chamber 52 f.
The embodiment of the adapter in FIGS. 8 to 15 differs from that in FIGS. 1 to 7 primarily in that the inlet valve and the adapter are produced in one piece.
FIG. 8 shows an adapter 20 g which is formed in one piece with a sleeve-shaped inlet valve 48 g . A connecting pipe 42 g of the adapter 20 g surrounds a valve housing 62 g at a distance, so that, in the cross section shown in FIG. 8 , they form U-shaped legs of an annular space 63 g for a connecting nipple 130 g of a pump housing 148 g . In this embodiment, again, a plurality of inlet slits 46 g are provided on the inside of the connecting pipe 42 g and are separated by longitudinal ribs 65 g on the interior wall of the connecting pipe 42 g . These longitudinal ribs end at their lower ends in stop shoulders 77 g for the lower end face of the connecting nipple 130 g of the pump housing 148 g , which are disposed at a radial distance from the exterior wall of the valve sleeve 62 g.
The connecting nipple 130 g is provided over approximately three quarters of its length and on the inside with a widened portion 29 g , which forms an annular space 31 g with the exterior wall of the valve sleeve 62 g , this annular space 31 g forming, in the cross section shown in FIG. 8 , the inner leg of the U-shaped inlet slit 46 g and ending only immediately in front of the upper end of the valve sleeve 62 g which seals the inlet slits 46 g relative to the interior wall of the connecting nipple 130 g . The annular space 31 g narrows toward the upper end, resting on the interior wall of the connecting nipple 130 g , of the valve sleeve 62 g in a manner such that the sealing, upper end of the valve sleeve 62 g can more easily be lifted away by the fluid product from the interior wall of the connecting nipple 130 g in the opening direction.
The lower end of a conical longitudinal section 21 g of the adapter housing 34 g is formed by a non-return valve seat 54 g for a spherical non-return valve 50 g within a valve chamber 52 g . The substantially cylindrical valve chamber 52 g is provided at equal circumferential intervals with longitudinal ribs 71 g , which guide the spherical non-return valve 50 g axially at a radial distance from the interior wall of the valve chamber 52 g and thus form bypass flow channels 60 g , through which the fluid product of the container can flow around the non-return valve 50 g.
The lower ends of the longitudinal ribs 71 g are configured as radially inward-projecting bearing beadings 73 g for the spherical non-return valve 50 g . Below the seat for the non-return valve 50 g formed by the bearing beadings 73 g , the upper end, again pointed in the manner of a gabled roof, of an ascending pipe 32 g is inserted and retained in an axially immovable manner by a constriction of the interior wall of an ascending pipe nipple 44 g.
The interior diameter of the valve chamber 52 g and of the ascending pipe connector 44 g are again of equal size, in the same way as the exterior diameter of the valve chamber 52 g and of the ascending pipe connector 44 g.
The modification of an adapter 20 h shown in FIG. 9 relates solely to the support of a spherical non-return valve 50 h , which is supported solely by the two diametrally opposite tips 33 h of an ascending pipe 32 h , throttle ports 58 h being left free. Accordingly, longitudinal ribs 71 h in a valve chamber 52 h for the non-return valve 50 h are provided over their entire length with the same cross section, so that the non-return valve 50 h is axially guided by the longitudinal ribs 71 h in the axial direction only at a radial distance from the interior wall of the valve chamber 52 h . FIG. 10 clarifies, in a view rotated through 90°, the position of the spherical non-return valve 50 h on the end, cut to the shape of a gabled roof, of the ascending pipe 32 h.
FIG. 11 shows an embodiment in which both a housing 148 i of a pump 120 i and an adapter 20 i are modified. A base 360 i of the pump housing 148 i is provided with passage channels 25 i , a tubular guide pin 346 i extending beyond the base 360 i of the pump housing 148 i freely downward through a valve sleeve 62 i and engaging only with its lower end into a valve chamber 52 i for a spherical non-return valve 50 i and closing the valve chamber 52 i in the direction of the pump 120 i . At the same time, the lower end of this tubular guide pin 346 i forms a non-return valve seat 54 i for the non-return valve 50 i.
In the lower end of the valve chamber 52 i , a supporting device 56 i for the spherical non-return valve 50 i is again provided, as has already been described above in connection with FIG. 1 . At a distance below this supporting device 56 i , again, the upper end 76 i , cut to the shape of a gabled roof, of an ascending pipe 32 i inserted into an ascending pipe nipple 44 i is identifiable.
The upper end of the valve sleeve 62 i again forms a flexible seal relative to the interior wall of a connecting nipple 130 i of the pump housing 148 i , inlet slits 46 i , as in FIGS. 8 and 9 , being provided in connection with the upper end of the adapter 20 i.
In order that the upper, normally sealing end of the valve sleeve 62 i can lift away from the cylindrical interior wall of the connecting nipple 130 i in the event of a pressure difference, the cylindrical interior wall of the valve sleeve 62 i is disposed at a radial distance from the cylindrical circumference of the tubular guide pin 346 i , through which a passage channel 347 i extends. It can be seen that the cylindrical interior diameter of the smooth-walled valve chamber 52 i is a smaller size than the interior diameter of the valve sleeve 62 i and is exactly matched to the exterior diameter of the guide pin 346 i , in order to ensure a seal between the guide pin 346 i and the interior wall of the valve chamber 52 i . In this region, the adapter housing 34 i is again shaped to taper conically toward the valve chamber 52 i.
FIG. 12 shows a further embodiment of an adapter 20 k with an adapter housing 34 k , which is of extremely compact design and combines with one another in a compact construction a sleeve-shaped inlet valve 48 k , a non-return valve seat 54 k for a spherical non-return valve 50 k and an ascending pipe nipple 44 k . In the present example of embodiment, a connecting nipple 130 k of a pump housing 148 k is extended to the point where it comprises not only a valve sleeve 62 k but also a valve chamber 52 k as far as the height of the open end position of the spherical non-return valve 50 k . The adapter housing 34 k is there provided with an annular flange 35 k whose outside is approximately flush with the outer circumference of the connecting nipple 130 k.
The interior wall of the connecting nipple 130 k is widened upward as far as the vicinity of a sleeve base 64 k , to form inlet slits 46 k which are disposed on the outside of the wall of the adapter housing 34 k surrounding the valve chamber 52 k and extend from the annular flange 35 k to a height below the throttle valve seat 54 k for the non-return valve 50 k.
The spherical non-return valve 50 k is supported, in its lower, open end position, only by the tips 33 k of an ascending pipe 32 k , as was described in detail in connection with FIG. 9 . In the reversed position of the device shown in FIG. 12 , a pressure difference acting on the fluid, as described, will lift the upper end of the valve sleeve 62 k inward away from the interior wall of a connecting nipple 130 k , so that the fluid product can penetrate through an aspiration channel 347 k into the housing 148 k of the pump 120 k.
Finally, FIG. 13 shown an adapter 20 l , which engages with a connecting pipe 42 l over a connecting nipple 130 l of a housing 148 l of a pump. 120 l at a radial distance, forming a plurality of inlet slits 46 l . The inlet slits 46 l are again disposed with a U-shaped cross section, so that they also extend between the exterior wall of a valve sleeve 62 l until immediately in front of the upper end thereof, which is again flexibly configured and rests sealingly on the interior wall of the connecting nipple 130 l in the upright position and in the inactive state of the device. The interior wall of the connecting nipple 130 l is provided with longitudinal ribs 31 l , which separate the inlet slits 46 l from one another in the circumferential direction. Preferably, three or four such inlet slits 46 l are provided.
In the mounted position of the adapter 30 l , a non-return valve seat 54 l is disposed within the connecting nipple 130 l . As the non-return valve seat 54 l is formed by an annular wall 55 l tapering conically toward the upper end of the adapter 20 l , the length of an adapter housing 34 l can be economized on or the distance between the closed position and the lower, open position of a spherical non-return valve 50 l can be increased. An ascending pipe nipple 44 l for an ascending pipe 32 l is provided on the outside with reinforcing ribs 69 l , which extend from the lower end of the ascending pipe nipple 44 l to the lower end of the upper connecting pipe 42 l , which is set on a shoulder 41 l which extends radially outward from the exterior wall of the adapter 20 l at a distance below the non-return valve seat 54 l . The connecting pipe 42 l in turn forms, together with the valve sleeve 62 l , an inlet valve 48 l , the connecting nipple 130 l engaging into the connecting pipe 42 l , so that the valve sleeve 62 l seals the connecting nipple on the interior wall. It can further be seen that a valve chamber 52 l is of smoothly cylindrical design and has a much greater diameter than the spherical non-return valve 50 l , which is held in its lower, open position merely by tips 33 l of the ascending pipe 32 l and, consequently, a large free cross section is available between the spherical non-return valve 50 l and the interior wall of the valve chamber 52 l for the aspiration of the fluid product into the housing 148 l of the pump 120 l in its upright position.
The above description of numerous examples of embodiment of the invention gives an impression of the advantages achieved by means of the adapter according to the invention. These consist in the use of a positive contact seal for the upright dispensing position of the dispensing device in comparison with a ball valve in the case of conventional systems. In addition, all components, specifically the housing of the dispensing device, the adapter and the ascending tube are oriented coaxially with one another. Finally, the basic concept of the invention of using three parts for a large number of immersion pipe sizes can be applied to reduce costs and/or improve performance. Not least, the positive contact seal achieved by means of the sleeve-shaped inlet valve in every type of upside-down position of the device achieves a substantially uniform output performance of the dispensing device. Furthermore, immersion pipes and valve balls of different sizes can be used in connection with the adapter according to the invention. Moreover, there are a plurality of possibilities for retaining the ball valve in the adapter and securing it on the housing assigned to a pump or a valve. Finally, the invention can be embodied with a minimum number of parts.
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The invention relates to an adapter ( 2 ) for a manually operated dispensing device ( 120 ) for a fluid that is/can be pressurized in a container. The dispensing device includes a housing ( 148 ) having a passage channel ( 30 ). A tubular adapter housing ( 34 ) connects the uptake tube ( 32 ) and the channel ( 30 ) of the housing ( 148 ) of the dispensing device ( 120 ). The adapter housing ( 34 ) has a connecting sleeve ( 42 ) for connection to the connecting nipple of the housing ( 148 ) and an uptake tube sleeve ( 44 ) for connection to the uptake tube ( 32 ). There are several inlets ( 46 ) for the fluid in the upside down position of the dispensing device. The adapter housing ( 34 ) defines at least one section of the inlets. An inlet valve ( 48 ) is defined within the adapter housing ( 34 ) for releasing the inlets substantially simultaneously when a pressure acts on the fluid in the container in the substantially upside down position of the container. A shut-off valve ( 50 ) is positioned inside a large diameter valve chamber ( 52 ) of the adapter housing ( 34 ), in such a way that the valve ( 50 ) can be freely displaced axially between two end positions.
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RELATED APPLICATIONS
[0001] This application is a continuation of, and incorporates by reference in its entirety, U.S. application Ser. No. 10/418,509, filed Apr. 16, 2003, which is a continuation of U.S. application Ser. No. 10/141,652, filed May 7, 2002, which is a continuation of U.S. application Ser. No. 09/695,757, filed Oct. 24, 2000, now U.S. Pat. No. 6,419,608, which issued Jul. 16, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The field of the invention relates to transmissions. More particularly the invention relates to continuously variable transmissions.
[0004] 2. Description of the Related Art
[0005] In order to provide an infinitely variable transmission, various traction roller transmissions in which power is transmitted through traction rollers supported in a housing between torque input and output discs have been developed. In such transmissions, the traction rollers are mounted on support structures which, when pivoted, cause the engagement of traction rollers with the torque discs in circles of varying diameters depending on the desired transmission ratio.
[0006] However, the success of these traditional solutions has been limited. For example, in U.S. Pat. No. 5,236,403 to Schievelbusch, a driving hub for a vehicle with a variable adjustable transmission ratio is disclosed. Schievelbusch teaches the use of two iris plates, one on each side of the traction rollers, to tilt the axis of rotation of each of the rollers. However, the use of iris plates can be very complicated due to the large number of parts which are required to adjust the iris plates during shifting the transmission. Another difficulty with this transmission is that it has a guide ring which is configured to be predominantly stationary in relation to each of the rollers. Since the guide ring is stationary, shifting the axis of rotation of each of the traction rollers is difficult. Yet another limitation of this design is that it requires the use of two half axles, one on each side of the rollers, to provide a gap in the middle of the two half axles. The gap is necessary because the rollers are shifted with rotating motion instead of sliding linear motion. The use of two axles is not desirable and requires a complex fastening system to prevent the axles from bending when the transmission is accidentally bumped, is as often the case when a transmission is employed in a vehicle. Yet another limitation of this design is that it does not provide for an automatic transmission.
[0007] Therefore, there is a need for a continuously variable transmission with a simpler shifting method, a single axle, and a support ring having a substantially uniform outer surface. Additionally, there is a need for an automatic traction roller transmission that is configured to shift automatically. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission.
SUMMARY OF THE INVENTION
[0008] The present invention includes a transmission for use in rotationally or linearly powered machines and vehicles. For example the present transmission may be used in machines such as drill presses, turbines, and food processing equipment, and vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
[0009] In one embodiment of the invention, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is centrally located within each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, at least one platform for actuating axial movement of the support member and for actuating a shift in the axis of rotation of the power adjusters, wherein the platform provides a convex surface, at least one stationary support that is non-rotatable about the axis of rotation that is defined by the support member, wherein the at least one stationary support provides a concave surface, and a plurality of spindle supports, wherein each of the spindle supports are slidingly engaged with the convex surface of the platform and the concave surface of the stationary support, and wherein each of the spindle supports adjusts the axes of rotation of the power adjusters in response to the axial movement of the platform.
[0010] In another embodiment, the transmission comprises a rotatable driving member; three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is respectively central to the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, a rotatable driving member for rotating each of the power adjusters, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a coiled spring for biasing the rotatable driving member against the power adjusters, at least one lock pawl ratchet, wherein the lock pawl ratchet is rigidly attached to the rotatable driving member, wherein the at least one lock pawl is operably attached to the coiled spring, and at least one lock pawl for locking the lock pawl ratchet in response to the rotatable driving member becoming disengaged from the power adjusters.
[0011] In still another embodiment, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis that is respectively central to each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a screw that is coaxially and rigidly attached to the rotatable driving member or the bearing disc, and a nut that, if the screw is attached to the rotatable driving member, is coaxially and rigidly attached to the bearing disc, or if the screw is rigidly attached to the bearing disc, coaxially and rigidly attached to the rotatable driving member, wherein the inclined ramps of the bearing disc have a higher lead than the screw.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a cutaway side view of the transmission of the present invention.
[0013] FIG. 2 is a partial perspective view of the transmission of FIG. 1 .
[0014] FIG. 3 is a perspective view of two stationary supports of the transmission of FIG. 1 .
[0015] FIG. 4 is a partial end, cross-sectional view of the transmission of FIG. 1 .
[0016] FIG. 5 is a perspective view of a drive disc, bearing cage, screw, and ramp bearings of the transmission of FIG. 1 .
[0017] FIG. 6 is a perspective view of a ratchet and pawl subsystem of the transmission of FIG. 1 that is used to engage and disengage the transmission.
[0018] FIG. 7 is partial perspective view of the transmission of FIG. 1 , wherein, among other things, a rotatable drive disc has been removed.
[0019] FIG. 8 is a partial perspective view of the transmission of FIG. 1 , wherein, among other things, the hub shell has been removed.
[0020] FIG. 9 is a partial perspective view of the transmission of FIG. 1 , wherein the shifting is done automatically.
[0021] FIG. 10 is a perspective view of the shifting handlegrip that is mechanically coupled to the transmission of FIG. 1 .
[0022] FIG. 11 is an end view of a thrust bearing, of the transmission shown in FIG. 1 , which is used for automatic shifting of the transmission.
[0023] FIG. 12 is an end view of the weight design of the transmission shown in FIG. 1 .
[0024] FIG. 13 is a perspective view of an alternate embodiment of the transmission bolted to a flat surface.
[0025] FIG. 14 is a cutaway side view of the transmission shown in FIG. 13 .
[0026] FIG. 15 is a schematic end view of the transmission in FIG. 1 showing the cable routing across a spacer extension of the automatic portion of the transmission.
[0027] FIG. 16 is a schematic end view of the cable routing of the transmission shown in FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions herein described.
[0029] The present invention includes a continuously variable transmission that may be employed in connection with any type of machine that is in need of a transmission. For example, the transmission may be used in (i) a motorized vehicle such as an automobile, motorcycle, or watercraft, (ii) a non-motorized vehicle such as a bicycle, tricycle, scooter, exercise equipment or (iii) industrial equipment, such as a drill press, power generating equipment, or textile mill.
[0030] Referring to FIGS. 1 and 2 , a continuously variable transmission 100 is disclosed. The transmission 100 is shrouded in a hub shell 40 covered by a hub cap 67 . At the heart of the transmission 100 are three or more power adjusters 1 a , 1 b , 1 c which are spherical in shape and are circumferentially spaced equally around the centerline or axis of rotation of the transmission 100 . As seen more clearly in FIG. 2 , spindles 3 a , 3 b , 3 c are inserted through the center of the power adjusters 1 a , 1 b , 1 c to define an axis of rotation for the power adjusters 1 a , 1 b , 1 c . In FIG. 1 , the power adjuster's axis of rotation is shown in the horizontal direction. Spindle supports 2 a - f are attached perpendicular to and at the exposed ends of the spindles 3 a , 3 b , 3 c . In one embodiment, each of the spindles supports have a bore to receive one end of one of the spindles 3 a , 3 b , 3 c . The spindles 3 a , 3 b , 3 c also have spindle rollers 4 a - f coaxially and slidingly positioned over the exposed ends of the spindles 3 a , 3 b , 3 c outside of the spindle supports 2 a - f.
[0031] As the rotational axis of the power adjusters 1 a , 1 b , 1 c is changed by tilting the spindles 3 a , 3 b , 3 c , each spindle roller 4 a - f follows in a groove 6 a - f cut into a stationary support 5 a , 5 b . Referring to FIGS. 1 and 3 , the stationary supports 5 a , 5 b are generally in the form of parallel discs with an axis of rotation along the centerline of the transmission 100 . The grooves 6 a - f extend from the outer circumference of the stationary supports 5 a , 5 b towards the centerline of the transmission 100 . While the sides of the grooves 6 a - f are substantially parallel, the bottom surface of the grooves 6 a - f forms a decreasing radius as it runs towards the centerline of the transmission 100 . As the transmission 100 is shifted to a lower or higher gear by changing the rotational axes of the power adjusters 1 a , 1 b , 1 c , each pair of spindle rollers 4 a - f , located on a single spindle 3 a , 3 b , 3 c , moves in opposite directions along their corresponding grooves 6 a - f.
[0032] Referring to FIGS. 1 and 3 , a centerline hole 7 a , 7 b in the stationary supports 5 a , 5 b allows the insertion of a hollow shaft 10 through both stationary supports 5 a , 5 b . Referring to FIG. 4 , in an embodiment of the invention, one or more of the stationary support holes 7 a , 7 b may have a non-cylindrical shape 14 , which fits over a corresponding non-cylindrical shape 15 along the hollow shaft 10 to prevent any relative rotation between the stationary supports 5 a , 5 b and the hollow shaft 10 . If the rigidity of the stationary supports 5 a , 5 b is insufficient, additional structure may be used to minimize any relative rotational movement or flexing of the stationary supports 5 a , 5 b . This type of movement by the stationary supports 5 a , 5 b may cause binding of the spindle rollers 4 a - f as they move along the grooves 6 a - f.
[0033] As shown in FIGS. 4 and 7 , the additional structure may take the form of spacers 8 a , 8 b , 8 c attached between the stationary supports 5 a , 5 b . The spacers 8 a , 8 b , 8 c add rigidity between the stationary supports 5 a , 5 b and, in one embodiment, are located near the outer circumference of the stationary supports 5 a , 5 b . In one embodiment, the stationary supports 5 a , 5 b are connected to the spacers 8 a , 8 b , 8 c by bolts or other fastener devices 45 a - f inserted through holes 46 a - f in the stationary supports 5 a , 5 b.
[0034] Referring back to FIGS. 1 and 3 , the stationary support 5 a is fixedly attached to a stationary support sleeve 42 , which coaxially encloses the hollow shaft 10 and extends through the wall of the hub shell 40 . The end of the stationary support sleeve 42 that extends through the hub shell 40 attaches to the frame support and preferentially has a non-cylindrical shape to enhance subsequent attachment of a torque lever 43 . As shown more clearly in FIG. 7 , the torque lever 43 is placed over the non-cylindrical shaped end of the stationary support sleeve 42 , and is held in place by a torque nut 44 . The torque lever 43 at its other end is rigidly attached to a strong, non-moving part, such as a frame (not shown). A stationary support bearing 48 supports the hub shell 40 and permits the hub shell 40 to rotate relative to the stationary support sleeve 42 .
[0035] Referring back to FIGS. 1 and 2 , shifting is manually activated by axially sliding a rod 11 positioned in the hollow shaft 10 . One or more pins 12 are inserted through one or more transverse holes in the rod 11 and further extend through one or more longitudinal slots 16 (not shown) in the hollow shaft 10 . The slots 16 in the hollow shaft 10 allow for axial movement of the pin 12 and rod 11 assembly in the hollow shaft 10 . As the rod 11 slides axially in the hollow shaft 10 , the ends of the transverse pins 12 extend into and couple with a coaxial sleeve 19 . The sleeve 19 is fixedly attached at each end to a substantially planar platform 13 a , 13 b forming a trough around the circumference of the sleeve 19 .
[0036] As seen more clearly in FIG. 4 , the planar platforms 13 a , 13 b each contact and push multiple wheels 21 a - f . The wheels 21 a - f fit into slots in the spindle supports 2 a - f and are held in place by wheel axles 22 a - f . The wheel axles 22 a - f are supported at their ends by the spindle supports 2 a - f and allow rotational movement of the wheels 21 a - f.
[0037] Referring back to FIGS. 1 and 2 , the substantially planar platforms 13 a , 13 b transition into a convex surface at their outer perimeter (farthest from the hollow shaft 10 ). This region allows slack to be taken up when the spindle supports 2 a - f and power adjusters 1 a , 1 b , 1 c are tilted as the transmission 100 is shifted. A cylindrical support member 18 is located in the trough formed between the planar platforms 13 a , 13 b and sleeve 19 and thus moves in concert with the planar platforms 13 a , 13 b and sleeve 19 . The support member 18 rides on contact bearings 17 a , 17 b located at the intersection of the planar platforms 13 a , 13 b and sleeve 19 to allow the support member 18 to freely rotate about the axis of the transmission 100 . Thus, the bearings 17 a , 17 b , support member 18 , and sleeve 19 all slide axially with the planar platforms 13 a , 13 b when the transmission 100 is shifted.
[0038] Now referring to FIGS. 3 and 4 , stationary support rollers 30 a - l are attached in pairs to each spindle leg 2 a - f through a roller pin 31 a - f and held in place by roller clips 32 a - l . The roller pins 31 a - f allow the stationary support rollers 30 a - l to rotate freely about the roller pins 31 a - f . The stationary support rollers 30 a - l roll on a concave radius in the stationary support 5 a , 5 b along a substantially parallel path with the grooves 6 a - f . As the spindle rollers 4 a - f move back and forth inside the grooves 6 a - f , the stationary support rollers 30 a - l do not allow the ends of the spindles 3 a , 3 b , 3 c nor the spindle rollers 4 a - f to contact the bottom surface of the grooves 6 a - f , to maintain the position of the spindles 3 a , 3 b , 3 c , and to minimize any frictional losses.
[0039] FIG. 4 shows the stationary support rollers 30 a - l , the roller pins, 31 a - f , and roller clips 32 a - l , as seen through the stationary support 5 a , for ease of viewing. For clarity, i.e., too many numbers in FIG. 1 , the stationary support rollers 30 a - l , the roller pins, 31 a - f , and roller clips 32 a - l , are not numbered in FIG. 1 .
[0040] Referring to FIGS. 1 and 5 , a concave drive disc 34 , located adjacent to the stationary support 5 b , partially encapsulates but does not contact the stationary support 5 b . The drive disc 34 is rigidly attached through its center to a screw 35 . The screw 35 is coaxial to and forms a sleeve around the hollow shaft 10 adjacent to the stationary support 5 b and faces a driving member 69 . The drive disc 34 is rotatively coupled to the power adjusters 1 a , 1 b , 1 c along a circumferential bearing surface on the lip of the drive disc 34 . A nut 37 is threaded over the screw 35 and is rigidly attached around its circumference to a bearing disc 60 . One face of the nut 37 is further attached to the driving member 69 . Also rigidly attached to the bearing disc 60 surface are a plurality of ramps 61 which face the drive disc 34 . For each ramp 61 there is one ramp bearing 62 held in position by a bearing cage 63 . The ramp bearings 62 contact both the ramps 61 and the drive disc 34 . A spring 65 is attached at one end to the bearing cage 63 and at its other end to the drive disc 34 , or the bearing disc 60 in an alternate embodiment, to bias the ramp bearings 62 up the ramps 61 . The bearing disc 60 , on the side opposite the ramps 61 and at approximately the same circumference contacts a hub cap bearing 66 . The hub cap bearing 66 contacts both the hub cap 67 and the bearing disc 60 to allow their relative motion. The hub cap 67 is threaded or pressed into the hub shell 40 and secured with an internal ring 68 . A sprocket or pulley 38 is rigidly attached to the rotating driving member 69 and is held in place externally by a cone bearing 70 secured by a cone nut 71 and internally by a driver bearing 72 which contacts both the driving member 69 and the hub cap 67 .
[0041] In operation, an input rotation from the sprocket or pulley 38 , which is fixedly attached to the driver 69 , rotates the bearing disc 60 and the plurality of ramps 61 causing the ramp bearings 62 to roll up the ramps 61 and press the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . Simultaneously, the nut 37 , which has a smaller lead than the ramps 61 , rotates to cause the screw 35 and nut 37 to bind. This feature imparts rotation of the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . The power adjusters 1 a , 1 b , 1 c , when rotating, contact and rotate the hub shell 40 .
[0042] When the transmission 100 is coasting, the sprocket or pulley 38 stops rotating but the hub shell 40 and the power adjusters 1 a , 1 b , 1 c , continue to rotate. This causes the drive disc 34 to rotate so that the screw 35 winds into the nut 37 until the drive disc 34 no longer contacts the power adjusters 1 a , 1 b , 1 c.
[0043] Referring to FIGS. 1, 6 , and 7 , a coiled spring 80 , coaxial with the transmission 100 , is located between and attached by pins or other fasteners (not shown) to both the bearing disc 60 and drive disc 34 at the ends of the coiled spring 80 . During operation of the transmission 100 , the coiled spring 80 ensures contact between the power adjusters 1 a , 1 b , 1 c and the drive disc 34 . A pawl carrier 83 fits in the coiled spring 80 with its middle coil attached to the pawl carrier 83 by a pin or standard fastener (not shown). Because the pawl carrier 83 is attached to the middle coil of the coiled spring 80 , it rotates at half the speed of the drive disc 34 when the bearing disc 60 is not rotating. This allows one or more lock pawls 81 a , 81 b , 81 c , which are attached to the pawl carrier 83 by one or more pins 84 a , 84 b , 84 c , to engage a drive disc ratchet 82 , which is coaxial with and rigidly attached to the drive disc 34 . The one or more lock pawls 84 a , 84 b , 84 c are preferably spaced asymmetrically around the drive disc ratchet 82 . Once engaged, the loaded coiled spring 80 is prevented from forcing the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . Thus, with the drive disc 34 not making contact against the power adjusters 1 a , 1 b , 1 c , the transmission 100 is in neutral and the ease of shifting is increased. The transmission 100 can also be shifted while in operation.
[0044] When operation of the transmission 100 is resumed by turning the sprocket or pulley 38 , one or more release pawls 85 a , 85 b , 85 c , each attached to one of the lock pawls 81 a , 81 b , 81 c by a pawl pin 88 a , 88 b , 88 c , make contact with an opposing bearing disc ratchet 87 . The bearing disc ratchet 87 is coaxial with and rigidly attached to the bearing disc 60 . The bearing disc ratchet 87 actuates the release pawls 85 a , 85 b , 85 c because the release pawls 85 a , 85 b , 85 c are connected to the pawl carrier 83 via the lock pawls 81 a , 81 b , 81 c . In operation, the release pawls 85 a , 85 b , 85 c rotate at half the speed of the bearing disc 60 , since the drive disc 34 is not rotating, and disengage the lock pawls 81 a , 81 b , 81 c from the drive disc ratchet 82 allowing the coiled spring 80 to wind the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . One or more pawl tensioners (not shown), one for each release pawl 85 a , 85 b , 85 c , ensures that the lock pawls 81 a , 81 b , 81 c are pressed against the drive disc ratchet 82 and that the release pawls 85 a , 85 b , 85 c are pressed against the bearing disc ratchet 87 . The pawl tensioners are attached at one end to the pawl carrier 83 and make contact at the other end to the release pawls 85 a , 85 b , 85 c . An assembly hole 93 (not shown) through the hub cap 67 , the bearing disc 60 , and the drive disc 34 , allows an assembly pin (not shown) to be inserted into the loaded coiled spring 80 during assembly of the transmission 100 . The assembly pin prevents the coiled spring 80 from losing its tension and is removed after transmission 100 assembly is complete.
[0045] Referring to FIGS. 1, 11 , 12 , and 15 , automatic shifting of the transmission 100 , is accomplished by means of spindle cables 602 , 604 , 606 which are attached at one end to a non-moving component of the transmission 100 , such as the hollow shaft 10 or the stationary support 5 a . The spindle cables 602 , 604 , 606 then travel around spindle pulleys 630 , 632 , 634 , which are coaxially positioned over the spindles 3 a , 3 b , 3 c . The spindle cables 602 , 604 , 606 further travel around spacer pulleys 636 , 638 , 640 , 644 , 646 , 648 which are attached to a spacer extension 642 which may be rigidly attached to the spacers 8 a , 8 b , 8 c . As more clearly shown in FIGS. 11 and 12 , the other ends of the spindle cables 602 , 604 , 606 are attached to a plurality of holes 620 , 622 , 624 in a non-rotating annular bearing race 816 . A plurality of weight cables 532 , 534 , 536 are attached at one end to a plurality of holes 610 , 612 , 614 in a rotating annular bearing race 806 . An annular bearing 808 , positioned between the rotating annular bearing race 806 and the non-rotating annular bearing race 816 , allows their relative movement.
[0046] Referring to FIG. 15 , the transmission 100 is shown with the cable routing for automatic shifting.
[0047] As shown in FIGS. 1, 9 , 11 , and 12 , the weight cables 532 , 534 , 536 then travel around the hub shell pulleys 654 , 656 , 658 , through holes in the hub shell 40 , and into hollow spokes 504 , 506 , 508 (best seen in FIG. 12 ) where they attach to weights 526 , 528 , 530 . The weights 526 , 528 , 530 are attached to and receive support from weight assisters 516 , 518 , 520 which attach to a wheel 514 or other rotating object at there opposite end. As the wheel 514 increases its speed of rotation, the weights 526 , 528 , 530 are pulled radially away from the hub shell 40 , pulling the rotating annular bearing race 806 and the non-rotating annular bearing race 816 axially toward the hub cap 67 . The non-rotating annular bearing race 816 pulls the spindle cables 602 , 604 , 606 , which pulls the spindle pulleys 630 , 632 , 634 closer to the hollow shaft 10 and results in the shifting of the transmission 100 into a higher gear. When rotation of the wheel 514 slows, one or more tension members 9 positioned inside the hollow shaft 10 and held in place by a shaft cap 92 , push the spindle pulleys 630 , 632 , 634 farther from the hollow shaft 10 and results in the shifting of the transmission 100 into a lower gear.
[0048] Alternatively, or in conjunction with the tension member 9 , multiple tension members (not shown) may be attached to the spindles 3 a , 3 b , 3 c opposite the spindle pulleys 630 , 632 , 634 .
[0049] Still referring to FIG. 1 , the transmission 100 can also be manually shifted to override the automatic shifting mechanism or to use in place of the automatic shifting mechanism. A rotatable shifter 50 has internal threads that thread onto external threads of a shifter screw 52 which is attached over the hollow shaft 10 . The shifter 50 has a cap 53 with a hole that fits over the rod 11 that is inserted into the hollow shaft 10 . The rod 11 is threaded where it protrudes from the hollow shaft 10 so that nuts 54 , 55 may be threaded onto the rod 11 . The nuts 54 , 55 are positioned on both sides of the cap 53 . A shifter lever 56 is rigidly attached to the shifter 50 and provides a moment arm for the rod 11 . The shifter cable 51 is attached to the shifter lever 56 through lever slots 57 a , 57 b , 57 c . The multiple lever slots 57 a , 57 b , 57 c provide for variations in speed and ease of shifting.
[0050] Now referring to FIGS. 1 and 10 , the shifter cable 51 is routed to and coaxially wraps around a handlegrip 300 . When the handlegrip 300 is rotated in a first direction, the shifter 50 winds or unwinds axially over the hollow shaft 10 and pushes or pulls the rod 11 into or out of the hollow shaft 10 . When the handlegrip 300 is rotated in a second direction, a shifter spring 58 , coaxially positioned over the shifter 50 , returns the shifter 50 to its original position. The ends of the shifter spring 58 are attached to the shifter 50 and to a non-moving component, such as a frame (not shown).
[0051] As seen more clearly in FIG. 10 , the handlegrip 300 is positioned over a handlebar (not shown) or other rigid component. The handlegrip 300 includes a rotating grip 302 , which consists of a cable attachment 304 that provides for attachment of the shifter cable 51 and a groove 306 that allows the shifter cable 51 to wrap around the rotating grip 302 . A flange 308 is also provided to preclude a user from interfering with the routing of the shifter cable 51 . Grip ratchet teeth 310 are located on the rotating grip 302 at its interface with a rotating clamp 314 . The grip ratchet teeth 310 lock onto an opposing set of clamp ratchet teeth 312 when the rotating grip 302 is rotated in a first direction. The clamp ratchet teeth 312 form a ring and are attached to the rotating clamp 314 which rotates with the rotating grip 302 when the grip ratchet teeth 310 and the clamp ratchet teeth 312 are locked. The force required to rotate the rotating clamp 314 can be adjusted with a set screw 316 or other fastener. When the rotating grip 302 , is rotated in a second direction, the grip ratchet teeth 310 , and the clamp ratchet teeth 312 disengage. Referring back to FIG. 1 , the tension of the shifter spring 58 increases when the rotating grip 302 is rotated in the second direction. A non-rotating clamp 318 and a non-rotating grip 320 prevent excessive axial movement of the handlegrip 300 assembly.
[0052] Referring to FIGS. 13 and 14 , another embodiment of the transmission 900 , is disclosed. For purposes of simplicity, only the differences between the transmission 100 and the transmission 900 are discussed.
[0053] Replacing the rotating hub shell 40 are a stationary case 901 and housing 902 , which are joined with one or more set screws 903 , 904 , 905 . The set screws 903 , 904 , 905 may be removed to allow access for repairs to the transmission 900 . Both the case 901 and housing 902 have coplanar flanges 906 , 907 with a plurality of bolt holes 908 , 910 , 912 , 914 for insertion of a plurality of bolts 918 , 920 , 922 , 924 to fixedly mount the transmission 900 to a non-moving component, such as a frame (not shown).
[0054] The spacer extension 930 is compressed between the stationary case 901 and housing 902 with the set screws 903 , 904 , 905 and extend towards and are rigidly attached to the spacers 8 a , 8 b , 8 c . The spacer extension 930 prevents rotation of the stationary supports 5 a , 5 b . The stationary support 5 a does not have the stationary support sleeve 42 as in the transmission 100 . The stationary supports 5 a , 5 b hold the hollow shaft 10 in a fixed position. The hollow shaft 10 terminates at one end at the stationary support 5 a and at its other end at the screw 35 . An output drive disc 942 is added and is supported against the case 901 by a case bearing 944 . The output drive disc 942 is attached to an output drive component, such as a drive shaft, gear, sprocket, or pulley (not shown). Similarly, the driving member 69 is attached to the input drive component, such as a motor, gear, sprocket, or pulley.
[0055] Referring to FIG. 16 , shifting of the transmission 900 is accomplished with a single cable 946 that wraps around each of the spindle pulleys 630 , 632 , 634 . At one end, the single cable 946 is attached to a non-moving component of the transmission 900 , such as the hollow shaft 10 or the stationary support 5 a . After traveling around each of the spindle pulleys 630 , 632 , 634 and the spacer pulleys 636 , 644 , the single cable 946 exits the transmission 900 through a hole in the housing 902 . Alternatively a rod (not shown) attached to one or more of the spindles 3 a , 3 b , 3 c , may be used to shift the transmission 900 in place of the single cable 946 .
[0056] The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof.
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A continuously variable transmission is disclosed for use in rotationally or linearly powered machines and vehicles. The single axle transmission provides a simple manual shifting method for the user. An additional embodiment is disclosed which shifts automatically dependent upon the rotational speed of the wheel. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission. The disclosed transmission may be used in vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/688,339 ('339 application) filed Jan. 15, 2010, the entirety of which is incorporated herein by reference. The '339 application is a continuation to U.S. patent application Ser. No. 12/055,963 ('963 application), filed Mar. 26, 2008 the entirety of which is incorporated herein by reference. The '963 application claims the benefit of the following provisional applications, each of which is incorporated herein by reference in its entirety: U.S. Provisional Patent Application 60/908,383 filed Mar. 27, 2007; and U.S. Provisional Patent Application 60/908,666, filed Mar. 28, 2007.
[0002] The '963 application is a continuation-in-part of co-pending United States patent application entitled WIRELESS NON-RADIATIVE ENERGY TRANSFER filed on Jul. 5, 2006 and having Ser. No. 11/481,077 ('077 application), the entirety of which is incorporated herein by reference. The '077 application claims the benefit of provisional application Ser. No. 60/698,442 filed Jul. 12, 2005 ('442 Application), the entirety of which is incorporated herein by reference.
[0003] The '963 application, pursuant to U.S.C. §120 and U.S.C. §363, is a continuation-in-part of International Application No. PCT/US2007/070892, filed Jun. 11, 2007, which is incorporated herein by reference in its entirety, and which claims priority to the following provisional applications, each of which is incorporated herein by reference in its entirety: U.S. Provisional Patent Application 60/908,383 filed Mar. 27, 2007; and U.S. Provisional Patent Application 60/908,666, filed Mar. 28, 2007.
STATEMENT REGARDING GOVERNMENT FUNDING
[0004] This invention was made with government support awarded by the National Science Foundation under Grant No. DMR 02-13282. The government has certain rights in this invention.
BACKGROUND
[0005] The disclosure relates to wireless energy transfer. Wireless energy transfer may for example, be useful in such applications as providing power to autonomous electrical or electronic devices.
[0006] Radiative modes of omni-directional antennas (which work very well for information transfer) are not suitable for such energy transfer, because a vast majority of energy is wasted into free space. Directed radiation modes, using lasers or highly-directional antennas, can be efficiently used for energy transfer, even for long distances (transfer distance L TRANS L DEV , where L DEV is the characteristic size of the device and/or the source), but require existence of an uninterruptible line-of-sight and a complicated tracking system in the case of mobile objects. Some transfer schemes rely on induction, but are typically restricted to very close-range (L TRANS L DEV ) or low power (˜mW) energy transfers.
[0007] The rapid development of autonomous electronics of recent years (e.g. laptops, cell-phones, house-hold robots, that all typically rely on chemical energy storage) has led to an increased need for wireless energy transfer.
SUMMARY
[0008] The inventors have realized that resonant objects with coupled resonant modes having localized evanescent field patterns may be used for non-radiative wireless energy transfer. Resonant objects tend to couple, while interacting weakly with other off-resonant environmental objects. Typically, using the techniques described below, as the coupling increases, so does the transfer efficiency. In some embodiments, using the below techniques, the energy-transfer rate can be larger than the energy-loss rate. Accordingly, efficient wireless energy-exchange can be achieved between the resonant objects, while suffering only modest transfer and dissipation of energy into other off-resonant objects. The nearly-omnidirectional but stationary (non-lossy) nature of the near field makes this mechanism suitable for mobile wireless receivers. Various embodiments therefore have a variety of possible applications including for example, placing a source (e.g. one connected to the wired electricity network) on the ceiling of a factory room, while devices (robots, vehicles, computers, or similar) are roaming freely within the room. Other applications include power supplies for electric-engine buses and/or hybrid cars and medical implantable devices.
[0009] In some embodiments, resonant modes are so-called magnetic resonances, for which most of the energy surrounding the resonant objects is stored in the magnetic field; i.e. there is very little electric field outside of the resonant objects. Since most everyday materials (including animals, plants and humans) are non-magnetic, their interaction with magnetic fields is minimal. This is important both for safety and also to reduce interaction with the extraneous environmental objects.
[0010] In one aspect, an apparatus is disclosed for use in wireless energy transfer, which includes a first resonator structure configured to transfer energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure. The apparatus may include any of the following features alone or in combination.
[0011] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure. In some embodiments, the apparatus includes the second resonator structure.
[0012] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0013] In some embodiments Q 1 >100 and Q 2 >100, Q 1 >300 and Q 2 >300, Q 1 >500 and Q 2 >500, or Q 1 >1000 and Q 2 >1000. In some embodiments, Q 1 >100 or Q 2 >100, Q 1 >300 or Q 2 >300, Q 1 >500 or Q 2 >500, or Q 1 >1000 or Q 2 >1000.
[0014] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0015] In some embodiments, Q 1 >1000 and Q 2 >1000, and the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
10
,
κ
Γ
1
Γ
2
>
25
,
or
κ
Γ
1
Γ
2
>
40.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, as large as 10.
[0016] In some embodiments, Q κ ω/2κ is less than about 50, less than about 200, less than about 500, or less than about 1000. In some such embodiments, D/L 2 is as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0017] In some embodiments, the quantity κ/√{square root over (Γ 1 Γ 2 )} is maximized at an angular frequency {tilde over (ω)} with a frequency width {tilde over (Γ)} around the maximum, and the absolute value of the difference of the angular frequencies ω 1 and {tilde over (ω)} is smaller than the width {tilde over (Γ)}, and the absolute value of the difference of the angular frequencies ω 2 and {tilde over (ω)} is smaller than the width {tilde over (Γ)}.
[0018] In some embodiments, the energy transfer operates with an efficiency η work greater than about 1%, greater than about 10%, greater than about 30%, greater than about 50%, or greater than about 80%.
[0019] In some embodiments, the energy transfer operates with a radiation loss η rad less that about 10%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
0.1
.
[0020] In some embodiments, the energy transfer operates with a radiation loss η rad less that about 1%. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0021] In some embodiments, in the presence of a human at distance of more than 3 cm from the surface of either resonant object, the energy transfer operates with a loss to the human η h of less than about 1%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0022] In some embodiments, in the presence of a human at distance of more than 10 cm from the surface of either resonant object, the energy transfer operates with a loss to the human η h of less than about 0.2%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0023] In some embodiments, during operation, a device coupled to the first or second resonator structure with a coupling rate Γ work receives a usable power P work from the resonator structure.
[0024] In some embodiments, P work is greater than about 0.01 Watt, greater than about 0.1 Watt, greater than about 1 Watt, or greater than about 10 Watt.
[0025] In some embodiments, if the device is coupled to the first resonator, then ½≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or ¼≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or ⅛≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8, and, if the device is coupled to the second resonator, then ½≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or ¼≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or ⅛≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8.
[0026] In some embodiments, the device includes an electrical or electronic device. In some embodiments, the device includes a robot (e.g. a conventional robot or a nano-robot). In some embodiments, the device includes a mobile electronic device (e.g. a telephone, or a cell-phone, or a computer, or a laptop computer, or a personal digital assistant (PDA)). In some embodiments, the device includes an electronic device that receives information wirelessly (e.g. a wireless keyboard, or a wireless mouse, or a wireless computer screen, or a wireless television screen). In some embodiments, the device includes a medical device configured to be implanted in a patient (e.g. an artificial organ, or implant configured to deliver medicine). In some embodiments, the device includes a sensor. In some embodiments, the device includes a vehicle (e.g. a transportation vehicle, or an autonomous vehicle).
[0027] In some embodiments, the apparatus further includes the device.
[0028] In some embodiments, during operation, a power supply coupled to the first or second resonator structure with a coupling rate Γ supply drives the resonator structure at a frequency f and supplies power P total . In some embodiments, the absolute value of the difference of the angular frequencies ω=2πf and ω 1 is smaller than the resonant width Γ 1 , and the absolute value of the difference of the angular frequencies ω=2πf and ω 2 is smaller than the resonant width Γ 2 . In some embodiments, f is about the optimum efficiency frequency.
[0029] In some embodiments, if the power supply is coupled to the first resonator, then ½≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or ¼≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or ⅛≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8, and, if the device is coupled to the second resonator, then ½≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or ¼≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or ⅛≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8.
[0030] In some embodiments, the apparatus further includes the power source.
[0031] In some embodiments, the resonant fields are electromagnetic. In some embodiments, f is about 50 GHz or less, about 1 GHz or less, about 100 MHz or less, about 10 MHz or less, about 1 MHz or less, about 100 KHz or less, or about 10 kHz or less. In some embodiments, f is about 50 GHz or greater, about 1 GHz or greater, about 100 MHz or greater, about 10 MHz or greater, about 1 MHz or greater, about 100 kHz or greater, or about 10 kHz or greater. In some embodiments, f is within one of the frequency bands specially assigned for industrial, scientific and medical (ISM) equipment.
[0032] In some embodiments, the resonant fields are primarily magnetic in the area outside of the resonant objects. In some such embodiments, the ratio of the average electric field energy to average magnetic filed energy at a distance D p from the closest resonant object is less than 0.01, or less than 0.1. In some embodiments, L R is the characteristic size of the closest resonant object and D p /L R is less than 1.5, 3, 5, 7, or 10.
[0033] In some embodiments, the resonant fields are acoustic. In some embodiments, one or more of the resonant fields include a whispering gallery mode of one of the resonant structures.
[0034] In some embodiments, one of the first and second resonator structures includes a self resonant coil of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include self resonant coils of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include self resonant coils of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0035] In some embodiments, one or more of the self resonant conductive wire coils include a wire of length land cross section radius a wound into a helical coil of radius r, height h and number of turns N. In some embodiments, N=√{square root over (l 2 −h 2 )}/2πr
[0036] In some embodiments, for each resonant structure r is about 30 cm, h is about 20 cm, a is about 3 mm and N is about 5.25, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 10.6 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
40
,
κ
Γ
1
Γ
2
≥
15
,
or
κ
Γ
1
Γ
2
≥
5
,
or
κ
Γ
1
Γ
2
≥
1.
[0000] In some such embodiments D/L R is as large as about 2, 3, 5, or 8.
[0037] In some embodiments, for each resonant structure r is about 30 cm, h is about 20 cm, a is about 1 cm and N is about 4, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f′. In some embodiments, f is about 13.4 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
70
,
κ
Γ
1
Γ
2
≥
19
,
or
κ
Γ
1
Γ
2
≥
8
,
or
κ
Γ
1
Γ
2
≥
3.
[0000] In some such embodiments D/L R is as large as about 3, 5, 7, or 10.
[0038] In some embodiments, for each resonant structure r is about 10 cm, h is about 3 cm, a is about 2 mm and N is about 6, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 21.4 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
59
,
κ
Γ
1
Γ
2
≥
15
,
or
κ
Γ
1
Γ
2
≥
6
,
or
κ
Γ
1
Γ
2
≥
2.
[0000] In some such embodiments D/L R is as large as about 3, 5, 7, or 10.
[0039] In some embodiments, one of the first and second resonator structures includes a capacitively loaded loop or coil of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include capacitively loaded loops or coils of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include capacitively loaded loops or coils of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0040] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 1 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 mm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 380 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
14.9
,
κ
Γ
1
Γ
2
≥
3.2
,
κ
Γ
1
Γ
2
≥
1.2
,
or
κ
Γ
1
Γ
2
≥
0.4
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0041] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 10 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 43 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
15.9
,
κ
Γ
1
Γ
2
≥
4.3
,
κ
Γ
1
Γ
2
≥
1.8
,
or
κ
Γ
1
Γ
2
≥
0.7
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0042] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some such embodiments, f is about 9 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
67.4
,
κ
Γ
1
Γ
2
≥
17.8
,
κ
Γ
1
Γ
2
≥
7.1
,
or
κ
Γ
1
Γ
2
≥
2.7
.
[0043] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0044] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 mm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 17 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
6.3
,
κ
Γ
1
Γ
2
≥
1.3
,
κ
Γ
1
Γ
2
≥
0.5
.
,
or
κ
Γ
1
Γ
2
≥
0.2
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0045] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 1 m, and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 5 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
6.8
,
κ
Γ
1
Γ
2
≥
1.4
,
κ
Γ
1
Γ
2
≥
0.5
.
,
κ
Γ
1
Γ
2
≥
0.2
.
[0000] In some such embodiments, D L R is as large as about 3, about 5, about 7, or about 10.
[0046] In some embodiments, during operation, one of the resonator structures receives a usable power P w , from the other resonator structure, an electrical current I s flows in the resonator structure which is transferring energy to the other resonant structure, and the ratio
[0000]
I
s
P
w
[0000] is less than about 5 Amps/√{square root over (Watts)} or less than about 2 Amps/√{square root over (Watts)}. In some embodiments, during operation, one of the resonator structures receives a usable power P w from the other resonator structure, a voltage difference V S appears across the capacitive element of the first resonator structure, and the ratio
[0000]
V
s
P
w
[0000] is less than about 2000 Volts/√{square root over (Watts)} or less than about 4000 Volts/√{square root over (Watts)}.
[0047] In some embodiments, one of the first and second resonator structures includes a inductively loaded rod of conducting wire or conducting Litz wire or conducting ribbon. In some embodiments, both of the first and second resonator structures include inductively loaded rods of conducting wire or conducting Litz wire or conducting ribbon. In some embodiments, both of the first and second resonator structures include inductively loaded rods of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0048] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 10 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 14 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
32
,
κ
Γ
1
Γ
2
≥
5.8
,
κ
Γ
1
Γ
2
≥
2
,
or
κ
Γ
1
Γ
2
≥
0.6
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0049] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some such embodiments, f is about 2.5 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
105
,
κ
Γ
1
Γ
2
≥
19
,
κ
Γ
1
Γ
2
≥
6.6
,
or
κ
Γ
1
Γ
2
≥
2.2
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0050] In some embodiments, one of the first and second resonator structures includes a dielectric disk. In some embodiments, both of the first and second resonator structures include dielectric disks. In some embodiments, both of the first and second resonator structures include dielectric disks, and Q 1 >300 and Q 2 >300.
[0051] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure is L R and the real part of the permittivity of said resonator structure ε is less than about 150. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
42.4
,
κ
Γ
1
Γ
2
≥
6.5
,
κ
Γ
1
Γ
2
≥
2.3
,
κ
Γ
1
Γ
2
≥
0.5
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0052] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure is L R and the real part of the permittivity of said resonator structure ε is less than about 65. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
30.9
,
κ
Γ
1
Γ
2
≥
2.3
,
or
κ
Γ
1
Γ
2
≥
0.5
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7.
[0053] In some embodiments, at least one of the first and second resonator structures includes one of: a dielectric material, a metallic material, a metallodielectric object, a plasmonic material, a plasmonodielectric object, a superconducting material.
[0054] In some embodiments, at least one of the resonators has a quality factor greater than about 5000, or greater than about 10000.
[0055] In some embodiments, the apparatus also includes a third resonator structure configured to transfer energy with one or more of the first and second resonator structures, where the energy transfer between the third resonator structure and the one or more of the first and second resonator structures is mediated by evanescent-tail coupling of the resonant field of the one or more of the first and second resonator structures and a resonant field of the third resonator structure.
[0056] In some embodiments, the third resonator structure is configured to transfer energy to one or more of the first and second resonator structures.
[0057] In some embodiments, the first resonator structure is configured to receive energy from one or more of the first and second resonator structures.
[0058] In some embodiments, the first resonator structure is configured to receive energy from one of the first and second resonator structures and transfer energy to the other one of the first and second resonator structures.
[0059] Some embodiments include a mechanism for, during operation, maintaining the resonant frequency of one or more of the resonant objects. In some embodiments, the feedback mechanism comprises an oscillator with a fixed frequency and is configured to adjust the resonant frequency of the one or more resonant objects to be about equal to the fixed frequency. In some embodiments, the feedback mechanism is configured to monitor an efficiency of the energy transfer, and adjust the resonant frequency of the one or more resonant objects to maximize the efficiency.
[0060] In another aspect, a method of wireless energy transfer is disclosed, which method includes providing a first resonator structure and transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0061] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure.
[0062] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0063] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0064] In another aspect, an apparatus is disclosed for use in wireless information transfer which includes a first resonator structure configured to transfer information by transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0065] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure. In some embodiments the apparatus includes, the second resonator structure.
[0066] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0067] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0068] In another aspect, a method of wireless information transfer is disclosed, which method includes providing a first resonator structure and transferring information by transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0069] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure.
[0070] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0071] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0072] It is to be understood that the characteristic size of an object is equal to the radius of the smallest sphere which can fit around the entire object. The characteristic thickness of an object is, when placed on a flat surface in any arbitrary configuration, the smallest possible height of the highest point of the object above a flat surface. The characteristic width of an object is the radius of the smallest possible circle that the object can pass through while traveling in a straight line. For example, the characteristic width of a cylindrical object is the radius of the cylinder.
[0073] The distance D over which the energy transfer between two resonant objects occurs is the distance between the respective centers of the smallest spheres which can fit around the entirety of each object. However, when considering the distance between a human and a resonant object, the distance is to be measured from the outer surface of the human to the outer surface of the sphere.
[0074] As described in detail below, non-radiative energy transfer refers to energy transfer effected primarily through the localized near field, and, at most, secondarily through the radiative portion of the field.
[0075] It is to be understood that an evanescent tail of a resonant object is the decaying non-radiative portion of a resonant field localized at the object. The decay may take any functional form including, for example, an exponential decay or power law decay.
[0076] The optimum efficiency frequency of a wireless energy transfer system is the frequency at which the figure of merit
[0000]
κ
Γ
1
Γ
2
[0000] is maximizes, all other factors held constant.
[0077] The resonant width (Γ) refers to the width of an object's resonance due to object's intrinsic losses (e.g. loss to absorption, radiation, etc.).
[0078] It is to be understood that a Q-factor (Q) is a factor that compares the time constant for decay of an oscillating system's amplitude to its oscillation period. For a given resonator mode with angular frequency ω and resonant width Γ, the Q-factor Q=ω/2Γ.
[0079] The energy transfer rate (κ) refers to the rate of energy transfer from one resonator to another. In the coupled mode description described below it is the coupling constant between the resonators.
[0080] It is to be understood that Q κ =ω/2κ.
[0081] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict with publications, patent applications, patents, and other references mentioned incorporated herein by reference, the present specification, including definitions, will control.
[0082] Various embodiments may include any of the above features, alone or in combination. Other features, objects, and advantages of the disclosure will be apparent from the following detailed description.
[0083] Other features, objects, and advantages of the disclosure will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0084] FIG. 1 shows a schematic of a wireless energy transfer scheme.
[0085] FIG. 2 shows an example of a self-resonant conducting-wire coil.
[0086] FIG. 3 shows a wireless energy transfer scheme featuring two self-resonant conducting-wire coils
[0087] FIG. 4 shows an example of a capacitively loaded conducting-wire coil, and illustrates the surrounding field.
[0088] FIG. 5 shows a wireless energy transfer scheme featuring two capacitively loaded conducting-wire coils, and illustrates the surrounding field.
[0089] FIG. 6 shows an example of a resonant dielectric disk, and illustrates the surrounding field.
[0090] FIG. 7 shows a wireless energy transfer scheme featuring two resonant dielectric disks, and illustrates the surrounding field.
[0091] FIGS. 8 a and 8 b show schematics for frequency control mechanisms.
[0092] FIGS. 9 a through 9 c illustrate a wireless energy transfer scheme in the presence of various extraneous objects.
[0093] FIG. 10 illustrates a circuit model for wireless energy transfer.
[0094] FIG. 11 illustrates the efficiency of a wireless energy transfer scheme.
[0095] FIG. 12 illustrates parametric dependences of a wireless energy transfer scheme. The figure shows efficiency, total (loaded) device Q, and source and device currents, voltages and radiated powers, normalized to 1 Watt of output working power, as functions of frequency for a particular choice of source and device loop dimensions, wp and N s and different choices of N d =1, 2, 3, 4, 5, 6, 10.
[0096] FIG. 13 plots the parametric dependences of a wireless energy transfer scheme. Efficiency, total (loaded device Q, and source and device currents, voltages and radiated powers (normalized to 1 Watt of output working power) as functions of frequency and wp for a particular choice of source and device loop dimensions, and number of turns Ns and Nd.
[0097] FIG. 14 is a schematic of an experimental system demonstrating wireless energy transfer.
[0098] FIGS. 15-17 . Plot experiment results for the system shown schematically in FIG. 14 . FIG. 15 shows a comparison of experimental and theoretical values for κ as a function of the separation between the source and device coils. FIG. 16 shows a comparison of experimental and theoretical values for the parameter κ/Γ as a function of the separation between the two coils. The theory values are obtained by using the theoretically obtained and the experimentally measured Γ. The shaded area represents the spread in the theoretical κ/Γ due to the ˜5% uncertainty in Q.
DETAILED DESCRIPTION
[0099] FIG. 1 shows a schematic that generally describes one embodiment of the invention, in which energy is transferred wirelessly between two resonant objects.
[0100] Referring to FIG. 1 , energy is transferred, over a distance D, between a resonant source object having a characteristic size L 1 and a resonant device object of characteristic size L 2 . Both objects are resonant objects. The source object is connected to a power supply (not shown), and the device object is connected to a power consuming device (e.g. a load resistor, not shown). Energy is provided by the power supply to the source object, transferred wirelessly and non-radiatively from the source object to the device object, and consumed by the power consuming device. The wireless non-radiative energy transfer is performed using the field (e.g. the electromagnetic field or acoustic field) of the system of two resonant objects. For simplicity, in the following we will assume that field is the electromagnetic field.
[0101] It is to be understood that while two resonant objects are shown in the embodiment of FIG. 1 , and in many of the examples below, other embodiments may feature 3 or more resonant objects. For example, in some embodiments a single source object can transfer energy to multiple device objects. In some embodiments energy may be transferred from a first device to a second, and then from the second device to the third, and so forth.
[0102] Initially, we present a theoretical framework for understanding non-radiative wireless energy transfer. Note however that it is to be understood that the scope of the invention is not bound by theory.
[0103] Coupled Mode Theory
[0104] An appropriate analytical framework for modeling the resonant energy-exchange between two resonant objects 1 and 2 is that of “coupled-mode theory” (CMT). The field of the system of two resonant objects 1 and 2 is approximated by F(r,t)≈a 1 (t)F 1 (r)+a 2 (t)F 2 (r), where F 1,2 (r) are the eigenmodes of 1 and 2 alone, normalized to unity energy, and the field amplitudes a 1,2 (t) are defined so that |a 1,2 (t)| 2 is equal to the energy stored inside the objects 1 and 2 respectively. Then, the field amplitudes can be shown to satisfy, to lowest order:
[0000]
a
1
t
=
-
(
ω
1
-
Γ
1
)
a
1
+
κ
a
2
a
2
t
=
-
(
ω
2
-
Γ
2
)
a
2
+
κ
a
1
,
(
1
)
[0000] where ω 1,2 are the individual angular eigenfrequencies of the eigenmodes, Γ 1,2 are the resonance widths due to the objects' intrinsic (absorption, radiation etc.) losses, and κ is the coupling coefficient. Eqs. (1) show that at exact resonance (ω 1 =ω 2 and Γ 1 =Γ 2 ), the eigenmodes of the combined system are split by a; the energy exchange between the two objects takes place in time ˜π/2κ and is nearly perfect, apart for losses, which are minimal when the coupling rate is much faster than all loss rates (κ Γ 1,2 ). The coupling to loss ratio κ/√{square root over (Γ 1 Γ 2 )} serves as a figure-of-merit in evaluating a system used for wireless energy-transfer, along with the distance over which this ratio can be achieved. The regime κ/√{square root over (Γ 1 Γ 2 )} 1 is called “strong-coupling” regime.
[0105] In some embodiments, the energy-transfer application preferably uses resonant modes of high Q=ω/2Γ corresponding to low (i.e. slow) intrinsic-loss rates Γ. This condition may be satisfied where the coupling is implemented using, not the lossy radiative far-field, but the evanescent (non-lossy) stationary near-field.
[0106] To implement an energy-transfer scheme, usually finite objects, namely ones that are topologically surrounded everywhere by air, are more appropriate. Unfortunately, objects of finite extent cannot support electromagnetic states that are exponentially decaying in all directions in air, since, from Maxwell's Equations in free space: {right arrow over (k)} 2 =ω 2 /c 2 where {right arrow over (k)} is the wave vector, ω the angular frequency, and c the speed of light. Because of this, one can show that they cannot support states of infinite Q. However, very long-lived (so-called “high-Q”) states can be found, whose tails display the needed exponential or exponential-like decay away from the resonant object over long enough distances before they turn oscillatory (radiative). The limiting surface, where this change in the field behavior happens, is called the “radiation caustic”, and, for the wireless energy-transfer scheme to be based on the near field rather than the far/radiation field, the distance between the coupled objects must be such that one lies within the radiation caustic of the other.
[0107] Furthermore, in some embodiments, small Q κ =ω/2κ corresponding to strong (i.e. fast) coupling rate κ is preferred over distances larger than the characteristic sizes of the objects. Therefore, since the extent of the near-field into the area surrounding a finite-sized resonant object is set typically by the wavelength, in some embodiments, this mid-range non-radiative coupling can be achieved using resonant objects of subwavelength size, and thus significantly longer evanescent field-tails. As will be seen in examples later on, such subwavelength resonances can often be accompanied with a high Q, so this will typically be the appropriate choice for the possibly-mobile resonant device-object. Note, though, that in some embodiments, the resonant source-object will be immobile and thus less restricted in its allowed geometry and size, which can be therefore chosen large enough that the near-field extent is not limited by the wavelength. Objects of nearly infinite extent, such as dielectric waveguides, can support guided modes whose evanescent tails are decaying exponentially in the direction away from the object, slowly if tuned close to cutoff, and can have nearly infinite Q.
[0108] In the following, we describe several examples of systems suitable for energy transfer of the type described above. We will demonstrate how to compute the CMT parameters ω 1,2 , Q 1,2 and Q κ described above and how to choose these parameters for particular embodiments in order to produce a desirable figure-of-merit κ/√{square root over (Γ 1 Γ 2 )}=√{square root over (Q 1 Q 2 )}/Q κ . In particular, this figure of merit is typically maximized when ω 1,2 are tuned to a particular angular frequency {tilde over (ω)}, thus, if {tilde over (Γ)} is half the angular-frequency width for which √{square root over (Q 1 Q 2 )}/Q κ is above half its maximum value at {tilde over (ω)}, the angular eigenfrequencies ω 1,2 should typically be tuned to be close to {tilde over (ω)} to within the width {tilde over (Γ)}.
[0109] In addition, as described below, Q 1,2 can sometimes be limited not from intrinsic loss mechanisms but from external perturbations. In those cases, producing a desirable figure-of-merit translates to reducing Q κ (i.e. increasing the coupling). Accordingly we will demonstrate how, for particular embodiments, to reduce Q κ .
[0110] Self-Resonant Conducting Coils
[0111] In some embodiments, one or more of the resonant objects are self-resonant conducting coils. Referring to FIG. 2 , a conducting wire of length l and cross-sectional radius a is wound into a helical coil of radius r and height h (namely with N=√{square root over (l 2 −h 2 )}/2πr number of turns), surrounded by air. As described below, the wire has distributed inductance and distributed capacitance, and therefore it supports a resonant mode of angular frequency ω. The nature of the resonance lies in periodic exchange of energy from the electric field within the capacitance of the coil, due to the charge distribution ρ(x) across it, to the magnetic field in free space, due to the current distribution j(x) in the wire. In particular, the charge conservation equation ∇·j=iωρ implies that: (i) this periodic exchange is accompanied by a π/2 phase-shift between the current and the charge density profiles, namely the energy U contained in the coil is at certain points in time completely due to the current and at other points in time completely due to the charge, and (ii) if ρ l (x) and I(x) are respectively the linear charge and current densities in the wire, where x runs along the wire, q o =½∫dx|ρ l (x)| is the maximum amount of positive charge accumulated in one side of the coil (where an equal amount of negative charge always also accumulates in the other side to make the system neutral) and I o =max{|I(x)|} is the maximum positive value of the linear current distribution, then I o =ωq o . Then, one can define an effective total inductance L and an effective total capacitance C of the coil through the amount of energy U inside its resonant mode:
[0000]
U
≡
1
2
I
o
2
L
⇒
L
=
μ
o
4
π
I
o
2
∫
∫
x
x
′
j
(
x
)
·
j
(
x
′
)
x
-
x
′
,
(
2
)
U
≡
1
2
q
o
2
1
C
⇒
1
C
=
1
4
πɛ
o
q
o
2
∫
∫
x
x
′
ρ
(
x
)
·
ρ
(
x
′
)
x
-
x
′
(
3
)
[0000] where μ o and ε o are the magnetic permeability and electric permittivity of free space. With these definitions, the resonant angular frequency and the effective impedance are given by the common formulas ω=1/√{square root over (LC)} and Z=√{square root over (L/C)} respectively.
[0112] Losses in this resonant system consist of ohmic (material absorption) loss inside the wire and radiative loss into free space. One can again define a total absorption resistance R abs from the amount of power absorbed inside the wire and a total radiation resistance R rad from the amount of power radiated due to electric- and magnetic-dipole radiation:
[0000]
P
abs
≡
1
2
I
o
2
R
abs
⇒
R
abs
≈
ζ
c
l
2
π
a
·
I
rms
2
I
o
2
(
4
)
P
rad
≡
1
2
I
o
2
R
rad
⇒
R
rad
≈
ζ
o
6
π
[
(
ω
p
c
)
2
+
(
ω
m
c
)
4
]
,
(
5
)
[0000] where c=1/√{square root over (μ o ε o )} and ζ o =√{square root over (μ o /ε o )} are the light velocity and light impedance in free space, the impedance ζ c is ζ c =1/·σδ=√{square root over (μ o ω/2σ)} with σ the conductivity of the conductor and δ the skin depth at the frequency ω,
[0000]
I
rms
2
=
1
l
∫
x
I
(
x
)
2
,
[0000] p=∫dx rρ l (x) is the electric-dipole moment of the coil and m=½∫dx r×j(x) is the magnetic-dipole moment of the coil. For the radiation resistance formula Eq. (5), the assumption of operation in the quasi-static regime (h, r λ=2πc/ω) has been used, which is the desired regime of a subwavelength resonance. With these definitions, the absorption and radiation quality factors of the resonance are given by Q abs =Z/R abs and Q rad =Z/R rad respectively.
[0113] From Eq. (2)-(5) it follows that to determine the resonance parameters one simply needs to know the current distribution j in the resonant coil. Solving Maxwell's equations to rigorously find the current distribution of the resonant electromagnetic eigenmode of a conducting-wire coil is more involved than, for example, of a standard LC circuit, and we can find no exact solutions in the literature for coils of finite length, making an exact solution difficult. One could in principle write down an elaborate transmission-line-like model, and solve it by brute force. We instead present a model that is (as described below) in good agreement (˜5%) with experiment. Observing that the finite extent of the conductor forming each coil imposes the boundary condition that the current has to be zero at the ends of the coil, since no current can leave the wire, we assume that the resonant mode of each coil is well approximated by a sinusoidal current profile along the length of the conducting wire. We shall be interested in the lowest mode, so if we denote by x the coordinate along the conductor, such that it runs from −l/2 to +l/2, then the current amplitude profile would have the form I(x)=I o cos(πx/l), where we have assumed that the current does not vary significantly along the wire circumference for a particular x, a valid assumption provided a r . It immediately follows from the continuity equation for charge that the linear charge density profile should be of the form ρ l (x)=ρ o sin(πx/l), and thus q o =∫ 0 l/2 dx ρ o |sin(πx/l)|=ρ o l/π. Using these sinusoidal profiles we find the so-called “self-inductance” L s and “self-capacitance” C s of the coil by computing numerically the integrals Eq. (2) and (3); the associated frequency and effective impedance are ω s and Z s respectively. The “self-resistances” R s are given analytically by Eq. (4) and (5) using
[0000]
I
rms
2
=
1
l
∫
-
l
2
l
2
x
I
o
cos
(
π
x
/
l
)
2
=
1
2
I
o
2
,
p
=
q
o
(
2
π
h
)
2
+
(
4
N
cos
(
π
N
)
(
4
N
2
-
1
)
π
r
)
2
and
m
=
I
o
(
2
π
N
π
r
2
)
2
+
(
cos
(
π
N
)
(
12
N
2
-
1
)
-
sin
(
π
N
)
π
N
(
4
N
2
-
1
)
(
16
N
4
-
8
N
2
+
1
)
π
hr
)
2
,
[0000] and therefore the associated Q s factors may be calculated.
[0114] The results for two particular embodiments of resonant coils with subwavelength modes of λ s /r≧70 (i.e. those highly suitable for near-field coupling and well within the quasi-static limit) are presented in Table 1. Numerical results are shown for the wavelength and absorption, radiation and total loss rates, for the two different cases of subwavelength-coil resonant modes. Note that, for conducting material, copper (σ=5.998·10̂−7 S/m) was used. It can be seen that expected quality factors at microwave frequencies are Q s abs ≧1000 and Q s rad ≧5000.
[0000]
TABLE 1
single coil
λ s /r
f (MHz)
Q s rad
Q s abs
Q s = ω s /2Γ s
r = 30 cm, h = 20 cm,
74.7
13.39
4164
8170
2758
a = 1 cm, N = 4
r = 10 cm, h = 3 cm,
140
21.38
43919
3968
3639
a = 2 mm, N = 6
[0115] Referring to FIG. 3 , in some embodiments, energy is transferred between two self-resonant conducting-wire coils. The electric and magnetic fields are used to couple the different resonant conducting-wire coils at a distance D between their centers. Usually, the electric coupling highly dominates over the magnetic coupling in the system under consideration for coils with h 2r and, oppositely, the magnetic coupling highly dominates over the electric coupling for coils with h 2r. Defining the charge and current distributions of two coils 1 , 2 respectively as ρ 1,2 (x) and j 1,2 (x), total charges and peak currents respectively as q 1,2 and I 1,2 , and capacitances and inductances respectively as C 1,2 and L 1,2 , which are the analogs of ρ(x), j(x), g o , I o , C and L for the single-coil case and are therefore well defined, we can define their mutual capacitance and inductance through the total energy:
[0000]
U
≡
U
1
+
U
2
+
1
2
(
q
1
*
q
2
+
q
2
*
q
1
)
/
M
C
+
1
2
(
I
1
*
I
2
+
I
2
*
I
1
)
M
L
⇒
1
/
M
C
=
1
4
πɛ
o
q
1
q
2
∫
∫
x
x
′
ρ
1
(
x
)
·
ρ
2
(
x
′
)
x
-
x
′
u
,
M
L
=
μ
o
4
π
I
1
I
2
∫
∫
x
x
′
j
1
(
x
)
·
j
2
(
x
′
)
x
-
x
′
u
,
(
6
)
[0000] where U 1 =½q 1 2 /C 1 =½I 1 2 L 1 , U 2 =½q 2 2 /C 2 =½I 2 2 L 2 , and the retardation factor of u=exp (iω|x−{dot over (x)}′|/c) inside the integral can been ignored in the quasi-static regime D 2 of interest, where each coil is within the near field of the other. With this definition, the coupling coefficient is given by κ=ω√{square root over (C 1 C 2 )}/2M C +ωM L /2√{square root over (L 1 L 2 )} Q κ −1 =(M C /√{square root over (C 1 C 2 )}) −1 +(√{square root over (L 1 L 2 )}/M L ) −1 .
[0116] Therefore, to calculate the coupling rate between two self-resonant coils, again the current profiles are needed and, by using again the assumed sinusoidal current profiles, we compute numerically from Eq. (6) the mutual capacitance M C,s and inductance M L,s between two self-resonant coils at a distance D between their centers, and thus Q κ,s is also determined.
[0000]
TABLE 2
pair of coils
D/r
Q = ω/2Γ
Q κ = ω/2κ
κ/Γ
r = 30 cm, h = 20 cm,
3
2758
38.9
70.9
a = 1 cm, N = 4
5
2758
139.4
19.8
λ/r ≈ 75
7
2758
333.0
8.3
Q s abs ≈ 8170, Q s rad ≈ 4164
10
2758
818.9
3.4
r = 10 cm, h = 3 cm,
3
3639
61.4
59.3
a = 2 mm, N = 6
5
3639
232.5
15.7
λ/r ≈ 140
7
3639
587.5
6.2
Q s abs ≈ 3968, Q s rad ≈ 43919
10
3639
1580
2.3
[0117] Referring to Table 2, relevant parameters are shown for exemplary embodiments featuring pairs or identical self resonant coils. Numerical results are presented for the average wavelength and loss rates of the two normal modes (individual values not shown), and also the coupling rate and figure-of-merit as a function of the coupling distance D, for the two cases of modes presented in Table 1. It can be seen that for medium distances D/r=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜2−70.
[0118] Capacitively-Loaded Conducting Loops or Coils
[0119] In some embodiments, one or more of the resonant objects are capacitively-loaded conducting loops or coils. Referring to FIG. 4 a helical coil with N turns of conducting wire, as described above, is connected to a pair of conducting parallel plates of area A spaced by distance d via a dielectric material of relative permittivity ε, and everything is surrounded by air (as shown, N=1 and h=0). The plates have a capacitance C P =ε o εA/d, which is added to the distributed capacitance of the coil and thus modifies its resonance. Note however, that the presence of the loading capacitor modifies significantly the current distribution inside the wire and therefore the total effective inductance L and total effective capacitance C of the coil are different respectively from L s and C s , which are calculated for a self-resonant coil of the same geometry using a sinusoidal current profile. Since some charge is accumulated at the plates of the external loading capacitor, the charge distribution ρ inside the wire is reduced, so C<C s , and thus, from the charge conservation equation, the current distribution j flattens out, so L>L s . The resonant frequency for this system is ω=1/√{square root over (L(C+C p ))}<ω s =1/√{square root over (L s C s )}, and I(x)→I o cos(πx/l) C→C s ω→ω s , as C p →0.
[0120] In general, the desired CMT parameters can be found for this system, but again a very complicated solution of Maxwell's Equations is required. Instead, we will analyze only a special case, where a reasonable guess for the current distribution can be made. When C p C s >C, then ω≈1/√{square root over (LC p )} ω s and Z≈√{square root over (L/C p )} Z s , while all the charge is on the plates of the loading capacitor and thus the current distribution is constant along the wire. This allows us now to compute numerically L from Eq. (2). In the case h=0 and N integer, the integral in Eq. (2) can actually be computed analytically, giving the formula L=μ o r[ln(8r/a)−2]N 2 . Explicit analytical formulas are again available for R from Eq. (4) and (5), since I rms =I o , |p|≈0 and |m|=I o Nπr 2 (namely only the magnetic-dipole term is contributing to radiation), so we can determine also Q abs =ωL/R abs and Q rad =ωL/R rad . At the end of the calculations, the validity of the assumption of constant current profile is confirmed by checking that indeed the condition C p C s ω ω s is satisfied. To satisfy this condition, one could use a large external capacitance, however, this would usually shift the operational frequency lower than the optimal frequency, which we will determine shortly; instead, in typical embodiments, one often prefers coils with very small self-capacitance C s to begin with, which usually holds, for the types of coils under consideration, when N=1, so that the self-capacitance comes from the charge distribution across the single turn, which is almost always very small, or when N>1 and h 2Na, so that the dominant self-capacitance comes from the charge distribution across adjacent turns, which is small if the separation between adjacent turns is large.
[0121] The external loading capacitance C p provides the freedom to tune the resonant frequency (for example by tuning A or d). Then, for the particular simple case h=0, for which we have analytical formulas, the total Q=ωL/(R abs +R rad ) becomes highest at the optimal frequency
[0000]
ω
~
=
[
c
4
π
ɛ
o
2
σ
·
1
aNr
3
]
2
/
7
,
(
7
)
[0000] reaching the value
[0000]
Q
~
=
6
7
π
(
2
π
2
η
o
σ
a
2
N
2
r
)
3
/
7
·
[
ln
(
8
r
a
)
-
2
]
.
(
8
)
[0122] At lower frequencies it is dominated by ohmic loss and at higher frequencies by radiation. Note, however, that the formulas above are accurate as long as {tilde over (ω)} ω s and, as explained above, this holds almost always when N=1, and is usually less accurate when N>1, since h=0 usually implies a large self-capacitance. A coil with large h can be used, if the self-capacitance needs to be reduced compared to the external capacitance, but then the formulas for L and {tilde over (ω)}, {tilde over (Q)} are again less accurate. Similar qualitative behavior is expected, but a more complicated theoretical model is needed for making quantitative predictions in that case.
[0123] The results of the above analysis for two embodiments of subwavelength modes of λ/r≦70 (namely highly suitable for near-field coupling and well within the quasi-static limit) of coils with N=1 and h=0 at the optimal frequency Eq. (7) are presented in Table 3. To confirm the validity of constant-current assumption and the resulting analytical formulas, mode-solving calculations were also performed using another completely independent method: computational 3D finite-element frequency-domain (FEFD) simulations (which solve Maxwell's Equations in frequency domain exactly apart for spatial discretization) were conducted, in which the boundaries of the conductor were modeled using a complex impedance ζ c =√{square root over (λ o ω/2σ)} boundary condition, valid as long as ζ c /ζ o 1 (<10 −5 for copper in the microwave). Table 3 shows Numerical FEFD (and in parentheses analytical) results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-loop resonant modes. Note that for conducting material copper (σ=5.998·10 7 S/m) was used. (The specific parameters of the plot in FIG. 4 are highlighted with bold in the table.) The two methods (analytical and computational) are in very good agreement and show that, in some embodiments, the optimal frequency is in the low-MHz microwave range and the expected quality factors are Q abs ≧1000 and Q rad ≧10000.
[0000]
TABLE 3
single coil
λ/r
f (MHz)
Q rad
Q abs
Q = ω/2Γ
r = 30 cm, a = 2 cm
111.4
(112.4)
8.976
(8.897)
29546
(30512)
4886
(5117)
4193
(4381)
ε = 10, A = 138 cm 2 , d = 4 mm
r = 10 cm, a = 2 mm
69.7
(70.4)
43.04
(42.61)
10702
(10727)
1545
(1604)
1350
(1395)
ε = 10, A = 3.14 cm 2 , d = 1 mm
[0124] Referring to FIG. 5 , in some embodiments, energy is transferred between two capacitively-loaded coils. For the rate of energy transfer between two capacitively-loaded coils 1 and 2 at distance D between their centers, the mutual inductance M L can be evaluated numerically from Eq. (6) by using constant current distributions in the case ω ω s . In the case h=0, the coupling is only magnetic and again we have an analytical formula, which, in the quasi-static limit r D λ and for the relative orientation shown in FIG. 4 , is M L ≈πμ o /2·(r 1 r 2 ) 2 N 1 N 2 /D 3 , which means that Q κ ∞(D√{square root over (r 1 r 2 )}) 3 is independent of the frequency w and the number of turns N 1 , N 2 , Consequently, the resultant coupling figure-of-merit of interest is
[0000]
κ
Γ
1
Γ
2
=
Q
1
Q
2
Q
κ
≈
(
r
1
r
2
D
)
3
·
π
2
η
o
r
1
r
2
λ
·
N
1
N
2
∏
j
=
1
,
2
(
πη
o
λσ
·
r
j
a
j
N
j
+
8
3
π
5
η
o
(
r
j
λ
)
4
N
j
2
)
1
/
2
,
(
9
)
[0000] which again is more accurate for N 1 =N 2 =1.
[0125] From Eq. (9) it can be seen that the optimal frequency {tilde over (ω)}, where the figure-of-merit is maximized to the value , is that where √{square root over (Q 1 Q 2 )} is maximized, since Q κ does not depend on frequency (at least for the distances D λ of interest for which the quasi-static approximation is still valid). Therefore, the optimal frequency is independent of the distance D between the two coils and lies between the two frequencies where the single-coil Q 1 and Q 2 peak. For same coils, it is given by Eq. (7) and then the figure-of-merit Eq. (9) becomes
[0000]
(
κ
Γ
)
~
=
Q
~
Q
κ
≈
(
r
D
)
3
·
3
7
(
2
π
2
η
o
σ
a
2
N
2
r
)
3
/
7
.
(
10
)
[0000] Typically, one should tune the capacitively-loaded conducting loops or coils, so that their angular eigenfrequencies are close to {tilde over (ω)} within {tilde over (Γ)}, which is half the angular frequency width for which √{square root over (Q 1 Q 2 )}/Q κ > /2.
[0126] Referring to Table 4, numerical FEFD and, in parentheses, analytical results based on the above are shown for two systems each composed of a matched pair of the loaded coils described in Table 3. The average wavelength and loss rates are shown along with the coupling rate and coupling to loss ratio figure-of-merit κ/Γ as a function of the coupling distance D, for the two cases. Note that the average numerical Γ rad shown are again slightly different from the single-loop value of FIG. 3 , analytical results for Γ rad are not shown but the single-loop value is used. (The specific parameters corresponding to the plot in FIG. 5 are highlighted with bold in the table.) Again we chose N= 1 to make the constant-current assumption a good one and computed M L numerically from Eq. (6). Indeed the accuracy can be confirmed by their agreement with the computational FEFD mode-solver simulations, which give is through the frequency splitting (=2κ) of the two normal modes of the combined system. The results show that for medium distances D/r=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜0.5−50.
[0000]
TABLE 4
pair of coils
D/r
Q rad
Q = ω/2Γ
Q κ = ω/2κ
κ/Γ
r = 30 cm, a = 2 cm
3
30729
4216
62.6
(63.7)
67.4
(68.7)
ε = 10, A = 138 cm 2 , d = 4 mm
5
29577
4194
235
(248)
17.8
(17.6)
λ/r ≈ 112
7
29128
4185
589
(646)
7.1
(6.8)
Q abs ≈ 4886
10
28833
4177
1539
(1828)
2.7
(2.4)
r = 10 cm, a = 2 mm
3
10955
1355
85.4
(91.3)
15.9
(15.3)
ε = 10, A = 3.14 cm 2 , d = 1 mm
5
10740
1351
313
(356)
4.32
(3.92)
λ/r ≈ 70
7
10759
1351
754
(925)
1.79
(1.51)
Q abs ≈ 1546
10
10756
1351
1895
(2617)
0.71
(0.53)
[0127] Optimization of √{square root over (Q 1 Q 2 )}/Q κ
[0128] In some embodiments, the results above can be used to increase or optimize the performance of a wireless energy transfer system which employs capacitively-loaded coils. For example, the scaling of Eq. (10) with the different system parameters one sees that to maximize the system figure-of-merit is/r one can, for example:
Decrease the resistivity of the conducting material. This can be achieved, for example, by using good conductors (such as copper or silver) and/or lowering the temperature. At very low temperatures one could use also superconducting materials to achieve extremely good performance. Increase the wire radius a. In typical embodiments, this action is limited by physical size considerations. The purpose of this action is mainly to reduce the resistive losses in the wire by increasing the cross-sectional area through which the electric current is flowing, so one could alternatively use also a Litz wire or a ribbon instead of a circular wire. For fixed desired distance D of energy transfer, increase the radius of the loop r. In typical embodiments, this action is limited by physical size considerations. For fixed desired distance vs. loop-size ratio D/r, decrease the radius of the loop r. In typical embodiments, this action is limited by physical size considerations. Increase the number of turns N, (Even though Eq. (10) is expected to be less accurate for N>1, qualitatively it still provides a good indication that we expect an improvement in the coupling-to-loss ratio with increased N.) In typical embodiments, this action is limited by physical size and possible voltage considerations, as will be discussed in following sections. Adjust the alignment and orientation between the two coils. The figure-of-merit is optimized when both cylindrical coils have exactly the same axis of cylindrical symmetry (namely they are “facing” each other). In some embodiments, particular mutual coil angles and orientations that lead to zero mutual inductance (such as the orientation where the axes of the two coils are perpendicular) should be avoided. Finally, note that the height of the coil h is another available design parameter, which has an impact to the performance similar to that of its radius r, and thus the design rules are similar.
[0136] The above analysis technique can be used to design systems with desired parameters. For example, as listed below, the above described techniques can be used to determine the cross sectional radius a of the wire which one should use when designing as system two same single-turn loops with a given radius in order to achieve a specific performance in terms of κ/Γ at a given D/r between them, when the material is copper (σ=5.998·10 7 S/m):
D/r=5, κ/Γ≧10, r=30 cm a≧9 mm D/r=5, κ/Γ≧10, r=5 cm a≧3.7 mm D/r=5, κ/Γ≧20, r=30 cm a≧20 mm D/r=5, κ/Γ≧20, r=5 cm a≧8.3 mm D/r=10, κ/Γ≧1, r=30 cm a≧7 mm D/r=10, κ/Γ≧1, r=5 cm a≧2.8 mm D/r=10, κ/Γ≧3, r=30 cm a≧25 mm D/r=10, κ/Γ≧3, r=5 cm a≧10 mm
[0145] Similar analysis can be done for the case of two dissimilar loops. For example, in some embodiments, the device under consideration is very specific (e.g. a laptop or a cell phone), so the dimensions of the device object (r d ,h d ,a d ,N d ) are very restricted. However, in some such embodiments, the restrictions on the source object (r s ,h s ,a s ,N s ) are much less, since the source can, for example, be placed under the floor or on the ceiling. In such cases, the desired distance is often well defined, based on the application (e.g. D˜1 m for charging a laptop on a table wirelessly from the floor). Listed below are examples (simplified to the case N s =N d =1 and h s =h d =0) of how one can vary the dimensions of the source object to achieve the desired system performance in terms of κ/√{square root over (Γ s Γ d )}, when the material is again copper (σ=5.998·10 7 S/m):
D=1.5 m, κ/√{square root over (Γ s Γ d )}≧15, r d =30 cm, a d =6 mm r s =1.158 m, a s ≧5 mm D=1.5 m, κ/√{square root over (Γ s Γ d )}≧30, r d =30 cm, a d =6 mm r s =1.15 m, a s ≧33 mm D=1.5 m, κ/√{square root over (Γ s Γ d )}≧1, r d =5 cm, a d =4 mm r s =1.119 m, a s ≧7 mm D=1.5 m, κ/√{square root over (Γ s Γ d )}≧2, r d =5 cm, a d =4 mm r s =1.119 m, a s ≧52 mm D=2 m, κ/√{square root over (Γ s Γ d )}≧10, r d =30 cm, a d =4 mm r s =1.518 m, a s ≧7 mm D=2 m, κ/√{square root over (Γ s Γ d )}≧20, r d =30 cm, a d =4 mm r s =1.514 m, a s ≧50 mm D=2 m, κ/√{square root over (Γ s Γ d )}≧0.5, r d =5 cm, a d =4 mm r s =1.491 m, a s ≧5 mm D=2 m, κ/√{square root over (Γ s Γ d )}≧1, r d =5 cm, a d =4 mm r s =1.491 m, a s ≧36 mm
[0154] Optimization of Q κ
[0155] As will be described below, in some embodiments the quality factor Q of the resonant objects is limited from external perturbations and thus varying the coil parameters cannot lead to improvement in Q. In such cases, one may opt to increase the coupling to loss ratio figure-of-merit by decreasing Q κ (i.e. increasing the coupling). The coupling does not depend on the frequency and the number of turns. Therefore, the remaining degrees of freedom are:
Increase the wire radii a 1 and a 2 . In typical embodiments, this action is limited by physical size considerations. For fixed desired distance D of energy transfer, increase the radii of the coils r 1 and r 2 . In typical embodiments, this action is limited by physical size considerations. For fixed desired distance vs. coil-sizes ratio D/√{square root over (r 1 r 2 )}, only the weak (logarithmic) dependence of the inductance remains, which suggests that one should decrease the radii of the coils r 1 and r 2 . In typical embodiments, this action is limited by physical size considerations. Adjust the alignment and orientation between the two coils. In typical embodiments, the coupling is optimized when both cylindrical coils have exactly the same axis of cylindrical symmetry (namely they are “facing” each other). Particular mutual coil angles and orientations that lead to zero mutual inductance (such as the orientation where the axes of the two coils are perpendicular) should obviously be avoided. Finally, note that the heights of the coils h 1 and h 2 are other available design parameters, which have an impact to the coupling similar to that of their radii r 1 and r 2 , and thus the design rules are similar.
[0161] Further practical considerations apart from efficiency, e.g. physical size limitations, will be discussed in detail below.
[0162] It is also important to appreciate the difference between the above described resonant-coupling inductive scheme and the well-known non-resonant inductive scheme for energy transfer. Using CMT it is easy to show that, keeping the geometry and the energy stored at the source fixed, the resonant inductive mechanism allows for ˜Q 2 (˜10 6 ) times more power delivered for work at the device than the traditional non-resonant mechanism. This is why only close-range contact-less medium-power (˜W) transfer is possible with the latter, while with resonance either close-range but large-power (˜kW) transfer is allowed or, as currently proposed, if one also ensures operation in the strongly-coupled regime, medium-range and medium-power transfer is possible. Capacitively-loaded conducting loops are currently used as resonant antennas (for example in cell phones), but those operate in the far-field regime with D/r 1,r/λ˜1, and the radiation Q's are intentionally designed to be small to make the antenna efficient, so they are not appropriate for energy transfer.
[0163] Inductively-Loaded Conducting Rods
[0164] A straight conducting rod of length 2h and cross-sectional radius a has distributed capacitance and distributed inductance, and therefore it supports a resonant mode of angular frequency ω. Using the same procedure as in the case of self-resonant coils, one can define an effective total inductance L and an effective total capacitance C of the rod through formulas (2) and (3). With these definitions, the resonant angular frequency and the effective impedance are given again by the common formulas ω=1/√{square root over (LC)} and Z=√{square root over (L/C)} respectively. To calculate the total inductance and capacitance, one can assume again a sinusoidal current profile along the length of the conducting wire. When interested in the lowest mode, if we denote by x the coordinate along the conductor, such that it runs from −h to +h, then the current amplitude profile would have the form I(x)=I o cos(πx/2h), since it has to be zero at the open ends of the rod. This is the well-known half-wavelength electric dipole resonant mode.
[0165] In some embodiments, one or more of the resonant objects are inductively-loaded conducting rods. A straight conducting rod of length 2h and cross-sectional radius a, as in the previous paragraph, is cut into two equal pieces of length h, which are connected via a coil wrapped around a magnetic material of relative permeability μ, and everything is surrounded by air. The coil has an inductance L c , which is added to the distributed inductance of the rod and thus modifies its resonance. Note however, that the presence of the center-loading inductor modifies significantly the current distribution inside the wire and therefore the total effective inductance L and total effective capacitance C of the rod are different respectively from L s and C S , which are calculated for a self-resonant rod of the same total length using a sinusoidal current profile, as in the previous paragraph. Since some current is running inside the coil of the external loading inductor, the current distribution j inside the rod is reduced, so L<L s , and thus, from the charge conservation equation, the linear charge distribution ρ l flattens out towards the center (being positive in one side of the rod and negative in the other side of the rod, changing abruptly through the inductor), so C>C S . The resonant frequency for this system is w=1/√{square root over ((L+L c )C)}<ω s =1/√{square root over (L s C s )}, and I(x)→cos(πx/2h) L→L s ω→ω s , as L c →0.
[0166] In general, the desired CMT parameters can be found for this system, but again a very complicated solution of Maxwell's Equations is required. Instead, we will analyze only a special case, where a reasonable guess for the current distribution can be made. When L c L s >L, then ω≈1/√{square root over (L c C)} ω s and Z≈√{square root over (L c /C)} Z s , while the current distribution is triangular along the rod (with maximum at the center-loading inductor and zero at the ends) and thus the charge distribution is positive constant on one half of the rod and equally negative constant on the other side of the rod. This allows us now to compute numerically C from Eq. (3). In this case, the integral in Eq. (3) can actually be computed analytically, giving the formula 1/C=1/(πε o h)[ln(h/a)−1]. Explicit analytical formulas are again available for R from Eq. (4) and (5), since I rms =I o , |p|=q o h and |m|=0 (namely only the electric-dipole term is contributing to radiation), so we can determine also Q abs =1/ωCR abs and Q rad =1/ωCR rad . At the end of the calculations, the validity of the assumption of triangular current profile is confirmed by checking that indeed the condition L c L s ω ω s is satisfied. This condition is relatively easily satisfied, since typically a conducting rod has very small self-inductance L s to begin with.
[0167] Another important loss factor in this case is the resistive loss inside the coil of the external loading inductor L c and it depends on the particular design of the inductor. In some embodiments, the inductor is made of a Brooks coil, which is the coil geometry which, for fixed wire length, demonstrates the highest inductance and thus quality factor. The Brooks coil geometry has N Bc turns of conducting wire of cross-sectional radius a Bc wrapped around a cylindrically symmetric coil former, which forms a coil with a square cross-section of side r Bc , where the inner side of the square is also at radius r Bc (and thus the outer side of the square is at radius 2r Bc ), therefore N Bc ≈(r Bc /2a Bc ) 2 . The inductance of the coil is then L c =2.0285μ o r Bc N Bc 2 ≈2.0285μ o r Bc 5 /8a Bc 4 and its resistance
[0000]
R
c
≈
1
σ
l
Bc
π
a
Bc
2
1
+
μ
o
ωσ
2
(
a
Bc
2
)
2
,
[0000] where the total wire length is l Bc ≈2π(3r Bc /2)N Bc ≈3πr Bc 3 /4a Bc 2 and we have used an approximate square-root law for the transition of the resistance from the dc to the ac limit as the skin depth varies with frequency.
[0168] The external loading inductance L c provides the freedom to tune the resonant frequency. (For example, for a Brooks coil with a fixed size r Bc , the resonant frequency can be reduced by increasing the number of turns N Bc by decreasing the wire cross-sectional radius a Bc . Then the desired resonant angular frequency ω=1/√{square root over (L c C)} is achieved for a Bc ≈(2.0285μ o r Bc 5 ω 2 C) 1/4 and the resulting coil quality factor is Q c ≈0.169μ o σr Bc 2 ω/√{square root over (1+ω 2 μ o σ√{square root over (2.0285μ o (r Bc /4) 5 C)})}). Then, for the particular simple case L c L s , for which we have analytical formulas, the total Q=1/ωC(R c +R abs +R rad ) becomes highest at some optimal frequency {tilde over (ω)}, reaching the value {tilde over (Q)}, both determined by the loading-inductor specific design. (For example, for the Brooks-coil procedure described above, at the optimal frequency) {tilde over (Q)}≈Q c ≈0.8(μ o σ 2 r Bc 3 /C) 1/4 ) At lower frequencies it is dominated by ohmic loss inside the inductor coil and at higher frequencies by radiation. Note, again, that the above formulas are accurate as long as {tilde over (ω)} ω s and, as explained above, this is easy to design for by using a large inductance.
[0169] The results of the above analysis for two embodiments, using Brooks coils, of subwavelength modes of λ/h≧200 (namely highly suitable for near-field coupling and well within the quasi-static limit) at the optimal frequency w are presented in Table 5. Table 5 shows in parentheses (for similarity to previous tables) analytical results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-loop resonant modes. Note that for conducting material copper (σ=−5.998·10 7 S/m) was used. The results show that, in some embodiments, the optimal frequency is in the low-MHz microwave range and the expected quality factors are Q abs >1000 and Q rad >100000.
[0000]
TABLE 5
single rod
λ/h
f (MHz)
Q rad
Q abs
Q = ω/2Γ
h = 30 cm, a = 2 cm
(403.8)
(2.477)
(2.72*10 6 )
(7400)
(7380)
μ = 1, r Bc = 2 cm, a Bc = 0.88 mm, N Bc = 129
h = 10 cm, a = 2 mm
(214.2)
(14.010)
(6.92*10 5 )
(3908)
(3886)
μ = 1, r Bc = 5 mm, a Bc = 0.25 mm,
[0170] In some embodiments, energy is transferred between two inductively-loaded rods. For the rate of energy transfer between two inductively-loaded rods 1 and 2 at distance D between their centers, the mutual capacitance M c can be evaluated numerically from Eq. (6) by using triangular current distributions in the case ω ω s . In this case, the coupling is only electric and again we have an analytical formula, which, in the quasi-static limit h D λ and for the relative orientation such that the two rods are aligned on the same axis, is 1/M C ≈½πε o ·(h 1 h 2 ) 2 /D 3 , which means that Q κ ∝(D/√{square root over (h 1 h 2 )}) 3 is independent of the frequency w. Consequently, one can get the resultant coupling figure-of-merit of interest
[0000]
κ
Γ
1
Γ
2
=
Q
1
Q
2
Q
κ
.
[0000] It can be seen that the optimal frequency {tilde over (ω)}, where the figure-of-merit is maximized to the value , is that where √{square root over (Q 1 Q 2 )} is maximized, since Q κ does not depend on frequency (at least for the distances D<<λ of interest for which the quasi-static approximation is still valid). Therefore, the optimal frequency is independent of the distance D between the two rods and lies between the two frequencies where the single-rod Q 1 and Q 2 peak. Typically, one should tune the inductively-loaded conducting rods, so that their angular eigenfrequencies are close to {tilde over (ω)} within {tilde over (Γ)}, which is half the angular frequency width for which √{square root over (Q 1 Q 2 )}/Q κ /2.
[0171] Referring to Table 6, in parentheses (for similarity to previous tables) analytical results based on the above are shown for two systems each composed of a matched pair of the loaded rods described in Table 5. The average wavelength and loss rates are shown along with the coupling rate and coupling to loss ratio figure-of-merit κ/Γ as a function of the coupling distance D, for the two cases. Note that for Γ rad the single-rod value is used. Again we chose L c L s to make the triangular-current assumption a good one and computed M C numerically from Eq. (6). The results show that for medium distances D/h=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜0.5−100.
[0000]
TABLE 6
pair of rods
D/h
Q κ = ω/2κ
κ/Γ
h = 30 cm, a = 2 cm
3
(70.3)
(105.0)
μ = 1, r Bc = 2 cm,
5
(389)
(19.0)
a Bc = 0.88 mm, N Bc = 129
7
(1115)
(6.62)
λ/h ≈ 404
10
(3321)
(2.22)
Q ≈ 7380
h = 10 cm, a = 2 mm
3
(120)
(32.4)
μ = 1, r Bc = 5 mm,
5
(664)
(5.85)
a Bc = 0.25 mm, N Bc = 103
7
(1900)
(2.05)
λ/h ≈ 214
10
(5656)
(0.69)
Q ≈ 3886
[0172] Dielectric Disks
[0173] In some embodiments, one or more of the resonant objects are dielectric objects, such as disks. Consider a two dimensional dielectric disk object, as shown in FIG. 6 , of radius r and relative permittivity ε surrounded by air that supports high-Q “whispering-gallery” resonant modes. The loss mechanisms for the energy stored inside such a resonant system are radiation into free space and absorption inside the disk material. High-Q rad and long-tailed subwavelength resonances can be achieved when the dielectric permittivity ε is large and the azimuthal field variations are slow (namely of small principal number m). Material absorption is related to the material loss tangent: Q abs ˜Re{ε}/Im{ε}. Mode-solving calculations for this type of disk resonances were performed using two independent methods: numerically, 2D finite-difference frequency-domain (FDFD) simulations (which solve Maxwell's Equations in frequency domain exactly apart for spatial discretization) were conducted with a resolution of 30 pts/r; analytically, standard separation of variables (SV) in polar coordinates was used.
[0000]
TABLE 7
single disk
λ/r
Q abs
Q rad
Q
Re{ε} = 147.7, m = 2
20.01
(20.00)
10103
(10075)
1988
(1992)
1661
(1663)
Re{ε} = 65.6, m = 3
9.952
(9.950)
10098
(10087)
9078
(9168)
4780
(4802)
[0174] The results for two TE-polarized dielectric-disk subwavelength modes of λ/r≧10 are presented in Table 7. Table 7 shows numerical FDFD (and in parentheses analytical SV) results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-disk resonant modes. Note that disk-material loss-tangent Im{ε}/Re{ε}=10 −4 was used. (The specific parameters corresponding to the plot in FIG. 6 . are highlighted with bold in the table.) The two methods have excellent agreement and imply that for a properly designed resonant low-loss-dielectric object values of Q rad ≧2000 and Q abs ˜10000 are achievable. Note that for the 3D case the computational complexity would be immensely increased, while the physics would not be significantly different. For example, a spherical object of ε=147.7 has a whispering gallery mode with m=2, Qrad=13962, and λ/r=17.
[0175] The required values of E, shown in Table 7, might at first seem unrealistically large. However, not only are there in the microwave regime (appropriate for approximately meter-range coupling applications) many materials that have both reasonably high enough dielectric constants and low losses (e.g. Titania, Barium tetratitanate, Lithium tantalite etc.), but also ε could signify instead the effective index of other known subwavelength surface-wave systems, such as surface modes on surfaces of metallic materials or plasmonic (metal-like, negative-ε) materials or metallo-dielectric photonic crystals or plasmono-dielectric photonic crystals.
[0176] To calculate now the achievable rate of energy transfer between two disks 1 and 2 , as shown in FIG. 7 we place them at distance D between their centers. Numerically, the FDFD mode-solver simulations give x through the frequency splitting (=2/c) of the normal modes of the combined system, which are even and odd superpositions of the initial single-disk modes; analytically, using the expressions for the separation-of-variables eigenfields E 1,2 (r) CMT gives κ through κ=ω 1 /2·∫d 3 rε 2 (r)E 2 *(r)E 1 (r)/∫d 3 rε(r)|E 1 (r)| 2 where ε j (r) and ε(r) are the dielectric functions that describe only the disk j (minus the constant ε o background) and the whole space respectively. Then, for medium distances D/r==10−3 and for non-radiative coupling such that D<2r c , where r c =mλ/2π is the radius of the radiation caustic, the two methods agree very well, and we finally find, as shown in Table 8, coupling-to-loss ratios in the range κ/Γ˜1-50. Thus, for the analyzed embodiments, the achieved figure-of-merit values are large enough to be useful for typical applications, as discussed below.
[0000]
TABLE 8
two disks
D/r
Q rad
Q = /2Γ
ω/2κ
κ/Γ
Re{ε} = 147.7, m = 2
3
2478
1989
46.9
(47.5)
42.4
(35.0)
λ/r ≈ 20
5
2411
1946
298.0
(298.0)
6.5
(5.6)
Q abs ≈ 10093
7
2196
1804
769.7
(770.2)
2.3
(2.2)
10
2017
1681
1714
(1601)
0.98
(1.04)
Re{ε} = 65.6, m = 3
3
7972
4455
144
(140)
30.9
(34.3)
λ/r ≈ 10
5
9240
4824
2242
(2083)
2.2
(23)
Q abs ≈ 10006
7
9187
4810
7485
(7417)
0.64
(0.65)
[0177] Note that even though particular embodiments are presented and analyzed above as examples of systems that use resonant electromagnetic coupling for wireless energy transfer, those of self-resonant conducting coils, capacitively-loaded resonant conducting coils and resonant dielectric disks, any system that supports an electromagnetic mode with its electromagnetic energy extending much further than its size can be used for transferring energy. For example, there can be many abstract geometries with distributed capacitances and inductances that support the desired kind of resonances. In any one of these geometries, one can choose certain parameters to increase and/or optimize √{square root over (Q 1 Q 2 )}/Q κ or, if the Q's are limited by external factors, to increase and/or optimize for Q κ .
[0178] System Sensitivity to Extraneous Objects
[0179] In general, the overall performance of particular embodiment of the resonance-based wireless energy-transfer scheme depends strongly on the robustness of the resonant objects' resonances. Therefore, it is desirable to analyze the resonant objects' sensitivity to the near presence of random non-resonant extraneous objects. One appropriate analytical model is that of “perturbation theory” (PT), which suggests that in the presence of an extraneous object e the field amplitude a 1 (t) inside the resonant object 1 satisfies, to first order:
[0000]
a
1
t
=
-
(
ω
1
-
Γ
1
)
a
1
+
(
κ
11
-
e
+
Γ
1
-
e
)
a
1
(
11
)
[0000] where again ω 1 is the frequency and Γ 1 the intrinsic (absorption, radiation etc.) loss rate, while κ 11-e is the frequency shift induced onto 1 due to the presence of e and σ 1-e is the extrinsic due to e (absorption inside e, scattering from e etc.) loss rate. The first-order PT model is valid only for small perturbations. Nevertheless, the parameters κ 11-e , Γ 1-e are well defined, even outside that regime, if a 1 is taken to be the amplitude of the exact perturbed mode. Note also that interference effects between the radiation field of the initial resonant-object mode and the field scattered off the extraneous object can for strong scattering (e.g. off metallic objects) result in total radiation-Γ 1-e 's that are smaller than the initial radiation-Γ 1 (namely Γ 1-e is negative).
[0180] The frequency shift is a problem that can be “fixed” by applying to one or more resonant objects a feedback mechanism that corrects its frequency. For example, referring to FIG. 8 a , in some embodiments each resonant object is provided with an oscillator at fixed frequency and a monitor which determines the frequency of the object. Both the oscillator and the monitor are coupled to a frequency adjuster which can adjust the frequency of the resonant object by, for example, adjusting the geometric properties of the object (e.g. the height of a self-resonant coil, the capacitor plate spacing of a capacitively-loaded loop or coil, the dimensions of the inductor of an inductively-loaded rod, the shape of a dielectric disc, etc.) or changing the position of a non-resonant object in the vicinity of the resonant object. The frequency adjuster determines the difference between the fixed frequency and the object frequency and acts to bring the object frequency into alignment with the fixed frequency. This technique assures that all resonant objects operate at the same fixed frequency, even in the presence of extraneous objects.
[0181] As another example, referring to FIG. 8 b , in some embodiments, during energy transfer from a source object to a device object, the device object provides energy to a load, and an efficiency monitor measures the efficiency of the transfer. A frequency adjuster coupled to the load and the efficiency monitor acts to adjust the frequency of the object to maximize the transfer efficiency.
[0182] In various embodiments, other frequency adjusting schemes may be used which rely on information exchange between the resonant objects. For example, the frequency of a source object can be monitored and transmitted to a device object, which is in turn synched to this frequency using frequency adjusters as described above. In other embodiments the frequency of a single clock may be transmitted to multiple devices, and each device then synched to that frequency.
[0183] Unlike the frequency shift, the extrinsic loss can be detrimental to the functionality of the energy-transfer scheme, because it is difficult to remedy, so the total loss rate Γ 1[e] =Γ 1 +Γ 1-e (and the corresponding figure-of-merit ε [e] /√{square root over (Γ 1[e] Γ 2[e] )}, where κ [ε] the perturbed coupling rate) should be quantified.
[0184] Capacitively-Loaded Conducting Loops or Coils
[0185] In embodiments using primarily magnetic resonances, the influence of extraneous objects on the resonances is nearly absent. The reason is that, in the quasi-static regime of operation (r λ) that we are considering, the near field in the air region surrounding the resonator is predominantly magnetic (e.g. for coils with h 2r most of the electric field is localized within the self-capacitance of the coil or the externally loading capacitor), therefore extraneous non-conducting objects e that could interact with this field and act as a perturbation to the resonance are those having significant magnetic properties (magnetic permeability Re{μ}>1 or magnetic loss/m{μ}>0). Since almost all every-day non-conducting materials are non-magnetic but just dielectric, they respond to magnetic fields in the same way as free space, and thus will not disturb the resonance of the resonator. Extraneous conducting materials can however lead to some extrinsic losses due to the eddy currents induced on their surface.
[0186] As noted above, an extremely important implication of this fact relates to safety considerations for human beings. Humans are also non-magnetic and can sustain strong magnetic fields without undergoing any risk. A typical example, where magnetic fields B˜1T are safely used on humans, is the Magnetic Resonance Imaging (MRI) technique for medical testing. In contrast, the magnetic near-field required in typical embodiments in order to provide a few Watts of power to devices is only B˜10 −4 T, which is actually comparable to the magnitude of the Earth's magnetic field. Since, as explained above, a strong electric near-field is also not present and the radiation produced from this non-radiative scheme is minimal, it is reasonable to expect that our proposed energy-transfer method should be safe for living organisms.
[0187] One can, for example, estimate the degree to which the resonant system of a capacitively-loaded conducting-wire coil has mostly magnetic energy stored in the space surrounding it. If one ignores the fringing electric field from the capacitor, the electric and magnetic energy densities in the space surrounding the coil come just from the electric and magnetic field produced by the current in the wire; note that in the far field, these two energy densities must be equal, as is always the case for radiative fields. By using the results for the fields produced by a subwavelength (r λ) current loop (magnetic dipole) with h=0, we can calculate the ratio of electric to magnetic energy densities, as a function of distance D from the center of the loop (in the limit r D p ) and the angle θ with respect to the loop axis:
[0000]
u
e
(
x
)
u
m
(
x
)
=
ɛ
o
E
(
x
)
2
μ
o
H
(
x
)
2
=
(
1
+
1
x
2
)
sin
2
θ
(
1
x
2
+
1
x
4
)
4
cos
2
θ
+
(
1
-
1
x
2
+
1
x
4
)
sin
2
θ
;
x
=
2
π
D
p
λ
⇒
∯
S
p
u
e
(
x
)
S
∯
S
p
u
m
(
x
)
S
=
1
+
1
x
2
1
+
1
x
2
+
3
x
4
;
x
=
2
π
D
p
λ
,
(
12
)
[0000] where the second line is the ratio of averages over all angles by integrating the electric and magnetic energy densities over the surface of a sphere of radius D p . From Eq. (12) it is obvious that indeed for all angles in the near field (x 1) the magnetic energy density is dominant, while in the far field (x 1) they are equal as they should be. Also, the preferred positioning of the loop is such that objects which may interfere with its resonance lie close to its axis (θ=0), where there is no electric field. For example, using the systems described in Table 4, we can estimate from Eq. (12) that for the loop of r=30 cm at a distance D=10r=3 m the ratio of average electric to average magnetic energy density would be ˜12% and at D p =3r=90 cm it would be ˜1%, and for the loop of r=10 cm at a distance D p =10r=1m the ratio would be ˜33% and at D p =3r=30 cm it would be ˜2.5%. At closer distances this ratio is even smaller and thus the energy is predominantly magnetic in the near field, while in the radiative far field, where they are necessarily of the same order (ratio→1), both are very small, because the fields have significantly decayed, as capacitively-loaded coil systems are designed to radiate very little. Therefore, this is the criterion that qualifies this class of resonant system as a magnetic resonant system.
[0188] To provide an estimate of the effect of extraneous objects on the resonance of a capacitively-loaded loop including the capacitor fringing electric field, we use the perturbation theory formula, stated earlier, Γ 1-e abs =ω 1 /4·∫d 3 rIm{ε e (r)}|E 1 (r)| 2 /U with the computational FEFD results for the field of an example like the one shown in the plot of FIG. 5 and with a rectangular object of dimensions 30 cm×30 cm×1.5 m and permittivity ε=49+16i (consistent with human muscles) residing between the loops and almost standing on top of one capacitor (−3 cm away from it) and find Q c-h abs ˜10 5 and for ˜10 cm away C c-h abs ˜5·10 5 . Thus, for ordinary distances (˜1 m) and placements (not immediately on top of the capacitor) or for most ordinary extraneous objects e of much smaller loss-tangent, we conclude that it is indeed fair to say that Q c-e abs →∞. The only perturbation that is expected to affect these resonances is a close proximity of large metallic structures.
[0189] Self-resonant coils are more sensitive than capacitively-loaded coils, since for the former the electric field extends over a much larger region in space (the entire coil) rather than for the latter (just inside the capacitor). On the other hand, self-resonant coils are simple to make and can withstand much larger voltages than most lumped capacitors.
[0190] In general, different embodiments of resonant systems have different degree of sensitivity to external perturbations, and the resonant system of choice depends on the particular application at hand, and how important matters of sensitivity or safety are for that application. For example, for a medical implantable device (such as a wirelessly powered artificial heart) the electric field extent must be minimized to the highest degree possible to protect the tissue surrounding the device. In such cases where sensitivity to external objects or safety is important, one should design the resonant systems so that the ratio of electric to magnetic energy density u e /u m is reduced or minimized at most of the desired (according to the application) points in the surrounding space.
[0191] Dielectric Disks
[0192] In embodiments using resonances that are not primarily magnetic, the influence of extraneous objects may be of concern. For example, for dielectric disks, small, low-index, low-material-loss or far-away stray objects will induce small scattering and absorption. In such cases of small perturbations these extrinsic loss mechanisms can be quantified using respectively the analytical first-order perturbation theory formulas All perturbations
[0000] Γ 1-e rad =ω 1 ∫d 3 rRe{ε e ( r )}| E 1 ( r )| 2 /U
[0000] and
[0000] Γ 1-e abs =ω 1 /4 ·∫d 3 rIm{ε e ( r )}| E 1 ( r )| 2 /U
[0000] where U=½∫d 3 rε(r)|E 1 (r)| 2 is the total resonant electromagnetic energy of the unperturbed mode. As one can see, both of these losses depend on the square of the resonant electric field tails E 1 at the site of the extraneous object. In contrast, the coupling rate from object 1 to another resonant object 2 is, as stated earlier,
[0000] κ=ω 1 /2 ·∫d 3 rε 2 ( r ) E 2 *( r ) E 1 ( r )/∫ d 3 r ε( r )| E 1 ( r )| 2
[0000] and depends linearly on the field tails E 1 of 1 inside 2. This difference in scaling gives us confidence that, for, for example, exponentially small field tails, coupling to other resonant objects should be much faster than all extrinsic loss rates (κ r 1-e ), at least for small perturbations, and thus the energy-transfer scheme is expected to be sturdy for this class of resonant dielectric disks. However, we also want to examine certain possible situations where extraneous objects cause perturbations too strong to analyze using the above first-order perturbation theory approach. For example, we place a dielectric disk c close to another off-resonance object of large Re{ε}, Im{ε} and of same size but different shape (such as a human being h), as shown in FIG. 9 a , and a roughened surface of large extent but of small Re{ε}, Im{ε} (such as a wall w), as shown in FIG. 9 b . For distances D h/w /r=10 −3 between the disk-center and the “human”-center or “wall”, the numerical FDFD simulation results presented in FIGS. 9 a and 9 b suggest that, the disk resonance seems to be fairly robust, since it is not detrimentally disturbed by the presence of extraneous objects, with the exception of the very close proximity of high-loss objects. To examine the influence of large perturbations on an entire energy-transfer system we consider two resonant disks in the close presence of both a “human” and a “wall”. Comparing FIG. 7 to FIG. 9 c , the numerical FDFD simulations show that the system performance deteriorates from κ/Γ c ˜1-50 to κ[hw]Γ c[hw] ˜0.5-10 i.e. only by acceptably small amounts.
[0193] Inductively-loaded conducting rods may also be more sensitive than capacitively-loaded coils, since they rely on the electric field to achieve the coupling.
[0194] System Efficiency
[0195] In general, another important factor for any energy transfer scheme is the transfer efficiency. Consider again the combined system of a resonant source s and device d in the presence of a set of extraneous objects e. The efficiency of this resonance-based energy-transfer scheme may be determined, when energy is being drained from the device at rate Γ work for use into operational work. The coupled-mode-theory equation for the device field-amplitude is
[0000]
a
d
t
=
-
(
ω
-
Γ
d
[
e
]
)
a
d
+
κ
[
e
]
a
s
-
Γ
work
a
d
,
(
13
)
[0000] where Γ d[e] =Γ d[e] rad +Γ d[e] abs =Γ d[e] rad +(Γ d abs +Γ d-e abs ) is the net perturbed-device loss rate, and similarly we define Γ s[c] for the perturbed-source. Different temporal schemes can be used to extract power from the device (e.g. steady-state continuous-wave drainage, instantaneous drainage at periodic times and so on) and their efficiencies exhibit different dependence on the combined system parameters. For simplicity, we assume steady state, such that the field amplitude inside the source is maintained constant, namely a s (t)=A s e −iωt , so then the field amplitude inside the device is a d (t)=A d e −iωt with A d /A s =iκ [e] /(Γ d[e] +Γ work ). The various time-averaged powers of interest are then: the useful extracted power is P work =2Γ work |A d | 2 , the radiated (including scattered) power is P rad =2Γ s[e] rad |A s | 2 +2Γ d[e] rad |A d | 2 , the power absorbed at the source/device is P s/d =2Γ s/d abs |A s/d | 2 , and at the extraneous objects P e =2Γ s-e abs |A s | 2 +2Γ d-e abs |A d | 2 . From energy conservation, the total time-average power entering the system is P total =P work +P rad +P s +P d +P c . Note that the reactive powers, which are usually present in a system and circulate stored energy around it, cancel at resonance (which can be proven for example in electromagnetism from Poynting's Theorem) and do not influence the power-balance calculations. The working efficiency is then:
[0000]
η
work
≡
P
work
P
total
=
1
1
+
Γ
d
[
e
]
Γ
work
·
[
1
+
1
fom
[
e
]
2
(
1
+
Γ
work
Γ
d
[
e
]
)
2
]
,
(
14
)
[0000] where fom [e] =κ [e] /√{square root over (Γ s[e] Γ d[e] )} is the distance-dependent figure-of-merit of the perturbed resonant energy-exchange system. To derive Eq. (14), we have assumed that the rate Γ supply , at which the power supply is feeding energy to the resonant source, is Γ supply =Γ s[e] +κ 2 /(r d[e] +Γ work ), such that there are zero reflections of the fed power P total back into the power supply.
Example
Capacitively-Loaded Conducting Loops
[0196] Referring to FIG. 10 , to rederive and express this formula (14) in terms of the parameters which are more directly accessible from particular resonant objects, e.g., the capacitively-loaded conducting loops, one can consider the following circuit-model of the system, where the inductances L s , L d represent the source and device loops respectively, R s , R d their respective losses, and C s , C d are the required corresponding capacitances to achieve for both resonance at frequency ω. A voltage generator V g is considered to be connected to the source and a work (load) resistance A ω to the device. The mutual inductance is denoted by M.
[0197] Then from the source circuit at resonance (ωL s =1/ωC s ):
[0000] V g =I s R s −jωMI d ½ V g *I s =½ |I s | 2 R s +½ jωMI d *I s ,
[0000] and from the device circuit at resonance (ωL d =1/ωC d ):
[0000] 0 =I d ( R d +R w )− jωMI s jωMI s =I d ( R d +R ω* )
[0000] So by substituting the second to the first:
[0000] ½ V g *I s =½ [I s ] 2 R s +½ |I d | 2 ( R d +R ω ).
[0000] Now we take the real part (time-averaged powers) to find the efficiency:
[0000]
P
g
≡
Re
{
1
2
V
g
*
I
s
}
=
P
s
+
P
d
+
P
w
⇒
η
work
≡
P
w
P
tot
=
R
w
I
s
I
d
2
·
R
s
+
R
d
+
R
w
.
Namely,
[0198]
η
work
=
R
w
(
R
d
+
R
w
)
2
(
ω
M
)
2
·
R
s
+
R
d
+
R
w
,
[0000] which with Γ work =R ω /2L d =R d /2L d , Γ s =R s /2L s , and κ=ωM/2√{square root over (L s L d )}, becomes the general Eq. (14). [End of Example]
[0199] From Eq. (14) one can find that the efficiency is optimized in terms of the chosen work-drainage rate, when this is chosen to be Γ work /Γ d[e] =Γ supply /Γ s[e] =√{square root over (1+fom [c] 2 )}>1. Then, η work is a function of the fom [e] parameter only as shown in FIG. 11 with a solid black line. One can see that the efficiency of the system is η>17% for fom [e] >1, large enough for practical applications. Thus, the efficiency can be further increased towards 100% by optimizing fom [c] as described above. The ratio of conversion into radiation loss depends also on the other system parameters, and is plotted in FIG. 5 for the conducting loops with values for their parameters within the ranges determined earlier.
[0200] For example, consider the capacitively-loaded coil embodiments described in Table 4, with coupling distance D/r=7, a “human” extraneous object at distance D h from the source, and that P work =10 W must be delivered to the load. Then, we have (based on FIG. 11 ) Q s[h] rad =Q d[h] rad ˜10 4 , Q s abs =Q d abs ˜10 3 , Q κ ˜500, and Q d-h abs →∞, Q s-h abs ˜10 5 at D h ˜3 cm and Q s-h abs ˜5·10 5 at D h ˜10 cm. Therefore fom [h] ˜2, so we find η≈38%, P rad ≈1.5 W, P s ≈11 W, P d ≈4 W, and most importantly n h ≈0.4%, P h =0.1 W at D h ˜3 cm and η h ≦0.1%, P h =0.02 W at D h ˜10 cm.
[0201] Overall System Performance
[0202] In many cases, the dimensions of the resonant objects will be set by the particular application at hand. For example, when this application is powering a laptop or a cell-phone, the device resonant object cannot have dimensions larger that those of the laptop or cell-phone respectively. In particular, for a system of two loops of specified dimensions, in terms of loop radii r s,d and wire radii a s,d , the independent parameters left to adjust for the system optimization are: the number of turns N s,d , the frequency f, the work-extraction rate (load resistance) Γ work and the power-supply feeding rate Γ supply .
[0203] In general, in various embodiments, the primary dependent variable that one wants to increase or optimize is the overall efficiency η. However, other important variables need to be taken into consideration upon system design. For example, in embodiments featuring capacitively-loaded coils, the design may be constrained by, for example, the currents flowing inside the wires I s,d and the voltages across the capacitors V s,d . These limitations can be important because for ˜Watt power applications the values for these parameters can be too large for the wires or the capacitors respectively to handle. Furthermore, the total loaded Q tot =ωL d /(R d +R w ) of the device is a quantity that should be preferably small, because to match the source and device resonant frequencies to within their Q's, when those are very large, can be challenging experimentally and more sensitive to slight variations. Lastly, the radiated powers P rad,s,d should be minimized for safety concerns, even though, in general, for a magnetic, non-radiative scheme they are already typically small.
[0204] In the following, we examine then the effects of each one of the independent variables on the dependent ones. We define a new variable wp to express the work-drainage rate for some particular value of fom [e] through Γ work /Γ d[c] =√{square root over (1+wp·fom [e] 2 )}. Then, in some embodiments, values which impact the choice of this rate are: Γ work /Γ d[e] =1 wp=0 to minimize the required energy stored in the source (and therefore I s and V s ), Γ work /Γ d[e] >1 wp=1 to increase the efficiency, as seen earlier, or Γ work /Γ d[e] 1 wp 1 to decrease the required energy stored in the device (and therefore I d and V d ) and to decrease or minimize Q tot =ωL d /(R d +R w )=ω/[2(Γ d +Γ work )]. Similar is the impact of the choice of the power supply feeding rate Γ supply , with the roles of the source and the device reversed.
[0205] Increasing N s and N d increases κ/√{square root over (Γ s Γ d )} and thus efficiency significantly, as seen before, and also decreases the currents I s and I d , because the inductance of the loops increases, and thus the energy U s,d =½L s,d |I s,d | 2 required for given output power P work can be achieved with smaller currents. However, increasing N d increases Q tot , P rad,d and the voltage across the device capacitance V d , which unfortunately ends up being, in typical embodiments one of the greatest limiting factors of the system. To explain this, note that it is the electric field that really induces breakdown of the capacitor material (e.g. 3 kV/mm for air) and not the voltage, and that for the desired (close to the optimal) operational frequency, the increased inductance L d implies reduced required capacitance C d , which could be achieved in principle, for a capacitively-loaded device coil by increasing the spacing of the device capacitor plates d d and for a self-resonant coil by increasing through h d the spacing of adjacent turns, resulting in an electric field (≈V d /d d for the former case) that actually decreases with N d ; however, one cannot in reality increase d d or h d too much, because then the undesired capacitance fringing electric fields would become very large and/or the size of the coil might become too large; and, in any case, for certain applications extremely high voltages are not desired. A similar increasing behavior is observed for the source P rad,s and V s upon increasing N s . As a conclusion, the number of turns N s and N d have to be chosen the largest possible (for efficiency) that allow for reasonable voltages, fringing electric fields and physical sizes.
[0206] With respect to frequency, again, there is an optimal one for efficiency, and Q tot is approximately maximum, close to that optimal frequency. For lower frequencies the currents get worse (larger) but the voltages and radiated powers get better (smaller). Usually, one should pick either the optimal frequency or somewhat lower.
[0207] One way to decide on an operating regime for the system is based on a graphical method. In FIG. 12 , for two loops of r s =25 cm, r d =15 cm, h s =h d =0, a s =a d =3 mm and distance D=2 m between them, we plot all the above dependent variables (currents, voltages and radiated powers normalized to 1 Watt of output power) in terms of frequency and N d , given some choice for wp and N s . The Figure depicts all of the dependencies explained above. We can also make a contour plot of the dependent variables as functions of both frequency and wp but for both N s and N d fixed. The results are shown in FIG. 13 for the same loop dimensions and distance. For example, a reasonable choice of parameters for the system of two loops with the dimensions given above are: N s =2, N d =6, f=10 MHz and wp=10, which gives the following performance characteristics: η work =20.6%, Q tot =1264, I s =7.2 A, I d =1.4 A, V s =2.55 kV, V d =2.30 kV, P rad,s =0.006 W. Note that the results in FIGS. 12 and 13 , and the just above calculated performance characteristics are made using the analytical formulas provided above, so they are expected to be less accurate for large values of N s ,N d , still they give a good estimate of the scalings and the orders of magnitude.
[0208] Finally, one could additionally optimize for the source dimensions, since usually only the device dimensions are limited, as discussed earlier. Namely, one can add r s and a s in the set of independent variables and optimize with respect to these too for all the dependent variables of the problem (we saw how to do this only for efficiency earlier). Such an optimization would lead to improved results.
[0209] Experimental Results
[0210] An experimental realization of an embodiment of the above described scheme for wireless energy transfer consists of two self-resonant coils of the type described above, one of which (the source coil) is coupled inductively to an oscillating circuit, and the second (the device coil) is coupled inductively to a resistive load, as shown schematically in FIG. 14 . Referring to FIG. 14 , A is a single copper loop of radius 25 cm that is part of the driving circuit, which outputs a sine wave with frequency 9.9 MHz. s and d are respectively the source and device coils referred to in the text. B is a loop of wire attached to the load (“light-bulb”). The various κ's represent direct couplings between the objects. The angle between coil d and the loop A is adjusted so that their direct coupling is zero, while coils s and d are aligned coaxially. The direct coupling between B and A and between B and s is negligible.
[0211] The parameters for the two identical helical coils built for the experimental validation of the power transfer scheme were h=20 cm, a=3 mm, r=30 cm, N=5.25. Both coils are made of copper. Due to imperfections in the construction, the spacing between loops of the helix is not uniform, and we have encapsulated the uncertainty about their uniformity by attributing a 10% (2 cm) uncertainty to h. The expected resonant frequency given these dimensions is f o =10.56±0.3 MHz, which is about 5% off from the measured resonance at around 9.90 MHz.
[0212] The theoretical Q for the loops is estimated to be ˜2500 (assuming perfect copper of resistivity ρ=1/σ=1.7×10 −8 Ωm) but the measured value is 950±50.
[0213] We believe the discrepancy is mostly due to the effect of the layer of poorly conducting copper oxide on the surface of the copper wire, to which the current is confined by the short skin depth (˜20 μm) at this frequency. We have therefore used the experimentally observed Q (and Γ 1 =Γ 2 =Γ=ω/(2Q) derived from it) in all subsequent computations.
[0214] The coupling coefficient κ can be found experimentally by placing the two self-resonant coils (fine-tuned, by slightly adjusting h, to the same resonant frequency when isolated) a distance D apart and measuring the splitting in the frequencies of the two resonant modes in the transmission spectrum. According to coupled-mode theory, the splitting in the transmission spectrum should be Δω=2√{square root over (κ 2 −Γ 2 )}. The comparison between experimental and theoretical results as a function of distance when the two the coils are aligned coaxially is shown in FIG. 15 .
[0215] FIG. 16 shows a comparison of experimental and theoretical values for the parameter κ/Γ as a function of the separation between the two coils. The theory values are obtained by using the theoretically obtained κ and the experimentally measured Γ. The shaded area represents the spread in the theoretical κ/Γ due to the ˜5% uncertainty in Q.
[0216] As noted above, the maximum theoretical efficiency depends only on the parameter κ/√{square root over (Γ 1 Γ 2 )}=κ/Γ, plotted as a function of distance in FIG. 17 . The coupling to loss ratio κ/Γ is greater than 1 even for D=2.4 m (eight times the radius of the coils), thus the system is in the strongly-coupled regime throughout the entire range of distances probed.
[0217] The power supply circuit was a standard Colpitts oscillator coupled inductively to the source coil by means of a single loop of copper wire 25 cm in radius (see FIG. 14 ). The load consisted of a previously calibrated light-bulb, and was attached to its own loop of insulated wire, which was in turn placed in proximity of the device coil and inductively coupled to it. Thus, by varying the distance between the light-bulb and the device coil, the parameter Γ work /Γ was adjusted so that it matched its optimal value, given theoretically by √{square root over (1+κ 2 /(Γ 1 Γ 2 ))}. Because of its inductive nature, the loop connected to the light-bulb added a small reactive component to Γ work which was compensated for by slightly retuning the coil. The work extracted was determined by adjusting the power going into the Colpitts oscillator until the light-bulb at the load was at its full nominal brightness.
[0218] In order to isolate the efficiency of the transfer taking place specifically between the source coil and the load, we measured the current at the mid-point of each of the self-resonant coils with a current-probe (which was not found to lower the Q of the coils noticeably.) This gave a measurement of the current parameters I 1 and I 2 defined above. The power dissipated in each coil was then computed from P 1,2 =ΓL|I 1,2 | 2 , and the efficiency was directly obtained from η=P work +(P 1 +P 2 +P work ). To ensure that the experimental setup was well described by a two-object coupled-mode theory model, we positioned the device coil such that its direct coupling to the copper loop attached to the Colpitts oscillator was zero. The experimental results are shown in FIG. 17 , along with the theoretical prediction for maximum efficiency, given by Eq. (14).
[0219] Using this embodiment, we were able to transfer significant amounts of power using this setup, fully lighting up a 60 W light-bulb from distances more than 2 m away, for example. As an additional test, we also measured the total power going into the driving circuit. The efficiency of the wireless transfer itself was hard to estimate in this way, however, as the efficiency of the Colpitts oscillator itself is not precisely known, although it is expected to be far from 100%. Nevertheless, this gave an overly conservative lower bound on the efficiency. When transferring 60 W to the load over a distance of 2 m, for example, the power flowing into the driving circuit was 400 W. This yields an overall wall-to-load efficiency of ˜15%, which is reasonable given the expected ˜40% efficiency for the wireless power transfer at that distance and the low efficiency of the driving circuit.
[0220] From the theoretical treatment above, we see that in typical embodiments it is important that the coils be on resonance for the power transfer to be practical. We found experimentally that the power transmitted to the load dropped sharply as one of the coils was detuned from resonance. For a fractional detuning Δf/f o of a few times the inverse loaded Q, the induced current in the device coil was indistinguishable from noise.
[0221] The power transfer was not found to be visibly affected as humans and various everyday objects, such as metallic and wooden furniture, as well as electronic devices large and small, were placed between the two coils, even when they drastically obstructed the line of sight between source and device. External objects were found to have an effect only when they were closer than 10 cm from either one of the coils. While some materials (such as aluminum foil, styrofoam and humans) mostly just shifted the resonant frequency, which could in principle be easily corrected with a feedback circuit of the type described earlier, others (cardboard, wood, and PVC) lowered Q when placed closer than a few centimeters from the coil, thereby lowering the efficiency of the transfer.
[0222] We believe that this method of power transfer should be safe for humans. When transferring 60 W (more than enough to power a laptop computer) across 2 m, we estimated that the magnitude of the magnetic field generated is much weaker than the Earth's magnetic field for all distances except for less than about 1 cm away from the wires in the coil, an indication of the safety of the scheme even after long-term use. The power radiated for these parameters was ˜5 W, which is roughly an order of magnitude higher than cell phones but could be drastically reduced, as discussed below.
[0223] Although the two coils are currently of identical dimensions, it is possible to make the device coil small enough to fit into portable devices without decreasing the efficiency. One could, for instance, maintain the product of the characteristic sizes of the source and device coils constant.
[0224] These experiments demonstrated experimentally a system for power transfer over medium range distances, and found that the experimental results match theory well in multiple independent and mutually consistent tests.
[0225] We believe that the efficiency of the scheme and the distances covered could be appreciably improved by silver-plating the coils, which should increase their Q, or by working with more elaborate geometries for the resonant objects. Nevertheless, the performance characteristics of the system presented here are already at levels where they could be useful in practical applications.
[0226] Applications
[0227] In conclusion, we have described several embodiments of a resonance-based scheme for wireless non-radiative energy transfer. Although our consideration has been for a static geometry (namely κ and Γ e were independent of time), all the results can be applied directly for the dynamic geometries of mobile objects, since the energy-transfer time κ −1 (˜1 μs-1 ms for microwave applications) is much shorter than any timescale associated with motions of macroscopic objects. Analyses of very simple implementation geometries provide encouraging performance characteristics and further improvement is expected with serious design optimization. Thus the proposed mechanism is promising for many modern applications.
[0228] For example, in the macroscopic world, this scheme could potentially be used to deliver power to for example, robots and/or computers in a factory room, or electric buses on a highway. In some embodiments source-object could be an elongated “pipe” running above the highway, or along the ceiling.
[0229] Some embodiments of the wireless transfer scheme can provide energy to power or charge devices that are difficult or impossible to reach using wires or other techniques. For example some embodiments may provide power to implanted medical devices (e.g. artificial hearts, pacemakers, medicine delivery pumps, etc.) or buried underground sensors.
[0230] In the microscopic world, where much smaller wavelengths would be used and smaller powers are needed, one could use it to implement optical inter-connects for CMOS electronics, or to transfer energy to autonomous nano-objects (e.g. MEMS or nano-robots) without worrying much about the relative alignment between the sources and the devices. Furthermore, the range of applicability could be extended to acoustic systems, where the source and device are connected via a common condensed-matter object.
[0231] In some embodiments, the techniques described above can provide non-radiative wireless transfer of information using the localized near fields of resonant object. Such schemes provide increased security because no information is radiated into the far-field, and are well suited for mid-range communication of highly sensitive information.
[0232] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention.
|
Described herein are embodiments of a transmitter system for wireless power that may include a high-Q resonator that may include an inductive element and a capacitor that are collectively magnetically resonant at a first frequency, and a coupling loop assembly, that may include a first coupling loop part adjustably connected to said high-Q resonator. Another embodiment of the transmitter system for wireless power may include a first high-Q magnetic resonator that may include an inductive element and a capacitor that are collectively magnetically resonant at a first frequency, said first high-Q magnetic resonator positioned for wirelessly supplying power to devices on the ground.
| 7
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This application is a continuation-in-part application of pending application Ser. No. 323,421, filed Jan. 19, 1973, now U.S. Pat. No. 3,955,566, which in turn is a continuation-in-part application of application Ser. No. 318,201, filed Jan. 8, 1973, now abandoned, which in turn is a continuation-in-part of application Ser. No. 224,220, filed Feb. 7, 1972 now abandoned.
This invention relates to an improved system and method for preparing enclosed bodies, casts, craft and toy articles, and similar molded items.
BACKGROUND OF THE INVENTION
Several attempts have been made to adopt modern plastic technology to the production of rigid enclosures for such segments as a living body, human or animal. The use of rigid body and body member casts are important to assist in the healing of tissues and in knitting of fractures of the bone.
Such methods have incorporated systems, which have been disadvantageous for one of many reasons. For example, one method is dependent upon a closed plastic bag which is wrapped around the member and a plastic foam is allowed to develop in the bag. This system of encasement is slow, difficult to apply and very hot and uncomfortable for the wearer. The system does not allow air to enter or leave the appliance.
The conventional plaster of Paris systems have many dissatisfactory properties. Particularly, the casts formed therewith are heavy, X-ray impervious, absorb excessive moisture which thereby destroys the mechanical property, soil rapidly, are difficult to clean, poor shock resistance, lack elasticity, slow to reach ultimate strength, poor abrasive resistance and receptive to bacterial and fungal browth.
It also has been proposed to soften sheets of plastic materials and apply them to the part of the body to be immobilized so as to set upon cooling to a desired position. Unfortunately, the temperature to which such thermoplastic materials must be raised to make them moldable is too high to be endured by a patient unless an insulating intermediate material is first applied.
Certain systems and methods of casting have been proposed which utilize polymerizing systems and polymerizing bandages. However, these systems employ large amounts of liquid volatile and non-volatile diluents to replace part of the monomer as liquid extenders or wetting material. The presence of such volatile liquids are unsatisfactory. The presence of non-volatile viscous diluents do not cause vapor cells and form weak casts due to inadequate wetting of the solid filter or inability to satisfactorily dissolve the polymer formed and the like. Various catalyzed and accelerated mixtures of monomeric solvents within the prior diluent systems attempt to overcome the disadvantages thereof by addition of non-polymerizable polyalcohol esters. The problem of noxious volatile fumes remains. This is highly undesirable when such a system is used in a confined area. Further, the method for body use requires the coating of the body member with petrolatum or other protectant, this prevents air from reaching the injured member.
The prior art, U.S. Pat. No. 3,089,486, discloses a methacrylate polymer impregnant which is imbued into a bandage. The bandage in this form can be stored, however, this requires constant monitoring to insure a usable material. Further, the system described therein requires applying a barrier to the body member prior to applying the monomer component. This presents the disadvantage of placing an air impervious barrier which allows moisture to collect under the barrier from body perspiration, thereby inducing skin irritation.
Means, in U.S. Pat. No. 2,576,027, describes impregnating a cloth such as surgical gauze or the like, with a chemical that acts as a catalyst with reference to a solution of synthetic resin. The solution of synthetic resin is applied to the gauze to form a rigid solid. The catalyst and synthetic resin relates to a specific urea-formaldehyde system. The catalyst system described by Means is not effective in curing vinyl-type monomers and cannot be used with the instant invention.
The prior art, U.S. Pat. Nos. 3,421,501 and 3,613,675, describe bandages which contain an activated resin. The bandages are cured by exposure to ultraviolet light.
SUMMARY OF THE INVENTION
The present invention possesses definite advantages over the above-described systems. Primarily, it requires neither a pail of plaster of Paris, nor the soaking of a prepared plaster gauze material. Further, there is no need for actinic radiation to catalyze the system into a rigid form. The requirement of ultraviolet irradiation includes the distinct advantage that such a system must be necessarily employed near a source of electrical power. Further, such systems produce a slower cured resin enclosure. It is inherently difficult to irradiate certain areas such as in a cast utility, as under the arm or crouch. Further advantages of the present invention are fast curing and the presence of no volatile solvents. The cured system is light in weight and possesses an open configuration which allows good air exchange with the underlying member. The physical properties of the system are not greatly affected by exposure to water allowing for the possibility of washing the encased or immobilized member.
The present invention relates to a fully usable system which functions without further reference to any other system. It is understood that to be usable, a catalyzed fabric and a resin must be used in combination. Therefore, the improved operable system of this invention relates to the use of wrapping material treated and impregnated with a free radical catalyst, such as peroxides, then applying by a suitable means a resin containing active unsaturated radicals, as found in polyesters and acrylics, and containing tertiary aromatic amine accelerator.
The instant invention is contemplated for resin structures and enclosures for a wide variety of uses, e.g., models, toys, linings, shaped articles generally. Porous surgical dressings, orthopedic supports, and like objects, can be readily prepared. Further, for easily prepared plastic shells and molded items, the present system is easily applicable as well as for repairs and maintenance of such items, e.g. fiber glass bodies on cars and boats. Without the requirement of heat or special preparation, the instant system is especially useful.
Therefore, the instant invention is easily adopted for use in craft, toy and repair and maintenance technology. By employing a mold of the item or article to be repreduced, the present system may be used with many advantages, including low toxicity. A solid substrate or filler with a catalyst as described herein is treated with an activated non-volatile di- or polyvinyl resin system. Upon contact and mixing, the mass will cure to a rigid item prescribed by the mold. The curing time will vary with the mass of the material formed. Normally, the cure time will be within about 30 seconds to about 3 minutes. However, larger masses may cure in a shorter time, but can be controlled by adjusting the amount of accelerator.
Accordingly, it is a principal object of this invention to provide for the preparation of craft and toy resin articles which comprises applying to a mold of the desired article, or enclosing a mold of the article, a pre-catalyzed solid substrate and applying thereto an activated non-volatile di- or polyvinyl resin system which polymerizes upon contacting or mixing with the pre-catalyzed solid substrate. The activated resin system comprises a thermosetting polyester or thermosetting acrylic monomer of the dimethacrylate type, containing a tertiary aromatic amine accelerator to form together with the solid substrate, a hard, lightweight, rigid non-toxic physiologically inert enclosure or molded item.
Accordingly, it is a principal object of this invention to provide for the application of orthopedic casts of body members or enclosures of other articles which comprises enclosing said member in a peroxide catalyst impregnated, woven or non-woven fabric and applying to said enclosed member a thermosetting polyester or thermosetting acrylic monomer of the dimethacrylate type, containing a tertiary aromatic amine accelerator to form a hard, lightweight, rigid physiologically inert intergral enclosure or case.
A further object of this invention is to provide for the application of orthopedic casts or enclosures for articles formed of lightweight plastic wherein the hardening or setting of the plastic is accomplished by a peroxide catalyst impregnated in the enclosing fabric.
A further object of this invention is to provide for a craft and toy resin system requiring no pre-mixing, no heating, low toxicity and low volatility. It is the object of this invention to provide a resin system useable by children for craft and toy projects with no hazard from the resin system. As will become apparent hereinafter, these objects will be accomplished, although heretofore unknown and unexpected from the teachings of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
As a general definition, the group of resins include the members defined as thermosetting polyesters and thermosetting acrylics, also known as vinyl resins, those members having active terminal ethylene unsaturation or poly functional unsaturated ester moieties. Representative of this group is the following list:
ethylene glycol dimethacrylate
diethylene glycol dimethacrylate
triethylene glycol dimethacrylate
hexamethylene glycol dimethacrylate
2,2-bis(2-methacrylatoethoxyphenyl)propane
2,2-bis(3-methacrylato-2-hyroxypropoxyphenyl)propane
phthalic-maleic-propylene glycol polyester
Resin blends comprising two or more thermosetting acrylic monomers are also contemplated. Resin blends comprising at least one thermosetting acrylic monomer and one or more thermosetting polyester resins are within the resins defined herein. In some instances, these blends constitute a preferred resin composition for the method of the instant invention, in that they produce the least amount of heat during the curing (i.e., polymerization) of the resin. The cast material can contain a blend of resins of up to about 90 percent, preferably about 65 to 75 percent, of acrylic resin and from about 5 to 35 percent polyester resin, perferably about 25 to 35 percent. These percentages are based upon the total weight of the blended resin.
The monomer or resin-forming component is preferably advanced to an activated state. The activation develops in the resin when the system is combined with an accelerator and in which condition the activated monomer thus prepared retains a reasonable shelf-life. In order to arrive at this activated state in the resin, it is preferred to employ, as an accelerator, a tertiary aromatic amine, which is particularly useful in the instant invention. Examples of members of the class tertiary aromatic amine include N-3-tolyl-diethanol amine and N-4-tolyl-diethanol amine. When the activated resin is employed, application to the catalyst-impregnating fabric causes a very rapid curing to a desirable rigid structure. The monomer or resin is generally used in an amount of from about one-half the weight of fabric to two times the weight of fabric. The amount of tertiary aromatic amine as accelerator in the resin is about 0.1 to about 2.0 phr (parts per hundred of resin).
It has been found that certain properties of the resins can be enhanced by the addition of suitable plasticizer to the system. A plasticizer is a material incorporated in a plastic to increase the workability and flexibility or distensibility of the plastic product. Plasticizers may improve impact resistance of the final product. Organic plasticizers are usually moderately high-molecular-weight liquids or occasionally low-melting solids. Most commonly, organic plasticizers are esters of carboxylic acids such as polyethylene glycol, polypropylene glycol, methyl stearate and others, as the phthalates. Other types of plasticizers also include hydrocarbons, halogenated hydrocarbons, ethers, polyglycols and sulfonamides. The choice of a specific plasticizer for a given use requires a compromise of desirable properties in each case. It is therefore a preferred embodiment of this invention that the resin system contain a plasticizer to enhance the properties as desired. More preferably, a plasticizer content of from about 10 percent to about 50 percent based on the total resin formulation including the plasticizer. By the term "resin" is meant resin blends comprising two or more thermosetting acrylic monomers; blends comprising at least one thermosetting acrylic monomer and one or more thermosetting polyester resin. The percentage composition of the blended resins include the above-mentioned percentages for acrylic resin and polyester resin.
Catalyst for the production of free radical initiators of polymerization may be used to impregnate the solid substrate of this invention, but preferred is the peroxide type. The catalyst-impregnated solid substrate should be stable at ambient temperatures. Of the preferred catalyst peroxides which are within the class include for example:
2,4-dichlorobenzoyl peroxide
caprylyl peroxide
lauraoyl peroxide
benzoyl peroxide
acetyl peroxide
Some mixed peroxides such as acetyl benzoyl peroxides are also suitable.
Prior to the application of the desired catalyst to the solid substrate, such as fabric, sand, glass, silica, fibers, sugar, dusts of various materials, plastic "sand" or chips, lint and the like, the catalyst may be dissolved in a suitable solvent. For example, benzoyl peroxide in chloroform. Actually, any nonprotonic organic solvent, such as methylene chloride, benzene, cyclohexane and the like, may be employed. The solution of catalyst contains generally the amount from about 1 percent to about 10 percent of catalyst. The solution is applied to the solid substrate by a suitable means, so as to treat and impregnate the solid substrate. After application, the catalyst treated solid substrate is dried to remove the solvent. The solid substrate then is usable in the dry state. No special handling is required for the peroxide impregnated solid substrate. Storage should not expose the treat solid substrate to excessive heat. A variety of techniques may be employed to apply the catalyst, for example, dipping or spraying. The condition to be achieved within or withon the solid substrate is a thorough intermingling with and in the surrounding area in relation to the threads, fibers, chips or particles of the solid substrate. It is not indicated that the catalyst is to any extent absorbed by the particles or fibers of the solid substrate. It is preferred that for certain uses the fabric or particles have a relatively open knit structure and the applied resin thereby able to flow in and around the fibers or particles to become rigidly bonded to the fibers or particles and yet retain any open mesh latic-work or solid appearance. The catalyst impregnated or treated solid substrate is furnished in the dry state. The presence of a wet state would be undesirable to the advantages of the instant invention and would incorporate exposure to undesirale solvents.
The fabric or solid substrate material which is impregnated or treated with the preferred peroxide-type catalyst described above, may be in the form of a continuous sheet, or of short or long strips, particles, short fibers and the like. The fabric base can comprise two or more layers folded on each other as in cotton gauze bandages. The material of construction may be of woven or non-woven material, including felt-type materials, as an air-laid felt. The fabric itself is preferably made of cotton, synthetic fiber or fiberglass. However, the particular fabric selected will depend upon the particular application, and accordingly, this invention is not limited to any particular choice of fabric material. The amount of catalyst on the impregnated fabric will depend upon the nature of the fabric. The amount of catalyst present will further depend upon the amount of catalyst retained from the application thereof, i.e. by spraying, dipping, brushing, rolling, or flow techniques.
The solid substrate filler material which is treated or impregnated with the preferred peroxide-type catalyst described above may be of various particulate matter. For example, suitable materials include sand, glass, plastic beads of various types and colors, fibers and fluff of the synthetic or natural variety in any color. The glass particles may be colorless, opaque, transparent or mirror-like, each used to achieve a desirable effect in the final product.
When employed as a molding means, it is preferable to use self-releasing molds. The treated solid substrate is placed in the mold and the activated resin applied by pouring into the mold. The molds may be constructed of one or more parts for ease of removal of the final product. Molds of polyethylene, polypropylene, tetra-fluoroethylene, (TEFLON®) or Teflon® coated molds, as well as silicon rubber molds are acceptable. To those skilled in the art of molding and casting, it will be readily apparent that various other mold materials may be used with the present resin system of this invention.
For increased utility and decoration, the molded items may be attached to pins, clasps, decorations of glass, metal, plastic, jewels and the like. By imbedding these decorative or utilitarian attachments to the molded items, there usefulnes may be increased. By means of the present resin system, such attachments can be easily accomplished.
An important feature of the entire resin and catalyst system of the present invention is the safety and low toxicity. In using the system as a toy or craft molding means where children or adults would use the system, low toxicity is a necessary requirement. Together with low toxicity, there is low volatility with low or no odors. Further, there is no vapor phase toxicity. Additionally, there is contingent with the system low flammability. Important factors to usability of the system by laymen and others is the acceptable low toxicity with high LD 50 values, low volatility and low flammability.
The activated monomer with the selected accelerator is applied to the dry peroxide catalyst-impregnated fabric. The method of application will vary with the specific use. Contemplated within this invention is the application of the activated vinyl monomer of the polyester or acrylic type described herein by spraying, painting, swabbing and the like. Upon contact with the catalyst-impregnated fabric, the activated resin beings to polymerize almost immediately, such that within a few minutes the composite system is rigid and servicable. The cast or enclosure is light in weight, has an open configuration and conforms to the position and shape of the dry impregnated fabric prior to application of the activated resin. Other layers of fabric can be overlaid the initial form almost immediately to obtain a more closed configuration if desired.
Thus, within the skill of those qualified in the orthopedic sciences, the preparation and application of orthopedic casts for use in the treatment of bone fractures or other conditions requiring immobilization of body members may be advantageously formed from the materials and method of this invention. In applying the peroxide catalyst-impregnated fabric from a rolled-up material to a body member, the strip of fabric is wrapped around the member in an advancing overlapping manner. When the member has been completely wrapped in the impregnated fabric, an activated vinyl monomer resin described herein is applied, as by spraying, on the fabric. Within one to two minutes, the component system is rigid and usable. The resulting cast thickness will depend upon location of the body portion to be cast; upon the strength and rigidity required.
The examples presented herein serve solely to illustrate the composite system and method of this invention. Accordingly, the examples should not be regarded as limiting the invention in any way. In the examples, the parts and percentages are by weight unless otherwise indicated.
EXAMPLE I
An activated resin was prepared by dissolving 1.0 g. of N-3-tolyldiethanol amine in 100.0 g. of ethylene glycol dimethacrylate. This activate resin was sprayed onto a sample of each cotton, nylon and glass cloths which had been dipped into a chloroform solution containing 5 percent benzoyl peroxide. The benzoyl peroxide treated fabric cloths were allowed to dry before application of the activated resin. The resin on the cloth samples began to polymerize and became comfortably warm in 40 seconds. At the end of one minute, the composite system was rigid, hard and servicable.
EXAMPLE II
In a similar method as described in Example I, the following dimethacrylate resins each were used on cotton, nylon and glass cloths. The results in each case are comparable.
(a) diethylene glycol dimethacrylate
(b) triethylene glycol dimethacrylate
(c) hexamethylene glycol dimethacrylate
(d) 2,2-bis(2-methacrylatoethoxyphenyl)propane
EXAMPLE III
An activated resin blend was prepared by mixing 100 parts of ethylene glycol dimethacrylate, 100 parts of 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane and 2 parts of N-3-tolyldiethanol amine. This resin system was sprayed on to benzoyl peroxide catalyzed cloths, prepared in the same manner as Example I. After 20 seconds, the applied resin began to gel and at 30 seconds, the composite system was rigid and servicable. No undesirable heat evolution was detected during gelling of this system.
EXAMPLE IV
In a similar manner as Example III, an activated resin blend was prepared using triethylene glycol dimethacrylate instead of ethylene glycol dimethacrylate. Comparable results were obtained.
EXAMPLE V
An activated vinyl resin blend was prepared by mixing 60 parts triethylene glycol dimethacrylate, 1 part of N-3-tolyldiethanol amine and 40 parts of polyester resin prepared from 2 moles of phthalic anhydride, 1 mole of maleic anhydride and 3 moles of propylene glycol. This resin system was sprayed on to benzoyl peroxide catalyzed cloths, prepared as in Example I. The system gelled in about 2 minutes and became rigid in about 2.5 minutes. No appreciable heat was evolved during the curing of this system. The composite system was rigid and servicable.
EXAMPLE VI
A 4 g. mixture containing 70 percent 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane and 30 percent of polypropylene glycol (average molecular weight = 400) and 1 percent N-3-tolyldiethanol amine was cured by adding, with mixing 12 drops (about 0.6 g.) of a catalyst solution made from 10 g. triethylene glycol dimethacrylate, 1 g. benzoyl peroxide, and 0.1 g. butylated hydroxytoluene. The system became a hard amber solid in 20 seconds. When a 50-50 percent mixture of resin to polyglycol was used, a milky solid with much poorer physical properties was obtained. Both resin ratios cured when placed upon cloth which had been treated with benzoyl peroxide.
EXAMPLE VII
A resin system was prepared from 70 g. 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane, 40 g. triethylene glycol dimethacrylate, 30 g. polypropylene glycol (average molecular weight = 400) and 1 g. N-3-tolyldiethanol amine. This system produced a tough amber colored composite solid when applied to cloth which had been treated with benzoyl peroxide.
EXAMPLE VIII
A resin blend was prepared from 25 g. 2,2-bis(3-methacrylato-2-hydroxypropoxyphenol)propane, 25 g. of triethylene glycol dimethacrylate, 25 g. of an isophthalate-maleic acid polyester resin, 25 g. polypropylene glycol (average molecular weight = 400) and 0.7 g. N-3-tolyldiethanol amine. This resin system was applied to glass cloth which had been treated with benzoyl peroxide. The resin began to gel in 20 seconds and was hard in 60 seconds. The composite system was rigid and servicable.
EXAMPLE IX
An activated resin was prepared by dissolving 1.0 g. of N-3-tolyldiethanol amine in 100.0 g. of ethylene glycol dimethacrylate. This activated resin was poured onto a sample of sand pre-catalyzed with a 5 percent solution of benzoyl peroxide in chloroform. The benzoyl peroxide-treated sand was allowed to dry before placement in the mold and addition of the activated resin. The resin on the sand began to polymerize and become warm. Upon drying, in about one minute, the composite system of sand and resin in the mold was hard, rigid and servicable. Detail of the mold was readily apparent.
Within the method and process of this invention, premixing of the reagents is taught by mixing the free radical organic peroxide catalyzed solid substrate with an activated thermosetting vinyl resin prior to introduction or placement in the mold of the article to be molded. Then allowing the mixture to harden in the mold. Removal of the formed article is easily accomplished using quick release molds as described hereinabove.
EXAMPLE X
In a similar method described in Example IX, the following dimethacrylate resins each were used on pre-catalyzed plastic "sand" and nylon chips. The results in each case are comparable.
(a) diethylene glycol dimethacrylate
(b) triethylene glycol dimethacrylate
(c) hexamethylene glycol dimethacrylate
(d) 2,2-bis(2-methacrylatoethoxyphenyl)propane
After pouring onto the solid substrate the resulting product in each case gelled and became rigid and serviceable.
EXAMPLE XI
An activated vinyl resin blend was prepared by mixing 60 parts triethylene glycol dimethacrylate, 1 part of N-3-tolyldiethanol amine and 40 parts of polyester resin prepared from 2 moles of phthalic anhydride, 1 mole of maleic anhydride and 3 moles of propylene glycol. This resin system was poured onto benzoyl peroxide pre-catalyzed table salt in a suitable self-releasing mold. The system gelled in about 2 minutes and became rigid in about 2.5 to 3 minutes. The product was rigid and serviceable.
EXAMPLE XII
An activated resin blend was prepared by mixing 100 parts of ethylene glycol dimethacrylate, 100 parts of 2,2-bis(3-methacrylato-2-hyroxypropoxyphenyl)propane and 2 parts of N-3-tolyldiethanol amine. This resin system was poured into a mold containing absorbent fibrous material made from comminuted wood pulp fibers and cotton linters. The absorbent fibrous material was previously treated with benzoyl peroxide as a catalyst. After 20 seconds, the applied resin blend began to gel and at 30 seconds, the composite system was rigid and functional conforming to the mold shape. No undesirable heat evolution was detected.
It will readily be appreciated by those skilled in the art that the proportions of the various components of the system may vary widely depending upon the identity of the components and the conditions under which the system is to be applied and the hardened composite system is to be used. The best proportions in any particular instance can readily be determined on the basis of prior experience and by trial and error. It is also within the scope of the invention to add to the mixture such modifying agents as therapeutic compounds, disinfectants, deodorants and coloring agents, e.g. dyes and pigments. Proportions of such optional components as therapeutic compounds, deodorants, disinfectants, coloring materials, inactive fillers, and the like, are largely a matter of choice, it being understood of course that they should be present only in minor amounts sufficient to accomplish their intended functions and not in quantities large enough to interfere with the primary objectives of the system.
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An improved method for providing lightweight and strong rigid enclosures and molded items formed by enclosing, wrapping or filling a mold of said items or articles with a dry peroxide catalyst-impregnated fabric or solid substrate filler material and applying thereto or mixing therewith an activated thermosetting vinyl-type resin and allowing said fabric or filler material to harden about the article or within the mold of said article. Said resin system and molding procedure is safe and of low toxicity.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation-In-Part of my co-pending U.S. Patent Application Ser. No. 153,324, filed Feb. 8, 1988, now U.S. Pat. No. 4,850,167.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to structural glazing systems for skylights in solaria, greenhouses, barrel vaults and like structures and more particularly, to skylight structural glazing systems having an internal fastening network which effectively eliminates the need for exterior fasteners, holes and slots normally used in conventional skylight mounting and support systems. The structural glazing systems of this invention include a bottom closure system for securing glass or plastic skylight panels between straight runs of the carrier beam supporting members and a side closure system for mounting the panels between carrier beam structural members extending over walls, headers, sills or jambs in a structure. Each of the bottom and side closure systems includes multiple, specially designed, open-chamber carrier beams which are each shaped to receive a pair of spaced, parallel, elevated carrier glazing strips for engaging the edges of the bottom surfaces of a pair of adjacent glass or plastic skylight panels to be mounted. Multiple companion exterior glazing caps, each of which includes a pair of spaced cap glazing strips for engaging the edges of the top surfaces of the glass or plastic skylight panels are also provided, for securing the skylight panels between the exterior glazing caps and the corresponding carrier beams by means of spaced cap bolts, which are inserted from the underside of the carrier beams through spaced openings provided therein, into the exterior glazing caps. A carrier beam closure is removably fastened to the bottom edges of some of the carrier beams and to the side edges of other carrier beams, to close the chamber, conceal the cap bolts and facilitate access to the cap bolts from the inside structure for removal of the skylight panels without the necessity of traversing the roof of the structure. Moreover, where necessary for structural purposes, stabilizer clips are mounted in the carrier beams, in order to stiffen the carrier beams.
Conventional skylight glazing systems for residential, commercial and other structures, such as fixed or movable, sloped or curved glazing in solaria, greenhouses and barrel vaults, in non-exclusive particular, are normally designed to facilitate access to the glass or plastic skylight panels from the roof of the structure in which the skylight panels are installed. These glazing systems typically include various fasteners and sealing systems which are accessed from the roof of the structure, in order to replace damaged glass or plastic skylight panels or to perform routine maintenance on the glazing system structural elements. A primary problem which is frequently realized in conventional structural glazing systems is that of seating and sealing the panels within the structural members in such a manner as to prevent leakage of water and infiltration of dust and other undesirable elements through the system and yet facilitate efficient maintenance of the installation.
Sloped or overhead skylight glazing systems generally include multiple horizontal framing members interconnected with cooperating vertical framing members to form a structural framing grid or lattice which defines multiple glazed openings of selected size, into which openings glass or plastic panels are installed. The grid may be pitched or sloped at a selected angle with respect to the horizontal or it may be rounded, as in a greenhouse, and various forms of connecting and sealing components are employed to secure the panels within the glazing openings, to minimize infiltration of moisture, air and dust from the outside to the inside of the structure. Typical sealing components include resilient ceiling gaskets which grip the inner and outer panel surfaces, together with means for tightening these gaskets against these surfaces to create water and air-tight connections. Calk is also sometimes used to facilitate such water, air and dust-tight connections.
2. Description of the Prior Art
Various structural glazing systems are known in the prior art for mounting glass skylight panels on sloped or overhead glazing systems, including greenhouses. Typical of these systems is the Modular Solar Greenhouse detailed in U.S. Pat. No. 4,462,390, dated July 31, 1984, to Holdridge, et al. The modular solar greenhouse detailed in this patent incorporates rigid, curving overhead frames provided with screw and nut tracks for ease of assembly and also uses companion east side and west side end modules for mounting a thermally broken glazing system. The exterior and interior portions of the aluminum frame extrusions are bonded together by a strong plastic material and at least one overhead heat storage unit is carried by the rigid frame. A "Ventilating Skylight" is detailed in U.S. Pat. No. 4,449,340, dated May 22, 1984, to Arthur P. Jentoft, et al. The skylight includes a domed or flat glazing which is adapted to fit within the opening of a roof having a peripheral frame which is fixed to the roof about the opening. The frame is characterized by a base frame and an operating leaf frame and a retainer is used to secure the skylight cover over the operating leaf frame. U.S. Pat. No. 4,621,472, dated Nov. 11, 1986, to Werner Kloke, details a "Glazed Structural System and Components Therefore". The patent discloses skylight structures wherein the supporting and supported structural members defining the metal framework, including flange formations upon which the glass panels are secured, are provided with longitudinally-extending drainage channel formations. The open ends of the drainage channel formations of the supported structural members intersect and overlap the drainage channel formations of the supporting structural members. Accordingly, water collected therein is discharged into the drainage channel formations of the supporting structural members at a point remote from the intersections thereof. The structural members are interconnected by displaceable clamping means carried by the overlapping ends, including a clip embracing the ends from below in the region of overlap and upon displacement, upwardly engage the flange formations of the supporting structural members from below. A "Rafter with Internal Drainage Feature and Sloping Glazing System Incorporating Same" is detailed in U.S. Pat. No. 4,680,905, dated July 21, 1987, to James A. Rockar. The patent details a sloped curtain wall or glazing system for a building, which system includes a plurality of rafters and purlins interconnected to provide at least one panel opening for retaining a panel. The rafters have an upwardly sloping vertical glazing pocket adapted to receive a vertical marginal edge portion of a panel and the purlins have a horizontal glazing pocket adapted to receive a horizontal marginal edge portion of a panel. The rafters further include a semi-enclosed drainage channel and a condensate gutter which are not disposed in fluid communication with either the drainage channel or the vertical glazing pocket. The purlins further include a condensation gutter and the purlin and rafter condensation gutters are disposed in fluid communication with each other. The drainage channel is provided with at least one opening to put the vertical and horizontal glazing pockets in communication therewith. The glazing system further includes a seal for separately collecting and discharging the infiltration moisture collected in the drainage system and the condensation moisture collected in the rafter condensation gutter.
It is an object of this invention to provide new and improved sloped or curved structural glazing systems for skylights which effectively eliminate the need for conventional exterior fasteners, slots, sealing devices and holes commonly used for installing, maintaining and replacing glass and plastic skylight panels.
Another object of the invention is to provide a new and improved structural skylight glazing system which is characterized by a bottom closure carrier beam system wherein the skylight panels can be installed, maintained and replaced from inside a structure by detaching bottom-mounted closure members from the carrier beams and installing or removing multiple cap bolts from the carrier beams and companion exterior glazing caps, to secure and free the skylight panels, respectively.
Another object of the invention is to provide new and improved structural glazing systems for skylights which include a side closure carrier beam system utilizing carrier beam closures which are side-mounted on selected carrier beams to facilitate installation, maintenance and removal of the glass or plastic skylight panels from inside a structure without traversing the roof.
A still further object of this invention is to provide structural glazing systems for skylights which include multiple, spaced carrier beams oriented in a lattice or grid configuration and fitted with elevated glazing strips for receiving the bottom edges of adjacent glass or plastic skylight panels and multiple companion exterior glazing caps fitted with additional glazing strips for receiving and contacting the corresponding top edges of the adjacent panels for securing the panels between the glazing strips from inside the structure using cap bolts which extend upwardly through the carrier beams to threadably engage the exterior glazing caps. Still another object of the invention is to provide structural glazing systems for sloped and curved skylights in structures such as solaria, greenhouses, barrel vaults and like structures, which systems include multiple carrier beams mounted in spaced and intersecting relationship in the structure, the carrier beams each having an open chamber, an intersecting system of condensate gutters and a pair of bottom glazing strips attached to elevated glazing strip supports extending from flat shoulders in the carrier beams, for receiving the bottom edges of glass or plastic skylight panels, and further including cooperating exterior glazing caps for mounting on companion carrier beams, respectively, the exterior glazing caps characterized by top glazing strips for engaging the top corresponding edges of the skylight panels and securing the panels in position in the structure by means of cap bolts inserted through the carrier beams from inside the open chamber and threadably engaging the exterior glazing caps.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in structural glazing systems for skylights which include both bottom and side carrier beam closure systems, each of which systems is characterized by multiple, open-chamber carrier beams arranged in interconnecting relationship in a building or structure to define a lattice or grid; optional stabilizer clips spanning the carrier beams for enhancing the structural integrity of the carrier beams; a pair of bottom glazing strips provided on elevated glazing strip supports having support cradles extending from spaced shoulders formed in the carrier beams, for engaging the edges of the bottom surface of glass or plastic skylight panels to be installed in the system; multiple exterior glazing caps shaped and adapted to mount on the tops of the carrier beams, respectively, the exterior glazing caps provided with an additional pair of glazing strips for seating on the corresponding edges of the top surfaces of the glass panels; and spaced cap bolts extending into the open chamber and through openings provided in the carrier beams and threaded into a continuous screwboss provided in each of the exterior glazing caps, respectively, for mounting the glass or plastic skylight panels in a lattice or grid between the respective parallel and intersecting sets of exterior glazing caps and carrier beams. In a most preferred embodiment of the invention the carrier beams are fitted with elongated, removable closure strips that close the internal chambers in the carrier beams and conceal the cap bolt heads and optional stabilizer clips may be provided in the carrier beams for additional structural integrity, as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawings, wherein:
FIGURE 1 is a sectional view of an assembled bottom closure carrier beam embodiment of the sloped structural glazing system of this invention;
FIGURE 2 is an exploded view of the bottom closure carrier beam illustrated in FIG. 1;
FIGURE 3 is a sectional view of an assembled side closure carrier beam embodiment of the sloped structural glazing system;
FIGURE 4 is a top view, partially in section, of an installed sloped structural glazing system according to this invention; and
FIGURE 5 is a perspective view, partially in section, of a typical curved roof or greenhouse structural glazing system embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 and 2-4 of the drawings, a roof structure 29, provided with the carrier beam 2 and head and sill carrier beam 34 embodiments of the structural glazing system of this invention is illustrated. The roof structure 29 is depicted as a sloped glazing system for purposes of illustration only and it will be appreciated that the structural components of the roof structure 29 can be utilized in many other glazing systems, as hereinafter further described. The roof structure 29 is characterized by a lattice or grid structure created by multiple, spaced and intersecting carrier beams 2 and head and sill carrier beams 34, which intersect at a 90-degree angle in spaced relationship, in order to define openings therebetween. While the angle of intersection of the carrier beams 2 and the head and sill carrier beams 34 is illustrated as 90 degrees, it will be further appreciated that the carrier beams 2 and head and sill carrier beams 34 may be installed in the roof structure 29 in any desired spatial orientation at any desired angle, according to the teachings of this invention. The head and sill carrier beams 34 lie over or adjacent to a wall 40, or a header, sill or jamb (not illustrated) in the roof structure 29 and are characterized by a side-access or closure design, as illustrated in FIG. 3, whereas the carrier beams 2 which extend across the roof of the roof structure 29 and are spaced from the walls 40 and the headers, sills or jambs, are characterized by a bottom access or closure design, as illustrated in FIGS. 1 and 2. Each of the carrier beams 2 and head and sill carrier beams 34 receive a corresponding exterior glazing cap 19,which fits over the top of a corresponding carrier beam 2 and head and sill carrier beam 34, respectively. Each exterior glazing cap 19 is designed to secure glass or plastic panels 16 between parallel carrier glazing strips 12, mounted in the support cradle 18 of upward-standing glazing strip supports 17 in the carrier beams 2 and the head and sill carrier beams 34, respectively, and cooperating parallel cap glazing strips 22, mounted on the exterior glazing caps 19, as hereinafter further described. Multiple cap bolts 25 project through openings provided in the carrier beams 2 in spaced relationship and threadably engage the exterior glazing caps 19, to secure the glass or plastic panels 16 between the carrier glazing strips 12 and the cap glazing strips 22, respectively, as hereinafter further described. An elongated carrier beam closure 30 removably seats in the bottom of each of the carrier beams 2 and in the sides of the head and sill carrier beams 34, respectively, to close the open chambers 32 in the carrier beams 2 and the head and sill carrier beams 34, conceal the cap bolts 25 and provide aesthetically pleasing bottom and side surfaces of the sloped structural glazing system 1 inside the host structure.
Referring now to FIGS. 1 and 2 of the drawings, the bottom closure or access embodiment of the sloped structural glazing system 1 is more particularly illustrated. The carrier beam 2 utilized in the bottom closure design includes a pair of parallel carrier beam sides 3, each of which terminates at the bottom in oppositely-disposed, spaced side flanges 4, for receiving the flange connectors 31 of a cooperating carrier beam closure 30, to close the chamber 32, as illustrated. A pair of primary condensate gutters 5 are defined in parallel relationship on each side of the carrier beam 2 by the top segments of the upward-standing carrier beam sides 3 and corresponding, parallel gutter extensions 6, respectfully. The gutter extensions 6 extend upwardly to define one side of the upward-standing glazing strip supports 17, which are mounted in spaced relationship on the carrier beam shoulders 7 and are each fitted with a support cradle 18, having an anchor slot 11 provided therein, as illustrated in FIG. 3. The carrier beam shoulders 7 terminate inwardly in a pair of upward-standing cap receiver sides 10, which, together with a connecting cap receiver base 9, define a central channel or cap receiver 8, wherein the cap receiver base 9 is coplanar with the carrier beam shoulders 7 and extends longitudinally along the entire length of each of the carrier beams 2 and runs parallel to and inwardly of the primary condensate gutters 5. Multiple base openings 15 are drilled or otherwise provided in spaced relationship in the cap receiver base 9 of the cap receiver 8 and the threaded shanks 27 of multiple cap bolts 25 are designed to extend through the base openings 15, to locate the bolt head 26 of each cap bolt 25 against the cap receiver base 9, as hereinafter further described. The top plate 20 of each exterior glazing cap 19 is fitted with a pair of longitudinal, parallel top plate flanges 21 on the outer edges thereof and a pair of parallel anchor slots 11 are provided in the top plate flanges 21, respectively, as further illustrated in FIG. 2. A continuous screwboss 23 projects downwardly from the center of the top plate 20 of the exterior glazing cap 19, between the top plate flanges 21 and screwboss threads 24 may be provided as an option in the parallel cap receiver sides 10 of the continuous screwboss 23 at spaced locations which correspond to each of the base openings 15 located in the cap receiver base 9 of the cap receiver 8. Alternatively, under circumstances where the continuous screwboss 23 is extruded from, or otherwise fabricated of a soft metal such as aluminum, the threaded shank 27 of each cap bolt 27 threads its way into the cap receiver sides 10 at spaced intervals when installed by a driving tool. Accordingly, the continuous screwboss 23 is designed to register with and seat inside the cap receiver 8 as the threaded shank 27 of each of the cap bolts 25 extends through a companion base opening 15 in the cap receiver base 9 and threadably engages screwboss threads 24 or alternatively, the soft metal in the parallel cap receiver sides 10, to secure each exterior glazing cap 19 to the top edge of a corresponding carrier beam 2. Referring again to FIG. 2 of the drawings, a pair of resilient sealing carrier glazing strips 12 are fitted on the support cradle 18 of the glazing strip supports 17, located on the carrier beam shoulders 7 of each carrier beam 2, by inserting the projecting glazing strip anchors 14 in the respective corresponding anchor slots 11. Similarly, the cap glazing strips 22 are fitted on the parallel top plate flanges 21 of each exterior glazing cap 19, by inserting the corresponding glazing strips anchors 14 into the corresponding anchor slots 11, respectively. Alternatively, under circumstances where the carrier glazing strips 12 and cap glazing strips 22 are not provided with companion glazing strip anchors 14, respectively, the carrier glazing strips 12 and cap glazing strips 22 may be glued into the positions noted above, according to the knowledge of those skilled in the art. Accordingly, a section of glass or plastic panel 16 can be inserted between the glazing strip body 13 of each of the carrier glazing strips 12 and the corresponding cap glazing strips 22 and the spaced cap bolts 25 then tightened in the cap receiver sides 10 to secure the glass or plastic panels 16 in place, as illustrated in FIGURE
After this installation step is completed, the respective carrier beam closures 30 may be installed on the bottom edges of the corresponding carrier beam sides 3 to cover and conceal the cap bolts 25, by matching the side flanges 4 with the flange connectors 31, as further illustrated in FIG. 2. Under circumstances where the carrier beam sides 3 are long and the chamber 32 is large, or the carrier beam structure otherwise requires reinforcement, a stabilizer clip 43 may be inserted between the carrier beam sides 3. In a preferred embodiment, a pair of upward-standing stabilizer clip legs 44 terminate each end of the stabilizer clip 43 and are fitted with leg serrations 45, for engaging corresponding flange serrations 47 provided in companion stabilizer clip flanges 46, downwardly-extending from the carrier beam sides 3.
Referring again to FIGS. 3 and 4 of the drawings, the side closure or access embodiment of the structural glazing system 1 is more particularly detailed. In the side closure design, a head and sill carrier beam 34 is constructed parallel to and above each wall 40 and a corresponding head and sill carrier beam base 36 extends from one of each of the head and sill carrier beam sides 35. A space is provided between the respective side flanges 4 and the opposite, shorter head and sill carrier beam side 35, in order to accommodate a side-mounted carrier beam closure 30, which removably seats in the shorter one of the head and sill carrier beam sides 35 by means of cooperating oppositely-disposed flange connectors 31 and the corresponding side flanges 4, as illustrated. The location of this space facilitates access to the chamber 32 provided in each of the head and sill carrier beams 34, to install and remove the spaced cap bolts 25, since the head and sill carrier beam base 36 is normally resting on or is in close proximity to the wall 40 or an extension of the wall 40, or above a header, sill or jamb (not illustrated) in the structure, and bottom access to the chamber 32 is difficult or impossible. As in the case of the carrier beam 2 illustrated in FIGS. 2 and 3, the head and sill carrier beam 34 is provided with a pair of parallel primary condensate gutters 5. The walls of the primary condensate gutters 5 extend upwardly from a pair of spaced, flat carrier beam shoulders 7, one of which walls in each of the primary condensate gutters 5 is characterized by a gutter extension 6, shaping one side of a pair of upward-standing glazing strip supports 17, respectively. The glazing strip supports 17 each terminate in a support cradle 18, which receives a resilient, sealing carrier glazing strip 12, as in the case of the carrier beams 2 illustrated in FIGS. 1 and 2. A cap receiver 8 also projects upwardly from the carrier beam shoulders 7 and receives multiple cap bolts 25 through spaced base openings 15, located in the cap receiver base 9, in order to threadably secure the continuous screwboss 23 of a corresponding exterior glazing cap 19 in the cap receiver 8, and the top plate 20, fitted with cap glazing strips 22, on the head and sill carrier beam 34. Further as in the case of the carrier beam 2, glass or plastic panels 16 are sandwiched between corresponding parallel pairs of the respective carrier glazing strips 12 and cap glazing strips 22 and are mounted and sealed in this position by tightening the spaced cap bolts 25 from inside each chamber 32. A stabilizer clip 43 may also be mounted in the carrier beam 2 between the parallel head and sill carrier beam sides 35 by means of the upward-standing stabilizer clip legs 44 and companion downwardly-projecting stabilizer clip flanges 46, as in the carrier beam 2 illustrated in FIGS. 1 and 2.
Referring again to the drawings, it will be appreciated that the bottom closure and side closure designs of the sloped structural glazing system 1 are designed to facilitate mounting one or more glass or plastic panels 16 in a lattice or grid which is characterized by joints, intersections or connecting points between respective carrier beams 2 and between the carrier beams 2 and cooperating head and sill carrier beams 34. In these intersectional connections, it should be remembered that the bottom closure carrier beams 2 are constructed as illustrated in FIGS. 1 and 2, while the side closure head and sill carrier beams 34 are constructed as illustrated in FIG. 3, as heretofore described. The intersection of these structural components is illustrated in FIG. 4. In a most preferred embodiment of the invention, the respective top plates 20 of the exterior glazing caps 19 which correspond to the subject carrier beams 2 are cut and shaped to butt against the sides of the companion top plates 20 which correspond to the corresponding head and sill carrier beams 34. Furthermore, the respective primary condensate gutters 5 are mitered at the point of intersection (not illustrated) to more efficiently carry condensate away from the glass or plastic panels 16.
Referring again to FIG. 5 of the drawings, it will be appreciated that the structural elements of the sloped structural glazing system 1 can be utilized to create a curved roof structure, as in the case of the greenhouse structure 28, as well as in the sloped system as illustrated in FIG. 4. Under these circumstances, a head and sill carrier beam 34 may be utilized at the top of the greenhouse structure 28, in combination with a strip of head flashing 39.
It will be appreciated by those skilled in the art that the various structural components of the structural glazing system of this invention are preferably extruded from a soft, light metal such as aluminum. However, certain components in specific applications not requiring large glass or plastic panels or characterized by minimum load-bearing requirements, may be injection-molded or extruded of plastic materials, according to the knowledge of those skilled in the art. Furthermore, the structural glazing system may be used to mount skylight panels of any desired size, shape, thickness and composition, with the appropriate adjustment for panel thickness effected by using cap bolts 25 having a threaded shank 27 of suitable length. Panels which may be mounted and maintained according to the structural glazing system of this invention are typically constructed of glass and plastic, such as "Plexiglass" and other transparent materials, in non-exclusive particular.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
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Structural glazing systems for skylights which are designed to facilitate installation, maintenance and replacement of skylight panels from inside a host structure. The internal fastening apparatus of the structural glazing systems include multiple, open-chamber carrier beams which are interconnected in a lattice or grid configuration and include upward-standing glazing strip supports shaped to receive a pair of parallel, spaced bottom glazing strips for accommodating the bottom edges of separate glass or plastic skylight panels. Companion exterior glazing caps each carry a pair of spaced top glazing strips for seating on the top edges of the skylight panels. The exterior glazing caps are shaped to facilitate bolting to the carrier beams and securing the glass or plastic skylight panels in position between the top and bottom glazing strips. A carrier beam closure is designed to removably close the open chamber of each hollow carrier beam and to facilitate concealment of, and access to, the multiple cap bolts which are used to bolt the carrier beams to the corresponding exterior glazing caps, respectively. A system of condensate gutters is provided on the carrier beams, which gutters meet at the points of intersection of the carrier beams to carry condensate away from the glass or plastic panels.
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This is a division of application Ser. No. 423,693 filed Dec. 11, 1973.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved process for producing carbon fibers from pitch which has been transformed, in part, to a liquid crystal or so-called "mesophase" state. More particularly, this invention relates to an improved process for producing carbon fibers from pitch of this type wherein the mesophase content is produced in substantially shorter periods of time than heretofore possible, at a given temperature, by passing an inert gas through the pitch during formation of the mesophase.
2. Description of the Prior Art
As a result of the rapidly expanding growth of the aircraft, space and missile industries in recent years, a need was created for materials exhibiting a unique and extraordinary combination of physical properties. Thus materials characterized by high strength and stiffness, and at the same time of light weight, were required for use in such applications as the fabrication of aircraft structures, re-entry vehicles, and space vehicles, as well as in the preparation of marine deep-submergence pressure vessels and like structures. Existing technology was incapable of supplying such materials and the search to satisfy this need centered about the fabrication of composite articles.
One of the most promising materials suggested for use in composite form was high strength, high modulus carbon textiles, which were introduced into the market place at the very time this rapid growth in the aircraft, space and missile industries was occurring. Such textiles have been incorporated in both plastic and metal matrices to produce composites having extraordinary high-strength- and high-modulus-to-weight ratios and other exceptional properties. However, the high cost of producing the high-strength, high-modulus carbon textiles employed in such composites has been a major deterrent to their widespread use, in spite of the remarkable properties exhibited by such composites.
One recently proposed method of providing high-modulus, high-strength carbon fibers at low cost is described in copending application Ser. No. 338,147, entitled "High Modulus, High Strength Carbon Fibers Produced From Mesophase Pitch". Such method comprises first spinning a carbonaceous fiber from a carbonaceous pitch which has been transformed, in part, to a liquid crystal or so-called mesophase state, then thermosetting the fiber so produced by heating the fiber in an oxygen-containing atmosphere for a time sufficient to render it infusible, and finally carbonizing the thermoset fiber by heating in an inert atmosphere to a temperature sufficiently elevated to remove hydrogen and other volatiles and produce a substantially all-carbon fiber. The carbon fibers produced in this manner have a highly oriented structure characterized by the presence of carbon crystallites preferentially aligned parallel to the fiber axis, and are graphitizable materials which when heated to graphitizing temperatures develop the three-dimensional order characteristic of polycrystalline graphite and graphitic-like properties associated therewith, such as high density and low electrical resistivity. At all stages of their development from the as-drawn condition to the graphitized state, the fibers are characterized by the presence of large oriented elongated graphitizable domains preferentially aligned parallel to the fiber axis.
When natural or synthetic pitches having an aromatic base are heated under quiescent conditions at a temperature of about 350°C.-500°C., either at constant temperature or with gradually increasing temperature, small insoluble liquid spheres begin to appear in the pitch and gradually increase in size as heating is continued. When examined by electron diffraction and polarized light techniques, these spheres are shown to consist of layers of oriented molecules aligned in the same direction. As these spheres continue to grow in size as heating is continued, they come in contact with one another and gradually coalesce with each other to produce larger masses of aligned layers. As coalescence continues, domains of aligned molecules much larger than those of the original spheres are formed. These domains come together to form a bulk mesophase wherein the transition from one oriented domain to another sometimes occurs smoothly and continuously through gradually curving lamellae and sometimes through more sharply curving lamellae. The differences in orientation between the domains create a complex array of polarized light extinction contours in the bulk mesophase corresponding to various types of linear discontinuity in molecular alignment. The ultimate size of the oriented domains produced is dependent upon the viscosity, and the rate of increase of the viscosity, of the mesophase from which they are formed, which, in turn are dependent upon the particular pitch and the heating rate. In certain pitches, domains having sizes in excess of two hundred microns up to in excess of one thousand microns are produced. In other pitches, the viscosity of the mesophase is such that only limited coalescence and structural rearrangement of layers occur, so that the ultimate domain size does not exceed one hundred microns.
The highly oriented, optically anisotropic, insoluble material produced by treating pitches in this manner has been given the term "mesophase", and pitches containing such material are known as "mesophase pitches". Such pitches, when heated above their softening points, are mixtures of two essentially immiscible liquids, one the optically anisotropic, oriented mesophase portion, and the other the isotropic non-mesophase portion. The term mesophase is derived from the Greek "mesos" or "intermediate" and indicates the pseudo-crystalline nature of this highly-oriented, optically anisotropic material.
Carbonaceous pitches having a mesophase content of from about 40 per cent by weight to about 90 per cent by weight are suitable for spinning into fibers which can subsequently be converted by heat treatment into carbon fibers having a high Young's modulus of elasticity and high tensile strength. In order to obtain the desired fibers from such pitch, however, it is not only necessary that such amount of mesophase be present, but also that it form, under quiescent conditions, a homogeneous bulk mesophase having large coalesced domains, i.e., domains of aligned molecules in excess of two hundred microns up to in excess of one thousand microns in size. Pitches which form stringy bulk mesophase under quiescent conditions, having small oriented domains, rather than large coalesced domains, are unsuitable. Such pitches form mesophase having a high viscosity which undergoes only limited coalescence, insufficient to produce large coalesced domains having sizes in excess of two hundred microns. Instead. small oriented domains of mesophase agglomerate to produce clumps or stringy masses wherein the ultimate domain size does not exceed one hundred microns. Certain pitches which polymerize very rapidly are of this type. Likewise, pitches which do not form a homogeneous bulk mesophase are unsuitable. The latter phenomenon is caused by the presence of infusible solids (which are either present in the original pitch or which develop on heating) which are enveloped by the coalescing mesophase and serve to interrupt the homogeneity and uniformity of the coalesced domains, and the boundaries between them.
Another requirement is that the pitch be non-thixotropic under the conditions employed in the spinning of the pitch into fibers, i.e., it must exhibit a Newtonian or plastic flow behavior so that the flow is uniform and well behaved. When such pitches are heated to a temperature where they exhibit a viscosity of from about 10 poises to about 200 poises, uniform fibers may be readily spun therefrom. Pitches, on the other hand, which do not exhibit Newtonian or plastic flow behavior at the temperature of spinning, do not permit uniform fibers to be spun therefrom which can be converted by further heat treatment into carbon fibers having a high Young's modulus of elasticity and high tensile strength.
Carbonaceous pitches having a mesophase content of from about 40 per cent by weight to about 90 per cent by weight can be produced in accordance with known techniques, as disclosed in aforementioned copending application Ser. No. 338,147, by heating a carbonaceous pitch in an inert atmosphere at a temperature above about 350°C. for a time sufficient to produce the desired quantity of mesophase. By an inert atmosphere is meant an atmosphere which does not react with the pitch under the heating conditions employed, such as nitrogen, argon, xenon, helium, and the like. The heating period required to produce the desired mesophase content varies with the particular pitch and temperature employed, with longer heating periods required at lower temperatures than at higher temperatures. At 350°C., the minimum temperature generally required to produce mesophase, at least one week of heating is usually necessary to produce a mesophase content of about 40 per cent. At temperatures of from about 400°C. to 450°C., conversion to mesophase proceeds more rapidly, and a 50 per cent mesophase content can usually be produced at such temperatures within about 1-40 hours. Such temperatures are generally employed for this reason. Temperatures above about 500°C. are undesirable, and heating at this temperature should not be employed for more than about 5 minutes to avoid conversion of the pitch to coke.
Although the time required to produce a mesophase pitch having a given mesophase content is reduced as the temperature of preparation rises, it has been found that heating at elevated temperatures adversely affects the rheological properties of the pitch by altering the molecular weight distribution of both the mesophase and non-mesophase portions of the pitch. Thus, heating at elevated temperatures tends to increase the amount of high molecular weight molecules in the mesophase portion of the pitch. At the same time, heating at such temperatures also results in an increased amount of low molecular weight molecules in the non-mesophase portion of the pitch. As a result, mesophase pitches of a given mesophase content prepared at elevated temperatures in relatively short periods of time have been found to have a higher average molecular weight in the mesophase portion of the pitch and a lower average molecular weight in the non-mesophase portion of the pitch, than mesophase pitches of like mesophase content prepared at more moderate temperatures over more extended periods. This wider molecular weight distribution has been found to have an adverse effect on the rheology and spinnability of the pitch, evidently because of a low degree of compatibility between the very high molecular weight fraction of the mesophase portion of the pitch and the very low molecular weight fraction of the non-mesophase portion of the pitch. The very high molecular weight material in the mesophase portion of the pitch can only be adequately plasticized at very high temperatures where the tendency of the very low molecular weight molecules in the non-mesophase portion of the pitch to volatilize is greatly increased. As a result, when such pitches are heated to a temperature where they have a viscosity suitable for spinning and attempts are made to produce fibers therefrom, excessive expulsion of volatiles occurs which greatly interferes with the processability of the pitch into fibers of small and uniform diameter. For these reasons, means have been sought for shortening the time required to produce mesophase pitch at relatively moderate temperatures of preparation where more favorable rheological properties are imparted to the pitch.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has now been discovered that mesophase pitch of a given mesophase content can be prepared in substantially shorter periods of time than heretofore possible, at a given temperature, if an inert gas is passed through the pitch during formation of the mesophase. Treating the pitch with an inert gas in this manner aids in the removal of volatile low molecular weight components initially present, together with low molecular weight polymerization by-products of the pitch, and results in the more efficient conversion of the precursor pitch to mesophase pitch. Mesophase pitches having a mesophase content of from about 40 per cent by weight to about 90 per cent by weight can be prepared in this manner, at a given temperature, at a rate of up to more than twice as fast as that normally required in the absence of such treatment, i.e., in periods of time as little as less than one-half of that normally required when mesophase is produced without an inert gas being passed through the pitch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As a carbonaceous pitch is heated to a temperature sufficiently elevated to produce mesophase, the more volatile low molecular weight molecules present therein are slowly volatilized from the pitch. As heating is continued above a temperature at which mesophase is produced, the more reactive higher molecular weight molecules polymerize to form still higher molecular weight molecules, which then orient themselves to form mesophase. While the less reactive lower molecular weight molecules which have not been volatilized can also polymerize, they often form hydrogenated and/or substituted polymerization by-products having a molecular weight below about 600 which do not orient to form mesophase. Although these low molecular weight polymerization by-products are gradually volatilized as heating of the pitch is continued, the presence of large amounts of these by-products during much of the time that the pitch is being converted to mesophase has been found to impede the formation of mesophase by the more reactive molecules, and, as a result, to considerably lengthen the time necessary to produce a pitch of a given mesophase content. Further, because of their small size and low aromaticity, these polymerization by-products are not readily compatible with the larger, higher molecular weight, more aromatic molecules present in the mesophase portion of the pitch, and the lack of compatibility between these high and low molecular weight molecules adversely affects the rheology and spinnability of the pitch. As pointed out previously, the very high molecular weight fraction of the mesophase portion of the pitch can only be adequately plasticized at very high temperatures where the tendency of the very low molecular weight molecules in the non-mesophase portion of the pitch to volatilize is greatly increased, and when pitches having large amounts of such materials are heated to a temperature where they have a viscosity suitable for spinning and attempts are made to produce fibers therefrom, excessive expulsion of volatiles occurs which greatly interferes with the processability of the pitch into fibers of small and uniform diameter.
This invention takes advantage of the differences in molecular weight and volatility between the mesophase-forming molecules present in the pitch and those low molecular weight components and polymerization by-products which do not form mesophase to effect removal of the undesirable more volatile low molecular weight materials and more rapidly convert the pitch to mesophase. The molecules which do not convert to mesophase are of lower molecular weight than the higher molecular weight mesophase-forming molecules and, facilitated by the inert gas purge during conversion of the pitch to mesophase, are preferentially volatilized from the pitch during formation of the mesophase, allowing the pitch to obtain a given mesophase content in substantially reduced periods of time. Thus, in addition to shortening the time required to produce a pitch of a given mesophase content, this procedure has the effect of lessening the amount of low molecular weight molecules in the non-mesophase portion of the pitch and raising the average molecular weight thereof. Consequently, such pitches can more easily be spun into fibers of small and uniform diameter with little evolution of volatiles.
Removal of the more volatile components of the pitch which do not convert to mesophase is effected by passing an inert gas through the pitch, during preparation of the mesophase, at a rate of at least 0.5 scfh. per pound of pitch, preferably at a rate of 0.7 scfh. to 5.0 scfh. per pound of pitch. Any inert gas which does not react with the pitch under the heating conditions employed can be used to facilitate removal of these components. Illustrative of such gases are nitrogen, argon, xenon, helium, steam and the like.
As aforementioned, removal of the undesirable more volatile low molecular weight materials hastens conversion of the pitch to mesophase, and when mesophase is produced while passing an inert gas through the pitch in this manner, the time required to produce a pitch of a given mesophase content, at a given temperature, is reduced by as much as more than one-half of that normally required in the absence of such treatment. Generally, the time required to produce a pitch of a given mesophase content is reduced by at least 25 per cent, usually from 40 per cent to 70 per cent, when the mesophase is prepared while passing an inert gas through the pitch as described as opposed to when it is prepared under identical conditions but in the absence of such treatment.
While any temperature above about 350°C. up to about 500°C. can be employed to convert the precursor pitch to mesophase, it has been found that mesophase pitches possess improved rheological and spinning characteristics when they are prepared at a temperature of from 380°C. to 440°C., most preferably from 380°C. to 410°C., so as to produce a mesophase content of from 50 per cent by weight to 65 per cent by weight. Usually from 2 hours to 60 hours of heating are required at such temperatures to produce the desired amount of mesophase. Mesophase pitches prepared under these conditions have been found to possess a smaller differential between the number average molecular weights of the mesophase and non-mesophase portions of the pitch, than mesophase pitches having the same mesophase content which have been prepared at more elevated temperatures in shorter periods of time. The attendant rheological and spinning properties accompanying this narrower molecular weight distribution has been found to substantially facilitate the processability of the pitch into fibers of small and uniform diameter.
The mesophase pitches prepared under the preferred conditions, i.e., by heating at a temperature of from 380°C. to 440°C. so as to produce a mesophase content of from 50 per cent by weight to 65 per cent by weight possess a lesser amount of high molecular weight molecules in the mesophase portion of the pitch and a lesser amount of low molecular weight molecules in the non-mesophase portion of the pitch, and have a lower number average molecular weight in the mesophase portion of the pitch and a higher number average molecular weight in the non-mesophase portion of the pitch, than mesophase pitches having the same mesophase content which have been prepared at more elevated temperatures in shorter periods of time. When mesophase pitches are prepared under such conditions, less than 50 per cent of the molecules in the mesophase portion of the pitch have a molecular weight in excess of 4000, while the remaining molecules have a number average molecular weight of from 1400 to 2800. The molecules in the non-mesophase portion of such pitches have a number average molecular weight of from 800 to 1200, with less than 20 per cent of such molecules having a molecular weight of less than 600. When such pitches are prepared by heating at the most preferred temperature range of from 380°C. to 410°C., from 20 per cent to 40 per cent of the molecules in the mesophase portion of the pitch have a molecular weight in excess of 4000, while the remaining molecules have a number average molecular weight of from 1400 to 2600. The molecules in the non-mesophase portion of pitches prepared by heating at the most preferred temperature range have a number average molecular weight of from 900 to 1200, with from 10 per cent to 16 per cent of such molecules having a molecular weight of less than 600. When mesophase pitches are prepared at temperatures in excess of 440°C., on the other hand, more than 80 per cent of the molecules in the mesophase portion of the pitch have a molecular weight in excess of 4000, while in excess of 25 per cent of the molecules in the non-mesophase portion of the pitch have a molecular weight of less than 600. The molecules in the non-mesophase portion of the pitch have a number average molecular weight of less than 800, while the number average molecular weight of the molecules in the mesophase portion of the pitch which do not have a molecular weight in excess of 4000 is from 1400 to 2800.
Mesophase pitches prepared by heating at a temperature of from 380°C. to 440°C. so as to produce a mesophase content of from 50 per cent by weight to 65 per cent by weight usually exhibit a viscosity of from 10 poises to 200 poises at a temperature of from 320°C. to 440°C., and can readily be spun into fibers of small and uniform diameter at such temperatures with little evolution of volatiles. Because of their excellent rheological properties, such pitches are eminently suitable for spinning carbonaceous fibers which may subsequently be converted by heat treatment into fibers having a high Young's modulus of elasticity and high tensile strength.
In order to produce pitches having the preferred mesophase content and molecular weight characteristics, it is usually necessary to heat a carbonaceous pitch at a temperature of from 380°C. to 440°C. for at least 2 hours, preferably for from 2 hours to 60 hours. Excessive heating should be avoided so as not to produce a mesophase content in excess of 65 per cent by weight, or adversely affect the desired molecular weight distribution. To obtain the desired molecular weight characteristics it is also necessary that the pitch be agitated during formation of the mesophase so as to produce a homogeneous emulsion of the immiscible mesophase and non-mesophase portions of the pitch. Such agitation can be effected by any conventional means, e.g., by stirring or rotation of the pitch, so long as it is sufficient to effectively intermix the mesophase and non-mesophase portions of the pitch.
The degree to which the pitch has been converted to mesophase can readily be determined by polarized light miscroscopy and solubility examinations. Except for certain non-mesophase insolubles present in the original pitch or which, in some instances, develop on heating, the non-mesophase portion of the pitch is readily soluble in organic solvents such as quinoline and pyridine, while the mesophase portion is essentially insoluble..sup.(1) In the case of pitches which do not develop non-mesophase insolubles when heated, the insoluble content of the heat treated pitch over and above the insoluble content of the pitch before it has been heat treated corresponds essentially to the mesophase content..sup.(2) In the case of pitches which do develop non-mesophase insolubles when heated, the insoluble content of the heat treated pitch over and above the insoluble content of the pitch before it has been heat treated is not solely due to the conversion of the pitch to mesophase, but also represents non-mesophase insolubles which are produced along with the mesophase during the heat treatment. Pitches which contain infusible non-mesophase insolubles (either present in the original pitch or developed by heating) in amounts sufficient to prevent the development of homogeneous bulk mesophase are unsuitable for use in the present invention, as noted above. Generally, pitches which contain in excess of about 2 per cent by weight of such infusible materials are unsuitable. The presence or absence of such homogeneous bulk mesophase regions, as well as the presence or absence of infusible non-mesophase insolubles, can be visually observed by polarized light microscopy examination of the pitch (see, e.g., Brooks, J.D., and Taylor, G. H., "The Formation of Some Graphitizing Carbons," Chemistry and Physics of Carbon, Vol. 4, Marcel Dekker, Inc., New York, 1968, pp. 243-268; and Dubois, J., Agache, C., and White, J. L., "The Carbonaceous Mesophase Formed in the Pyrolysis of Graphitizable Organic Materials," Metallography 3, pp. 337-369, 1970). The amounts of each of these materials may also be visually estimated in this manner.
Conventional molecular weight analysis techniques, can be employed to determine the molecular weight characteristics of the mesophase pitches produced in accordance with the present invention. In order to permit molecular weight determinations to be conducted independently on both the mesophase and non-mesophase portions of the pitch, the two phases may be conveniently separated through the use of a suitable organic solvent. As noted above, except for certain non-mesophase insolubles present in the original pitch or which, in some instances, develop on heating, the non-mesophase portion of the pitch is readily soluble in organic solvents such as quinoline and pyridine, while the mesophase portion is essentially insoluble..sup.(3) After separation of the two phases with a solvent in this manner, the non-mesophase portion of the pitch may be recovered from the solvent by vacuum distillation of the solvent.
One means which has been employed to determine the number average molecular weight of the mesophase pitches produced in accordance with the present invention involves the use of a vapor phase osmometer. The utilization of instruments of this type for molecular weight determinations has been described by A. P. Brady et al. (Brady, A. P., Huff, H., and McGain, J. W., J. Phys. & Coll. Chem 55, 304, (1951)). The osmometer measures the difference in electrical resistance between a sensitive reference thermistor in contact with a pure solvent, and a second thermistor in contact with a solution of said solvent having dissolved therein a known concentration of a material whose molecular weight is to be determined. The difference in electrical resistance between the two thermistors is caused by a difference in temperature between the thermistors which is produced by the different vapor pressures of the solvent and the solution. By comparing this value with the differences in resistance obtained with said solvent and standard solutions of said solvent containing known concentrations of compounds of known molecular weights, it is possible to calculate the molecular weight of the solute material. A drop of pure solvent and a drop of a solution of said solvent having dissolved therein a known concentration of the material whose molecular weight is being determined are suspended side by side on a reference thermistor and sample thermistor, respectively, contained in a closed thermostated chamber saturated with solvent vapor, and the resistance of the two thermistors is measured and the difference between the two recorded. Since a solution of a given solvent will always have a lower vapor pressure than the pure solvent, a differential mass transfer occurs between the two drops and the solvent vapor phase, resulting in greater overall condensation on (and less evaporation from) the solution drop than on the solvent drop. This difference in mass transfer causes a temporary temperature difference between the two thermistors (due to differences in loss of heat of vaporization between the two drops) which is proportional to the difference in vapor pressure between the two drops. Since the difference in vapor pressure between the two drops, and hence the difference in temperature and resistance, (ΔR), between the two thermistors depends solely upon the number of molecules of the solute material dissolved in the solvent, and is independent of the chemical composition of the molecules, the mole fraction of solute in the solution, (N), can be determined from a plot of ΔR vs. N for such solvent and solutions of such solvent containing known concentrations of compounds of known molecular weight,.sup.(4) ΔR and N bear a direct linear relationship to each other, and from a determination of N it is possible to calculate the calibration constant, (K), for the solvent employed from the formula: ##EQU1## Having determined the value of K, the molecular weight of the material may be determined from the formula: ##EQU2## wherein M x is the molecular weight of the material upon which the determination is being made, K is the calibration constant for the solvent employed, ΔR is the difference in the resistance between the two thermistors, M y is the molecular weight of the solvent, W y is the weight of the solvent, and W x is the weight of the material whose molecular weight is being determined. Of course, having once determined the value of the calibration constant of a given solvent, (K), the molecular weight of a given material may be determined directly from the formula.
While the molecular weight of the soluble portion of the pitch can be determined directly on a solution thereof, in order to determine the molecular weight of the insoluble portion, it is necessary that it first be solubilized, e.g., by chemical reduction of the aromatic bonds of such material with hydrogen. A suitable means for solubilizing coals and carbons by reduction of the aromatic bonds of these materials has been described by J. D. Brooks et al. (Brooks, J.D., and Silberman, H., "The Chemical Reduction of Some Cokes and Chars", Fuel 41, pp, 67-69, 1962). This method involves the use of hydrogen generated by the reaction of lithium with ethylenediamine, and has been found to effectively reduce the aromatic bonds of carbonaceous materials without rupturing carbon-carbon bonds. Such method has been suitably employed to solubilize the insoluble portion of the pitches prepared in accordance with the invention.
Another means which has been employed to determine the molecular weight characteristics of the mesophase pitches produced in accordance with the present invention is gel permeation chromatography (GPC). This technique has been described by L. R. Snyder (Snyder, L. R., "Determination of Asphalt Molecular Weight Distributions by Gel Permeation Chromatography", Anal. Chem. 41, pp. 1223-1227, 1969). A gel permeation chromatograph is employed to fractionate a solution of polymer or polymer related molecules of various sizes, and the molecular weight distribution of the sample is determined with the aid of a detection system which is linearly responsive to solute concentration, such as a differential refractometer or a differential ultraviolet absorption spectrometer. As in the case of the vapor phase osmometry technique, in order to permit molecular weight determinations to be conducted independently on both the mesophase and non-mesophase portions of the pitch, the two phases must first be separated through the use of a suitable organic solvent. Again, while the molecular weight of the soluble portion of the pitch can be determined directly on a solution thereof, in order to determine the molecular weight of the insoluble portion, it is necessary that it first be solubilized.
Fractionation of the sample whose molecular weight distribution is being determined is effected by dissolving the sample in a suitable solvent and passing the solution through the chromatograph and collecting measured fractions of the solution which elute through the separation column of the chromatograph. A given volume of solvent is required to pass molecules of a given molecular size through the chromatograph, so that each fraction of solution which elutes from the chromatograph contains molecules of a given molecular size. The fractions which flow through the column first contain the higher molecular weight molecules, while the fractions which take the longest time to elute through the column contain the lower molecular weight molecules.
After the sample has been fractionated, the concentration of solute in each fraction is determined by means of a suitable detection system, such as a differential refractometer or a differential ultraviolet absorption spectrometer. When a differential refractometer is employed, the refractive index of each fraction is automatically compared to that of the pure solvent by means of two photoelectric cells which are sensitive to the intensity of light passing through such fractions and solvent, and the differences in signal intensities between the two cells are automatically plotted against the cumulative elution volume of the solution. Since the magnitude of these differences in signal intensity is linearly related to the concentration by weight of solute molecules present, the relative concentration by weight of molecules in each fraction can be determined by dividing the differential signal intensity for that fraction by the total integrated differential signal intensity of all the fractions. This relative concentration may be graphically depicted by a plot of the differential signal intensity for each fraction against the cumulative elution volume of the sample.
The molecular weight of the molecules in each fraction can then be determined by standard techniques, e.g., by the osmometry techniques described above. Since most conventional pitches are composed of similar types of molecular species, once the molecular weights of the various fractions of a particular sample have been determined, that sample may be used as a standard and the molecular weights of the fractions of subsequent samples can be determined from the known molecular weights of like fractions of the standard. Thus, molecular weight determinations need not be repeatedly made on each fraction of each sample, but may be obtained from the molecular weights determined for like fractions of the standard. For convenience, a molecular weight distribution curve depicting the relationship of the molecular weight to the elution volume of the standard may be prepared by plotting the molecular weights determined for the standard fractions against the cumulative elution volume of the standard. The molecular weights of the molecules of the various chromatographic fractions of any given sample can then be directly read from this curve. As aforementioned, the relative concentration by weight of solute molecules in each fraction can be determined by differential refractive index measurements.
To facilitate the molecular weight determinations, the differential signal intensities and elution volume values obtained on a given sample, together with previously determined molecular weight data relating to the various chromatographic fractions of a standard pitch, can be processed by a computer and transcribed into a complete molecular weight distribution analysis. By this procedure, complete printouts are routinely provided of number average molecular weight (M n ), weight average molecular weight (M w ), molecular weight distribution parameter (M w /M.sub. n), as well as a compilation of molecular weight and percentage by weight of solute present in each chromatographic fraction of a sample.
Aromatic base carbonaceous pitches having a carbon content of from about 92 per cent by weight to about 96 per cent by weight and a hydrogen content of from about 4 per cent by weight to about 8 per cent by weight are generally suitable for producing mesophase pitches which can be employed to produce fibers capable of being heat treated to produce fibers having a high Young's modulus of elasticity and a high tensile strength. Elements other than carbon and hydrogen, such as oxygen, sulfur and nitrogen, are undesirable and should not be present in excess of about 4 per cent by weight. The presence of more than such amount of extraneous elements may disrupt the formation of carbon crystallities during subsequent heat treatment and prevent the development of a graphitic-like structure within the fibers produced from these materials. In addition, the presence of extraneous elements reduces the carbon content of the pitch and hence the ultimate yield of carbon fiber. when such extraneous elements are present in amounts of from about 0.5 per cent by weight to about 4 per cent by weight, the pitches generally have a carbon content of from about 92-95 per cent by weight, the balance being hydrogen.
petroleum pitch, coal tar pitch and acenaphthylene pitch, which are well-graphitizing pitches, are preferred starting materials for producing the mesophase pitches which are employed to produce the fibers of the instant invention. Petroleum pitch, of course, is the residuum carbonaceous material obtained from the distillation of crude oils or the catalytic cracking of petroleum distillates. Coal tar pitch is similarly obtained by the distillation of coal. Both of these materials are commercially available natural pitches in which mesophase can easily be produced, and are preferred for this reason. Acenaphthylene pitch, on the other hand, is a synthetic pitch which is preferred because of its ability to produce excellent fibers. Acenaphthylene pitch can be produced by the pyrolysis of polymers of acenaphthylene as described by Edstrom et al. in U.S. Pat. No. 3,574,653.
Some pitches, such as fluoranthene pitch, polymerize very rapidly when heated and fail to develop large coalesced domains of mesophase, and are, therefore, not suitable precursor materials. Likewise, pitches having a high infusible non-mesophase insoluble content in organic solvents such as quinoline or pyridine, or those which develop a high infusible non-mesophase insoluble content when heated, should not be employed as starting materials, as explained above, because these pitches are incapable of developing the homogeneous bulk mesophase necessary to produce highly oriented carbonaceous fibers capable of being converted by heat treatment into carbon fibers having a high Young's modulus of elasticity and high tensile strength. For this reason, pitches having an infusible quinoline-insoluble or pyridine-insoluble content of more than about 2 per cent by weight (determined as described above) should not be employed, or should be filtered to remove this material before being heated to produce mesophase. Preferably, such pitches are filtered when they contain more than about 1 per cent by weight of such infusible, insoluble material. Most petroleum pitches and synthetic pitches have a low infusible, insoluble content and can be used directly without such filtration. Most coal tar pitches, on the other hand, have a high infusible, insoluble content and require filtration before they can be employed.
As the pitch is heated at a temperature between 350°C. and 500°C. to produce mesophase, the pitch will, of course, pyrolyze to a certain extent and the composition of the pitch will be altered, depending upon the temperature, the heating time, and the composition and structure of the starting material. Generally, however, after heating a carbonaceous pitch for a time sufficient to produce a mesophase content of from about 40 per cent by weight to about 90 per cent by weight, the resulting pitch will contain a carbon content of from about 94-96 per cent by weight and a hydrogen content of from about 4-6 per cent by weight. When such pitches contain elements other than carbon and hydrogen in amounts of from about 0.5 per cent by weight to about 4 per cent by weight, the mesophase pitch will generally have a carbon content of from about 92-95 per cent by weight, the balance being hydrogen.
After the desired mesophase pitch has been prepared, it is spun into fibers by conventional techniques, e.g., by melt spinning, centrifugal spinning, blow spinning, or in any other known manner. As noted above, in order to obtain highly oriented carbonaceous fibers capable of being heat treated to produce carbon fibers having a high Young's modulus of elasticity and high tensile strength, the pitch must, under quiescent conditions, form a homogeneous bulk mesophase having large coalesced domains, and be nonthixotropic under the conditions employed in the spinning. Further, in order to obtain uniform fibers from such pitch, the pitch should be agitated immediately prior to spinning so as to effectively intermix the immiscible mesophase and non-mesophase portions of the pitch.
The temperature at which the pitch is spun depends, of course, upon the temperature at which the pitch exhibits a suitable viscosity. Since the softening temperature of the pitch, and its viscosity at a given temperature, increases as the mesophase content of the pitch increases, the mesophase content should not be permitted to rise to a point which raises the softening point of the pitch to excessive levels. For this reason, pitches having a mesophase content of more than about 90 per cent are generally not employed. Pitches containing a mesophase content of about 40 per cent by weight usually have a viscosity of about 200 poises at about 300°C. and about 10 poises at about 375°C., while pitches containing a mesophase content of about 90 per cent by weight exhibit similar viscosities at temperatures above 430°C. Within this viscosity range, fibers may be conveniently spun from such pitches at a rate of from about 50 feet per minute to about 1000 feet per minute and even up to about 3000 feet per minute. Preferably, the pitch employed has a mesophase content of from about 50 per cent by weight to about 65 per cent by weight and exhibits a viscosity of from about 30 poises to about 150 poises at temperatures of from about 340°C. to about 380°C. At such viscosity and temperature, uniform fibers having diameters of from about 5 microns to about 25 microns can be easily spun. As previously mentioned, however, in order to obtain the desired fibers, it is important that the pitch be nonthixotropic and exhibit Newtonian or plastic flow behavior during the spinning of the fibers.
The carbonaceous fibers produced in this manner are highly oriented graphitizable materials having a high degree of preferred orientation of their molecules parallel to the fiber axis. By "graphitizable" is meant that these fibers are capable of being converted thermally (usually by heating to a temperature in excess of about 2500°C., e.g., from about 2500°C. to about 3000°C.) to a structure having the three-dimensional order characteristic of polycrystalline graphite.
The fibers produced in this manner, of course, have the same chemical composition as the pitch from which they were drawn, and like such pitch contain from about 40 per cent by weight to about 90 per cent by weight mesophase. When examined under magnification by polarized light microscopy techniques, the fibers exhibit textural variations which give them the appearance of a "mini-composite". Large elongated anisotropic domains, having a fibrillarshaped appearance, can be seen distributed throughout the fiber. These anisotropic domains are highly oriented and preferentially aligned parallel to the fiber axis. It is believed that these anisotropic domains, which are elongated by the shear forces exerted on the pitch during spinning of the fibers, are not composed entirely of mesophase, but are also made up of non-mesophase. Evidently, the non-mesophase is oriented, as well as drawn into elongated domains, during spinning by these shear forces and the orienting effects exerted by the mesophase domains as they are elongated. Isotropic regions may also be present, although they may not be visible and are difficult to differentiate from those anisotropic regions which happen to show extinction. Characteristically, the oriented elongated domains have diameters in excess of 5000 A, generally from about 10,000 A to about 40,000 A, and because of their large size are easily observed when examined by conventional polarized light microscopy techniques at a magnification of 1000. (The maximum resolving power of a standard polarized light microscope having a magnification factor of 1000 is only a few tenths of a micron [1 micron = 10,000 A] and anisotropic domains having dimensions of 1000 A or less cannot be detected by this technique.)
While fibers spun from a pitch containing in excess of about 85 per cent by weight mesophase often retain their shape when carbonized without any prior thermosetting, fibers spun from a pitch containing less than about 85 per cent by weight mesophase require some thermosetting before they can be carbonized. Thermosetting of the fibers is readily effected by heating the fibers in an oxygen-containing atmosphere for a time sufficient to render them infusible. The oxygen-containing atmosphere employed may be pure oxygen or an oxygen-rich atmosphere. Most conveniently, air is employed as the oxidizing atmosphere.
The time required to effect thermosetting of the fibers will, of course, vary with such factors as the particular oxidizing atmosphere, the temperature employed, the diameter of the fibers, the particular pitch from which the fibers are prepared, and the mesophase content of such pitch. Generally, however, thermosetting of the fibers can be effected in relatively short periods of time, usually in from about 5 minutes to about 60 minutes.
The temperature employed to effect thermosetting of the fibers must, of course, not exceed the temperature at which the fibers will soften or distort. The maximum temperature which can be employed will thus depend upon the particular pitch from which the fibers were spun, and the mesophase content of such pitch. The higher the mesophase content of the pitch, the higher will be its softening temperature, and the higher the temperature which can be employed to effect thermosetting of the fibers. At higher temperatures, of course, fibers of a given diameter can be thermoset in less time than is possible at lower temperatures. Fibers prepared from a pitch having a lower mesophase content, on the other hand, require relatively longer heat treatment at somewhat lower temperatures to render them infusible.
A minimum temperature of at least 250°C. is generally necessary to effectively thermoset the carbonaceous fibers produced in accordance with the invention. Temperatures in excess of 400°C. may cause melting and/or excessive burn-off of the fibers and should be avoided. Preferably, temperatures of from about 275°C. to about 350°C. are employed. At such temperatures, thermosetting can generally be effected within from about 5 minutes to about 60 minutes. Since it is undesirable to oxidize the fibers more than necessary to render them totally infusible, the fibers are generally not heated for longer than about 60 minutes, or at temperatures in excess of 400°C.
After the fibers have been thermoset, the infusible fibers are carbonized by heating in an inert atmosphere, such as that described above, to a temperature sufficiently elevated to remove hydrogen and other volatiles and produce a substantially all-carbon fiber. Fibers having a carbon content greater than about 98 per cent by weight can generally be produced by heating to a temperature in excess of about 1000°C., and at temperatures in excess of about 1500°C., the fibers are completely carbonized.
Usually, carbonization is effected at a temperature of from about 1000°C. to about 2000°C., preferably from about 1500°C. to about 1900°C. Generally, residence times of from about 0.5 minute to about 25 minutes, preferably from about 1 minute to about 5 minutes, are employed. While more extended heating times can be employed with good results, such residence times are uneconomical and, as a practical matter, there is no advantage in employing such long periods.
In order to ensure that the rate of weight loss of the fibers does not become so excessive as to disrupt the fiber structure, it is preferred to heat the fibers for a brief period at a temperature of from about 700°C. to about 900°C. before they are heated to their final carbonization temperature. Residence times at these temperatures of from about 30 seconds to about 5 minutes are usually sufficient. Preferably, the fibers are heated at a temperature of about 700°C. for about one-half minute and then at a temperature of about 900°C. for like time. In any event, the heating rate must be controlled so that the volatization does not proceed at an excessive rate.
In a preferred method of heat treatment, continuous filaments of the fibers are passed through a series of heating zones which are held at successively higher temperatures. If desired, the first of such zones may contain an oxidizing atmosphere when thermosetting of the fibers is effected. Several arrangements of apparatus can be utilized in providing the series of heating zones. Thus, one furnace can be used with the fibers being passed through the furnace several times and with the temperature being increased each time. Alternatively, the fibers may be given a single pass through several furnaces, with each successive furnace being maintained at a higher temperature than that of the previous furnace. Also, a single furnace with several heating zones maintained at successively higher temperatures in the direction of travel of the fibers, can be used.
The carbon fibers produced in this manner have a highly oriented structure characterized by the presence of carbon crystallites preferentially aligned parallel to the fiber axis, and are graphitizable materials which when heated to graphitizing temperatures develop the three-dimensional order characteristic of polycrystalline graphite and graphitic-like properties associated therewith, such as high density and low electrical resistivity.
If desired, the carbonized fibers may be further heated in an inert atmosphere, as described hereinbefore, to a still higher temperature in a range of from about 2500°C. to about 3300°C., preferably from about 2800°C. to about 3000°C., to produce fibers having not only a high degree of preferred orientation of their carbon crystallites parallel to the fiber axis, but also a structure characteristic of polycrystalline graphite. A residence time of about 1 minute is satisfactory, although both shorter and longer times may be employed, e.g., from about 10 seconds to about 5 minutes, or longer. Residence times longer than 5 minutes are uneconomical and unnecessary, but may be employed if desired.
The fibers produced by heating at a temperature above about 2500°C., preferably above about 2800°C., are characterized as having the three-dimensional order of polycrystalline graphite. This three-dimensional order is established by the X-ray diffraction pattern of the fibers, specifically by the presence of the (112) cross-lattice line and the resolution of the (10) band into two distinct lines, (100) and (101). The short arcs which constitute the (00l) bands of the pattern show the carbon crystallites of the fibers to be preferentially aligned parallel to the fiber axis. Microdensitometer scanning of the (002) band of the exposed X-ray film indicate this preferred orientation to be no more than about 10°, usually from about 5° to about 10° (expressed as the full width at half maximum of the azimuthal intensity distribution). Apparent layer size (L a ) and apparent stack height (L c ) of the crystallites are in excess of 1000 A and are thus too large to be measured by X-ray techniques. The interlayer spacing (d) of the crystallites, calculated from the distance between the corresponding (00l) diffraction arcs, is no more than 3.37 A, usually from 3.36 A to 3.37 A.
EXAMPLE
The following example is set forth for purposes of illustration so that those skilled in the art may better understand the invention. It should be understood that it is exemplary only, and should not be construed as limiting the invention in any manner.
EXAMPLE 1
A commercial petroleum pitch was employed to produce a pitch having a mesophase content of about 53 per cent by weight. The precursor pitch had a number average molecular weight of 400, a density of 1.23 grams/cc., a softening temperature of 120°C., and contained 0.83 per cent by weight quinoline insolubles (Q.I. was determined by quinoline extraction at 75°C.). Chemical analysis showed a carbon content of 93.0%, a hydrogen content of 5.6%, a sulfur content of 1.1% and 0.044% ash.
The mesophase pitch was produced by heating 60 grams of the precursor pitch in a 86 cc. reactor to a temperature of about 200°C. over a one hour period, then increasing the temperature of the pitch from about 200°C. to about 400°C. at a rate of about 30°C. per hour, and maintaining the pitch at about 400°C. for an additional 12 hours. The pitch was continuously stirred during this time and nitrogen gas was continuously bubbled through the pitch at a rate of 0.2 scfh.
The pitch produced in this manner had a pyridine insoluble content of 53 per cent, indicating a mesophase content of close to 53 per cent. The pitch could be easily spun into fibers, and a considerable quantity of fiber was produced by spinning the pitch through a spinnerette (0.015 inch diameter hole) at a temperature of 368°C. The filament passed through a nitrogen atmosphere as it left the spinnerette and before it was taken up by a reel.
A portion of the fiber produced in this manner was heated in oxygen for six minutes at 390°C. The resulting oxidized fibers were totally infusible and could be heated at elevated temperatures without sagging. After heating the infusible fibers to 1900°C. over a period of about 10 minutes in a nitrogen atmosphere, the fibers were found to have a tensile strength of 171 × 10 3 psi. and a Young's modulus of elasticity of 46 × 10 6 psi. (Tensile strength and Young's modulus are the average values of 10 samples.)
For comparative purposes, a mesophase pitch was prepared from the same precursor pitch and in the same manner described above except that while the pitch was prepared under a nitrogen atmosphere, the nitrogen was not allowed to bubble through the pitch. Thirty-two hours of heating at 400°C. were required to produce a mesophase pitch having a pyridine insoluble content of 50 per cent.
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An improved process for producing carbon fibers from pitch which has been transformed, in part, to a liquid crystal or so-called "mesophase" state. According to the process, pitch of a given mesophase content, suitable for producing carbon fibers, is produced in substantially shorter periods of time than heretofore possible, at a given temperature, by passing an inert gas through the pitch during formation of the mesophase.
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FIELD OF THE INVENTION
The invention relates generally to water treatment systems. More particularly, the invention relates to water treatment systems employing ultraviolet light.
BACKGROUND OF THE INVENTION
With ultraviolet light, light and temperature can be precisely controlled to create an atmosphere for sterilization and purification of water. Of all the different characteristics of ultraviolet light, selection of a proper wavelength for use is generally most important. Natural light is an optimum light in the area of ultraviolet as in sunlight, however, in many areas an artificial supplement of ultraviolet light in a higher range may be realized.
Natural light and artificial light have different wavelengths or spectral qualities. There are many different types of artificial light depending on the light source used and the characteristics. The spectral characteristics can be altered or enhanced by the use of filters, coating or other means. Normally, the violet-blue segments of the spectrum are most important for sterilization and purification production.
A plethora of lighting systems for ultraviolet sterilization and purification are currently in use such as the one described in Canadian Patent No. 2,373,673, entitled Flow Cytometer and Ultraviolet Disinfecting Systems which was published on Aug. 27, 2002. In almost all cases, a high amount of light output results in considerable heat generated near the source and transferred into the water. As required, the light source can be placed close to the treated area. Significant temperature change develops near the water which can produce dangerous results. Light sources that have been used in the past include fluorescent ultraviolet lighting, high or low pressure lights and a variety of others.
Often times, water lighting systems must deal with excessive heat produced by existing technologies. Water lighting systems allow the placing of light sources close to the treatment area. The drawback is the heat build up around the light in conjunction with electricity is detrimental. This light intensity is very high to ensure the maximum rate of sterilzation and purification will occur. The water jacket enclosure surrounds the bulb and absorbs a percentage of ultraviolet light to the treatment area. The result is a reduction of light output through the surface.
Many disadvantages of the current systems are heat output, complexity, cost and difficulty of maintenance operations. Heat values with electricity are the most problematic.
It is, therefore, desirable to provide a water treatment system which overcomes some of the disadvantages of the prior art.
SUMMARY OF THE INVENTION
It is an object of the invention to obviate or mitigate at least one disadvantage of previous water treatment systems.
In a first aspect, the present invention provides an ultraviolet water treatment system comprising a water chamber having a water intake for untreated water to enter the chamber, and a water outlet for water to leave the chamber; an ultraviolet light source; and a fibre optic rod having a distributing end and a receiving end, wherein the receiving end is located to receive a focused ultraviolet light from the light source and convey the light through the rod and out the distributing end into the chamber to treat the water.
The UV water treatment system is directed at being installed in existing water plumbing in houses, cottages etc.; where water needs to be treated/sterilized before use.
Other aspects and features of the invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIG. 1 is a schematic view of a water system;
FIG. 2 is a perspective view of a first embodiment of a water treatment system;
FIG. 3 is a sectional view of the water treatment system of FIG. 2 ;
FIG. 4 is a sectional view of a fibre optic rod connected to a water treatment chamber in accordance with the water treatment system of FIG. 2 ;
FIGS. 5 a and 5 b are views of an ultraviolet (UV) source for use in the water treatment system; and
FIGS. 6 a , 6 b and 6 c are views of a second embodiment of the fibre optic rod of FIG. 4 .
DETAILED DESCRIPTION
Generally, the invention provides an ultraviolet water treatment system for treating water for personal use.
Turning to FIG. 1 , a schematic diagram of an ultraviolet water treatment system 10 installed in a water flow system is shown. The water flow system 1 comprises a water input (in which untreated water enters) which is connected to a shutoff valve 2 via a bypass T 3 . The bypass T 3 is connected to a solenoid valve 4 which is connected to the water treatment system 10 . The water treatment system 10 is then connected to a second shutoff valve 5 via a pressure/flow switch 6 . The second shutoff valve 5 is connected to a second bypass T 7 which allows the treated water to be transferred to a requesting tap in the water system. The two bypass Ts 3 and 7 are connected to each other by a bypass valve and line 8 . A power supply 9 is also connected to the UV water treatment system 10 the solenoid valve 4 and the pressure/flow switch 6 .
Turning to FIG. 2 , a perspective view of the ultraviolet water treatment system is shown. The water treatment system 10 generally comprises a water treatment section 12 , a lamp housing section 14 and a ventilation section 16 .
The water treatment section 12 comprises a water treatment chamber 18 preferably manufactured from stainless steel, connected to a water intake 20 and a water outlet 22 . The water intake 20 and the water outlet 22 are both channel milled into the water treatment chamber 18 . The water treatment section 14 also comprises a cap 24 which is removable to facilitate cleaning of the water treatment chamber 18 . The cap 24 is screwably attached to the water treatment chamber 18 for easy removal/replacement.
The lamp housing section 14 comprises a body section 26 (having a set of ventilation vents 28 on opposite sides) and a cover 30 atop which the ventilation section 16 sits. The cover 30 may be removed from the top of the lamp body section 26 in order to repair any parts which are housed by the lamp housing section 14 . These parts will be described in more detail below.
The ventilation section 16 houses a forced air ventilation fan 32 which is used to cool the inside of the lamp housing section 14 when the water treatment system 10 is in use. In general, the ventilation fan 32 is integrated into the top cover and is not removable on it's own.
Turning to FIG. 3 , a sectional view of a first embodiment of the ultraviolet (UV) water treatment system 10 is shown. When installed, the water intake 20 and the water outlet 22 are generally attached, via their connectors 34 , to standard plumbing parts in the water system. The cap 24 preferably has a polished reflective surface on its internal surface 36 facing the water treatment chamber 18 in order to assist in sterilization of the water. The internal surface 36 is preferably concave with a radius ground into it.
The lamp housing section 14 houses a UV source 38 comprising a UV lamp 39 for providing the necessary UV light to sterilize the water, a reflector 40 , preferably a spun aluminium reflector which is used to focus the UV light and a lamp socket 42 . The reflector may also be a dichroic ellipsoidal reflector. If any part of the UV source 38 breaks down, the entire UV source 38 is preferably replaced in order to maintain positional relationship between the UV lamp 39 and that reflector 40 . The lamp socket 42 is connected via wiring 44 to a power supply connector 46 for providing power to the lamp 39 . The power supply connector 46 is also connected by wiring 48 to the forced air ventilation fan 32 in the ventilation section 16 . As will be understood by one skilled in the art, the power supply connector 46 is connected to the power supply 9 .
At one end of the lamp housing body section 26 (near the water treatment chamber 18 ) is a UV conducting fibre optic rod 50 , which, in the present embodiment, is made of quartz. The fibre optic rod 50 provides a connection between the water treatment section 12 and the lamp housing section 14 as will be described in more detail below with respect to FIG. 3 . As can be seen, the optic rod 50 is preferably screwed into the water treatment chamber 18 with O-ring 52 to assist in sealing the connection. The O-ring 52 is preferably groove machined into the water treatment chamber 18 so that the rod 50 may be screwed down until the O-ring 52 is compressed thereby accurately locating the fibre optic rod 50 at a predetermined distance from the cap 24 .
Located near the ventilation vents 28 are a pair of light traps 54 which assist in covering the vents 28 so that the UV light from the UV lamp 34 does not escape the lamp housing body 26 , but is focused towards the fibre optic rod 50 , during the sterilization process. As described above, the reflector 40 also assists in focussing the UV light towards the fibre optic rod 50 in order to provide maximum UV light to the rod 50 and therefore the sterilization process, as illustrated by the arrows 51 , during the sterilization process.
The arrows 51 provide a schematic ray diagram showing various paths taken by the UV light from the lamp and the reflector during the sterilization process. After the UV lamp is powered on, the UV light rays reflect off the reflector towards the second optical end of the fibre optic rod. The UV light rays then travel from the second optical end to the first optical end via the middle section of the rod. The resultants rays fill up the lens at the first optical end which then transfers the UV rays into the water treatment chamber whereby the water is treated by the UV rays and sterilized.
Turning to FIG. 4 , a more detailed schematic of the connection between the first embodiment of the fibre optic rod 50 and the water treatment chamber 18 is shown.
The fibre optic rod 50 comprises a first optical end 56 where an optical lens is ground into the fibre optic rod and covered with an infra-red (IR) reflective coating and a rounded second optical end 58 made from quartz. The quartz used in the second optical end 58 is preferably a high grade UV transmitting quartz such as surpasil quartz. Furthermore, the first optical end 56 may also be manufactured out of suprasil quartz. The second optical end collects UV light from the UV lamp 49 and the reflector 40 and concentrates it for transmission into the water chamber.
The optical lens used in the first optical end 56 may also be quartz. A middle section 60 of the rod 50 , between the two optical ends 56 and 58 , is manufactured out of quartz which causes the fibre optic rod 50 to be a quartz rod.
The optical ends and the middle section are held in place by a cylindrical sleeve 61 , preferably manufactured out of stainless steel.
In an alternative embodiment, the rod 50 may be tapered in order to fit and seal in the opening between the lamp housing body section 26 and the water treatment chamber 18 rather than being screwed in. In this manner, the rod 50 is adhesively bonded to the chamber 18 .
An O-ring 62 is also located between the cap 24 and the water treatment chamber 18 to seal the connection between the cap 24 and the chamber 18 so that no water may escape from the chamber before, during and after the sterilization process.
Turning to FIGS. 5 a and 5 b , a perspective view and a front view of the UV source 38 are shown. As can be seen in FIG. 5 a , the UV lamp 39 is located centrally within the dichroic reflector 40 . The position of the lamp 39 with respect to the reflector 40 is quite important since the dichroic reflector is used to reflect/focus the UV light directly onto the second optical end 58 of the fibre optic rod 50 . If the lamp 39 is not centrally located, the impact of the focussed light is lessened. Therefore, when either the reflector 40 or UV lamp 39 needs to be replaced, in order to maintain the spatial relationship between the lamp 39 and the reflector 40 , the entire UV source 38 is replaced and the wiring (not shown) is plugged into the lamp socket 42 of the new UV source.
Turning to FIGS. 6 a , 6 b and 6 c , schematic views of a second embodiment of the fibre optic rod 100 are shown. As with the fibre optic rod described with respect to FIG. 4 , the fibre optic rod 100 comprises a first optical end 102 and a second optical end 104 connected together by a middle section 106 . As with the first embodiment, the first optical end 102 , the second optical end 104 and the middle section 106 are housed in a stainless steel sleeve 108 . In this embodiment, the middle section 106 comprises an index matching fluid which has optical qualities which are similar to quartz. In one embodiment, this index matching fluid is de-ionized water such that even if some of the index matching fluid was to escape or leak from the rod 100 , there are little or no health risks associated with the de-ionized water which provides further health benefits for using the water treatment system. The index matching fluid transmits and converges the UV light rays from the lamp 39 and the reflector 40 as if the rod was an entirely solid quartz optical rod as described above.
There is also an air ballast 110 connected to the middle section 106 of the rod 100 . The air ballast 110 is generally used to connect to a pump for insertion of the index matching fluid into the middle section 106 . The air ballast 110 also allows for expansion of the index matching fluid during the sterilization process since the fluid generally expands when subjected to heat such as from the UV light. Therefore, the air ballast 110 protects the fibre optic rod from exploding due to the increased pressure in the liquid during the sterilization process.
As with the first embodiment, the fibre optic rod 100 is screwed into the water treatment chamber 18 with the air ballast being located within the lamp housing body. Due to the presence of the air ballast, the level of index matching fluid in the middle section 106 of the rod 100 does not change since the amount of fluid which changes to gas during the sterilization process returns to a liquid form once the UV light is powered off. Therefore, in general, once the fibre optic rod has been installed in the water treatment system 10 there is little or no requirement to pump extra index matching fluid into the rod. The insertion of the index matching fluid takes place before the rod is connected with the water treatment chamber 18 .
Furthermore, due to a requirement that the air ballast 108 is required to be in a vertical position during use, in this embodiment of the water treatment system 10 the system is installed in the water system with the axis of the water intake, the water treatment chamber and the water outlet forming a line perpendicular to the ground.
In operation, the optic rod gathers the UV light in its second optical end and then conveys this light to the water while also acting to absorb/deflect infra-red rays from being transmitted into the water.
In one embodiment of operation, seen as an always-on embodiment, the water treatment system 10 is initially powered up by connecting the power supply connector 46 to the power supply 9 . This provides power to the treatment system 10 allowing for the forced air ventilation fan 32 to operate along with the UV lamp 39 . The forced air ventilation fan 32 operates to cool the inside of the lamp housing body 26 of the lamp housing section 14 since there is a high amount of heat generated by the UV lamp 39 during the sterilization process by drawing in atmospheric air through the ventilation slots 28 and up through the body section 14 to the fan section where the air exits out at the top of the water treatment system 10 thereby passing the UV lamp and the socket.
After the treatment system 10 is powered up, the UV lamp 39 also turns on. The UV light generated by the UV lamp 39 is then focussed by the reflector 40 at the second optical end 58 of the fibre optic rod 50 . The UV light is also trapped in the lamp housing body section 26 via the light traps 54 located in front of the ventilation vents 28 and directed at the second optical end 58 . The UV light is focussed at the second optical end 58 of the fibre optic rod 50 which then conveys the light through the middle section 60 to the first optical end 56 near the water treatment chamber 18 . The middle section, either the solid quartz rod or the index matching fluid act to reduce the heat being transmitted to the water treatment chamber from the UV lamp.
While the UV light heats up the fibre optic rod 50 untreated water travels into the water treatment chamber 18 via the water intake 20 to the water treatment chamber 18 where it is subjected to the UV light emitted by the first optical end of the fibre optic rod 50 which sterilizes the untreated water. In some cases, the water in the water treatment chamber may also contact the first optical end 56 of the fibre optic rod 50 without affecting the sterilization process. The treated water then travels out of the water treatment chamber 18 via the water outlet 22 where the water is then transferred for use.
In another embodiment of operation, seen as an on-demand embodiment, the UV source and the fan are initially unpowered. Once a flow sensor, located in the water outlet 22 , senses a request for treated water (i.e. a tap opening), a signal is sent to a processor which causes a gate, located between the water intake 20 and the water treatment chamber 18 to close in order to prevent further untreated water from entering the chamber and holds this water in the water intake 20 . The processor then sends a signal to power up the ventilation fan 32 and the UV source 38 . Once the fan and the source have been powered up (after a slight delay), a signal is sent to the gate to open allowing the untreated water to flow from the water intake 20 to the chamber 18 to be treated. After the water is treated, the water travels from the water outlet to the tap requesting the treated water. Once the tap is closed, the flow sensor senses this and sends a signal to the processor to power down the UV source and the ventilation fan 32 and close the gate once again.
One advantage of the water treatment system 10 is that the first embodiment (with a fibre optic rod manufactured entirely from quartz) may be installed either horizontally or vertically in the water system 1 . However, with the second embodiment of the water treatment system having the middle section of the fibre optic rod comprising an index matching fluid, the water treatment system must be installed with the axis of the water intake, water treatment chamber and the water outlet in a vertical position.
The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
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An ultraviolet water treatment system comprising a water chamber having a water intake for untreated water to enter the chamber, and a water outlet for water to leave the chamber; an ultraviolet light source; and a fibre optic rod having a distributing end and a receiving end, the receiving end is located to receive the focused ultraviolet light from the light source and convey the light through the rod and out the distributing end into the chamber to treat the water.
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This is a continuation of application Ser. No. 225,356, filed July 28, 1988 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and device for substantially pinpointing the emission of a pulsed seismic source adapted to be lowered inside a well and to be coupled to the walls of the well by retractable anchorage means.
2. Description of the Prior Art
Many seismic prospection methods comprise the use of seismic sources lowered into wells or boreholes and activated successively at a plurality of positions at different depths. The waves emitted are received by receivers disposed in other wells or boreholes, which makes it possible to obtain a high power of resolution, or else disposed on the surface so as to restore oblique seismic profiles. The energy efficiency of seismic sources in wells is generally much better than that of sources operated on the surface, because they emit seismic waves under the weathered surface layer whose propagation characteristics are unfavorable, but it is largely conditioned by the means used for coupling them to the surrounding geological formations.
Percussion seismic sources generally comprise an elongated body suspended at the end of an electric suspension cable or a pipe string. The body is connected to coupling elements formed of arms, claws or mobile shoes which may be moved apart by actuating hydraulic cylinders and are applied to or driven into the walls of the well.
In other embodiments, the body of the seismic source is connected to an element of the packer type, well known by specialists, of the type having an expandable member formed of a central portion and a peripheral portion which can be expanded by rotating it with respect to the central portion. Packers may also be used comprising an enclosure defined by a deformable wall and which is expanded by injection of a pressurized liquid.
Different seismic sources associated with anchorage means are described in the French patent applications published under the numbers 2 597 214, 2 552 553, 2 558 601 respectively corresponding to U.S. Pat. Nos. 4,770,268, 4,773,501 and 4,648,478, and French patent application no. 2590994 corresponding to commonly-assigned copending U.S. application Ser. No. 936,618, filed Dec. 1, 1986.
Attempts have also been made to use in wells sources known in the field of sea or land seismic prospection such as implosion sources operating by fluid ejection or by sudden contraction of the volume of a closed enclosure, such as described in the French patent application published under the number 2 55 761 (corresponding to the U.S. Pat. No. 4,682,309) or else sparkers which generate pulses by the sudden discharge of an electric current between immersed electrodes or else explosion sources.
It has been discovered, when studying the behavior of such sources, that when a shock is produced at the time of triggering a source, a greater or lesser amount of energy, depending on the degree of coupling with the walls, is transmitted to the liquid column generally filling the well and in which it propagates.
The result is that the waves vibrating the liquid column in the well disturb the reception of the useful echos corresponding to signals transmitted directly to the walls by the source and complicate the processing of the data collected. Because of this loss of energy and its dispersion, the use of seismic well sources does not always give good results.
SUMMARY OF THE INVENTION
With the method of the invention, the transmission of a pulsed seismic source adapted to be lowered inside a well or borehole and to be coupled with the walls of the well by retractable anchorage means is made substantially pinpoint. It is characterized in that it comprises the confinement of a zone of the well containing the seismic source coupled with the wall, so as to prevent the propagation, along the well outside the confined zone, of the fraction of the energy generated by the seismic source when triggered and not transmitted directly to the walls by direct coupling.
The confinement is obtained for example by closing off the wall substantially sealingly on each side of the zone where the seismic source is anchored against the walls of the well.
The seismic emission device of the invention comprises a pulsed seismic source adapted to be lowered into a well or borehole and coupled with the formations surrounding the well by retractable anchorage means, for applying the energy emitted by the source directly to the walls. It is characterized in that it comprises in combination at least two expandable confinement members disposed on each side of the seismic source and connected thereto, to prevent the propagation along the well of the fraction of energy not transmitted directly to the walls of the well.
The seismic energy not transmitted directly to the surrounding formations by the anchorage means at the time of firing the source, remains then localized in the confined well zone. The result is that the well source may be considered as pinpoint and the disturbing effects induced by vibration of the liquid column contained in the well are practically eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the method and characteristics of the device for implementing it will be clear from the following description of an embodiment given by way of non limitative example, with reference to the accompanying drawings.
FIG. 1 is a partial cross-sectional schematic view of a seismic wall source of an impact type associated on each side with confinement elements,
FIG. 2 is a partial cross-sectional longitudinal halfsection of a confinement element disposed between an electric suspension cable and a seismic source,
FIG. 3 is a partial cross-sectional longitudinal halfsection of another confinement element disposed on an opposite side of the seismic source and,
FIG. 4 is a partial cross-sectional view in longitudinal half section of the lower confinement element in an expanded position where it closes off the well and the compartment containing the hydraulic system controlling the confinement of the seismic source.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The device comprises a seismic well source 1 of a known type, associated with two confinement elements or members 2, 3. The first confinement element 2 is disposed on one side of the seismic well source 1 and the second confinement element 3 is disposed on the opposite side of the seismic well source 1. The seismic well source 1 is extended by a compartment 14 containing a hydraulic operating system which will be described in connection with FIG. 4. The assembly is connected by a multifunction cable 5 of a great length or an electric suspension cable to a surface installation (not shown) comprising control and operating means (not shown). The seismic well source 1 may be of any type such as, for example, an impact seismic source of the type disclosed in U.S. Pat. No. 4,648,478; however, the method of the present invention is particularly suitable for a seismic well source 1 which generates seismic energy within the liquid generally filling the bore holes in which the seismic source is lowered. This is the case of impulsion sources and, particularly, source of the type described in the aforementioned French patent application 2555761 and corresponding U.S. Pat. No. 4,682,309, wherein pulses are generated by a sudden reaction inside a cylindrical cavity of the piston in contact with the well liquid. The hydraulic system of the seismic well source permits resetting of the source and anchorage thereof in a well by opening out mobile arms under the effect of actuating cylinders. The high pressure hydraulic fluid is supplied by accumulator than by a pump, and an electric motor driving the pump as supplied by electric conductors contained in the electric suspension cable 5. It is also possible for sparkers to create shocks in the liquid of the well by an electric current discharge between two immersed electrodes, or else explosion seismic sources.
Each confinement element (FIGS. 2, 3) comprises a central tubular element 6 having at a first end a threaded bore 7. The seismic source is provided with an end piece 8 also threaded at each of its opposite ends. Thus, it may be screw-fitted to the associated confinement elements 2, 3. The tubular element 6 comprises from its first end to its opposite end four portions 9, 10, 11, 12 of decreasing section. On the largest section portion is engaged a pusher element 13 ending in a truncated cone shaped head 14. The pusher element 13 has an inner cavity 15 open on the side opposite the head 14, whose section is adapted to that of portion 9 of the tubular element 6. An opening 16 is formed along the axis of the head 14. A section of the opening 16 is substantially equal to that of the second portion 10 of the tubular element 6. Seals 17, 18 are disposed at the level of the head 14 and the inner cavity 16 so as to provide sealed sliding of the pusher element 13 along the tubular element 6. In a rest position shown in FIGS. 2, 3, the bottom of cavity 15 rests on the opening 16 between the two portions 9 and 10 of the tubular element 6.
An elastomer sheath 19 is engaged on the tubular element 6. At a first end the elastomer sheath 19 bears against the nose (or bevel) of the truncated cone shaped head 14. At an opposite end, at the level of shoulder 20 between the two portions 10 and 11 of the tubular element 6, the elastomer sheath 19 is applied and held thereagainst by a collar 21. In contact with collar 21 is disposed a ring 22 whose sidewall has an opening 23. At the level of opening 23 the tubular element 6 is provided with a circular groove 24. A channel 25 is formed in the wall of the tubular element 6 and opens into groove 24 at a first end and externally off the tubular element 6 under the sheath 19 at its opposite end. A second ring 26 is engaged after collar 21 and ring 22 about the tubular element 6 and locked against translation with respect thereto by a circlip 27. Ring 26 has an external threaded portion 28. A nut 29 is engaged after ring 26. The nut 29 has at a first end an inner threaded portion which screws on to the threaded portion 28 thereof. At its opposite end, the nut 29 has a threaded portion 30 on which an end piece is threadably secured. On one side the end piece comprises a sleeve or cap 31 containing means for fixing the electric suspension cable 5 and any other apparatus usually used in well tools.
On the opposite side, the end piece defines the closed compartment 4 containing the hydraulic system (see FIG. 1).
In the wall of the tubular element 6 of the confinement member 2 (on the electric suspension cable 5 side), at the level of its widest portion 9, a channel 32 is formed (FIG. 2). The channel 32 opens into a cavity 15 at a first end and outwardly of the confinement member 2 at its opposite end.
In the wall of the tubular element of the other confinement member 3 (FIG. 3) and over the whole of its length a first channel 33 is formed which opens outwardly in the vicinity of the threaded bore 7 at a first end and into the compartment 4 at its opposite end. Another channel 34 connects cavity 15 of the confinement member 3 to the first channel 33.
The ends of the two channels 32 and 33 opening out of the confinement members 2, 3 are respectively provided with hydraulic connectors 35, 36 on which are respectively connected the two ends of the same pipe 37. Similarly, the end of channel 33 opposite the connection 36 (FIG. 3) comprises another connector 38 for a pipe 39 connected to the hydraulic system.
Seals 40 are disposed between each tubular element 6 and the corresponding nut 29. Other seals 41 are disposed between nut 29 and the wall of the end piece, whether it is a question of the cap or sleeve 31 or of the compartment 4 containing the hydraulic system.
The hydraulic system comprises (FIG. 4) a hydraulic accumulator 42 charged to a pressure greater than the hydrostatic pressure prevailing in the well at the maximum depth of use of the seismic source and a reservoir 43 at a low pressure, e.g. atmospheric pressure. Accumulator 42 communicates with pipe 39 (see FIG. 3) through a duct 44 and an electro-valve 45 closed at rest. Similarly, pipe 39 communicates through an electro-valve 46 open at rest and a duct 47.
The two electro-valves are supplied with electric current by supply lines 48 connected to the multi-function cable 5.
In the rest position of the electro-valves 45, 46 shown in FIG. 4, the pressure applied in the cavities 15 of the two confinement members 2, 3 is that which prevails in the low pressure reservoir 43. The higher external hydrostatic pressure applies the sheaths 19 against the tubular elements 6 and the assembly shown schematically in FIG. 1 may move freely.
In operation, the multi-function cable 5 is operated so as to bring the assembly shown schematically in FIG. 1 into a desired depth of use. The electro-valves 45, 46 are switched through lines 48 and the second electro-valve 45 closes, isolating pipe 39 from the reservoir 43, with the first electrovalve opening thereby placing the pipe 39 in communication with the pressurized accumulator 42. The very high fluid is applied by pipes 32, 33, 34 to two cavities 15 (FIGS. 2, 3). Underthrust, each of the two pressure elements 13 slides, with the beveled heads 14 moving the free end of the two sheaths 19 aside laterally and are engaged from below. The length of the channel 25 is selected so as to open under the resilient sheath 19 in a vicinity of the bevel of the pusher element 13 in a maximum advance position thereof (FIG. 4). Depending upon a section of the well, the dimensions of the pusher element 13, of its truncated cone-shape head 14 and sheath 19 are determined so that the sheath 19 is applied intimately against the surrounding wall. The wall zone of the two confinement members 2, 3 is then sufficiently isolated from the rest of the well. The means for directly coupling a seismic source 1 to the walls of the well are actuated and the electric suspension cable is preferably relaxes so as to avoid radiation of energy therethrough, with the friction forces between the sheath 19 and the well being sufficient to maintain the device in position. The seismic source may then be fired.
The electrovalves 45, 46 are switched through lines 48. The second one 46 closes, isolating pipe 39 from reservoir 43. The first one 45 opening places pipe 39 in communication with the pressurized accumulator 42. The very high pressure fluid is applied by pipes 32, 33, 34 to the two cavities 15 (FIGS. 2, 3). Under the thrust, each of the two pusher elements 13 slides. Their bevelled heads 14 move the free end of the two sheaths aside laterally and are engaged below. The length of channel 25 is chosen so as to open under the resilient sheath 19 in the vicinity of the bevel of the pusher element in the maximum advanced position thereof (FIG. 4). Depending on the section of the well, the dimensions of the pusher element 13, of its truncated cone shaped head and sheath 19 are determined so that the latter is applied intimately against the surrounding wall. The well zone between the two confinement members is then well isolated from the rest of the well,
the means for coupling the seismic source to the walls of the well are actuated if it is provided therewith,
the electric suspension cable is preferably relaxed so as to avoid radiation of energy therethrough, the friction forces between the sheath and the well being sufficient to maintain the device in position.
The seismic source may then be fired.
If the device is to be moved from one position in the well to another, the electrovalves 45, 46 are actuated so as to isolate accumulator 42 and place pipe 39, and the cavities 15, in communication with reservoir 43 where the pressure is very low. The external pressure pushes the resilient sheat 19 against the tubular element 6. When tightening again it causes the tubular element 6 to move back to its rest position (FIGS. 2, 3). The permanent communication provided by channel 25 and orifice 23 between the well and the bottom of the sheath 19 in the neighborhood of the position of the pusher element 13 in the advanced position (FIG. 4) makes it possible for the hydrostatic pressure to be exerted on the nose thereof and so to overcome the friction forces more readily. Thus, possible jamming of the pressure element 13 under the sheath 19 is avoided.
With the device of the invention, the seismic energy developed by the seismic source within the liquid contained in the well practically does not propagate outside the confinement zone. The effective energy efficiency of the seismic source is therefore increased.
It will be also noted that the confinement elements 2,3 return to the rest position if the electric supply is interrupted, whatever its cause. This prevents any accidental jamming of the device in the well.
In the case where the seismic source used comprises its own hydraulic system, without departing from the scope and spirit of the invention, circuits 32, 33, 34 may be connected by electro-valves identical to 45, 46 to the supply circuits of said system.
Still within the scope of the invention, the confinement elements 2,3 described may be replaced by any expandable members of any type, e.g. packers.
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A method is provided for improving the coefficient of transmission to geological formations of the energy generated by the firing of a seismic source lowered inside a well or borehole and a device for implementing same. A zone of the wall containing the seismic source is defined by confinement so as to prevent the propagation along the well, outside the confined zone, of the energy generated therein by the seismic source, when fired. The confinement is achieved by closing off the wall on each side of the seismic source. Two expandable members are used disposed in the wall on each side of the source and each comprising for example an elastomer sheath, an annular piston whose movement causes expansion of the sheath and hydraulic means for moving the piston.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of an application Ser. No. 13/023,581, filed on Feb. 09, 2011, now pending. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.
FIELD OF THE INVENTION
[0002] The present invention relates to a fin field-effect transistor structure, and more particularly to a fin field-effect transistor structure applied to a semiconductor manufacturing process. The present invention also relates to a manufacturing process of such a fin field-effect transistor structure.
BACKGROUND OF THE INVENTION
[0003] Nowadays, as integrated circuits are increasingly developed toward miniaturization, the conventional transistor structure whose channel and substrate are coplanar usually fails to meet the practical requirements. Especially, the performance of the conventional transistor structure in high-speed circuitry is unsatisfied because the current driving capability is insufficient. For solving these drawbacks, a fin field-effect transistor (FinFET) structure has been disclosed.
[0004] FIG. 1 is a schematic view illustrating a FinFET structure according to the prior art. Like the typical FET structure, the FinFET structure of FIG. 1 comprises a substrate 10 , a source 11 , a drain 12 , a gate insulator layer 13 and a gate conductor layer 14 . However, since a channel (not shown) between the source 11 and the drain 12 is covered by the gate insulator layer 13 and the gate conductor layer 14 , plural surfaces are utilized to provide more current paths. In other words, the FinFET structure has better current driving capability than the typical FET structure. However, the performance of the FinFET structure needs to be further optimized by improving the configurations and the manufacturing process of the FinFET structure.
SUMMARY OF THE INVENTION
[0005] In accordance with another aspect, the present invention provides a fin field-effect transistor structure. The fin field-effect transistor structure includes a silicon substrate, a fin channel, a gate insulator layer and a gate conductor layer. The fin channel is formed on a surface of the silicon substrate, wherein the fin channel has at least one slant surface. The gate insulator layer is formed on the slant surface of the fin channel. The gate conductor layer is formed on the gate insulator layer.
[0006] In an embodiment, the surface of the silicon substrate is a ( 100 ) crystal plane, a top surface of the fin channel is a ( 100 ) crystal plane, and the fin channel extends along a < 100 > direction. The slant surface is a ( 110 ) crystal plane or a ( 111 ) crystal plane, and the overall length of the slant surface is greater than the height of the fin channel. In this situation, the fin channel is a p-type fin channel.
[0007] In an embodiment, the surface of the silicon substrate is a ( 110 ) crystal plane, a top surface of the fin channel is a ( 110 ) crystal plane, and the fin channel extends along a < 100 > direction. The slant surface is a ( 100 ) crystal plane, and the overall length of the slant surface is greater than the height of the fin channel. In this situation, the fin channel is an n-type fin channel.
[0008] In an embodiment, a second fin channel with a polarity opposite to the fin structure is further formed on the silicon substrate, wherein the second fin channel has at least one vertical sidewall.
[0009] In an embodiment, the fin channel has a sandglass-shaped cross section with a wide top region, a wide bottom region and a narrow middle region.
[0010] In an embodiment, an included angle between the slant surface and a normal vector of the silicon substrate is 54.7 degrees.
[0011] In an embodiment, the gate insulator layer and the gate conductor layer are further formed over the top surface of the fin channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above objects and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
[0013] FIG. 1 is a schematic view illustrating a FinFET structure according to the prior art;
[0014] FIGS. 2A , 2 B and 2 C schematically illustrate some crystal orientations;
[0015] FIGS. 2D and 2E schematically illustrate a fin channel of a FinFET structure according to the present invention;
[0016] FIGS. 3A , 3 B, 3 C and 3 D schematically illustrate some steps of a process of manufacturing a FinFET structure according to an embodiment of the present invention; and
[0017] FIGS. 4A , 4 B and 4 C schematically illustrate some steps of a process of manufacturing a FinFET structure according to another embodiment of the present invention; and
[0018] FIGS. 5A , 5 B, 5 C, 5 D, 5 E, 5 F and 5 G schematically illustrate some steps of a process of manufacturing a FinFET structure according to a further embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.
[0020] Since a silicon crystal has a diamond crystal lattice, the silicon crystal has many crystal orientations. FIGS. 2A , 2 B and 2 C schematically illustrate some crystal orientations. In FIG. 2A , an equivalent crystallographic orientation of a crystal plane ( 100 ) is represented as < 100 >. In FIG. 2B , an equivalent crystallographic orientation of a crystal plane ( 110 ) is represented as < 110 >. In FIG. 2C , an equivalent crystallographic orientation of a crystal plane ( 111 ) is represented as < 111 >.
[0021] As known, the highest electron mobility of the n-channel metal-oxide-semiconductor (NMOS) appears in the < 110 > direction on the ( 100 ) crystal plane; and the highest hole mobility of the p-channel metal-oxide-semiconductor (PMOS) appears in < 110 > direction of the ( 110 ) crystal plane. Since the common wafer used in the process of manufacturing a FinFET structure has a ( 100 ) crystal plane and a < 110 > notch direction, the wafer having the ( 100 ) crystal plane and the < 110 > notch direction is used for manufacturing a FinFET structure in this embodiment. FIG. 2D is a schematic top view illustrating a fin channel of a FinFET structure according to the present invention. FIG. 2E is a schematic cutaway view illustrating the fin channel of the FinFET structure taken along the dotted line. The fin channel 20 is directly formed on the ( 100 ) crystal plane of the wafer 2 by aligning the notch direction. The top surface 200 of the fin channel 20 is a ( 100 ) crystal plane, and the sidewall 201 of the fin channel 20 is a ( 110 ) crystal plane, and the fin channel 20 extends along the < 110 > direction. Due to the fin channel 20 , the highest hole mobility of the PMOS is achievable. However, in a case that the fin channel 20 is applied to the NMOS, the electron mobility of the NMOS is deteriorated. In other word, such fin channel needs to be further improved.
[0022] FIGS. 3A , 3 B, 3 C and 3 D schematically illustrate some steps of a process of manufacturing a FinFET structure according to an embodiment of the present invention. Firstly, as shown in FIG. 3A , a wafer 30 having a ( 100 ) crystal plane and a < 100 >notch direction is provided. The wafer 30 is a silicon wafer or a silicon-on-insulator (SOI) wafer. Then, a shown in FIG. 3B , hard masks 301 and 302 are formed on the surface of the ( 100 ) crystal plane of the wafer 30 . Then, an etching process is performed to form an n-type fin channel 303 and a p-type fin channel 304 , which extend along the < 100 > direction (see FIGS. 3C and 3D ). FIG. 3C is a schematic cross-sectional view illustrating the fin channels of the FinFET structure of FIG. 3B taken along the dotted line. FIG. 3D is a schematic cutaway view illustrating the fin channels of the FinFET structure of FIG. 3B taken along the dotted line. The top surface 3031 of the n-type fin channel 303 and the top surface 3041 of the p-type fin channel 304 are ( 100 ) crystal planes. The vertical sidewall 3032 of the n-type fin channel 303 and the vertical sidewall 3042 of the p-type fin channel 304 are ( 100 ) crystal planes, and both extend along the < 100 > direction. By means of these fin channels, the electron mobility of the NMOS of the FinFET structure is not degraded and the improvement on the hole mobility of the PMOS is about 10%-15%. Consequently, the purpose of the present invention is achieved. Since the top surfaces 3031 and 3041 and the vertical sidewalls 3032 and 3042 are all ( 100 ) crystal planes, the manufacturing process of this embodiment is suitable to fabricate a tri-gate FinFET structure or a double-gate FinFET structure.
[0023] FIGS. 4A , 4 B and 4 C schematically illustrate some steps of a process of manufacturing a FinFET structure according to another embodiment of the present invention. The purpose of this embodiment is to further improve the n-type fin channel 303 and the p-type fin channel 304 as shown in FIG. 3C . Firstly, as shown in FIG. 4A , the top surface 3031 and the vertical sidewall 3032 of the n-type fin channel 303 are completely covered by a hard mask 41 . Whereas, the top surface 3041 of the p-type fin channel 304 is covered by a hard mask 42 , but the vertical sidewall 3042 is exposed. Then, as shown in FIG. 4B , an anisotropic etching process is performed to etch the exposed vertical sidewall 3042 to form two slant surfaces 43 and 44 . In an embodiment, the anisotropic etching process is a wet etching process using an alkaline solution as an etchant. The alkaline solution is a tetramethylammonium hydroxide (TMAH) solution, an ammonium hydroxide (NH 4 OH) solution, a sodium hydroxide (NaOH) solution, a potassium hydroxide (KOH) solution, an ethylenediamine pyrocatechol (EDP) solution, or any other possible alkaline solution. By selecting a suitable etchant or adjusting the concentration of the etchant, the slant surfaces 43 and 44 may be formed at different etching rates. Since the anisotropic etching rates on the ( 110 ) crystal plane and the ( 111 ) crystal plane are different, the slant surfaces 43 and 44 may be fabricated as the ( 110 ) crystal planes or the ( 111 ) crystal planes by a well-known Wulff-Jaccodine process.
[0024] After the vertical sidewall 3042 of the p-type fin channel 304 is anisotropically etched by using the hard mask 42 as an etching mask, the slant surfaces 43 and 44 are formed. In accordance with a key feature of the present invention, the overall length of the slant surfaces 43 and 44 is greater than the height of the vertical sidewall 3042 . That is, the overall length of the slant surfaces is greater than the height of the p-type fin channel 304 . Whereas, the n-type fin channel 303 maintains the original cross-sectional shape. On the other hand, due to the slant surfaces 43 and 44 , the p-type fin channel 304 has a sandglass-shaped cross section with a wide top region, a wide bottom region and a narrow middle region. In this situation, the p-type fin channel 304 has increased effective channel width. Afterward, a gate insulator layer 48 and a gate conductor layer 49 are formed on the n-type fin channel 303 and the p-type fin channel 304 , thereby producing the FinFET structure of FIG. 4C . Moreover, due to good surface adhesive ability, an atomic layer deposition (ALD) process may be performed to successfully fill the gate insulator layer 48 and the gate conductor layer 49 in the space between the slant surfaces 43 and 44 . Since the top surface of the p-type fin channel 304 is a ( 100 ) crystal plane but the slant surfaces of the p-type fin channel 304 are ( 110 ) or ( 111 ) crystal planes, the manufacturing process of this embodiment is suitable to fabricate a double-gate FinFET structure.
[0025] In such way, sufficient effective channel width will be provided without the need of increasing the height of the p-type fin channel. The lower aspect ratio is good for fabricating the gate conductor layer in the subsequent process. As a consequence, the manufacturing process is simplified. For example, the fin channel of the conventional FinFET structure has an aspect ratio greater than 1 (e.g. 2-4). Whereas, according to the present invention, the aspect ratio of the sandglass-shaped fin channel of the FinFET structure is reduced to about 0.578. Moreover, the short channel effect and the drain induced barrier lowering (DIBL) of the sandglass-shaped fin channel are reduced when compared with the conventional vertical-sidewall channel.
[0026] Alternatively, a sidewall etching process may be performed to etch the n-type fin channel. FIGS. 5A , 5 B, 5 C, 5 D, 5 E, 5 F and 5 G schematically illustrate some steps of a process of manufacturing a FinFET structure according to a further embodiment of the present invention. Firstly, as shown in FIG. 5A , a wafer 50 having a ( 110 ) crystal plane and a < 100 > notch direction is provided. The wafer 50 is a silicon wafer or a silicon-on-insulator (SOI) wafer. Then, a shown in FIG. 5B , hard masks 501 and 502 are formed on the surface of the ( 110 ) crystal plane of the wafer 50 . Then, an etching process is performed to form an n-type fin channel 503 and a p-type fin channel 504 , which extend along the < 100 >direction (see FIGS. 5C and 5D ). FIG. 5C is a schematic cross-sectional view illustrating the fin channels of the FinFET structure of FIG. 5B taken along the dotted line. FIG. 5D is a schematic cutaway view illustrating the fin channels of the FinFET structure of FIG. 5B taken along the dotted line. The top surface 5031 of the n-type fin channel 503 and the top surface 5041 of the p-type fin channel 504 are ( 110 ) crystal planes. The vertical sidewall 5032 of the n-type fin channel 503 and the vertical sidewall 5042 of the p-type fin channel 504 are ( 110 ) crystal planes, and both extend along the < 100 > direction. Since all of the top surface and the vertical sidewalls are ( 110 ) crystal planes, the manufacturing process of this embodiment is suitable to fabricate a tri-gate FinFET structure or a double-gate FinFET structure.
[0027] However, as shown in FIG. 5E , if the top surface 5041 and the vertical sidewall 5042 of the p-type fin channel 504 are further completely covered by a hard mask 61 . Whereas, the top surface 5031 of the n-type fin channel 503 is covered by a hard mask 62 , but the vertical sidewall 5032 of the n-type fin channel 503 is exposed. Then, as shown in FIG. 5F , an anisotropic etching process is performed to etch the exposed vertical sidewall 5032 to form two slant surfaces 53 and 54 . In an embodiment, the anisotropic etching process is a wet etching process using an alkaline solution as an etchant. The alkaline solution is a tetramethylammonium hydroxide (TMAH) solution, an ammonium hydroxide (NH 4 OH) solution, a sodium hydroxide (NaOH) solution, a potassium hydroxide (KOH) solution, an ethylenediamine pyrocatechol (EDP) solution, or any other possible alkaline solution. By selecting a suitable etchant or adjusting the concentration of the etchant, the slant surfaces 53 and 54 may be formed at different etching rates. Consequently, the slant surfaces 53 and 54 may be fabricated as the ( 100 ) crystal planes by a well-known Wulff-Jaccodine process.
[0028] After the vertical sidewall 5032 of the n-type fin channel 503 is anisotropically etched, the slant surfaces 53 and 54 are formed. In addition, the overall length of the slant surfaces 53 and 54 is greater than the height of the vertical sidewall 5032 . That is, the overall length of the slant surfaces is greater than the height of the n-type fin channel 503 .
[0029] Whereas, the p-type fin channel 504 maintains the original cross-sectional shape. On the other hand, due to the slant surfaces 53 and 54 , the n-type fin channel 503 has a sandglass-shaped cross section, wherein the included angle between the slant surface and a normal vector of the silicon substrate is 54 . 7 degrees. In this situation, the n-type fin channel 503 has increased effective channel width. Afterward, a gate insulator layer 58 and a gate conductor layer 59 are formed on the n-type fin channel 503 and the p-type fin channel 504 , thereby producing the FinFET structure of FIG. 5G . Moreover, due to good surface adhesive ability, an atomic layer deposition (ALD) process may be performed to successfully fill the gate insulator layer 58 and the gate conductor layer 59 in the space between the slant surfaces 53 and 54 . Since the top surface is a crystal plane ( 100 ) but the slant surfaces are ( 100 ) crystal planes, the manufacturing process of this embodiment is suitable to fabricate a double-gate FinFET structure.
[0030] In such way, sufficient effective channel width will be provided without the need of increasing the height of the n-type fin channel. The lower aspect ratio is good for fabricating the gate conductor layer in the subsequent process. As a consequence, the manufacturing process is simplified. For example, the fin channel of the conventional FinFET structure has an aspect ratio greater than 1 (e.g. 2-4). Whereas, according to the present invention, the aspect ratio of the sandglass-shaped fin channel of the FinFET structure is reduced to about 0.578. Moreover, the short channel effect and the drain induced barrier lowering (DIBL) of the sandglass-shaped fin channel are reduced when compared with the conventional vertical-sidewall channel.
[0031] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
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A fin field-effect transistor structure includes a silicon substrate, a fin channel, a gate insulator layer and a gate conductor layer. The fin channel is formed on a surface of the silicon substrate, wherein the fin channel has at least one slant surface. The gate insulator layer formed on the slant surface of the fin channel. The gate conductor layer formed on the gate insulator layer.
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FIELD OF THE INVENTION
The present invention relates to a document processing apparatus and its control method for generating document data where contents respectively included in plural structured documents are arranged.
BACKGROUND OF THE INVENTION
Distribution document data or printable document data is generated by collecting images and texts used in documents as content data forming respective layouts and layouting the collected content data. In this case, necessary various processings including data collection processing and layout processing are tightly unified as one application. Conventionally, upon determination of document layout, an operator manually determines a layout using the substance of data, otherwise, manually generates a template to output those data in a predetermined layout.
U.S. Pat. No. 6,934,052 discloses a technique for enlarging digital images and positioning them so as to minimize blank space on a page.
In a case that various processings including data collection processing and layout processing are tightly unified as one application, the processings cannot be separated. Accordingly, it is impossible to incorporate a part of those processings into a device or a device with a small capacity resource. Further, in a case where layout information is not included, the layout processing cannot be realized without an operator's work. For this reason, layout generation requires much time and trouble, which is a factor of increase in human cost.
Further, the layouting may be performed by generating a template to output content data in a predetermined layout and outputting the content data using the template. However, in this case, as the layouting is performed with only several predetermined patterns, it is difficult to obtain a desired result by dynamically changing the layout in correspondence with the size or the like of input various content data.
SUMMARY OF THE INVENTION
The present invention has been proposed to solve the problems of the conventional art.
The feature of the present invention is to provide a document processing apparatus and its control method to generate a structured document by collecting and layouting plural structured documents each describing image and text as contents and to generate data where the structured document is rendered.
According to an aspect of the present invention, there is provided with a document processing apparatus comprising:
structured document creation means for inputting plural first structured documents, extracting contents included in the plural first structured documents, and creating second structured documents respectively corresponding to the first structured documents and having a predetermined data structure;
unification means for unifying the second structured documents to a third structured document;
layout means for arranging plural areas in a predetermined area based on area information included in the third structured document; and
rendering means for rendering the extracted contents corresponding to the respective areas described in the third structured document.
Further, according to other aspect of the present invention, there is provided with a document processing method comprising:
a structured document creation step of inputting plural first structured documents, extracting contents included in the plural first structured documents, and creating second structured documents respectively corresponding to the first structured documents and having a predetermined data structure;
a unification step of unifying the second structured documents to a third structured document;
a layout step of arranging plural areas in a predetermined area based on area information included in the third structured document; and
a rendering step of rendering the extracted contents corresponding to the respective areas described in the third structured document.
Other features, objects and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same name or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing the structural functions of an image processing apparatus according to an embodiment of the present invention;
FIG. 2 is a block diagram showing processing by a data exchange processor according to the embodiment;
FIG. 3 depicts a view illustrating a particular example of InformationData-A and the relation between the Information-Data-A and XML data according to the present embodiment;
FIGS. 4A and 4B depict a view illustrating a particular example of unification of the XML data in a data unification processor according to the present embodiment;
FIG. 5 is a block diagram showing processing by a layout processor according to the present embodiment;
FIG. 6 depicts a view illustrating a particular example of processing by a layout preparatory processor and the layout processor based on an optimization algorithm according to the present embodiment;
FIG. 7 is a block diagram showing processing by a rendering processor according to the present embodiment;
FIG. 8 depicts a view illustrating a particular example of rendering processing by the rendering processor according to the present embodiment; and
FIG. 9 depicts a view illustrating an example of processing by the rendering processor according to the present embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinbelow, a preferred embodiment of the present invention will now be described in detail in accordance with the accompanying drawings. Note that the following embodiment does not limit the present invention in the scope of the claims, and further, all the combinations of characteristic features described in the embodiment are not necessarily essential to the solution of the present invention.
In the present embodiment, when plural structured documents having different structures and including different contents are inputted, they are respectively replaced with structured documents which can be subjected to data unification processing, and they are unified to one structured document to be subjected to layout processing and rendering processing. Then the layout processing is performed on the structured document, thereby layout information to determine the layout of the respective contents is determined. The contents are actually arranged based on the layout information, then the document is converted to file data which can be handled by an application program, and the file data is outputted. Further, when an error occurs upon layouting based on the layout information, the layout processing is performed again, and a more appropriate layout is determined.
FIG. 1 is a block diagram showing the structural functions of an image processing apparatus according to the embodiment of the present invention.
In FIG. 1 , reference numeral 101 denotes a processing function unit of the image processing apparatus. XML data 102 to 104 are structured documents describing paths to image(s) and text(s) as content data. “inputA.xml”, “inputB.xml” and “inputC.xml” are XML data having different structures, respectively.
InformationData-A 105 , InformationData-B 106 and InformationData-C 107 are data (Data-A, Data-B and Data-C) describing data layout information of XML data accompanying the respective XML data. Each of XML data 102 to 104 and its corresponding InformationData are referred to as XML data 109 .
When the respective XML data 109 are inputted into an input unit 108 , processing is started. A data exchange processor 110 receives the XML data 109 and analyzes the data. At this time, the data exchange processor 110 extracts necessary data utilizing the InformationData, converts the extracted data to XML data structures analyzable by the subsequent-stage processing, and supplies the data as XML data 111 (LayoutA.xml, LayoutB.xml and LayoutC.xml) to a data unification processor 112 . The data unification processor 112 unifies plural XML data 111 to one XML data structure analyzable by the subsequent-stage processing, and supplies the data as XML data 113 (Layout.xml) to a layout processor 114 .
The layout processor 114 extracts necessary rectangular information from the XML data 113 , arranges the rectangular information at random in a predetermined area, and performs processing using an optimization algorithm to obtain an optimum result of layouting. The layout processor 114 describes the result in XML data 115 (LayoutResult.xml) and supplies the data to a rendering processor 116 . The rendering processor 116 extracts necessary information (paths to texts and images) from the XML data 115 , and obtains actual image data (image data body) from a actual data (data body) storage 117 . Then the rendering processor 116 draws these data in accordance with the layout determined by the layout processor 114 , and generates the result of processing as application data (PDF, SVG, XHTML or the like) 118 . The application data 118 is supplied to an output unit 119 . The output unit 119 outputs finally-completed application data 120 .
Next, the details of processings by the respective processors in the functional block diagram of FIG. 1 will be described.
FIG. 2 is a block diagram showing the contents of processing by the data exchange processor 110 according to the embodiment. FIG. 3 illustrates a particular example of the InformationData and the relation between the InformationData and XML data. Hereinbelow, the processing by the data exchange processor 110 will be described with reference to FIGS. 2 and 3 . In FIGS. 2 and 3 , the XML data “inputA.xml” 102 and InformationData-A 105 are processed. Further, the other XML data 103 , 104 and InformationData-B 106 and InformationData-C 107 are similarly processed.
In FIG. 2 , the XML data 102 and the InformationData-A 105 correspond to the XML data ( 109 in FIG. 1 ) received from the input unit 108 . The InformationData (Data-A) 105 indicates a tag to handle data information of the XML data 102 required in the subsequent processing. Further, XML data (Ori-LayoutA.xml) 204 indicates XML data (form) as a basis of XML format data to define a basic layout of the XML data (inputA.xml) 102 . The XML data 111 indicating the layout of the XML data 102 is generated in correspondence with the format of the XML data 204 . InformationData-OriA 205 is InformationData of the XML data (Ori-LayoutA.xml) 204 .
FIG. 3 depicts a particular example of the Information-Data-A 105 and an example of the relation between the Information-Data-A 105 and the XML data 102 according to the present embodiment.
The InformationData-A 105 has four items, i.e., the 1st item “rectangular size: width”, the 2nd item “rectangular size: height”, the 3rd item “image information”, and the 4th item “text information”. A path XPATH 209 indicates tag positions of the XML data 102 to respectively handle the related item data of the InformationData-A 105 .
In this example, as the path of the 1st item “rectangular size: width” is “inputA/block/width”, and indicates that the item relates to an element “width” in a tag “block” of the XML data (inputA.xml) 102 . When the data is to be extracted from the XML data 102 , the extraction is made from the location, while when data is to be inserted into the XML data 102 , the data is to be inserted in the location.
The structures of the XML data 102 and 204 are analyzed by corresponding structure analysis processings 210 and 222 . That is, the structure analysis processing sequentially reads the structure of the XML data from root tags, and determines a tag name, a value between tags, an attribute of the tag, the value of the attribute, tag parent-child relation, tag brother relation and the like, and holds these data as table data.
Further, the InformationData-A 105 and the InformationData-OriA 205 are respectively analyzed by InformationData analysis processings 212 and 213 . The InformationData analysis processing obtains data extraction location and data insertion location based on the above-described XPATH 209 . InformationData comparison processing 214 determines a location of the XML data (LayoutA.xml) 204 into which data extracted from the XML data (inputA.xml) 102 is inserted, based on the results of analysis of the corresponding InformationData-A 105 and the InformationData-OriA 205 . Thus, the necessary data included in the XML data 102 (inputA.xml) are imported to the XML data 204 (Ori-LayoutA.xml) based on the result of analysis of the XML data, and by exchange processing 215 based on the InformationData analysis processing, thereby the XML data 111 (LayoutA.xml) including the necessary data is generated and outputted. The above processing is performed on the respective XML data 102 to 104 inputted to the input unit 108 .
FIGS. 4A and 4B depict a view illustrating a particular example of unification of the XML data in the data unification processor 112 according to the present embodiment.
In FIGS. 4A and 4B , numeral 301 to 303 denote XML data (LayoutA.xml, LayoutB.xml and LayoutC.xml) having only necessary data included in the XML data (inputA.xml, inputB.xml and inputC.xml), generated by the data exchange processor 110 . Data unification processing 304 (corresponding to the data unification processor 112 in FIG. 1 ) inputs the XML data 301 to 303 , and generates XML data 308 (Layout.xml) (corresponding to the XML data 113 in FIG. 1 ) having a structure analyzable to the subsequent-stage layout processor 114 , using a DOM- or SAX-utilizing programming or using XSLT. In this example, the structure in the areas 305 to 307 in the XML data 301 to 303 are inserted as an <objectlist> into the XML data 308 (Layout.xml).
In the XML data 308 , the contents 305 to 307 of the LayoutA, LayoutB and LayoutC corresponding to the XML data 301 to 303 are described in areas 309 to 311 . A description 312 corresponds to the rectangular size: width “128” included in the LayoutA; a description 313 , to the rectangular size: height “64” included in the LayoutA; a description 314 , to text information “aaaaa” included in the LayoutA; and a description 315 , to information “photoA.jpg” included in the LayoutA. Thus, the plural XML data are unified into one XML data (Layout.xml).
FIG. 5 is a block diagram showing processing by the layout processor 114 according to the present embodiment. FIG. 6 illustrates a particular example of the processing by the layout processor 114 . Hereinbelow, the processing will be described with reference to FIGS. 5 and 6 .
In FIG. 5 , the XML data (Layout.xml) 113 outputted from the data unification processor 112 is the XML data unified from plural data by the data unification processor 112 . A structured document processor 403 reads the XML data 113 and extracts rectangular size information. A layout preparatory processor 404 performs processing to determine a layout of plural rectangles included in the XML data 113 based on the rectangular size information extracted by the structured document processor 403 .
FIG. 6 depicts a view illustrating a particular example of processing by the layout preparatory processor 404 and a layout processor 407 based on an optimization algorithm according to the present embodiment.
In FIG. 6 , numeral 406 denotes a random arrangement of respective rectangles (a) to (e) in an area based on the rectangular size information extracted by the structured document processor 403 . Numeral 408 denotes the result of centering processing by respectively moving the rectangles (a) to (e) in an enlargement, reduction, leftward, rightward, upward or downward direction by layout processing using an optimization algorithm by the layout processor 407 . Thus an optimum layout where the rectangles are centered without gap and within a predetermined area, is obtained. As the optimization algorithm, Simulated Annealing or genetic algorithm may be employed.
Note that FIG. 6 shows layout processing by centering, however, various layouts such as arrangement of rectangles along inside perimeter of an area and arrangement of rectangles from an upper-left position, as well as centering, can be determined and layout processing can be performed in accordance with the layout.
The structured document processor 409 inputs the optimum layout obtained by the layout processor 407 by the optimization algorithm, forms the data as XML data (LayoutResult.xml) 115 and outputs the data.
FIG. 7 is a block diagram showing processing by the rendering processor 116 according to the present embodiment.
FIG. 8 depicts a view illustrating a particular example of the processing by the rendering processor 116 . Further, FIG. 9 depicts a view illustrating a particular example of rendering processing on contents within a rectangle. Next, the processing by the rendering processor 116 according to the present embodiment will be described with reference to FIGS. 7 to 9 .
In FIG. 7 , the XML data 115 outputted from the layout processor 114 corresponds to the XML data (LayoutResult.xml) describing the result of layouting. In the rendering processor 116 , a structured document processor 503 reads the input XML data 115 , and reads layout information and paths to text and image data as content data to be subjected to actual rendering, described in the XML data. A actual data (data body) acquisition unit 504 utilizes the paths to obtain image data corresponding to the respective rectangular areas from the actual data storage 117 , and obtains all the data for rendering. The rendering processor 506 performs rendering processing based on the obtained actual data (data body).
FIG. 8 illustrates a particular example of the rendering processing by the rendering processor 506 . As indicated with a layout result 508 from the layout result 408 obtained by the layout processor 114 , images A to E and texts (English character strings in FIG. 8 ) are sequentially inserted into corresponding rectangles (a) to (e) by image enlargement/reduction and/or increasing/reducing text font size. Especially regarding the insertion of the image B into the rectangle (b) as indicated with numeral 510 , rendering is performed in accordance with the procedure shown in FIG. 9 .
FIG. 9 illustrates an example of the processing by the rendering processor 506 according to the present embodiment.
Numeral 512 indicates, as a result of insertion of text having a large number of characters into a rectangle (b), a state where the text protrudes from the lower side of a rectangle (b). Numeral 513 indicates the result of insertion by changing the font size of the text to a minimum font size. Also the text which is not fit in the rectangle (b) protrudes from the lower side of the rectangle. Numeral 514 indicates the result of insertion by further reducing the image B, expanding an area to draw the text in the rectangle (b), and then again inserting the text in the minimum font size the same as that in the case of the result 513 . In the result 514 , the image B and the text are fitted in the rectangle (b). Thus, rendering regarding the rectangle (b) is completed.
In this manner, in the respective layouted rectangles, rendering is performed so as to arrange images and texts in a balanced manner. A file generation processor 515 ( FIG. 7 ) forms the final data resulted from the rendering as application data 120 and outputs the data. As a particular example of the application data 120 , data in the format of PDF, XHTML, SVG or the like may be employed.
As described above, according to the present embodiment, plural structured documents are inputted and application data where contents included in the structured documents are arranged in a desired layout can be generated.
Note that in the above embodiment, it may be arranged such that in a case where an unintended result is obtained from layouting by the layout processor 114 , a desired layout is obtained by repeating the layout processing by the layout processor 114 instead of repeating the entire processing as shown in FIG. 1 .
Further, in the rendering processing described in the above embodiment, rendering is performed on contents as a combination of image(s) and text(s), however, the present invention is not limited to such combined contents. The rendering can be similarly performed on single content data such as image or text.
As described above, according to the present embodiment, in the flow of processing from collection of content data through automatic layouting to data output, as fragmented processings are individually performed, even a change of content data itself in the middle of processing does not influence layout processing. Further, as a dynamically optimized layout is determined from content data, any human task does not occur upon layout generation, and the costs can be reduced. Further, structured documents generated for various purposes can be applied to the conventional document solutions including scrap processing of newspaper and the like.
Other Embodiment
As described above, the object of the present invention can also be achieved by providing a storage medium holding software program code for performing the aforesaid processes to a system or an apparatus, reading the program code with a computer (e.g., CPU, MPU) of the system or apparatus from the storage medium, then executing the program. In this case, the program code read from the storage medium realizes the functions according to the embodiment, and the storage medium holding the program code constitutes the invention. Further, the storage medium, such as a floppy (registered trademark) disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a DVD, a magnetic tape, a non-volatile type memory card, and ROM can be used for providing the program code. Further, besides aforesaid functions according to the above embodiment are realized by executing the program code which is read by a computer, the present invention includes a case where an OS (operating system) or the like working on the computer performs a part or entire actual processing in accordance with designations of the program code and realizes functions according to the above embodiment.
Furthermore, the present invention also includes a case where, after the program code read from the storage medium is written in a function expansion card which is inserted into the computer or in a memory provided in a function expansion unit which is connected to the computer, CPU or the like contained in the function expansion card or unit performs a part or entire process in accordance with designations of the program code and realizes functions of the above embodiment.
The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to appraise the public of the scope of the present invention, the following claims are made.
CLAIM OF PRIORITY
This patent application claims priority from Japanese Patent Application No. 2004-300279 filed on Oct. 14, 2004, which is hereby incorporated by reference.
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A document processing apparatus has a data exchange processor for inputting plural first structured documents, extracting contents included in the respective first structured documents, and creating second structured documents respectively corresponding to the first structured documents and having a predetermined data structure, a data unification processor for unifying the plural second structured documents into a third structured document, a layout processor for arranging plural rectangles in a predetermined area based on rectangular size information included in the third structured document, and a rendering processor for rendering the contents corresponding to the respective rectangles described in the third structured document.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/129,849, filed Jul. 24, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to devices for the delivery of pharmaceuticals, and particularly to a bioinjection device for delivering bone morphogenic protein, antibiotics, etc., directly to the site of a bone fracture, degenerative bone tissue or cartilage, etc., during the course of surgery in the form of a bioabsorbable matrix enclosed within a membrane cartridge.
[0004] 2. Description of the Related Art
[0005] Bone is a living tissue and plays a structural role in the body. Disease and damage, however, is often difficult to treat in bones, due to their positioning within the soft tissues of the body. Bone consists of repeating Harvesian systems (concentric layers of lamellae deposited around a central canal containing blood vessels and nerves). The central canal is also known as the medullary cavity and is filled with bone marrow. Within the shaft of a long bone, many of these Harvesian systems are bundled together in parallel, forming a type of bone called compact bone, which is optimized to handle compressive and bending forces. In some bones, such as the metacarpals, for example, the bones themselves are hollow and contain little, if any, marrow. Near the ends of the bones, where the stresses become more complex, the Harvesian systems splay out and branch to form a meshwork of cancellous or spongy bone. Compact bone and cancellous bone differ in density, or how tightly the tissue is packed together.
[0006] Genetic or developmental irregularities, trauma, chronic stress, tumors, and disease can result in pathologies of bones. Some bone diseases that weaken the bones include, but are not limited to, osteoporosis, achondroplasia, bone cancer, fibrodysplasia ossificans progressiva, fibrous dysplasia, legg calve perthes disease, myeloma, osteogenesis imperfecta, osteomyelitis, osteopenia, osteoporosis, Paget's disease, and scoliosis. Weakened bones are more susceptible to fracture, and treatment to prevent bone fractures becomes important. Severe fractures, such as those that are open, multiple, or to the hip or back, are typically treated in a hospital. Surgery may be necessary when a fracture is open, severe, or has resulted in severe injury to the surrounding tissues. Severe fractures may require internal devices, such as screws, rods, or plates, to hold the bone in place or replace lost bone during the healing process.
[0007] In order to repair severe fractures, bone cement and the like is often applied within the fracture. However, other healing agents, such as antibiotics or bone morphogenic proteins, often need to be applied prior to cementing or performance of other operations on the bone. Due to the awkward positioning of bone fractures within other tissue, it is often quite difficult to properly apply medicaments and the like within the bone, particularly without damaging the tissue surrounding the bone. Thus, a bioinjection solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0008] The bioinjection device is directed towards a device for injecting or implanting a membrane-encased cartridge of pharmaceuticals and/or biologics, bone grafts, radioactive seeds and the like, in a bioabsorbable matrix or carrier directly into the site of a bone fracture, degenerative bone tissue or cartilage, or the like in the course of surgery. The cartridge may contain bone morphogenic protein, antibiotics, bone, bone substitute or the like.
[0009] The device includes a housing having an upper portion and a lower gripping portion. The lower gripping portion may be rotatable with respect to the upper portion and includes a handle member and a trigger member. The trigger member is pivotally secured to the handle member. Further, the upper portion of the housing has an open interior region formed therein.
[0010] A shaft is slidably mounted within the open interior region of the upper portion of the housing. The shaft has opposed forward and rear ends and is elongated along a longitudinal axis. Further, the shaft has a channel formed therethrough, also extending along the longitudinal axis from the forward end to the rear end.
[0011] At least one lever arm is pivotally mounted within the housing, with the at least one lever arm having opposed first and second ends. The first end of the lever arm is attached to the rear end of the shaft, and the second end is attached to the trigger member so that rotation of the trigger member with respect to the handle member drives sliding translation of the shaft with respect to the upper portion of the housing.
[0012] A needle is slidable within the channel formed through the shaft, the needle having opposed front and rear ends. The front end of the needle terminates in a relatively sharp point. The rear end thereof is attached to the at least one lever arm so that rotation of the trigger member with respect to the handle member drives forward sliding translation of the needle with respect to the upper portion of the housing and the shaft. Preferably, the at least one lever arm includes a pair of lever arms, including a first lever arm driving movement of the shaft and a second lever arm driving movement of the needle.
[0013] A retaining member has opposed front and rear ends. The front end is open and the rear end is attached to a forward portion of the upper portion of the housing. An opening is formed through the rear end of the retaining member and the forward portion of the upper portion so that the forward end of the shaft and the front end of the needle selectively and slidably project therethrough into an open interior region of the retaining member. The retaining member is preferably releasably attached to the forward portion of the upper portion of the housing.
[0014] A cartridge is releasably received within the open interior region of the retaining member. The cartridge includes an outer shell membrane and a medicament contained within the outer shell. The forward end of the shaft contacts the membrane so that actuation of the trigger member causes the shaft and the needle to slide forward, with the shaft pushing the cartridge out of the retaining member for deployment thereof into the bone fracture. As the shaft pushes the implant out of the retaining member, the needle pierces the outer shell membrane to release the medicament into the fracture or degenerative tissue.
[0015] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an environmental, perspective view of a bioinjection device according to the present invention.
[0017] FIG. 2 is a side view of the bioinjection device according to the present invention, broken away and partially in section to show details thereof.
[0018] FIG. 3 is a perspective view of a membranous cartridge for use with a bioinjection device according to the present invention.
[0019] FIG. 4 is a partial side view in section of the bioinjection device, showing a cartridge extended from the device for injection or implantation.
[0020] FIG. 5 is a side view of a plurality of removable and fillable heads of a bioinjection device according to the present invention.
[0021] FIG. 6A is a perspective view of an alternative embodiment of the bioinjection device according to the present invention.
[0022] FIG. 6B is a perspective view of another alternative embodiment of the bioinjection device according to the present invention.
[0023] FIG. 7 is an exploded view of a plurality of alternative bone implants for use with the bioinjection device according to the present invention.
[0024] FIG. 8 is a front view of a human leg broken away to show the bone implants of FIG. 7 inserted within a channel formed within a bone.
[0025] FIG. 9 is a side view of an alternative embodiment of the head of the bioinjection device according to the present invention.
[0026] FIG. 10 is a side view of another alternative embodiment of the bioinjection device according to the present invention.
[0027] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention relates to a bioinjection device 10 . As shown in FIG. 1 , device 10 is used to place a cartridge 12 into a fracture, degenerative tissue, or the like of a spinal segment S. The cartridge 12 contains a medicament (bone morphologic protein, antibiotics, or the like disposed in a bioabsorbable matrix or carrier) for the healing of the spinal segment S. It should be understood that spinal segment S, having vertebral bodies V, disc D and facet joint F, of FIG. 1 is shown for exemplary purposes only and is not intended to limit the type of bone or fracture that the cartridge 12 and device 10 may be used to treat.
[0029] As best shown in FIGS. 1 and 2 , the device 10 includes a housing 32 having a barrel-shaped upper portion 33 and a lower gripping portion 35 . The lower gripping portion 35 may be rotatable with respect to the upper portion 33 and includes a pistol grip handle member 34 and a trigger member 36 . The trigger member 36 is pivotally secured to the handle member 34 by a pivot pin 39 or the like. Trigger member 36 preferably has a plurality of finger receiving grooves or recesses 38 formed therein, as shown in FIG. 2 , allowing for optimal gripping and actuation by the surgeon. Further, an upper gripping handle 11 may be mounted on an upper surface of housing 32 , allowing the surgeon to better grip and secure tool 10 during the surgical operation.
[0030] As noted above, the lower portion 35 , including both handle member 34 and trigger member 36 , may be rotatable about pivot 37 , allowing the lower gripping portion 35 to be rotated if necessary, depending upon the nature of the particular operation. The lower portion 35 may further be selectively locked in place with respect to the upper portion 33 . Further, as shown in FIG. 2 , the barrel-shaped upper portion 33 of housing 32 has an open interior region formed therein.
[0031] As shown in FIG. 2 , a shaft 16 is slidably mounted within the open interior region of the upper portion 33 of the housing 32 . The shaft has opposed forward and rear ends 21 , 22 , respectively, and is elongated along a longitudinal axis, as shown. Further, the shaft 16 has a longitudinally extending channel 25 formed therethrough, extending from the forward end 21 to the rear end 22 . Shaft 16 is preferably resiliently or spring-biased with respect to housing 32 . In the preferred embodiment, a stop 13 , such as a disc, is mounted to a central portion of shaft 16 , as shown in FIG. 2 , with a spring 20 or other resilient element being biased between the stop 13 and the inner wall of forward portion 50 of housing 32 .
[0032] At least one lever arm is pivotally mounted within housing 32 for the actuation of shaft 16 . Preferably, the at least one lever arm includes a pair of lever arms with a first lever arm 28 driving movement of the shaft 16 , and a second lever arm 26 driving movement of needle 18 , as will be described in greater detail below. First lever arm 28 has opposed first and second ends, with the first end of first lever arm 28 being secured to the rear end 22 of shaft 16 , and the second end being secured to the trigger member 36 so that rotation of the trigger member 36 with respect to the handle member 34 drives sliding translation of the shaft 16 with respect to the upper portion 33 of the housing 32 .
[0033] Needle 18 is slidably received within the channel 25 formed through the shaft 16 , with the needle 18 having opposed front and rear ends 27 , 29 , respectively (the front end or tip 27 of needle 18 is best shown in FIG. 4 ). The front end 27 of needle 18 is preferably formed as a relatively sharp point. The rear end 29 of needle 18 is secured at 24 to the second lever arm 26 so that rotation of trigger member 36 with respect to the handle member 34 drives forward sliding translation of the needle 18 with respect to the upper portion 33 of the housing 32 and also with respect to the shaft 16 ; i.e., actuation of trigger member 36 causes forward sliding of shaft 16 within the housing 32 and also forward sliding of needle 18 within the shaft 16 .
[0034] A retaining member 14 is further provided, with the retaining member having opposed front and rear ends. As shown, retaining member 14 preferably forms a pair of gripping jaws for releasably holding implant 12 . The front end thereof is open and the rear end thereof is secured to mounting member 52 , which is fixed to a forward portion 50 of the upper portion 33 of the housing 32 . The rear portion of retaining member 14 is preferably releasably attached to the mounting member 52 through use of any suitable releasable fastener. The rear portion may have threads 58 formed thereon, as best shown in FIG. 4 , for reception by a threaded recess 53 formed in mounting member 52 .
[0035] Further, an opening 19 is formed through the rear end of the retaining member 14 , and a passage 17 is formed through the forward portion 50 of housing 32 so that the forward end 21 of shaft 16 and the front end 27 of the needle 18 selectively and slidably project therethrough into an open interior region of the retaining member 14 .
[0036] Cartridge 12 is releasably received within the open interior region of the retaining member 14 . As best shown in FIG. 3 , the cartridge 12 includes an outer shell membrane 40 and a medicament 42 contained within the outer shell 40 . The medicament 42 may be a bone morphogenic protein, an antibiotic, or any other desired medicament for the healing of the bone, and may be disposed in a bioabsorbable matrix or carrier. The outer shell may be formed from hydroxyapatite calcium phosphate, or any other biodegradable material that will dissolve and/or fuse within the bone. Preferably, the rear end 46 of shell 40 is formed as a relatively thin membrane that can be pierced by tip 27 of needle 18 . A further thin membrane 44 may be formed between the outer shell 40 and the medicament 42 .
[0037] In use, the cartridge 12 is positioned within retaining member 14 , as shown in FIG. 2 , with the forward end 21 of shaft 16 contacting the rear surface 46 of the bone implant 12 . Actuation of trigger member 36 causes the shaft 16 and the needle 18 to slide forward. Retaining member 14 is preferably formed from a flexible material, such as rubber, plastic or the like, so that forward movement of shaft 16 pushes the cartridge 12 out of the open front end of the retaining member 14 for deployment thereof into the bone fracture or other damaged or diseased area. As the shaft 16 pushes the cartridge 12 out of the retaining member 14 , the tip 27 of needle 18 pierces the thin membrane 46 to release the medicament 42 into the fracture. The surgeon lodges the pierced cartridge 12 within fracture F or the degenerative bone tissue.
[0038] In FIG. 9 , retaining member or head 14 of FIG. 4 has been replaced by an alternative head 214 , having a rear portion 216 with threads 258 , similar to threaded connection 58 of FIG. 4 . A pair of spring-biased jaws 218 are mounted to the rear portion 216 , with one or both of the jaws 218 being adapted for releasably gripping a bone dowel 220 or the like for insertion into a facet joint FJ. In the embodiments of FIGS. 2 and 9 , the heads 14 , 214 and the shaft have relatively small sizes, allowing for placement within the facet joint, as noted above. However, it should be understood that the head and/or shaft may have any suitable size, dependent upon the site for placement of the cartridge. As will be described in detail below, a longer shaft and head may be necessary for injection of cartridges within a larger or longer bone, such as a tibia, and the shaft and head may be appropriately sized dependent upon the intended injection site.
[0039] FIG. 6A illustrates an alternative embodiment of the bioinjection device. Bioinjection device 100 includes a housing 132 having upper and lower portions 133 , 135 , similar to that of the embodiment of FIGS. 1-4 . Similarly, the lower portion 135 includes a handle member 134 and a trigger member 136 , and the upper portion 133 has a handle 111 mounted thereon. Side handles 115 may also be mounted to upper portion 133 , as shown, offering the surgeon a variety of gripping surfaces for differing angles of insertion during an operation. In the embodiment of FIG. 6A , an elongated tube 114 is mounted to the front end of barrel-shaped upper portion 133 , allowing for the implanting of bone implants where immediate proximity of the surgeon's hands is not possible, such as in the implantation of implants 112 within channel C formed in tibia T of FIG. 8 .
[0040] The elongated tube 114 includes an adjustable portion 126 , allowing for angular adjustment of the tube 114 adjacent the front end of the upper portion 133 of housing 132 . Adjustable portion may be a rotating and selectively locking disc member, as shown, or may be any other suitable angular adjustment device. A central region 128 , preferably being solid and relatively non-flexible, is joined to the flexible portions 126 at one end thereof, and a head 120 is disposed at the other end of tube 114 . Head 120 has an open outer end with external threads 124 formed therearound.
[0041] The retaining jaws 14 of the embodiment of FIGS. 1-5 are replaced in FIG. 6A by a cylindrical retaining member 130 having opposed open ends. Retaining member 130 is formed from a resilient, flexible material, similar to that described above with regard to jaws 14 . Internal threads 140 are formed in one end of the retaining member 130 for releasable attachment to the head 120 via engagement with threads 124 . It should be understood that retaining member 130 may be releasably secured to head 120 through any suitable releasable fastener.
[0042] An implant 112 is received within retaining member 130 for selective dispensing thereof. Similar to that described above with regard to the embodiment of FIGS. 1-5 , an inner shaft 116 , similar to shaft 16 , extends through tube 114 and is shown in FIG. 6A slightly projecting from head 120 . Shaft 116 preferably has a plunger-type shape, as shown, with a relatively wide outer face for pushing the wider implant 112 . A needle 118 , similar to needle 18 , is housed within shaft 116 . The alternative embodiment of FIG. 6B is substantially similar to that shown in FIG. 6A , but shaft 116 terminates in a covering head 117 , which covers and surrounds the needle 118 and prevents the needle 118 from becoming caught in the implant 112 . In operation, the user actuates trigger 136 to slide the shaft 116 and needle 118 forward so that the shaft 116 pushes the implant 112 out of retaining member 130 and needle 118 pierces the implant 112 , as described above. When retaining member 130 is fixed to head 120 , the head of plunger 116 will project out from retaining member 130 (when the trigger is compressed) by approximately one or two mm.
[0043] Implant 112 is preferably formed from materials similar to those described above with reference to implant 12 . However, as best shown in FIG. 7 , implant 112 preferably includes an upper projecting member 113 and a lower recess 114 . As shown in FIG. 7 , multiple implants 112 may be stacked through insertion of an upper projecting member 113 into a lower recess 114 of an adjacent implant.
[0044] As shown in FIG. 5 , the removable retaining members 130 may be stored and filled within a tray 54 . In order to allow for quick insertion and replacement of cartridges 112 , cartridges 112 may be positioned within retaining members 130 , as shown. Tray 54 preferably includes a plurality of channels 56 for filling of cartridges 112 within the stored retaining members 130 . A syringe or other supply of medicament may be applied to ports 60 , which cover and seal channels 56 , allowing the medicament to be transferred to the cartridges 112 . Communication with, and filling of, cartridges 112 may be accomplished through any suitable fluid transfer mechanism.
[0045] FIG. 8 illustrates this stacked implantation within a channel C formed within an exemplary tibia T. Such channels C are often formed from the talus to the knee during the implantation of rods and the like in tibial reconstruction. The device 100 of FIG. 6 allows for easy insertion of multiple implants 112 within channel C after removal of such a rod.
[0046] In the alternative embodiment of FIG. 10 , device 200 allows for manual insertion and operation of the implant 112 . A gripping handle portion 204 is secured to a lower surface of mount 202 . Hollow insertion tube 206 is mounted on a front portion of the upper surface of mount 202 , as shown. The rear portion of the upper surface of mount 202 may have a groove, ridge or other means for slidably holding implant 112 . A plunger 208 is provided, with plunger 208 having a gripping, rear portion and a front portion terminating in a plunger head 210 , with needle 212 being positioned centrally therein. In operation, the user loads an implant 112 onto the rear, upper surface of mount 202 , as shown, and pushes implant 112 through tube 206 , for insertion, with plunger head 210 pushing implant through tube 206 and needle 212 piercing the rear end of implant 112 , as described above.
[0047] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The bioinjection device has a housing including a pistol grip and an elongated barrel. A trigger is pivotally mounted to the housing. A plunger and needle are slidable between a first position in which the plunger and needle are slidably disposed in the barrel and a second position in which the plunger and needle extend from an opening in the end of the barrel. A retaining member is disposed about the opening at the end of the barrel. A spring-biased actuation mechanism connects the trigger with the plunger and needle. A membranous cartridge containing bone morphogenic protein, antibiotics, and/or other medication is loaded into the retaining member. A surgeon can inject the cartridge into a bone fracture or degenerative bone tissue during surgery to deliver the medicament directly to the affected site.
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TECHNICAL FIELD
The present invention relates to a grain-oriented electrical steel sheet advantageously utilized for an iron core of a transformer or the like.
BACKGROUND ART
A grain-oriented electrical steel sheet is mainly utilized as an iron core of a transformer and is required to exhibit superior magnetization characteristics, in particular low iron loss.
In this regard, it is important to highly accord secondary recrystallized grains of a steel sheet with (110)[001] orientation, i.e. the “Goss orientation”, and reduce impurities in a product steel sheet. Furthermore, since there are limits on controlling crystal grain orientations and reducing impurities, a technique has been developed to introduce non-uniformity into a surface of a steel sheet by physical means to subdivide the width of a magnetic domain to reduce iron loss, i.e. a magnetic domain refining technique.
For example, JP S57-2252 B2 (PTL 1) proposes a technique of irradiating a steel sheet as a finished product with a laser to introduce high-dislocation density regions into a surface layer of the steel sheet, thereby narrowing magnetic domain widths and reducing iron loss of the steel sheet. Furthermore, JP H6-072266 B2 (PTL 2) proposes a technique for controlling the magnetic domain width by means of electron beam irradiation.
CITATION LIST
Patent Literature
PTL 1: JP S57-2252 B2
PTL 2: JP H6-072266 B2
SUMMARY OF INVENTION
Technical Problem
In recent years, there has been strong demand for a reduction in the noise generated when stacking steel sheets as the iron core of a transformer. In particular, there has been demand for suppression of transformer noise when providing the iron core of a transformer with a grain-oriented electrical steel sheet for which low iron loss properties have been achieved by the above magnetic domain refining.
An object of the present invention is therefore to propose a measure allowing for a reduction in noise generated by the iron core of a transformer or the like when grain-oriented electrical steel sheets, having reduced iron loss due to magnetic domain refining treatment, are stacked for use in the iron core.
Solution to Problem
Transformer noise is mainly caused by magnetostrictive behavior occurring when an electrical steel sheet is magnetized. For example, an electrical steel sheet containing approximately 3 mass % of Si generally expands in the magnetization direction.
When linear strain is applied with a continuous laser, electron beam, or the like either in a direction orthogonal to the rolling direction of the steel sheet or at a fixed angle to the direction orthogonal to the rolling direction, a closure domain is generated in the strain portion. In an ideal case, with no closure domain whatsoever in the steel sheet, and the magnetic domain structure of the steel sheet consisting only of the 180° magnetic domain facing the rolling direction, the change in the magnetic domain structure upon magnetization of the steel sheet only involves domain wall displacement of the 180° magnetic domain, which is already fully extended in the rolling direction due to magnetic strain. Therefore, the steel sheet does not expand or contract due to a change in the magnetic strain. When a closure domain exists in the steel sheet, however, the change in the magnetic domain structure upon magnetization of the steel sheet includes generation and elimination of the closure domain, in addition to domain wall displacement of the 180° magnetic domain. Since the closure domain expands in the widthwise direction of the steel sheet, the steel sheet exhibits expansion and contraction as a result of generation and elimination of the closure domain, due to change of the magnetic strain in the rolling direction and in the widthwise and thickness directions of the steel sheet. Accordingly, it is thought that if the amount of the closure domain in the steel sheet varies, the magnetic strain occurring due to magnetization and the noise upon stacking as the iron core of the transformer will also change.
The inventors of the present invention therefore focused on the volume fraction of the closure domain included in the steel sheet and examined the effect on iron loss and on transformer noise.
First, the inventors examined the relationship between magnetic flux density B 8 of the steel sheet and noise. In other words, if magnetization within the 180° magnetic domain deviates from the rolling direction, magnetization rotation occurs near the saturation magnetization upon magnetization of the electrical steel sheet. Such rotation increases the expansion and contraction in the rolling direction and the widthwise direction of the steel sheet and leads to an increase in magnetic strain. Therefore, such rotation is not advantageous from the perspective of noise in the iron core of the transformer. For this reason, highly-oriented steel sheets stacked with the [001] orientation of the crystal grains in the rolling direction are useful, and the inventors discovered that when B 8 ≧1.930 T, the increase in noise in the iron core of the transformer due to magnetization rotation can be suppressed.
Next, the volume fraction of the closure domain is described. As described above, the generation of a closure domain is a factor in the magnetic strain occurring the rolling direction of a steel sheet. When this closure domain exists, the magnetization in the closure domain is oriented orthogonal to the magnetization of the 180° magnetic domain, causing the steel sheet to contract. When the closure domain in terms of volume fraction is E, then with respect to a state with no closure domain, the change in magnetic strain in the rolling direction is proportional to λ 100 ξ. Here, λ 100 represents the magnetic strain constant 23×10 −6 in the [100] orientation.
In an ideal electrical steel sheet, the [001] orientation of all of the crystal grains is parallel to the rolling direction, and the magnetization of the 180° magnetic domain is also parallel to the rolling direction. In reality, however, the orientation of the crystal grains deviates at an angle from the rolling direction. Therefore, due to the magnetization in the rolling direction, magnetization rotation of the 180° magnetic domain occurs, generating magnetic strain in the rolling direction. At this time, with respect to when the magnetization of the 180° magnetic domain is parallel to the rolling direction, the change in magnetic strain in the rolling direction due to magnetization rotation is proportional to λ 100 (1−cos 2 θ). Upon exciting the steel sheet and measuring the magnetic strain in the rolling direction, a mix of the two factors above is observed. Here, when B 8 ≧1.930 T, the deviation of the [001] orientation of the crystal grains is 4° or less with respect to the rolling direction, yet the contribution of magnetization rotation to magnetic strain is (6×10 −4 ) λ 100 or less, which is extremely small as compared to the magnetic strain of an electrical steel sheet that includes 3% Si. Accordingly, in a steel sheet with an excellent noise property, for which B 8 ≧1.930 T, the magnetization rotation can be ignored as a factor in magnetic strain, and only the change in the volume fraction of the closure domain can fairly be considered to dominate. Therefore, by measuring the magnetic strain in the rolling direction, the volume fraction of the closure domain can be assessed.
In order to determine the volume fraction of the closure domain, it is necessary to compare a state when no closure domain at all exists and a state when the maximum amount of closure domain occurs in the steel sheet. With conventional magnetic strain assessment, however, measurement is performed without causing magnetic saturation in the steel sheet. In this state, a closure domain remains in the steel sheet, so that the volume fraction of the closure domain cannot be assessed accurately. The inventors therefore assessed the volume fraction of the closure domain based on magnetic strain measurement under saturated magnetic flux density. Under saturated magnetic flux density, the magnetic domain of the steel sheet is entirely the 180° magnetic domain, and as the magnetic flux density approaches zero due to an alternating magnetic field, a closure domain is generated, and magnetic strain occurs. Using the difference λ P-P between the maximum and minimum of the magnetic strain at this time, the volume fraction ξ of the closure domain was calculated using equation (A) below.
ξ
=
-
2
3
λ
p
-
p
λ
100
(
A
)
The volume fraction of the closure domain in the steel sheet was also calculated, the W 17/50 value was measured with a single sheet tester (SST), and the noise of the iron core in the transformer was measured. FIG. 1 lists the measurement results in order. The volume fraction of the closure domain was calculated using the above method, and the measurement of magnetic strain in the rolling direction was performed using a laser Doppler vibrometer at a frequency of 50 Hz and under saturated magnetic flux density. The W 17/50 value is the iron loss at a frequency of 50 Hz and a maximum magnetic flux density of 1.7 T. Furthermore, the excitation conditions for the iron core of the transformer were a frequency of 50 Hz and a maximum magnetic flux density of 1.7 T. The sample was a grain-oriented electrical steel sheet having a sheet thickness of 0.23 mm and satisfying B 8 ≧1.930 T. The method for applying strain was to irradiate the surface of the steel sheet with a continuous laser beam, setting the laser beam power to 100 W and the scanning rate to 10 m/s, and adopting a variety of conditions by changing the beam diameter on the surface of the steel sheet.
As the method of changing the beam diameter, the inventors changed the diameter of the laser beam striking the condenser lens for focusing the laser on the point to be irradiated with the laser beam and on the surrounding region of the surface of the steel sheet. In this way, the inventors discovered that with an increasingly larger beam diameter, the volume fraction of the closure domain applied to the sample continues to lower, and the accompanying noise of the iron core also continues to decrease.
On the other hand, the inventors discovered that as the beam diameter neared the minimum possible beam diameter for the laser irradiation device, the W 17/50 value reached a minimum, whereas upon expanding the beam diameter, the W 17/50 value tended to worsen. In particular, when the volume fraction of the closure domain became less than 1.00% due to expansion of the beam diameter, the W 17/50 so value became worse than 0.720 W/kg, and a good magnetic property could no longer be attained. Since the decrease in the volume fraction of the closure domain due to beam diameter expansion means a decrease in strain applied to the steel sheet, it is thought that such worsening of the magnetic property is due to an attenuated magnetic domain refining effect.
Based on the above results, the inventors managed to provide a grain-oriented electrical steel sheet that is suitable as an iron core of a transformer or the like and has an excellent noise property and magnetic property by adopting an excellent B 8 value and setting the amount of applied strain to be in a range of 1.00% or more to 3.00% or less in terms of the volume fraction of the closure domain occurring in the strain portion.
Specifically, primary features of the present invention are as follows.
(1) A grain-oriented electrical steel sheet with an excellent noise property, comprising linear strain in a rolling direction of the steel sheet periodically, the linear strain extending in a direction that forms an angle of 30° or less with a direction orthogonal to the rolling direction of the steel sheet, iron loss W 17/50 being 0.720 W/kg or less, a magnetic flux density B 8 being 1.930 T or more, and a volume occupied by a closure domain occurring in the strain portion being 1.00% or more and 3.00% or less of a total magnetic domain volume in the steel sheet.
(2) The grain-oriented electrical steel sheet according to (1), wherein the linear strain is applied by continuous laser beam irradiation.
(3) The grain-oriented electrical steel sheet according to (1), wherein the linear strain is applied by irradiation with an electron beam.
Advantageous Effect of Invention
According to the present invention, it is possible to achieve lower noise in a transformer in which are stacked grain-oriented electrical steel sheets that have reduced iron loss due to application of strain.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be further described below with reference to the accompanying drawings, wherein:
FIG. 1 illustrates a preferable range for the volume fraction of the closure domain in the present invention.
DESCRIPTION OF EMBODIMENTS
First, regarding transformer noise, i.e. magnetostrictive vibration of the steel sheet, the oscillation amplitude becomes smaller as the density of crystal grains of the material along the easy axis of magnetization is higher. Therefore, to suppress noise, a magnetic flux density B 8 of 1.930 T or higher is necessary. If the magnetic flux density B 8 is less than 1.930 T, rotational motion of magnetic domains becomes necessary to align magnetization in parallel with the excitation magnetic field during the magnetization process, yet such magnetization rotation yields a large change in the magnetic strain, causing the transformer noise to increase.
In addition, changing the orientation, interval, or region of the applied strain changes the resulting iron loss reduction effect. When appropriate strain is not applied, the iron loss properties might not be sufficiently reduced, resulting in a good magnetic property not being attained, and even if the volume fraction of the closure domain is controlled, the magnetic strain might not decrease, preventing suppression of transformer noise. Therefore, by using a steel sheet to which strain has been appropriately applied and for which the iron loss W 17/50 is 0.720 W/kg or less, a noise reduction effect via control of the closure domain can be obtained.
Next, as the method for applying strain, continuous laser beam irradiation, electron beam irradiation, or the like is suitable. The irradiation direction is a direction intersecting the rolling direction, preferably a direction within 60° to 90° with respect to the rolling direction (a direction that forms an angle of 30° or less with the direction orthogonal to the rolling direction). Irradiation is performed at intervals of approximately 3 mm to 15 mm in the rolling direction. The amount of applied strain can be assessed by measuring the magnetic strain in the rolling direction under an alternating magnetic field that provides saturated magnetic flux density and then calculating the volume fraction of the closure domain with equation (A) above. Measurement of the magnetic strain is preferably performed with a method to prepare a single electrical steel sheet and use a laser Doppler vibrometer or a strain gauge.
Here, preferable irradiation conditions when using a continuous laser beam are a beam diameter of 0.1 mm to 1 mm and a power density, which depends on the scanning rate, in a range of 100 W/mm 2 to 10,000 W/mm 2 . With respect to the condenser diameter of the laser beam, directly irradiating the surface of the steel sheet with a narrow beam, such that the minimum diameter determined by the configuration of the laser irradiation device is 0.1 mm or less, increases the amount of applied strain. The volume fraction of the closure domain also increases, causing the noise in the iron core of the transformer to increase. Accordingly, the volume fraction of the closure domain is adjusted by changing the diameter of the laser beam striking the condenser lens for focusing the laser. For example, irradiation is preferably performed under the condition that the beam diameter on the surface of the steel sheet is increased to approximately twice the minimum diameter. If the condenser diameter becomes too large, the magnetic domain refining effect lessens, suppressing the improvements in iron loss properties. Therefore, expansion of the condenser diameter is preferably limited to a factor of approximately five. Effective excitation sources include a fiber laser excited by a semiconductor laser.
On the other hand, preferable irradiation conditions when using an electron beam are an acceleration voltage of 10 kV to 200 kV and a beam current of 0.005 mA to 10 mA. By adjusting the beam current, the volume fraction of the closure domain can be adjusted. While the acceleration voltage is also a factor, if the current exceeds this range, the amount of applied strain increases, causing the noise in the iron core of the transformer to increase.
Note that as long as the grain-oriented electrical steel sheet has iron loss W 17/50 of 0.720 W/kg or less and a magnetic flux density B 8 of 1.930 T or more, the chemical composition is not particularly limited. However, an example of a preferable chemical composition includes, by mass %, C: 0.002% to 0.10%, Si: 1.0% to 7.0%, and Mn: 0.01% to 0.8%, and further includes at least one element selected from Al: 0.005% to 0.050%, N: 0.003% to 0.020%, Se: 0.003% to 0.030%, and S: 0.002% to 0.03%.
Example 1
A steel slab including, by mass %. C: 0.07%, Si: 3.4%, Mn: 0.12%, Al: 0.025%, Se: 0.025%, and N: 0.015%, and the balance as Fe and incidental impurities was prepared by continuous casting. The slab was heated to 1400° C. and then hot-rolled to obtain a hot-rolled steel sheet. The hot-rolled steel sheet was subjected to hot-band annealing, and subsequently two cold-rolling operations were performed with intermediate annealing therebetween to obtain a cold-rolled sheet for a grain-oriented electrical steel sheet having a final sheet thickness of 0.23 mm. The cold-rolled sheet for grain-oriented electrical steel sheets was then decarburized, and after primary recrystallization annealing, an annealing separator containing MgO as the primary component was applied, and final annealing including a secondary recrystallization process and a purification process was performed to yield a grain-oriented electrical steel sheet with a forsterite film. An insulating coating containing 60% colloidal silica and aluminum phosphate was then applied to the grain-oriented electrical steel sheet, which was baked at 800° C. Next, magnetic domain refining treatment was performed to irradiate with a continuous fiber laser in a direction orthogonal to the rolling direction. For the laser irradiation, the average laser power was set to 100 W and the beam scanning rate to 10 m/s, and a variety of conditions were adopted by changing the beam diameter on the surface of the steel sheet. W 17/50 measurement with an SST measuring instrument was performed on the resulting samples, which were sheared into rectangles 100 mm wide by 280 mm long. Using a laser Doppler vibrometer, the magnetic strain in the rolling direction was measured, and the volume fraction of the closure domain in each steel sheet was calculated in accordance with equation (A) above. As bevel-edged material with a width of 100 mm, the samples were stacked to a thickness of 15 mm to produce the iron core of a three-phase transformer. A capacitor microphone was used to measure the noise at a maximum magnetic flux density of 1.7 T and a frequency of 50 Hz. At this time, A-scale weighting was performed as frequency weighting.
Table 1 lists the measured noise of the iron core of the transformer along with the conditions on the focus of the laser beam and the beam diameter on the surface of the steel sheet, as well as the B 8 value of the steel sheet and the results of calculating the volume fraction of the closure domain. As is clear from Table 1, a steel sheet with B 8 ≧1.930 T and with the volume fraction of the closure domain within the designated range yielded good characteristics, with the noise from the iron core of the transformer being lower than 36 dBA and the W 17/50 value also being equal to or lower than 0.720 W/kg.
By contrast, in a region where the beam diameter was too narrow, the volume fraction of the closure domain deviated from the range of the present invention, and the noise also worsened. Furthermore, when the beam diameter was too wide, the volume fraction of the closure domain was within the range of the present invention and the noise property was also good, yet the W 17/50 value was high. Even when the volume fraction of the closure domain was within the range of the present invention and the iron loss properties were good, a steel sheet with a B 8 value lower than 1.930 T had worse noise from the iron core of the transformer. Based on these results, it is essential for all three of the following to fall within the range of the present invention in order to achieve a grain-oriented electrical steel sheet suitable as the iron core of a transformer or the like: the magnetic flux density B 8 , the iron loss W 17/50 , and the volume fraction of the closure domain.
TABLE 1
Beam
diameter
Volume
on
fraction of
Iron
Steel
surface of
closure
loss
sheet
steel sheet
domain
W 17/50
Noise
No.
(mm)
(%)
B s (T)
(W/kg)
(dBA)
Notes
1
0.08
4.47
1.931
0.711
40.2
Comparative
example
2
0.11
4.11
1.934
0.713
39.3
Comparative
example
3
0.17
3.42
1.932
0.714
37.0
Comparative
example
4
0.19
3.00
1.935
0.715
35.9
Inventive
example
5
0.21
2.93
1.924
0.716
37.2
Comparative
example
6
0.21
2.81
1.930
0.717
35.4
Inventive
example
7
0.24
2.48
1.921
0.717
36.6
Comparative
example
8
0.24
2.48
1.935
0.719
35.0
Inventive
example
9
0.28
1.58
1.933
0.720
34.7
Inventive
example
10
0.30
1.00
1.934
0.720
34.5
Inventive
example
11
0.40
0.79
1.936
0.726
34.1
Comparative
example
Example 2
The same samples as the electrical steel sheets that, before laser irradiation, were used for laser beam irradiation in Example 1 were irradiated with an electron beam, adopting a variety of conditions by changing the beam current under the conditions of an acceleration voltage of 60 kV and a beam scanning rate of 30 m/s. Like Example 1, the volume fraction of the closure domain in the steel sheet, the W 17/50 value, and the noise from the iron core of the transformer were measured for the resulting samples.
Table 2 lists the measured noise from the iron core of the transformer, along with the beam current, the B 8 value, and the volume fraction of the closure domain. For the electron beam as well, reduced noise was achieved, with noise of 36 dBA or less, in samples for which B 8 ≧1.930 T and the beam current was lowered so that the volume fraction of the closure domain was within the designated range.
By contrast, when the current density was raised, the volume fraction of the closure domain exceeded the range of the present invention, resulting in increased noise, whereas when the current density was lowered, the volume fraction of the closure domain fell below the range of the present invention, and the W 17/50 value worsened. Furthermore, even when the volume fraction of the closure domain was within the range of the present invention, and the W 17/50 value was 0.720 W/kg or less, the samples had noise greater than 36 dBA when B 8 <1.930 T. Hence, for electron beam irradiation as well, the magnetic property can be made compatible with the noise property only by all three of the following falling within the range of the present invention: the magnetic flux density B 8 , the iron loss W 17/50 , and the volume fraction of the closure domain.
TABLE 2
Volume
Iron
Steel
Beam
fraction of
loss
sheet
current
closure
W 17/50
Noise
No.
(mA)
domain (%)
B s (T)
(W/kg)
(dBA)
Notes
1
10
4.70
1.932
0.704
41.4
Comparative
example
2
9
3.76
1.930
0.707
41.1
Comparative
example
3
8
3.45
1.934
0.711
38.6
Comparative
example
4
7.5
3.00
1.936
0.712
35.8
Inventive
example
5
7
2.88
1.920
0.720
36.7
Comparative
example
6
7
2.46
1.930
0.714
35.5
Inventive
example
7
6
2.12
1.935
0.717
35.2
Inventive
example
8
4
1.24
1.933
0.719
35.0
Inventive
example
9
3.5
1.00
1.934
0.720
34.7
Inventive
example
10
3
0.86
1.931
0.731
34.5
Comparative
example
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The present invention proposes a method that can reduce the noise generated by a transformer core and the like when formed by laminations of a grain-oriented electrical steel sheet in which core loss has been reduced by a magnetic domain refinement process. In this steel sheet, linear distortion extending with an orientation in which an angle formed with a direction perpendicular to the rolling direction of the steel sheet is an angle of 30° or less is periodic in the direction of rolling of the steel sheet, core loss (W 17/50 ) is 0.720 W/kg or less, and magnetic flux density (B 8 ) is 1.930 T. The volume of the closure domain arising in the distortion part is 1.00-3.00% of the total magnetic domain volume within the steel sheet.
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BACKGROUND
This invention relates generally to metal structural members for use in building construction, and more particularly to metal roof trusses for construction of roof framing for supporting roofs.
A roof truss generally comprises two or more top chord members and a bottom chord member. The ends of the top chords are secured together, and the ends of the bottom chord are connected to the lower, free ends of the top chords for forming the exterior of the roof truss. One or more web members span between and interconnect the top and bottom chords. The web members are secured at their ends to the top chords and to the bottom chord.
In building construction, a plurality of trusses are set out across a building frame. When erected upon the building frame, the bottom chord spans the wall frames of the building and is fixed to the top plate of the wall frames. The sub-roof material is then fastened to the top chords, and ceiling material may be fastened to the bottom chord. The combined load of the roof trusses, and the roofing and ceiling material attached to the trusses, is transferred through the outer edges of the trusses to the top plate of the wall frames.
In the past, roof trusses have been constructed of wooden chords and web members. More recently, various types of building systems incorporate metal trusses.
Metal trusses include chord members and web members rolled from metal sheets and formed into substantially rectangular U-shaped or C-shaped channels. The open sides of the chord members are adapted to receive the ends of the other chord members and the web members. The ends of the chords and web members are then fastened together for securing the truss elements in position. The materials cost for metal trusses is competitive with other building materials. Using metal as the material of construction also has a number of other advantages, including relatively stable price, strength, flexibility, durability, light weight, reliability, minimum waste in use, and noncombustability.
A significant problem with the use of metal trusses is the high installed cost. One factor influencing the installed cost of metal trusses is the thermal performance of metal, which is well below that of lumber framing when using standard framing techniques. This is due to the thermal conductivity of metal and the potential for thermal bridging. For example, steel conducts heat more than 300 times faster than wood. The rapid heat flow through steel reduces the insulating value of cavity insulation between 53 and 72%. With respect to metal roof trusses, heat passing through the ceiling material, if present, migrates into the bottom chord. Usually the bottom chord is covered with insulation spread on the attic floor, but heat can still be transferred into the truss at the points where the web members are fastened to the bottom chord. Heat is then conducted by the web members into the attic area and to the top chord at the underside of the roof. The result is a wicking effect whereby heat is transferred out of the building. Special considerations are necessary to reduce the tendency of metal roof trusses to transfer heat in this manner.
As a solution, some builders using metal wall frame construction, but top the building frame with wood roof trusses in order to minimize thermal bridging. However, this defeats the purpose of opting for metal frame construction. Other common solutions to improve energy efficiency include increasing the amount of cavity insulation and applying insulation to the exterior of the metal frame elements to provide a “thermal break” to the heat conducting path. Other means for reducing heat loss include punchouts in the chord members, wide truss spacing, and using thicker gauge steel. All of these approaches add to the cost, installation time and the difficulty of using metal roof trusses.
For the foregoing reasons, there is a need to provide a metal roof truss for use in a metal frame building system that is more energy efficient. Ideally, the new metal roof truss should be inexpensive, light weight, and adapted to mass production.
SUMMARY
According to the present invention, a metal truss is provided comprising a pair of elongated top chord members each having a first end and a second end. The top chord members are connected to each other at the first ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
Also according to the present invention, a metal frame building system is provided including a building frame comprising a plurality of wall frames having top ends. The building system includes a metal truss comprising a pair of elongated top chord members each having a first end and a second end. The top chord members are connected to each other at the first ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. The plurality of trusses are adapted to be erected upon the building system frame such that the second bottom chord member spans the wall frames and is connected to the top ends of the respective wall frames.
Further according to the present invention, a building comprises a frame including a plurality of wall frames, each of the wall frames having a top end. A metal truss comprises a pair of elongated top chord members each having a first end and a second end and connected to each other at the first end. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the second ends of the top chord members such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member connected to the first bottom chord member. A plurality of the metal trusses are erected upon the frame such that the second bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames. Roof material is fastened to the top chord members.
Still further according to the present invention, a metal truss is provided comprising a plurality of elongated top chord members connected to each other end to end so that the connected top chord members have two free ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the connected top chord members. A second elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the connected top chord members such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member connected to the first bottom chord member.
According to another embodiment of the present invention, a metal truss is provided comprising a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
Also according to the other embodiment of the present invention, a metal frame building system is provided including a plurality of wall frames having top ends. The building system includes a metal truss comprising a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. A plurality of trusses are adapted to be erected upon the building system frame such that the first bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames, and the ends of the second bottom chord member extend between the inner surfaces of the wall frames.
Further according to the other embodiment of the present invention, a building comprises a frame including a plurality of wall frames, each of the wall frames having a top end. A metal truss comprises a pair of elongated top chord members connected together at their first ends, a first elongated bottom chord member, and means for connecting the first bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member. A plurality of trusses are adapted to be erected upon the frame such that the first bottom chord member spans at least two of the wall frames and is connected to the top ends of the respective wall frames, and the ends of the second bottom chord member extend between the inner surfaces of the wall frames. Roof material fastened to the top chord members.
Still further according to another embodiment of the present invention, a metal truss is provided comprising a plurality of elongated top chord members, the top chord members connected to each other end to end so that the connected top chord members have two free ends. Means are provided for connecting a first elongated bottom chord member to the top chord members adjacent the second ends of the top chord members. Means are also provided for connecting a second elongated bottom chord member to the first bottom chord member such that the second bottom chord member is spaced from the first bottom chord member. At least one web member positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference should now be had to the embodiment shown in the accompanying drawings and described below. In the drawings:
FIG. 1 is a schematic view of a roof truss assembly according to the present invention;
FIG. 2 is an elevational end view of a truss member for use in the truss assembly according to the present invention;
FIG. 3 is a schematic view of the roof truss assembly shown in FIG. 1 positioned on wall frames the bottom portion of which have been cut-away;
FIG. 3A is a schematic view of the roof truss assembly as shown in FIG. 3 including insulation between the bottom chord members.
FIG. 4 is a schematic view of another embodiment of a roof truss assembly according to the present invention;
FIG. 5 is a cross-section of a truss member taken along line 5 - 5 of FIG. 4 ;
FIG. 6 is a schematic view of one half of the truss assembly shown in FIG. 4 positioned on a wall frame the bottom portion of which has been cut-away.
DESCRIPTION
Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the Figures. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.
Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, FIG. 1 shows an embodiment of a roof truss assembly according to the present invention, generally designated at 10 . The roof truss assembly 10 comprises several structural truss members, including a pair of top, or upper, chord members 12 , a pair of spaced bottom, or lower, chord members 14 , 16 , and web members 18 . Adjacent upper ends of the top chord members 12 are secured together to form an apex joint. In this embodiment, the ends of both bottom chord members 14 , 16 are secured adjacent to the lower ends of the top chord members 12 . The top chord members 12 and the lower bottom chord member 14 form a triangle, with the lower bottom chord member 14 as the base and the top chord members 12 forming the sides of the triangle.
It is well known in the art that there are a number of roof truss profiles in addition to the triangular truss assembly 10 depicted in FIG. 1 . We do not intend to limit the application of the present invention to a triangular truss profile. Rather, the present invention is applicable to all such truss profiles.
The web members 18 extend between the top chord members 12 and the upper bottom chord member 16 . The opposite ends of the web members 18 are secured to the top chord members 12 and upper bottom chord member 16 for rigidifying the roof truss assembly 10 . Eight web members 18 are shown in FIG. 1 . It is understood that we do not intend to limit the application of the present invention to a roof truss assembly 10 having a predetermined position and number of web members 18 . The number and the position of web members 18 will vary as necessary depending upon the size of a building and the lengths of the chord members 12 , 14 , 16 in order to provide the required structural strength with an acceptable safety factor.
Each of the truss members is formed from a strip or sheet of metal. The preferred material of construction is steel. However, the present invention is not limited to steel, and other metals such as aluminum, copper, magnesium, or other suitable metal may be appropriate. The scope of the invention is not intended to be limited by the materials listed here, but may be carried out using any material which allows the construction and use of the metal roof truss assembly 10 described herein.
As shown in FIG. 2 , a truss member 20 which comprises the roof truss assembly 10 of the present invention is substantially C-shaped or U-shaped, having a web 24 spanning opposed side walls 26 defining a channel 22 section. When assembled ( FIG. 1 ), the open channels of the bottom chord members 14 , 16 face upwardly and the open channels of the top chord members 12 face downwardly. Joints are formed where the chord members 12 , 14 , 16 and web members 18 intersect one another. The joints can be secured using fasteners (not shown), such as metal screws, bolts and nuts, rivets, or any combination thereof. For this purpose, aligned holes may be punched or drilled through the truss members during production. A short connecting plate (not shown) may also be fitted to the chord members 12 , 14 , 16 and web members 18 on each side of a joint and fastened together with the chord members 12 , 14 , 16 and web members 18 to form a reinforced joint. Alternatively, the truss members may be joined by welding, soldering, and the like.
The truss members can all be produced on-site from coils of sheet metal using a portable roll forming machine, as is known in the art. Features for joining the truss members may be provided by the forming machine, including holes for fasteners. Notches are cut into the side walls 26 a sufficient distance to accommodate intersecting truss members, depending upon the angle at which the truss members meet each other, allowing a portion of one end of a truss member to be fitted within another truss member. All of the truss members can be formed with a common section to simplify production. Additionally, service holes may be provided in the structural member to accommodate electrical wiring or other utilities.
In accordance with the present invention, the lower bottom chord member 14 is separated from the upper bottom chord 16 . As a result of this arrangement, there is no direct thermal path from the lower bottom chord member 14 to the web members 18 of the truss assembly 10 . Moreover, the air space 27 between the bottom chord members 14 , 16 serves as an insulator. The air space 27 between the bottom chord members 14 , 16 can be insulated to further enhance thermal performance. FIG. 3A shows a length of insulating material 29 held between the lower bottom chord member 14 and the upper bottom chord member 16 .
In building construction, a plurality of truss assemblies 10 are set out across a building frame. As seen in FIG. 3 , the lower bottom chord 14 spans the wall frames 30 of the building and is fixed to the top plate (not shown) of the wall frames 30 . Ceiling material (not shown) may be attached directly to the lower bottom cord 14 . Tensile elements 28 , schematically shown in FIG. 3 , may be provided between the bottom chord members 14 , 16 where necessary to support the weight of the ceiling material. The tensile elements 28 are spaced from the points on the truss assembly 10 where the web members 18 are fastened to the upper bottom chord 16 to minimize the potential for thermal bridging. Preferably, the tensile elements 28 are formed from a material having a low thermal conductivity.
Another embodiment of the roof truss assembly according to the present invention is shown in FIG. 4 and generally designated at 40 . In this embodiment, the roof truss assembly 40 comprises a pair of top chord members 42 , a bottom chord member 44 and web members 46 . The web members 46 extend between and interconnect the top chord members 42 and the bottom chord member 44 . A vertically-positioned heel truss 48 is fastened between each end of the bottom chord member 44 and the free ends of the top chord members 42 . As noted above, the present invention is not limited to a triangular truss profile, but rather is applicable to all known roof truss profiles. Moreover, the number and position of the web members 46 will vary as necessary depending upon the truss profile, the size of a building, and the lengths of the chord members 42 , 44 , in order to provide the required structural strength with an acceptable safety factor. Thus, the triangular truss profile and the number and position of the web members 46 depicted in FIG. 4 are merely exemplary.
Spacers 50 are positioned along the length of, and fastened to, the bottom chord member 44 . The spacers 50 are located away from the points on the truss assembly 40 where the web members 46 are fastened to the bottom chord member 44 . A ceiling support 52 is secured to the spacers 50 . As seen in FIG. 5 , the ceiling support 52 may be slightly wider than the web 24 of the bottom chord member 44 . Ceiling material 54 may be attached to the ceiling support 52 . The spacers 50 and ceiling support 52 can be formed from any material as long as the combination, along with the means for fastening the ceiling support 52 through the spacer 50 to the bottom chord member 44 , is sufficiently strong to support the ceiling support 52 and ceiling material 54 . For example, wood, fiberboard, cardboard, plastic, and the like, are all suitable materials for the spacers 50 and ceiling support 52 . Preferably, the spacers 50 have a low thermal conductivity. In keeping with the invention, the spacers 50 function to provide an insulating air space 58 between the bottom chord member 44 and the ceiling support 52 ( FIG. 3 ), which minimizes the potential for thermal bridging.
Referring to FIG. 6 , one side of a truss assembly 40 according to the second embodiment of the present invention is shown in position on a wall frame 30 . The bottom chord 44 spans the wall frames 30 (only one of which is shown in FIG. 6 ) of the building and is fixed to the top plate of the wall frames 30 . The ends of the ceiling support 54 extend between the inner surfaces of the wall frames 30 . Ceiling material 54 is attached directly to the ceiling support 52 . Optionally, insulating material 56 may be disposed in the air space 58 . For example, as seen in FIG. 6 , a length of insulating material 56 is placed between the ceiling support 52 and the bottom chord 44 where the web members 46 attach to the bottom chord member 44 .
The thermal performance of the roof truss assembly of the present invention is significantly improved over conventional metal trusses. Separation of the lower bottom chord member or ceiling support from the bottom chord member connected to the web members provides an insulating air space between the ceiling and the bottom chord member and eliminates any direct thermal path from the ceiling to the bottom chord member and the web members of the truss assembly. Although the air space 27 can be insulated to further enhance thermal performance, the improvement in thermal performance can be achieved without the additional insulating material, or the use of insulating material as a thermal break. Moreover, a truss configuration according to the present invention allows the use of light gauge metal, preferably having a thickness of less than about 1.2 mm. For example, standard light gauge metal could be used, such as 12, 14, or 16 gauge.
Although the present invention has been shown and described in considerable detail with respect to a particular exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the invention to the embodiment since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. For example, the truss profile and the number and position of the truss members may be any of a number of arrangements known in the art. Accordingly, we intend to cover all such modifications, omissions, additions and equivalents as may be included within the spirit and scope of the invention as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a crew may be equivalent structures.
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A metal truss comprises elongated top chord members connected to each other at their ends. A first elongated bottom chord member is connected at its ends to the top chord members adjacent the free ends of the top chord members. A second elongated bottom chord member is connected at its ends to the top chord members, or directly to the first bottom chord member via spacers, such that the second bottom chord member is spaced below the first bottom chord member. At least one web member is positioned between and interconnecting at least one top chord member and the first bottom chord member. One end of the web member is connected to the at least one top chord member and the other end of the web member is connected to the first bottom chord member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to commode apparatus, and more particularly pertains to a new and improved commode seat spacer assembly wherein the same is arranged for the temporary mounting to a commode seat to provide for spaced orientation of an individual relative to a commode seat during its use.
2. Description of the Prior Art
The contemporary spread of various disease and the like relative to the use of commercially available commode structure requires individuals to exert caution in the use of such commode structure. The instant invention attempts to overcome deficiencies of the prior art by providing for a portable commode seat spacer assembly wherein the same is directed to the mounting upon a conventional commode seat for temporary use of the commode.
Prior art set forth relative to auxiliary seat structure as indicated in U.S. Pat. Nos. 4,839,929 and 4,998,297 to include a flexible ring-shaped member having an upper surface arranged for mounting to an associated commode seat.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of commode seat apparatus now present in the prior art, the present invention provides a commode seat spacer assembly wherein the same is directed to the temporary mounting upon a commode seat for spaced use of the commode seat in a sanitized relationship. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved commode seat spacer assembly which has all the advantages of the prior art commode seat apparatus and none of the disadvantages.
To attain this, the present invention provides a spacer assembly mounted to an associated commode seat to effect sanitized spacing for an individual utilizing the seat, wherein the spacer assembly includes a plurality of arcuate members, each having a plurality of spring finger leg portions extending from bottom walls of the assembly to secure opposed side walls of the commode seat.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlines, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, method and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved commode seat spacer assembly which has all the advantages of the prior art commode seat apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved commode seat spacer assembly which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved commode seat spacer assembly which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved commode seat spacer assembly which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such commode seat spacer assembly economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved commode seat spacer assembly which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularly in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art commode seat cover, as indicated in U.S. Pat. No. 4,998,297, providing for a ring-like member arranged for positioning upon a commode seat.
FIG. 2 is an isometric illustration of the spacer members mounted to a commode seat.
FIG. 3 is an isometric illustration of the spacer assemblies arranged for inter-fitting relationship relative to one another.
FIG. 4 is an orthographic view, taken along lines 4--4 of FIG. 2 in the direction indicated by the arrows.
FIG. 5 is an isometric illustration of the invention including an associated storage and transport bag member.
FIG. 6 is an orthographic cross-sectional illustration of a modified commode seat support member.
FIG. 7 is an isometric illustration of a further modified commode seat member.
FIG. 8 is an orthographic view, taken along the lines 8--8 of FIG. 7 in the direction indicated by the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 8 thereof, a new and improved commode seat spacer assembly embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the commode seat spacer assembly 10 of the instant invention essentially comprises cooperative association with a commode 11, having a commode arcuate seat 12, with the seat 12 including a seat inner wall 15 spaced from a seat outer wall 16. First and second support members 13 and 14 respectively are mounted in a facing relationship on the commode seat 12. The first support member 13 includes a first top wall 17 spaced from a first bottom wall 18, a first concave arcuate inner side wall 19 spaced from a first convex outer side wall 20. The second support member 14 includes a second top wall 21 spaced from a second bottom wall 22, and a second concave arcuate inner side wall 23 in a facing relationship relative to the first inner side wall 19. A second convex arcuate outer side wall 24 is spaced from the second inner side wall 23 (see FIG. 3). First and second U-shaped brackets 25 and 26 are mounted to the first bottom wall 18, with the first and second U-shaped brackets 25 and 26 having spring fingers biased towards one another to engage the seat's inner and outer side walls 15 and 16. Similarly, the second bottom wall 22 includes third and fourth U-shaped brackets 27 and 28 having cooperative spring fingers to engage the seat's side walls. As indicated in FIG. 3, the first and second support members 13 and 14 are arranged for transport relative to one another in an engaging relationship, wherein the first bottom wall 18 is arranged for a facing and coextensive relationship relative to the second bottom wall 22. To this end, the first and second U-shaped brackets 25 and 26 respectively are offset relative to the third and fourth U-shaped brackets 26 and 27 that are mounted to the second bottom wall 22. In this manner, the first and second support members 13 and 14 are arranged for an engaging relationship relative to one another, as indicated in FIG. 5, for reception within an associated flexible bag 29, having a bag cavity to receive the first and second support members 13 and 14 in a secured relationship relative to one another, with the flexible bag 29 further including a securement strap 30 mounted adjacent the entrance opening of the flexible bag, with the securement strap 30 having a first fastener 31 mounted to the bag, and a second fastener 32 secured to a free distal end of the securement strap 30, wherein the first and second fasteners 31 and 32 are typically of a hook and loop fastener construction.
The FIG. 6 indicates the use of a modified support member construction (for purposes of example only, the further modified structure 14a is indicated, but it should be understood that such construction is identical for both support members 13 and 14). The modified support member 14a includes a polymeric resilient web 33 mounted to the support member top wall.
The FIGS. 7 and 8 indicates the use of a further modified support member, wherein at least one of the support members, such as the second support member 14, is configured such that the further modified support member 14b includes a polymeric fluid impermeable layer 35 mounted coextensively to the side walls and the top wall, with the second top wall 21 having a recess 35 directed into the second top wall, and the recess having a recess floor, with the recess floor exposing a resilient diaphragm 38 projecting above the recess floor, with the diaphragm 38 formed of a shape-retentive material arranged in a projecting relationship relative to the recess floor, as illustrated in FIG. 8. A fluid reservoir cavity 37 is directed within the second support member 14 between the recess floor and the second bottom wall 22. The second bottom wall 22 includes a fill plug 39 to permit the positioning of various fluids within the fluid reservoir cavity 37, such as bactericides, deodorizers and the like. First and second conduits 40 and 42 respectively extend in fluid communication from the fluid reservoir cavity 37 to the respective second inner and outer side walls 23 and 24 respectively, as indicated in FIG. 8.
Respective first and second check valves 41 and 43 are mounted within the first and second conduits to permit fluid flow only from the reservoir through the first and second conduits and projection from the first and second conduits exteriorly of the second support member 14 relative to the second concave and convex arcuate inner and outer side walls 23 and 24 respectively. In this manner, such fluid may be deposited within the commode, as well as exteriorly of the commode, during use of the organization. Further, a foam insert 36 is arranged for reception within the recess 35 in a coextensive and complementary relationship permitting ease of removal of the foam insert 36 for its maintenance, cleaning, and the like.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description the, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A spacer assembly mounted to an associated commode seat is provided to effect sanitized spacing for an individual utilizing the seat, wherein the spacer assembly includes a plurality of arcuate members, each having a plurality of spring finger leg portions extending from bottom walls of the assembly to secure opposed side walls of the commode seat.
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CROSS-REFERENCE
The invention described and claimed hereinbelow is also described in PCT/DE 03/01522, filed on May 12, 2003 and DE 102 32 878. 1, filed Jul. 19, 2002. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119 (a)-(d).
BACKGROUND OF THE INVENTION
The present invention is directed to a device for distance measurement and/or a method for distance measurement.
Distance measurement devices and, in particular, optical distance measurement devices as such have been known for some time. These devices emit a modulated measuring beam, e.g., a light or laser beam, which is directed to a desired target object, the distance of which to the device is to be determined. A portion of the returning measurement signal that is reflected or scattered by the sighted target object is detected again by the device and used to determine the sought-after distance.
A distinction is made hereby between “phase measurement methods” and pure “transit time methods” for determining the sought-after distance to the target object. With the transmit time method, a light pulse having the shortest possible pulse duration is emitted by the measurement device, then its transit time to the target object and back to the measurement device is determined, for instance. Based on this, the distance of the measurement device to the target object can be calculated, with reference to the known value for the speed of light.
With the phase measurement method, in contrast, the variation of the phase of the measurement signal with the path that was covered is used to determine the distance between the measurement device and the target object. Based on the magnitude of the phase displacement of the returning light in comparison to the emitted light, the path covered by the light and, therefore, the distance of the measurement device to the target object can be determined.
The field of application of distance measurement devices of this type generally includes distances in the range of a few millimeters up to many hundred meters. Depending on the paths to be measured, the environmental conditions and the reflectance of the selected target object, different requirements on the performance of a measurement device of this type result. Measurement devices of this type are now available commercially in compact designs; they enable simple, handheld operation for the user.
Laser distance measurement devices are known that have a defined measurement accuracy that is defined essentially by the measurement system on which the measurement device is based. This accuracy of the distance measurement device is guaranteed for a specified measurement range of the measurement device, by the manufacturer, for instance.
A circuit arrangement and a method for optical distance measurement is known from DE 198 11 550 A1, for example, with which at least two different, closely adjacent measurement frequencies are derived from an oscillator. To permit measurement over the greatest possible measurement range and, simultaneously, to obtain the highest possible measurement accuracy in the distance measurement, three different frequencies in the range from approximately 1 MHz to approximately 300 MHz are used in the method according to DE 198 11 550 A1, and the sought-after path is measured with each of these frequencies.
An optical method for measuring distances according to the pulse transit time method is known from EP 0 885 3999 B1, with which a rough measurement procedure and a fine measurement procedure are carried out. Using a rough measurement procedure, a measurement time interval is determined that is greater than an estimated propagation time of the light signal to and from the desired target object. An appropriate measurement time range is fixed in advance within this measurement time interval. A series of sub-measurements is then carried out during the fine measurement procedure, whereby, for each sub-measurement, a measurement light signal is sent to the target object and the received, returned light pulse that is reflected by the target object is collected only within the appropriate measurement time range that was fixed during the rough measurement procedure. The exact distance of the measurement device to the target object is then determined by calculating the mean of the individual measurements in the fine measurement procedure.
The object of the present invention is to expand, using simple means, the distance range—that is, the distance range across which a distance measurement can be carried out with the device—that is usable with a compact, and, in particular, handheld measurement device for distance measurement.
This object is attained via a device for distance measurement according to the invention and via a method for distance measurement.
SUMMARY OF THE INVENTION
In contrast to devices of the related art, the device according to the invention and/or the method according to the invention have the advantage that they enable distances to be measured with different measurement accuracies. If a measurement accuracy is guaranteed and, therefore fixed, over a certain range of measurement distances, then this is a limiting criterium—due, e.g., to the decrease in signal intensity with the distance—for the measurement distance still to be determined with the predefined measurement uncertainty. The measurement uncertainty of a measurement is essentially determined by the signal-to-noise (S/N) ratio of the measurement signal. For small reflected signals, which occur when measurement distances are great or when a measurement is taken against surfaces with low reflectance, this results in a limitation of the measuring range which can be measured with a specified measurement uncertainty. If the measurement uncertainties with which a corresponding distance measurement is carried out are not fixed, but rather can be predetermined by the user or via an automatic procedure in the device, then the measurement range—which is accessible with a measurement device and/or, correspondingly, a method of this type—over which the distance measurements are possible can be markedly expanded, even if a higher measurement uncertainty must be tolerated.
For a large number of areas of application of a, e.g., handheld, compact distance measurement device, the advantages resulting from the expansion of the measurement range outweigh the possible disadvantages of greater measurement uncertainty and/or reduced measurement accuracy.
Advantageous further developments of the device indicated in the independent claims and/or the claimed method are possible due to the measures listed in the dependent claims.
The measurement inaccuracy of the measurement device may be optimally adapted to the particular measurement task in an advantageous manner. In many cases of the typical use of a compact distance measurement device of this type, high accuracy with a resolution in the range of a few millimeters is not required, for example. When measuring larger distances, in particular, it is desirable to first obtain a first measured value and starting point for the sought-after distance, so that, in this case, a determination of the sought-after distance with an accuracy of a few millimeters is not even required. Much too much measurement expenditure would be required to carry out distance measurements over a distance of a hundred or more meters with the same low level of measurement uncertainty as it would require to carry out a measurement over a few meters.
With the device for optical distance measurement according to the invention, it is advantageously possible to markedly expand the range of distances to be measured, in principle, with a device of this type. Instead of a fixed, predetermined measurement uncertainty of distance measurement and/or a corresponding resolution of the distance measured, a variable measurement uncertainty is made possible with the distance measurement carried out by the device. For example, the measurement distance of a distance measurement device of this type may be expanded markedly when the requirements on the measurement uncertainty of the value to be determined are reduced for the range of greater measurement distances, e.g., in the range of 50 to many hundred meters. Likewise, the measurement time needed to determine a measurement distance may be markedly reduced when the measurement uncertainty of the measurement system is raised accordingly for this purpose.
In advantageous fashion, a number of characteristic curves, e.g., characteristic curves that specify the course of the measurement uncertainty over a measurement distance, can be stored in a storage medium of the measurement device for this purpose.
Based on a target entered by the user, e.g., using a keypad on the device or via an automated system internal to the device, a characteristic curve can then be selected that specifies—as a function of the measurement distance—a measurement uncertainty on which the distance measurement is to be based.
For example, in an advantageous embodiment of the measurement device according to the invention and/or the method for distance measurement on which it is based, a maximum measurement time for a measurement can then be predetermined, and the device switches automatically between the available characteristic curves for the measurement uncertainty to select that characteristic curve—with consideration for the predetermined measurement time—which ensures the lowest possible measurement uncertainty.
In this manner, it is ensured that the minimum measurement uncertainty of the device is utilized in the range of small measurement distances and the measurement uncertainty does not gradually become greater until the distances are greater, so that an expanded measurement range is made available to the measurement device without the measurement uncertainty becoming too great in the range of small measurement distances.
In advantageous fashion, a value for the signal-to-noise ratio (S/N) of the returning amplitude signal to be detected can be specified to the control and evaluation unit of the device. This signal-to-noise ratio then essentially defines the accuracy with which a distance measurement is to be carried out.
In a likewise advantageous manner, the distance measurement device according to the invention is configurable such that the measurement time, the measurement uncertainty of the measurement and the resolution of the measured result are selectable individually or as a whole. A user of the measurement device according to the invention can enter a fixed measurement time or a desired accuracy for the distance measurement using an operating field, for example. The electronics in the measurement device then adjust, semi-automatically, the remaining measurement parameters via corresponding circuit means in such a manner that the desired measurement uncertainty and/or the desired measurement time are made possible.
The measurement device according to the invention can be set in this manner for a measurement uncertainty of 10 −3 m, for example, for working at close range up to approximately 10 m on highly reflective surfaces, whereby the measurement time would amount to one second at most, for example, and the resolution of the measurement device should be 10 −4 m. This setting may result in it being impossible to carry out a measurement on dark surfaces, which is irrelevant for the user's desired measurement situation anyway. The measurement device may also be configured optimally in a likewise advantageous manner for working at far range, e.g., between 50 m and 100 m, by reducing the accuracy of the measurements to 10 −1 and setting the resolution of the determined measured value to 10 −2 m.
In an exemplary embodiment of the measurement device according to the invention, a sensor is integrated that detects the light conditions in the environment of the measurement site and, based on this, determines a measure of the background signal that exists for a measurement. This background signal is incorporated in the signal-to-noise ratio that exists for a measurement and therefore influences the possible measurement uncertainty of a distance measurement. In an advantageous embodiment, this sensor function is performed by the detector element of the receive branch, so that the measurement signal and the background signal are both determined with only one detector.
An automatic switching over of the measurement uncertainty of the device based on the relative intensity of the ambient light can be predetermined in the method according to the invention and integrated accordingly in a measurement device that operates according to this method.
For example, the possible distance measurement range for a maximum predetermined measurement time can be expanded by reducing the requirements on the signal-to-noise ratio across the distance. When working outdoors in sunlight, i.e., with a strong background and/or noise signal, in particular, this results in a marked increase in the usability of the measurement device according to the invention.
Advantageously, only one measurement parameter (measurement time, resolution of the distance, measurement uncertainty, . . . ) can be fixed in the evaluation unit of the measurement device according to the invention, for example, so that the other measurement parameters are adjusted semi-automatically by the control electronics of the measurement device such that, given a fixed setting, e.g., the measurement time, the sought-after distance is determined with the best-possible accuracy, i.e., with minimal measurement uncertainty. This results in a depiction of the measured value that is adjusted for the resolution used, however.
The device for optical distance measurement according to the invention also makes it possible for the device to configure itself, independently and fully automatically, such that all parameters are adjusted such that an optimum setting of the measurement parameters is carried out depending on the distance and environmental conditions.
In an exemplary embodiment according to the invention, the value of the signal-to-noise ratio which determines the measurement accuracy is determined by a first “rough” measurement of the distance to the target object by the device itself, the rough measurement being carried out before the actual distance measurement. The subsequent, second measurement for determining the distance between the measurement device and the target object is then carried out with an accuracy and, therefore, measurement time requirement, that is adjusted to the rough distance range.
In an advantageous exemplary embodiment of the device according to the invention, various measurement uncertainties are set up for this purpose, which are allocated to individual distance intervals. Based on the approximate distance determined in the rough measurement, a measurement uncertainty for the actual distance measurement corresponding to this distance is then selected by the device.
It is also possible with the method according to the invention that the user himself specifies the resolution of the distance before a measurement by entering “mm”, “cm”, or “m” via an operating field, for example, and the measurement device selects an adjusted measurement uncertainty—with consideration for the measurement situation, that is, with consideration for the level of the background signal and the desired measurement time, for example—that is, it determines the signal-to-noise ratio up to which the measurement should be carried out. While the measurement is underway, the particular current signal-to-noise ratio is then determined by a control and evaluation unit of the measurement device, and a decision is made as to whether the measurement must be carried out for a longer period of time.
It is particularly advantageous when a plurality of characteristic curves is stored in the measurement device, which have a different course of measurement uncertainty with the measurement distance, so that, by selecting a characteristic curve of this nature, a measurement uncertainty that is still acceptable for a selected measurement range is selected.
This can also take place, for example, by a user roughly specifying an approximate distance range, and the device then selecting a corresponding, optimized characteristic curve for the measurement uncertainty.
In advantageous fashion, in the measurement device according to the invention, the setting for the accuracy of the length measurement on which a distance measurement is based is shown to the user via an optical display. For example, via a display of “millimeters”, “centimeters”, or “meters”, the user can be informed immediately as to which magnitude the measured result appearing in the display for his length measurement can be specified in and be accurate.
In a further exemplary embodiment of the device according to the invention, the display of the measured results of a distance measurement can be depicted, for example, with the number of decimal places corresponding to the accuracy of the distance measurement, in a display device of the measurement device. The measurement accuracy, which decreases as the measurement distance increases, can be visualized for the user of the measurement device in a simple but unequivocal manner by reducing the display resolution, for example.
The method, according to the invention, for distance measurement with phase displacement of amplitude-modulated light makes it possible in a simple and advantageous fashion to markedly expand the length range for the distance measurement that is possible with a measurement device of this nature. As an alternative, the method according to the invention makes it possible to reduce the measurement time for a measurement given a typical, predetermined distance from a target object, for example. The measurement range that is accessible with the method for distance measurement according to the invention is no longer limited by a measurement accuracy that is specified once and applies across the entire measurement range and for all applications of the device; instead, it can be markedly expanded in simple fashion by adapting the measurement accuracy to the measurement task. The method according to the invention permits the area of application of a measurement device of this type to be expanded markedly.
Further advantages of the device according to the invention and/or the method according to the invention result from the drawings and the associated description.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the device according to the invention and the method for optical distance measurement according to the invention are depicted in the drawing. The exemplary embodiment will be described in greater detail in the subsequent description. The figures in the drawing, their description, and the claims directed to the present invention contain numerous features in combination. One skilled in the art will also consider these features and/or the claims on which they are based them individually and combine them to form further reasonable combinations and claims.
FIG. 1 shows a device according to the general class for optical distance measurement in a schematic total overview,
FIG. 2 is a flow chart with the essential method steps on which the method according to the invention is based,
FIG. 3 shows the schematic course of the measurement uncertainty of a measurement device across the measurement distance, and a series of characteristic curves—which can be entered in advance in the device according to the invention—of the measurement uncertainty as a function of the measurement distance as examples, and
FIG. 4 shows the schematic course of the measurement time across the measurement distance in the case of an essentially constant measurement uncertainty and in the case of a measurement in accordance with the predetermined characteristic curves according to FIG. 3 .
FIG. 5 schematically represents one example of a collection, that is, a “group” or “set”, of measurement parameters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows, in schematic fashion, a distance measurement device 10 according to the general class with the most important components for describing its basic configuration. Device 10 has a housing 12 in which a transmission branch 14 for generating a measurement signal 16 and a receive branch 18 for detecting the measurement signal 17 returning from a target object 20 are located. Receive branch 18 forms a receive channel for returning measurement signal 17 .
Transmit branch 14 contains a light source 22 , which is realized in the exemplary embodiment in FIG. 1 by a semiconductor laser diode 24 . The use of other light sources and non-optical transmitters in the device according to the invention is also possible.
Laser diode 24 in the exemplary embodiment according to FIG. 1 emits a laser beam in the form of a light bundle 26 that is visible to the human eye. Laser diode 24 is operated via a control device 28 which, using corresponding electronics, generates a modulation of the electrical input signal 30 to diode 24 . Control device 28 receives the necessary frequency signals to modulate a control and evaluation unit 58 of the measurement device. In other exemplary embodiments, control device 28 can also be an integral component of the control and evaluation unit 58 .
Control and evaluation unit 58 includes a circuit arrangement 59 which also includes, among other things, at least one quartz oscillator for providing the necessary frequency signals. The measurement signal is modulated in known fashion with these signals of which typically a plurality having different frequencies is used during a distance measurement. The principle configuration of a circuit arrangement of this type is described in publication DE 198 11 550 A1, for example, and will therefore not be explicitly repeated here.
Intensity-modulated light bundle 26 exiting from semiconductor diode 24 passes through first optics 32 , which results in an improvement of the beam profile of the light bundle. Optics of this type can also be an integral part of the laser diode itself. Laser beam bundle 26 then passes through a collimation lens 34 , which generates a nearly parallel light beam bundle 36 that is emitted in the direction of target object 20 to be measured. For this purpose, a device 38 for generating a reference distance 40 internal to the device is located in transmit branch 14 of the device according to FIG. 1 , the reference distance serving as internal calibration of the measurement device.
Measurement signal 16 is coupled out of housing 12 of device 10 through an optical window 42 . To perform a measurement, device 10 is directed at a target object 20 , whose distance from the measurement device is to be determined. Signal 17 , which is reflected or scattered on the desired target object 20 , forms a returning measurement beam bundle 44 , a certain portion of which enters device 10 again. Returning measurement beam 17 is coupled into the measurement device through an entry window 46 in end face 48 of device 10 and directed to a receiving lens 50 . Receiving lens 50 bundles the returning measurement beam bundle 44 onto active surface 52 of a receive device 54 .
This receive device 54 can be a junction-type detector or a photodiode, for example, and a direct-mixing avalanche photodiode of a known type, for example. Active surface 52 of receive device 54 is a corresponding detection element. Receive device 54 converts incoming light signal 17 into an electrical signal, which is then forwarded via corresponding connecting means 56 to a control and evaluation unit 58 of device 10 . Control and evaluation unit 58 determines—based on returning optical signal 17 and, in particular, the phase displacement impressed on the returning signal in comparison with the signal sent originally—the sought-after distance between device 10 and target object 20 , and displays it in an optical display device 60 of the measurement device, for example.
In the case of a laser distance measurement using phase-displacement measurement of amplitude-modulated light, the phase displacement between the light returning from target object 20 and received in detector 54 and the light emitted from measurement device 10 in the direction of target object 20 is given by the equation:
φ
=
2
π
*
f
c
*
2
d
(
1
)
Wherein φ represents the phase displacement impressed on the light signal resulting from a distance d between measurement device 10 and target object 20 , f represents the modulation frequency of the amplitude-modulated measurement signal, and c is the phase velocity (speed of light) of the measurement signal that is utilized.
The signal-to-noise ratio of the measurement signal that is used determines the accuracy in the determination of the distance d of measurement device 10 to target object 10 in the laser distance measurement using phase displacement measurement.
The measurement uncertainty Δφ in a phase measurement is given by the equation:
Δφ
=
1
2
*
S
N
(
2
)
The signal-to-noise ratio S/N, which determines the measurement uncertainty, may be determined, for example, based on an amplitude measurement of the modulation signal and the direct component of ambient light that results in a corresponding noise in the measurement signal.
Since the signal-to-noise ratio can basically be measured, it is also possible according to the invention to influence a distance measurement such that a predetermined target value for the signal-to-noise ratio S/N and, therefore, for the measurement uncertainty Δφ (p, is achieved in the phase measurement, e.g., by adjusting the measurement time. With the method according to the invention, the target signal-to-noise ratio to be achieved in a measurement can be set by the user indirectly in the form of a preselected measurement time, e.g., via an operating field 62 of the control and evaluation unit 58 of measurement device 10 , or automatically or semi-automatically in optimized fashion by the measurement device itself.
Using a short distance measurement carried out before the actual measurement procedure, for example, an erroneous rough estimate of the sought-after distance can therefore be carried out, followed by a more exact measurement, which is carried out, however, with a requirement on the measurement uncertainty and, therefore, the signal-to-noise ratio S/N that is adjusted to the rough distance range.
A subset can also be selected from a series of distance measurements to adjust the measurement uncertainty, of the determined measurement distance, for example, based on these results. Since an increasing number of individual measurements, e.g., with different frequencies, is carried out to determine a distance, individual measurements of this type can be utilized to carry out information for adjusting measurement uncertainty. This means that the measurement uncertainty can also be adjusted and optimized during the determination of a distance of the measurement task.
As an alternative, the measurement range accessible by the measurement device can be expanded within a predetermined maximum measurement time by reducing the signal-to-noise ratio requirements across the distance. Especially in the outdoors with strong sunlight, which results in a raised noise level, this can result in a marked increase of the measurement distance that is possible with measurement device 10 according to the invention and, therefore, in an increase in the usability of the measurement device according to the invention. The accuracy of the distance measurement, which decreases as the distance increases, can be visualized and communicated to the user by reducing the resolution of the display of the measured results in display 60 of measurement device 10 .
FIG. 2 shows an exemplary embodiment of the essential steps of the method according to the invention using a flow chart of individual method steps.
At the beginning of the method, a measurement time for the upcoming distance measurement is defined in method step S 1 . It is translated inside the device into a target for the number n of sampling periods of the modulated measurement signal that are used by the evaluation unit to evaluate the measurement signal. The desired measurement time can be communicated to the measurement device and/or the evaluation unit of the measurement device manually by the user, e.g., via operating field 62 , or automatically by a corresponding routine of the control and evaluation unit 58 of device 10 .
After the measurement time is specified, a measurement is started, e.g., by actuating a corresponding “Start” button in operating field 62 of measurement device 10 , a measurement signal 16 is emitted from the device in the direction of sighted target object 20 , and measurement signal 17 reflected on target object 20 is detected by the measurement device. For known reasons and reasons cited in publication DE 198 11 550 A1, for example, it can be advantageous to repeat this measurement procedure with measurement signals having a different frequency. To simplify the further description of the method according to the invention, only the method for one frequency will be described below.
In method step S 2 , the amplitude-modulated measurement signal is detected and processed further in accordance with the previously selected measurement time over a period of n periods. In method step S 3 , the amplitude of the detected measurement signal is determined from the measurement signal arriving at receive detector 54 and, in a parallel or serial method step S 4 , the noise portion contained in the measurement signal is determined.
In method step S 5 according to FIG. 2 , the signal obtained from the amplitude determination is converted to a ratio with the noise portion determined in method step S 4 , thereby calculating the signal-to-noise ratio S/N on which the completed measurement is based.
In a method step S 6 , which is parallel to the measurement procedure, a desired, theoretical accuracy target is transmitted to the measurement device in the form of measurement uncertainty.
This can take place via manual input by the user before the actual measurement, or via an automatic or semi-automatic assignment by the measurement device itself. For example, the measurement device can also access a memory internal to the device, in which values for the measurement uncertainty are stored. These values can be stored as a function of distance ranges, for example, so that a smaller measurement uncertainty is used for a measurement in the range of 1 m to 3 m than in the range of 5 m to 20 m or in the range of 20 m to 100 m, for example. Various characteristic curves can also be stored in the measurement device itself, the characteristic curves reflecting the different functional interrelationships between the measurement uncertainty on which the measurement is based and the distance to be measured.
Based on the accuracy target in method step S 6 , i.e., based on the selected measurement uncertainty, the associated, necessary signal-to-noise ratio that must be adhered to to attain the measurement uncertainty according to method step S 6 is calculated in method step S 7 .
By using appropriate sensors, the measurement uncertainty to be applied can be adapted to the environmental parameters. For example, an adjusted measurement uncertainty can be selected with consideration for the level of the background signal and the desired measurement time, i.e., a signal-to-noise ratio can be specified, up to which the measurement should be carried out. The environmental parameters do not necessarily have to be purely optical environmental parameters. Using appropriate sensors, for example, any other type of radiation, e.g., cell phone interference, radar signals or “electro smog”, can be detected which could influence the signal-to-noise ratio. Using the control and evaluation unit of the device, the measurement uncertainty can then be set in a manner yet to be described.
At the same time, in method step S 8 , the resolution of display 60 of measurement device 10 is adjusted by the central control and evaluation unit 58 of measurement device 10 according to the invention to the accuracy target according to method step S 6 . For example, by reducing the number of decimal places in the depiction of the measurement results, the user can be informed as to which measurement accuracy or measurement uncertainty the completed measurement was based on.
It is also possible, for example, using corresponding operating buttons in operating field 62 of measurement device 10 , to indicate the number of decimal places in the display, e.g, before a measurement, and thereby notify control and evaluation unit 58 directly as to which measurement uncertainty the subsequent distance measurement is to be carried out. The device can then also call up a stored characteristic curve, for example. It is also possible to specify to the device the distance range in which the subsequent distance measurement will be located, so that a corresponding measurement accuracy can be selected semi-automatically by the device.
A comparison is carried out in method step S 9 between the desired “S/N target” signal-to-noise ratio according to method step S 7 and the “S/N actual” signal-to-noise ratio on which the actual measurement is based. If the measured actual value of the signal-to-noise ratio does not correspond to the targets of the actual value according to method step S 6 , the measurement time required to reach the target value is calculated and, out of this, the required number of measurement periods n for the evaluation unit is determined. In this case, the method branches off back to method step S 2 , so that a renewed measurement with the now-adjusted measurement time is started and/or the on-going measurement is carried out or continued with the now-adjusted number of sampling periods.
If it should arise that the measurement time required for the corresponding distance measurement with the required measurement uncertainty is too great, or if a predetermined measurement time were exceeded, it is provided that the measurement device automatically rounds the measurement uncertainty up. In this case, the method branches back to method step S 6 , in which the measurement uncertainty is specified. The decision in method step S 6 can then be made by selecting another characteristic curve of the measurement uncertainty as a function of the distance, or by specifying a fixed value for the measurement uncertainty. To this end, the measurement device according to the invention can also “scroll through” the individual characteristic curves of the measurement uncertainty in order to find the measurement uncertainty that just allows a measurement to be carried out in the desired measurement time.
If the measured “S/N actual” signal-to-noise ratio corresponds to the desired “S/N target” signal-to-noise ratio, the distance between the measured device and the target object is determined in method step S 10 in known fashion based on the phase displacement determined over n periods of the modulated measurement signal. The method disclosed in publication DE 198 11 550 A1 can be used for distance measurement, for example.
In final method step S 11 , the distance between measurement device 10 and target object 20 determined by evaluation unit 58 is depicted in display 60 of measurement device 10 , whereby to visualize the measurement uncertainty on which the measurement is based, the accuracy of the depicted distance value corresponds to the resolution of the corresponding predetermined measurement uncertainty.
The method according to the invention may be stored as a corresponding routine in the form of a control program, e.g., in control and evaluation unit 58 of a distance measurement device 10 , so that an automatic or semi-automatic variation of the measurement uncertainty can also be carried out by the device itself, as a function of the measurement parameters. To this end, the corresponding characteristic curves can be stored in a storage medium and read out by the control and evaluation unit.
FIG. 3 shows, in a schematic manner, various examples of curves for the measurement uncertainty δ on which a distance measurement is to be based, as a function of a measurement distance D. Curve a represents the measurement uncertainty that results alone based on the systematic error of the quartz oscillator that defines the measurement frequencies of the device. As indicated in equation (1), fluctuations in the frequency of the measurement signal also result in corresponding phase displacements in the signal that appear in errors for the distance to be determined therefrom and therefore contribute to measurement uncertainty. This measurement uncertainty reflected in curve a is therefore a measurement uncertainty that is internal to the device and can be optimized for the measurement device only by selecting qualitatively high-quality electronic components.
Curve b shows the measurement uncertainty that results when an additional statistical error is present due to a fixed signal-to-noise ratio S/N. Curve b therefore approximately reflects the minimum measurement uncertainty attainable with a measurement device as a function of measurement distance D.
Curves c, d, e and f show possible characteristic curves for the measurement uncertainty that can be stored in the device according to the invention. The characteristic curves can also have a non-linear function course and are not limited to the functional dependencies depicted in FIG. 3 . When performing a distance measurement, measurement device can thereby successively “scroll through” these characteristic curves in order to not exceed a measurement time T 0 that may be predetermined. An optimization routine in the control and evaluation unit of the measurement device can then select that characteristic curve for a certain measurement distance that represents the optimal compromise between measurement time and measurement accuracy, with consideration for the measurement time required for this distance measurement.
FIG. 4 shows, also in a simplified, schematic representation, the measurement times B through E—corresponding to characteristic curves b through e in FIG. 3 —as a function of the measured distance D. It is clear to see that the distance range D 0 yet to be measured over a certain measurement time T 0 can be markedly expanded by the selection, that is, by the free specification of a measurement uncertainty to the device by the device itself. The measurement uncertainty which can be specified to the device can also be located markedly above the measurement uncertainty that is specified as being conditional upon the device, as shown in FIG. 3 , for example.
The method according to the invention and the corresponding device according to the invention therefore make it possible to expand the distance range usable with a measurement device for distance measurement, that is, that distance range across which a distance measurement can be carried out with the device, using simple means.
The method according to the invention and the device according to the invention for carrying out this method are not limited to the exemplary embodiments depicted in the description.
In particular, the method according to the invention and the corresponding measurement device for carrying out the method are not limited to the use of a phase measurement principle. Distance measurement devices that function according to the transit time principle, for example, can also make use of the method according to the invention.
Furthermore, the method according to the invention is not limited to use in optical distance measurement devices. The method according to the invention can also be used in ultrasound devices for distance measurement.
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The present invention relates to a device ( 10 ) for distance measurement, with at least one transmitting branch ( 14 ) with a transmission source ( 22, 24 ) for a measurement signal for emitting a modulated measuring beam ( 16, 26, 36 ) in the direction of a target object ( 20 ), and with a receive branch ( 18 ) for the measurement radiation ( 17, 44 ) returning from the target object ( 30 ), and with a control and evaluation unit ( 28, 58 ) for determining the distance of the device ( 10 ) to the target object ( 20 ) from the measurement radiation returning from the target object ( 20 ).
It is proposed according to the invention that the device ( 10 ) include means that enable measurement of distances with predetermined measurement uncertainties.
The present invention further relates to a method for distance measurement, with which a measurement of distances with predetermined measurement uncertainties is possible. To ensure a distance measurement in a certain, predetermined measurement time, the value on which a distance measurement is based can be adjusted to the measurement uncertainty, and can be increased incrementally in particular.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of Korean Patent Application No. 2007-66010 filed on Jul. 2, 2007, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an aerostatic bearing spindle system using a unidirectional porous metal, and more particularly, to an aerostatic bearing spindle system using a unidirectional porous metal capable of being used to serve as bearings in a region is in contact with the porous metals when the porous metals are rotated at a high speed, the porous metals being manufactured to have high porosity and directionality.
2. Description of the Related Art
In general, devices using an air bearing system as a high-speed rotating apparatus have problems that, since a motor as a heat source is installed inside the air bearing system, the main axis may be deformed and burnt on due to the vibration, abrasion and friction heat when the main axis is rotated at a high speed, which adversely affects the precision and stability of machine tools.
Also, grooves (diameter: 0.2 to 0.3 mm) are formed in a sintered material or a metal pipe that has been used as a bearing material in the conventional air bearing systems, and an oil film is formed between the axis and the bearings by allowing air to flow in and out. As a result, the formed oil film serves as the bearings that prevent the direct contact between the axis and the bearings.
However, the balancing of the entire air bearing system may be made unstable since the pressure distribution of air may be made non-uniform due to the limitations of the precision machining technology to form micro grooves onto the conventional bearing materials, and therefore the hardness of the aerostatic bearing spindle system may be deteriorated due to the air hammer phenomenon, etc.
SUMMARY OF THE INVENTION
The present invention is designed to solve the problems of the prior art, and therefore it is an object of the present invention to provide an aerostatic bearing spindle system using a unidirectional porous metal having a directionality so that the flow distribution of air can be made uniform, wherein the unidirectional porous metal is prepared using a metallurgical method and applied to air bearings, and the aerostatic bearing spindle system has a simple structure, and may reduce the deformation and burning on of the main axis caused by vibration, abrasion and friction heat to the maximum extent, and simultaneously secure the balancing of the entire air bearing system and remove an air hammer phenomenon since the air bearings made of unidirectional porous metal are installed in a region that is in direct contact with the main axis when the main axis is rotated at a high speed.
According to an aspect of the present invention, there is provided an aerostatic bearing spindle system using a unidirectional porous metal including a motor housing; a bearing housing disposed in contact with the motor housing and formed integrally in the motor housing; a main axis installed through inner central regions of the motor housing and the bearing housing; a motor installed to surround the main axis disposed inside the motor housing; and a plurality of unidirectional porous metal bearings installed to coaxially surround a circumferential surface of the main axis disposed inside the bearing housing and having a plurality of pores formed therein, the pores having a predetermined directionality with respect to the circumferential surface, wherein an air inlet is formed integrally in a predetermined space between the motor housing and the bearing housing and arranged in parallel to the main axis, and an air outlet is formed integrally in the other space of the motor housing and the bearing housing and arranged in parallel to the main axis, a plurality of air supply channels are formed integrally between the air inlet and each of the unidirectional porous metal bearings, and air supply grooves are formed integrally between the air supply channels and each of the porous metal bearing, a plurality of the porous metal bearings are installed spaced apart from each other, and metal rings having an exhaust groove formed thereon are each installed between the porous metal bearings, and an exhaust channel communicating with the exhaust groove is formed integrally between the metal ring and the air outlet.
Here, a plurality of the pores formed in the circumferential surfaces of the unidirectional porous metal bearings may be formed in a 90° direction with respect to the central axes of the unidirectional porous metal bearings.
Also, a plurality of the pores formed in the circumferential surfaces of the unidirectional porous metal bearings may be formed in a 45° direction with respect to the central axes of the unidirectional porous metal bearings.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an optical microscopic photograph taken from a transverse section and a longitudinal section of porous metal copper (Cu) having a unidirectional structure;
FIG. 2 is a photograph illustrating unidirectional porous metal copper (Cu) having various pore sizes;
FIG. 3 is a photograph illustrating hardness test blocks of the unidirectional porous metal copper (Cu);
FIG. 4 is a photograph illustrating the analysis results of the prepared copper (Cu) test block using a scanning electron microscope (SEM);
FIG. 5A is a perspective view illustrating one example of using a unidirectional porous metal material as an air bearing;
FIG. 5B is an exploded view illustrating one portion of the unidirectional porous metal material as shown in FIG. 5B ; and
FIG. 6 is a cross-sectional view illustrating that pores in the unidirectional porous metal used as the air bearing are formed at an angle of 90° with respect to the central axis of the unidirectional porous metal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 1 is an optical microscopic photograph taken from a transverse section and a longitudinal section of a unidirectional porous metal. That is, FIG. 1 shows an optical microscopic photograph taken from a transverse section and a longitudinal section of porous metals having unidirectional multi pores as the copper (Cu) test blocks prepared under gas pressures of 0.4 MPa and 0.8 MPa, respectively.
A unidirectional porous copper having an average pore size of approximately 0.4 mm and a porosity of 44.9% may be obtained in the case of the test block prepared under the gas pressure of 0.4 MPa. A unidirectional porous material having an average pore size of approximately 0.1 mm and a porosity of 36.6% may be obtained in the case of the test block prepared under the gas pressure of 0.8 MPa.
As shown in the longitudinal section photograph, it is revealed that the unidirectional pores grow to a length from approximately 200 mm up to 200 mm in a growth direction (a proceeding direction of a solid-liquid interface).
As seen from the above results, the size and porosity of the pores are decreased as the gas pressure increases gradually, and therefore a material having a desired pore size and porosity may be prepared by controlling the gas pressure and other various parameters.
FIG. 2 is a photograph illustrating unidirectional porous metal copper (Cu) having various pore sizes. That is, FIG. 2 shows a photograph of a copper (Cu) test block having various pore sizes and porosity, which is prepared by controlling the gas pressure and other parameters.
FIG. 3 is a photograph illustrating hardness test blocks of the unidirectional porous metal copper (Cu). In order to measure the hardness of the copper (Cu) test blocks prepared in FIGS. 1 and 2 , the test blocks having a pore size of 4 mm are cut into pieces having a size of 1×1×1 cm, and each position of the cut test blocks to be grown is indicated, depending on the growth direction of pores. Then, the cut test blocks are subject to a Vickers hardness test.
Table 1 is illustrating the hardness measurement results of the unidirectional porous metal copper (Cu). In table 1, when the growth direction of pores is 90° with respect to the central axes of the unidirectional porous metal copper, the unidirectional porous metal copper has the highest hardness, and also shows a relatively uniform hardness value of approximately 50 Hv regardless of the growth direction of pores.
NO. OF MEASUREMENTS
TEST BLOCKS
1
2
3
4
5
AVERAGE
GROWTH
A
55.8
61.1
56.1
58.7
62.5
58.84
DIRECTION
B
41.7
47.8
46.6
50.6
49.9
47.32
OF PORES
(90°)
GROWTH
A
52.7
49.6
50.2
54.8
49.3
51.32
DIRECTION
B
49.7
47.5
44.4
41.5
46.4
45.90
OF PORES
C
49.2
53
54.9
59.2
52.7
53.80
(45°)
FIG. 4 is a photograph illustrating the analysis results of the prepared copper (Cu) test block using a scanning electron microscope (SEM). In FIG. 4 , the pores are formed in good shape and there is no fissure found in the pores.
FIG. 5A is a perspective view illustrating one example of using a unidirectional porous metal material as an air bearing. FIG. 5A is a representative view of the present invention. And, FIG. 5B is an exploded view illustrating one portion of the unidirectional porous metal material as shown in FIG. 5A .
The aerostatic bearing spindle system according to one embodiment of the present invention is characterized in that a motor 11 rotating the main axis is installed inside the aerostatic bearing spindle system.
The aerostatic bearing spindle system according to one embodiment of the present invention mainly includes a motor housing 10 ; a bearing housing 9 disposed in contact with the motor housing 10 and formed integrally in the motor housing 10 ; a main axis 3 installed through inner central regions of the motor housing 10 and the bearing housing 9 ; a motor 11 installed to surround the main axis 3 disposed inside the motor housing 10 ; and a plurality of unidirectional porous metal bearings 1 installed to coaxially surround a circumferential surface of the main axis 3 disposed inside the bearing housing 9 .
In this case, a plurality of the porous metal bearings 1 are installed spaced apart from each other, and metal rings 15 are interposed between the respective porous metal bearings 1 . An exhaust groove 7 is formed in an upper portion of the metal ring 15 .
A plurality of pores 2 having a predetermined directionality are formed in each of the porous metals 1 , and therefore the air may flow through the pores 2 .
Also, an air inlet 5 may be formed integrally in predetermined space between the motor housing 10 and the bearing housing 9 and arranged in parallel to the main axis 3 , and an air outlet 12 may be formed integrally in the other space of the motor housing 10 and the bearing housing 9 and arranged in parallel to the main axis 3 . In this case, a plurality of air supply channels 4 are formed integrally between the air inlet 5 and the unidirectional porous metal bearings 1 to supply the air, and the air passed through the air supply channels 4 is then supplied to the pores 2 via air supply grooves 6 . An exhaust groove 7 and an exhaust channel 8 are formed between the porous metal bearings 1 and the air outlet 12 to discharge the air, so that the exhaust groove 7 and the exhaust channel 8 can communicate with each other.
The unidirectional porous metal bearings 1 may have pores formed with a predetermined directionality, as shown in FIGS. 3 and 4 . In this case, a porous metal having pores formed in a 90° direction with respect to the central axis of the unidirectional porous metal bearings 1 may be prepared (see FIG. 6 ). According to another embodiment of the present invention, a porous metal having pores formed in a 45° direction with respect to the central axis of the unidirectional porous metal bearings 1 may also be prepared.
The unidirectional porous metal bearings 1 function as bearings in a space between the bearing housing 9 and the main axis 3 . In this case, when the air is allowed to flow between a plurality of the pores 2 formed in the unidirectional porous metal bearings 1 , an oil film is formed by the air between the main axis and the bearings, which facilitates the high-speed rotation of the main axis 3 .
Reference numeral 13 represents an air entrance cover.
Hereinafter, an operation of the aerostatic bearing spindle system according to one embodiment of the present invention will be described in detail.
When the motor 11 is rotated at a high speed by a power supply, the main axis 3 is rotated due to the rotation of the motor 11 . In this case, when the air is supplied to the porous metal bearings 1 via the air inlet 5 , the air supply channel 4 and the air supply groove 6 , the supplied air is passed through a plurality of the pores 2 of the unidirectional porous metal bearings 1 , and passed via passages between the main axis 3 and the metal bearings 1 and between the main axis 3 and the metal ring 15 , and then discharged through the exhaust groove 7 , the exhaust channel 8 and the air outlet 12 . The air is circulated as indicated by arrows of FIGS. 5A and 5B .
In this operation, a passage 25 as an air/oil film is formed between the main axis 3 and the unidirectional porous metal bearings 1 , and between the main axis 3 and the metal ring 15 due to the presence of the air supplied to the unidirectional porous metal bearings 1 . Therefore, the main axis 3 may be rotated at a high speed without any of the contact or friction between the main axis 3 and the unidirectional porous metal bearings 1 .
As described above, the aerostatic bearing spindle system using the unidirectional porous metal as the air bearings may be useful to reduce the deformation and burning on of the main axis caused by vibration, abrasion and friction heat to the maximum extent by forming an air/oil film in a region that is in direct contact with the main axis when the main axis is rotated by the air.
While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims.
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Provided is an aerostatic bearing spindle system using a unidirectional porous metal. The aerostatic bearing spindle system using a unidirectional porous metal may be used to serve as bearings in a region is in contact with the unidirectional porous metals when the unidirectional porous metals are rotated at a high speed, the unidirectional porous metals being manufactured with high porosity and directionality using the metallurgical method.
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BACKGROUND OF THE INVENTION
This invention relates to articles composed of resinous polymers of acrylonitrile (AN) and methacrylonitrile (MAN) and particularly to multiaxially oriented articles and more particularly to multiaxially oriented films of copolymers of arylonitrile and methacrylonitrile.
Polyacrylonitrile (PAN) has excellent barrier properties, chemical resistance, rigidity, and heat resistance. PAN, however, is not a thermoplastic, and must be dissolved in a solvent in order to be processed. The use of a solvent negatively effects the polymer's barrier properties.
Polyacrylonitrile (PAN) also has desirable barrier properties, chemical resistance, and rigidity although they are not as good as those of PAN. In contrast to PAN, PMAN is a melt processable thermoplastic, but it is prone to de-polymerization at high temperatures.
In this invention, copolymers of AN and MAN have been formed to obtain the best properties of both PAN and PMAN. A copolymer of these nitriles results in an article having excellent barrier properties, chemical resistance, rigidity and heat resistance, while desirable thermoplastic properties such as melt stability for melt processing are also obtained.
Prior to this invention, copolymers of AN and MAN were formed using only small amounts of AN, because polymers made with more than 20% by weight of polymerized acrylonitrile could not be extruded. For example, it is taught in U.S. Pat. No. 3,565,876 that up to about 20% by weight of acrylonitrile can be copolymerized with methacrylonitrile to form extrudible copolymers which can be readily oriented and possess excellent physical properties. Increasing the acrylonitrile content above 20% by weight in acrylonitrile/methacrylonitrile copolymers resulted in a resin which was unstable and not processable by any of the usual commercial techniques known today, including extrusion. Although the copolymers of the U.S. Pat. No. 3,565,876 had desirable qualities, their low AN content failed to take full advantage of AN's superior barrier characteristics.
In this art, therefore, it is desirable to have a processable, stable acrylonitrile/methacrylonitrile copolymer system wherein the acrylonitrile content is greater than 20% of the final polymer composition.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of this invention to provide an improved process for making an acrylonitrile/methacrylonitrile copolymer.
It is a further object of this invention to provide new and improved AN/MAN copolymers containing greater than 20% AN. It is a further object of this invention to provide a new and improved process for forming AN/MAN copolymers having greater than 20% AN which are melt processable and stable.
Additional objects and advantages of the invention will be set forth in part in the description which follows and in part will be obvious from the description or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out int he appended claims.
To achieve the foregoing objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the process of this invention comprises forming a viscous polymer by the polymerization, of a mixture of methacrylonitrile and acrylonitrile, wherein the addition of the monomers throughout the reaction is such that the ratio of acrylonitrile to methacrylonitrile remains relatively constant throughout the reaction. This results in a relatively homogeneous final polymer composition wherein there are no long sequences of AN units or long sequences of MAN units, but a somewhat random ordering of these units in the polymer chain. Relatively constant means a ratio of monomers which achieves this somewhat random ordering.
By practicing this process, processable and stable polymers of 10 to 80 percent by weight methacrylonitrile and 20 to 90 percent by weight acrylonitrile can be formed. Preferably, the polymer is 25 to 50 percent by weight MAN and 75 to 50 percent by weight AN.
DETAILED DESCRIPTION OF THE INVENTION
While the invention will be described in connection with a preferred procedure, it will be understood that it is not intended to limit the invention to that procedure. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention defined by the appended claims.
In accordance with the invention, a representative polymerization procedure, comprises contacting about 0.1% to 10% by weight of a suitable emulsifier or dispersing agent in an aqueous medium, about 0.01% to 5% by weight of a molecular weight modifier, about 0.01% to 5% by weight of an initiator, and monomers. The methacrylonitrile is 5 to 80 percent by weight of the monomers and the acrylonitrile is 95 to 20 percent by weight of the monomers. The mixture is placed in a purged reaction vessel which has a means of agitation, such as stirring or shaking. Preferably, the reaction vessel and reactants are initially purged with an inert gas, more preferably the gas used is nitrogen or argon. The mixture is heated to a temperature in the range of 40° C. to 80° C., preferably about 60° C. The mixture is continuously or intermittently agitated. Preferably, the mixture is continuously agitated. Preferably, a stirrer speed of about 200 rpm is used. The agitation is continued until polymerization has proceeded to the desired extent, usually 40%-100% conversion. Preferably, the polymerization continues to at least 60% to 80% of completion.
In the foregoing polymerization reaction, the molar ratios of AN and MAN reactants must be carefully controlled throughout the reaction, because the monomers react at different rates. MAN reacts faster with propagating free radicals in this system than does AN which leads to excess MAN in the polymer and excess AN in the unreacted monomer mixture. If too great an excess of AN becomes present in the monomer mixture, long strings of acrylonitrile units may form. Long AN strings lead to unprocessable products. For this reason, in the practice of the present invention, the polymerization reaction requires either incremental or continuous addition of the reactants.
In one embodiment, the monomer reactants are added in various increments, 10% of the total monomer reactants as starting materials to initiate the reaction, and three remaining 30% portions at later periods in the reaction. Each of the additions comprises AN/MAN in amounts controlled in order to obtain the desired AN/MAN ratio in the final product. This procedure continues until all of the monomer reactants have been added. Once the final reactant addition is made, polymerization is typically complete to at least 40% to 75%. Of course, other reactant addition increments may be used.
In another embodiment, it is possible to add most of the reactants at the initiation of the reaction. As the reaction proceeds, more of the highly reactive MAN monomer is added. This technique functions to steady the resultant polymer homogeneity by maintaining the same monomer ratio throughout the reaction through matching MAN addition to the conversion rate to polymer in the proper proportion.
In the most preferred embodiment, both reactants are added based on tracking of the polymer conversion in the same amounts as they are removed from the monomer mixture by polymerization.
As can be seen from the above embodiments, the primary objective of any procedure is to maintain the desired final AN/MAN ratio throughout the entire reaction. If the ratios become too unbalanced, MAN may polymerize into long strings and become used up from the monomer mixture, and the remaining AN may polymerize into long unprocessable strings. The identified procedures function to produce melt-processable AN/MAN copolymers with excellent physical properties, by preventing the formation of long AN strings.
The free radical initiator of the present invention may be selected from the group comprising Azo compounds, peroxides, hydroperoxides, alkyl peroxides, peroxydicarbonates, peroxyesters, dialkyl peroxides, persulfates, perphosphates or another initiator known to those skilled in the art. Of course, the reaction could also be initiated by thermal means rather than the above described chemical means.
The molecular weight modifier of the present invention can be mercaptans, alcohols or any other chain transfer agent known to those of ordinary skill in the art. Mercaptans are the preferred molecular weight modifier.
At the conclusion of the reaction, the polymer of this invention may be isolated as a finely divided powder by crumb coagulation.
The crumb coagulation procedure consists of adding the product emulsion to an appropriate electrolyte solution with rapid agitation at a temperature just below the point at which the precipitated particles tend to adhere. This procedure yields a polymer in a form of granules or particles which are filtered and washed. Suitable electrolytes include sodium chloride, sodium sulfate, hydrochloric acid, phosphoric acid, calcium chloride, magnesium sulfate and aluminum which is preferred. After precipitation, the polymer is filtered and washed repeatedly with water to minimize traces of electrolyte and dispersing agent which may adhere to the particles. Washing with dilute solutions of caustic soda or ammonium hydroxide may assist in removing the last traces of dispersing agent, and at the same time yield polymers of improved heat stability. It is also beneficial to employ a final wash of an organic solvent such as a lower aliphatic alcohol (methanol or ethanol) to remove any residual soap or impurities.
Other means for isolating the polymer include spraying the solution into a heated and/or evacuated chamber where the water vapors are removed and the polymer falls to the bottom of the chamber. If the polymer is prepared with sufficiently high solids content it can be isolated as a granular powder by filtration or centrifugation. The polymer may also be isolated by cooling eh dispersion below the freezing point of the aqueous medium or by the addition of a large volume of a lower aliphatic alcohol such as methanol or ethanol.
if desirable, lubricants, dyes, bleaching agents, plasticizers or pseudoplasticizers, pigments, stabilizers, antioxidants, reinforcing agents (including fillers and fibers) and antistatic agents may be incorporated into a polymer of this invention.
The polymers of this invention can be formed into films having extremely good barrier properties. Particularly, the oxygen transmission rate of films of this invention are generally below 0.30 (cc mil/100 in 2 atm--24 hr.). Preferably, the oxygen transmission rate is below 0.10 (cc mil/100 in 2 atm--24 hr.). Most preferably the oxygen transmission rate is below 0.05 (cc mil/100 in 2 atm--24 hr.). The water vapor transmission rate is generally below 3.25 (g--mil/100 in 2 --24 hr.). Preferably, the water vapor transmission rate is below 2.00 (g--mil/100 in 2 --24 hr.). Most preferably, the water vapor transmission rate is below 1.00 (g--mil/100 in 2 --24 hr.).
The films of this invention may be prepared by solvent casting or preferably by a thermal forming procedure such an extrusion, injection molding, compression molding or calendering, however, for economic reasons and for ease in processing it is most preferred that the polymer be extruded. The polymers of this invention may be extruded for any conventional type extruder at a temperature of about 160° C. to 250° C. Preferably, the extrusion is at about 200° C. to 220° C. A screw-type extruder employing an annular die to form a thin walled polymer cylinder or sheet die to form a continuous sheet may be used.
The polymers of this invention are also suitable for forming fibers. This can be accomplished by solution spinning by procedures known to those skilled in the art.
Because the copolymer AN/MAN is thermoplastic, it can be oriented as a solvent-free material. This is an advantage because the presence of any solvent int he polymer makes orientation difficult and adversely affects the barrier properties of the polymer.
EXAMPLES
Copolymers of methacrylonitrile/acrylonitrile were prepared by means of emulsion polymerization according to the following general procedure.
A two liter reactor containing 900 g of deionized water was used. 9 g of GAFAC RE-610 1 was dissolved int he water overnight. Acrylonitrile and methacrylonitrile totaling 300 g (the specific ratio dependent on the final product desired) were added. An initiator (generically 2,2'-azobis (2,4-dimethylvaleronitrile), specifically Vazo® 52 polymerization initiator made by DuPont Company) and N-dodecyl mercaptan were added to the reactants. The reactants and reactor were nitrogen purged. The reaction temperature was 60° C. with a stirrer speed of 200 rpm. At the end of the reaction time, (40-80% conversion of monomers to polymers) the products were isolated by crumb-coagulation in an aluminum sulfate solution at 77° C., water washed, methanol soaked, filtered, and fluid bed dried. The oxygen transmission rate and water vapor transmission rate results of films having different AN:MAN ratios can be seen in Table 1.
EXAMPLE 1
211.0 grams of acrylonitrile and 89.0 grams of methacrylonitrile were added as follows: 10% of the monomers were charged to the reactor before addition of the initiator; 30% of the monomers were added in each of three 90 minute periods; 6 g of N-dodecyl mercaptan were added in three 2 g installments, just prior to each of the three 90 minutes monomer addition periods. 1.5 g of Vazo® 52 polymerization initiator were added to the reactor when the reaction mass reached 60° C. The monomers resulted in a polymer composition of 72.4 mole percent acrylonitrile and 27.6 mole percent methacrylonitrile.
EXAMPLE 2
231.4 grams of AN and 68.6 grams of MAN were added at the beginning of the reaction. Additional MAN (13.6 grams) was added in each of three 90 minute stages of the reaction to compensate for its higher conversion rate and maintain the initial monomer feed ratio in the reactor. 6 g of N-dodecyl mercaptan were added in three 2 g installments, just prior to each of the three 90 minute monomer addition periods. 1.5 g of Vazo® 52 polymerization initiator were added to the reactor when the reaction mass reached 60° C. The reaction resulted in a polymer composition of 65.1 mole percent AN and 34.9 mole percent MAN.
EXAMPLE 3
183.9 grams of AN and 116.1 grams of MAN were charged to the reactor at the beginning of the reaction. Additional MAN (16.4 grams) was added in each of three 90 minute states of the reaction to compensate for its higher conversion rate and maintain the initial monomer feed ratio in the reactor. 6 g of N-dodecyl mercaptan were added in three 2 g installments, just prior to each of the three 90 minute monomer addition periods. 1.5 g of Vazo® 52 polymerization initiator were added to the reactor when the reaction mass reached 60° C. The reaction resulted in a polymer composition of 50.7 mole percent AN and 49.3 mole percent MAN.
EXAMPLE 4
126.6 grams of AN and 173.4 grams of MAN were added as follows: 10% of the monomers were charged to the reactor before addition of the initiator; 30% of the monomers were added in each of three 90 minute periods; 6 g of N-dodecyl mercaptan were added in three 2 g installments, just prior to each of the three 90 minute monomer addition periods. 1.5 g of Vazo® 52 polymerization initiator were added to the reactor when the reaction mass reached 60° C. The polymer composition consisted of 38.7 mole percent AN and 61.3 mole percent MAN.
PMAN
300 grams of MAN were added as follows: 10% of the monomer was charged to the reactor before addition of the initiator; 30% of the monomer was added in each of three 90 minute periods; 6 g of N-dodecyl mercaptan were added in three 2 g installments, just prior to each of the three 90 minute monomer addition periods. 1.5 g of Vazo® 52 polymerization initiator were added to the reactor when the reaction mass reached 60° C. The polymer was 100% MAN.
TABLE 1______________________________________ AN/MAN Oxygen Transmis- Water Vapor Trans- Ratio sion Rate (cc mil/ mission Rate (g-mil/Example (Mole %) 100 in.sup.2 atm-24 hr) 100 in.sup.2 - 24 hr)______________________________________1 72.4/27.6 0.03 0.622 65.1/34.9 0.03 1.743 50.7/49.3 0.05 2.274 38.7/61.3 0.28 3.18PMAN 0/100 0.33 2.52______________________________________
Each of the examples showed a good melt processability. Particularly, Brabendering at 235° C. showed torques of 400 to 2000 metergrams.
Thus is apparent that there has been provided, in accordance with the invention, new and improved copolymer compositions that fully satisfy the objects, aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modification, and variations will be apparent to those skilled int he art in light of the foregoing description. Accordingly, the invention is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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A process for forming a stable and processable polymer comprised of methacrylonitrile (10 to 80 percent) and acrylonitrile (20 to 90 percent) by controlling the ratio of the monomers in the reaction mixture.
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RELATED APPLICATION
A related application, entitled COLOR FILTER AND METHOD OF PRINTING and assigned to the same assignee as this application, Ser. No. 08/145,155, has been filed Nov. 3, 1993 in the names of P. L. Bocko and R. E. Johnson. That application is directed to a printed color filter for an AMLCD glass panel and to a method for printing such color filter on a glass substrate.
FIELD OF THE INVENTION
A method of printing a multi-color ink pattern on a substrate surface employing radiation-curable inks.
BACKGROUND OF THE INVENTION
It is a familiar practice in the decorating art to print a multi-color pattern on a substrate surface by transfer (offset) printing of individual ink patterns. Each individual pattern is formed with a different colored decorating ink. The substrate may, for example, be a glass, glass-ceramic, or ceramic body. Individual ink patterns are supplied separately to an elastomeric transfer (offset) roll from a series of patterned surfaces. Each surface is patterned to form an individual ink pattern for delivery to the transfer roll. A patterned surface may be provided by a gravure plate or roll, a lithographic roll , a typographic roll, or a silk screen.
Normally, when printing to non-porous surfaces, the ink pattern dries to a cohesive, tacky state on the elastomeric roll by evaporation or solvent penetration into the roll. The ink pattern is then brought into intimate mechanical contact with the substrate surface. It is completely transferred when it has sufficient cohesion and greater affinity for that surface than it has for the transfer roll. In some cases, when using solvent-based inks, complete transfer is not obtained, and print quality, particularly in regard to definition, may be reduced as a consequence.
Once the transferred ink pattern is sufficiently dry, successive patterns of other colors may be applied, each from its own pad or roll, to create a multi-colored pattern. Thus, each color pattern must be applied separately to form the multi-colored pattern.
U.S. Pat. No. 4,445,432 (Ford et al.) discloses a method and apparatus which utilize a double offset technique for applying thermoplastic decorating inks onto a substrate to form a multi-color pattern. In this procedure, an ink pattern of each color is successively transferred onto a collector roll to form a fully registered, multi-colored ink pattern on the collector roll. This multi-colored pattern is then transferred to the substrate in a single printing step. A primary advantage obtained by this procedure, with respect to conventional offset gravure practice, is that of superior registration, particularly for substrates of complex geometry. The collector roll renders pattern registration independent of substrate geometry.
U.S. Pat. No. 4,549,928 (Blanding et al.) describes using a double offset technique for printing the phosphors and the black matrix on color TV panels. In this procedure, thermoplastic, pressure-sensitive inks, corresponding to the red, green, and blue color phosphors and the black matrix, are applied separately to the collector roll to form the desired multi-color pattern. This pattern is then transferred as a complete pattern to the TV tube panel.
The double offset printing techniques described in the Ford et al. and Blanding et al. patents employ pressure-sensitive, hot-melt inks. These inks are printed from heated gravure rolls. The inks cool sufficiently on the offset surfaces to develop the cohesive strength required to achieve 100% ink transfer between the offset surfaces and the collector roll, and between the collector roll and the substrate.
To obtain complete transfer, the cohesive strength of the ink must exceed the adhesive strength to the surface of the transferring member. Adhesion must, of course, be greater to the receiving surface than to the releasing or transferring surface. This means that inks must exhibit less adhesion to the first offset surface than to the collector, and less adhesion to the collector than to the final substrate. Heretofore, silicones have been used as the materials for both offset surfaces.
The inks generally used have been thermoplastic in nature. They have been printed onto the first offset surface from heated gravure plates or rolls, and, even more recently, by use of heated screens. Once on the offset surface, the inks cool, developing sufficient cohesive strength for transfer. The inks were formulated to retain sufficient tack after cooling so that they would adhere to surfaces simply by applying sufficient pressure. Since the inks were subsequently fired to consolidate the pigmented glass frits and remove the organics, no particular durability of the organics was required. It has been demonstrated, however, that heat reactive (thermoset) inks can be printed as hot melts at 60°-70° C. and cured with a post-cure at higher temperatures of 150°-200° C.
The double offset procedure, employing hot-melt inks, has been found particularly useful for decorating articles such as dinnerware. However, problems have been encountered in attempting to apply the procedure to printing of precision patterns. This is particularly true for surfaces that may subsequently be required to withstand elevated temperatures, for example 250° C. In particular, the pressure-sensitive, hot-melt inks are not stable at elevated temperatures. Temperatures above 150° C. may result in plasticizer volatilization and oxidative degradation of the typical organic ingredients employed. Further, prolonged heating at 250° C. can even result in distortion of an ink pattern. Excessive flow of the ink elements of the pattern may occur on the substrate surface as viscosity decreases with increase in temperature.
It is possible to develop hot-melt inks that can be subsequently cured thermally or by radiation. However, the heated ink procedure is not preferred where precise registration is required. Slight temperature variations, either in the print surface, or through conduction into the printing apparatus, can result in registration variability.
It has been proposed by K. Mizuno and S. Okazaki, in Japanese Journal Of Applied Physics, Vol. 30, No. 118, Nov., 1991, pp. 3313-3317, to produce a color filter by a process wherein ink on a transfer roll is cured by UV exposure, and then transferred to a glass coated with an adhesive layer. It would, of course, be desirable to collect and transfer a complete pattern, and to do so without the need for an adhesive layer.
It has also been proposed to produce a color filter by photolithography in the form of film. The pattern may then be inspected, and, if necessary, discarded without printing. If the pattern is accepted, the film is transferred directly to the glass substrate. This proposal is described by K. Ikiaki in a publication entitled "Low Cost Technology for Producing LCD Color Filters Transfer Print Method" In Nikkei MIr Vo1: 58, pp. 83-87 (90-04). The process still involves photolithography.
In addition to the items mentioned above, attention is also to a publication by W.C. O'Mara, entitled "Active Matrix Liquid Crystal Displays Part I: Manufacturing Process" appearing at pages 65-70 in the Dec. 1991 issue of Solid State Technology.
It is then a basic purpose of the invention to provide an improved method of printing a multi-color ink pattern on a substrate surface. A further purpose is to provide a method of producing a multi-color ink pattern on a substrate surface that is particularly adapted to producing a precision pattern. Another purpose is to provide a method of producing a multi-color pattern that will withstand elevated temperatures up to about 250° C. without needing to first pyrolyze organics, and then to melt a glass frit at an even higher temperature. A further purpose is to adapt the double offset printing technique to the production of precision multi-color ink patterns.
SUMMARY OF THE INVENTION
The invention resides in a method of printing a multi-color ink pattern on a substrate surface which comprises the steps of arranging a series of surfaces in which each surface has a pattern that is unique to one of the colors, and to the pattern of that color, in the multi-color pattern, supplying to each patterned surface a radiation-curable ink formulation having an appropriate colorant to form an ink pattern thereon, transferring individually the colored ink pattern from each patterned surface to a collector roll, forming a composite of the color patterns on the collector roll, increasing the cohesiveness of the ink sufficiently to permit complete transfer of the pattern, and transferring the composite pattern in its entirety to the substrate surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I is a schematic view illustrating a prior art offset printing technique.
FIG. II is a perspective view of one form of apparatus for practicing the invention.
FIG. III is a partial side view of the apparatus of FIG. II.
FIG. IV is a perspective view of another form of apparatus for practicing the invention.
FIG. V is a partial side view of the apparatus of FIG. IV.
FIG. VI is an enlarged view of FIG. V.
DESCRIPTION OF THE INVENTION
FIG. I of the drawings is a schematic illustration of the double offset printing technique as disclosed in the Ford et al. --432 patent noted earlier. As there described, "n" printing stations are provided. In describing the present invention, we employ four printing stations, such as might be used in producing a multi-color pattern for LCD color filters. Thus, one station might print a linear black matrix that will surround the basic red, green, and blue color dots printed at the other three stations.
As described in the Ford et al. patent, each printing station includes a supply of ink 12; a heated gravure roll 14 with a patterned surface; a transfer roll 18; and a doctor blade 16. Rolls 18 and 14 are mounted in pairs at each station. Each gravure roll 14 has a particular pattern engraved therein. The pattern in each roll is determined by the pattern desired for that color ink in the pattern on the substrate 22.
Each ink is deposited in the pattern formed on its gravure roll 14 and doctored by blade 16. Each color pattern is carried into intimate contact with transfer roll 18 to reproduce the color pattern on roll 18. The color pattern is then brought into contact with collector 20. There, a 100% transfer from roll to collector 20 occurs due to cooling on the transfer roll. As explained more fully later, the need to cure before transfer is related to the type of ink employed, rather than the process. If a radiation-curable ink is employed, the ink must be partially cured, or gelled, to a tacky state before transfer. In the case of a thermoplastic ink, as used in the Ford et al. patent, it is only necessary to cool the ink on the roll.
At each station, the particular color pattern of that station is deposited on collector 20 to form a composite pattern on collector roll 20. This enables substrate 22 to receive a fully registered print in a single printing step.
A major advantage of the double offset, or collector, printing technique is that the color-to-color registration becomes independent of final substrate geometry. The more complex the geometry of the final substrate, the greater the advantage. Moreover, the tighter the registration requirements, the greater the advantage.
As illustrated in FIG. I, a transfer roll 18 is provided at each station. However, a different arrangement, which embodies a single transfer roll 18, may also be employed. In such an arrangement, the single transfer roll 18 is indexed from station to station. At each station, transfer roll 18 receives an ink pattern from the gravure roll 14 at that station. The ink pattern is transferred to collector roll 20 which is indexed in conjunction with transfer roll 18.
In any case, for complete transfer with radiation-curable inks, partial curing or gelling must occur during, or before, transfer of a pattern to the collector roll. Thus, each pattern must be cured to a tacky state before transfer.
Use of a single transfer roll 18 eliminates variability resultant from differences in the deformation of the individual rolls. Such differences can be caused by slight dimensional differences, compositional differences, or durometer differences. By using a single roll 18, there is no change in the relative axial position of roll 18 to roll 20 during the printing process. Consequently, optimum registration can be repeatably maintained through repetitive printing cycles.
Non-uniform pattern distortion from offset rolls between subsequent printing stations is a significant contributory factor to misregistration between colors in conventional printing. The collector process, however, can utilize a common transfer roll for all colors and can maintain a constant positional relationship between the transfer roll and collector throughout the process operation. By keeping the first and second offset rolls as a constant, as well as their positional relationships to one another, a higher level of consistency can be achieved than is feasible with conventional printing processes.
Consequently, use of a single roll pair for all color patterns, and the single step application of the registered print, offers registration advantages even when the substrate geometry is not complex. This is the case in printing patterns on a flat panel substrate.
The inks used in the process described in the Ford et al. --432 patent were pressure-sensitive, hot-melt inks. These inks were printed from heated gravure rolls. They were cooled on the offset surfaces to develop sufficient cohesive strength to achieve 100% ink transfer both between offset surfaces, and between the collector roll and the substrate. As pointed out earlier, however, hot melt inks have several disadvantages for color filter printing, but are not necessarily precluded from use.
The present invention utilizes the double offset printing technique disclosed in the Ford et al. --432 patent. However, rather than using pressure-sensitive, hot-melt inks as heretofore, we use inks that are specially formulated to permit radiation curing. Such inks can be formulated to cure rapidly to a pressure-sensitive (tacky) state. They subsequently undergo further curing, either by radiation or thermal post-cure, to achieve a hard, tack-free, durable state. There are two distinctly different approaches to formulating radiation-curable inks for compatibility with the collector process.
In the first approach, ultra-high viscosity, radiation- curable oligomers can be combined with just sufficient monomer to render the material into a tacky paste with good cohesiveness. These inks can be printed from heated gravure rolls much like the hot-melt inks. The cohesiveness needed for transfer between silicones, and to the final substrate, is developed by cooling on the silicone surface. Typically, viscosity increases, on average, about 10% for each ° C. that the ink cools. Cohesiveness may also be enhanced in the formulations by adding compatible, relatively high viscosity, thermoplastic polymers. An example is cellulose acetate butyrate in an amount up to about 20% by weight. The inks are cured after transfer to the glass by exposure to radiation. UV-light, an electron beam, or high intensity visible light, may be used, depending upon the photoinitiator employed.
In this approach, any type of radiation-curable ink can be used to meet these criteria. Curing takes place after transfer of an ink pattern to the substrate. Therefore, an intermediate cure by radiant energy on the roll provides no advantage, except possibly to enhance the cohesion. Consequently, a reactive hot melt can be a free-radical type ink, a cationic type, or a hybrid of the two. It can also be a hybrid between a radiation-curable ink component and a thermal-curing ink component.
These inks can readily be formulated to develop sufficient cohesiveness on cooling to achieve 100% transfer. They can then continue to be cured to a durable, tack-free state upon the substrate, either by radiation exposure or by thermal cure. Such inks can also be post-cured thermally to improve stability.
In a second approach, radiation-curable inks are printed from ambient temperature gravure rolls onto the silicone transfer rolls. The ink on the transfer rolls is then exposed to radiation to achieve a tacky, partially cured state. The partial curing increases the cohesiveness, to such extent, that the inks can be subsequently 100% transferred between silicone surfaces, as well as to the final substrate. Final curing can be accomplished by further radiation or thermal post-cure.
With inks that are formulated to print in the manner of hot-melt inks, there is typically no UV curing until after, or during, transfer of the ink to the substrate. Consequently, inks dependent on the free-radical mechanism for curing are quite satisfactory and have the advantage of a faster printing rate. However, for curing during printing, cationic or hybrid inks have the advantage of a potentially broader exposure window for curing.
The radiation-curable inks of interest here are of four general categories: Free-radical, cationic, a hybrid of the free-radical and cationic and a hybrid based on combined radiation and thermal curing mechanisms.
Free-radical inks are characterized by a free-radical photoinitiator. Under influence of radiation, resins having acrylate and methacrylate functional groups, as well as the vinyl group in unsaturated polyester resins, can be cured in the presence of such a photoinitiator.
Cationic inks utilize different resins, primarily epoxy functional resins or vinyl ether functional resins. The epoxy formulations consist principally of epoxide, a polyol and a cationic photoinitiator, primarily triaryl sulfonium salts. The photoinitiator has a positive charge that is activated by radiation to promote curing. Curing is based on ring opening in the epoxide through action of the Lewis acid that is produced by photolysis of a cationic photoinitiator.
The radiation-curable hybrid inks are mixtures of the cationic and free-radical formulations just discussed. These inks partially cure rapidly under light exposure via a free-radical mechanism. This is followed by a slower continuing cure via the cationic mechanism. Unlike the free-radical curing mechanism, the cationic curing mechanism does not cease curing after removal from the radiation exposure. Hybrid free-radical/cationic inks, in fact, are ideal for the process. The free-radical portion will cure rapidly upon radiation exposure, whereas the cationic portion will cure much more slowly. This allows the ink to remain tacky for a sufficient time to complete operation of the printing process. Such inks can be formulated to be curable with UV, electron beam, or high intensity visible light. However, either UV or visible light is preferred due to the ease of incorporation into the printing apparatus.
The following TABLE sets forth, in parts by weight, a typical formulation for each type of radiation-curable ink. In the TABLE, the initial column identifies the several ink components by their generic names. The second column sets forth the trade name for the particular material employed in a formulation. The further columns set forth the formulation for each ink.
In addition, a formulation will contain a suitable color pigment. Use of a dye is not precluded. However, we prefer to avoid use of dyes because of their temperature and light instability. Also, they can interfere with the curing chemistry of the radiation-curable inks.
The formulations in the TABLE represent inks that have been successfully employed. However, no claim is made that they are optimum, and that more effective inks for the purpose may not be formulated.
______________________________________ Free- Radical/ Free- CationicInk Components Tradename Radical Cationic Hybrid______________________________________Epoxidized Novolac Quatrex -- 70 50 2010Partially acrylated Ebecryl -- -- 35epoxide 3605Acrylate monomer Sartomer 30 -- 15 351 (TMPTA)Free-radical Darocur 3 -- .5Photoinitiator 4265Cationic UVI-6974 -- 1.5 1.5PhotoinitiatorSilane coupling Z6040 -- 1.75 1.75agentFluorosurfactant FC-430 .25 .25 .25Cycloaliphatic UVR 6105 -- 30 --epoxideAcrylated Ebecryl 70 -- --epoxidized novolac 3603with 20% acrylatedmonomerSilane coupling A-174 1.75 -- --agentCuring synergist Quantacure 1 -- -- ITX______________________________________
Hybrid inks that combine radiation and thermal curing mechanisms can also be formulated for the process. With such ink only the radiation-curable portion is cured upon radiation exposure during the printing process as herein described. The ink is fully cured thereafter by appropriate thermal treatment to cure the thermally-curable portion of the ink.
In the case of near UV (300-400 μm) or visible (400-600 μm) light, it is even possible to initiate cure in the ink from a light source within the transfer roll, or the collector roll. A transfer or collector roll may be constructed with a transparent, glass or plastic, outer shell, and covered with a layer of clear silicone. This allows high intensity visible, or near UV, light to reach the under side of the ink against the silicone roll surface. The ink can, of course, be exposed more conventionally from the top side. There, either high intensity, visible, or UV light can be employed, depending upon the photoinitiator in the ink formulation.
Use of radiation-curable inks, in lieu of thermoplastic inks, has an advantage in that lower viscosity inks can be utilized for printing from the gravure rolls onto the transfer rolls. This facilitates the printing of fine dots. The need to heat the transfer rolls is also obviated.
The low viscosity, light-curable inks, however, were found to bead readily upon silicone release surfaces unless formulated to exhibit plastic flow rheology; that is, a yield point followed by pseudoplastic flow. To minimize this problem, it is desirable to partially cure the inks on the transfer rolls as soon as possible after their deposition thereon. It is also desirable to select silicone materials for the rolls that have less releasing characteristics than would be employed for thermoplastic inks. The radiation-curable inks have higher cohesive strengths after partial curing. This enables satisfactory use of the tighter (less releasing) silicone materials
Color filters require thin fine dots or lines, accurately registered. A black matrix also must be printed in close register. The collector process, utilizing radiation-curable inks, can meet these objectives. Hence, it has significant advantages over alternative printing techniques.
The biggest advantage is inherent in use of the collector process because registration is independent of the glass substrate. In consequence, accurate positioning of the substrate is less critical. Also, there is no need for accurate repositioning between colors since the full four-color pattern is applied to the glass in one step.
A major disadvantage of printing, compared to photolithography, is the cross-sectional shape of the printed dot. Photolithography achieves a more flattened, rectangular cross-section which is preferred. The printed dot has a more rounded-top, triangular cross-section due to surface tension and rheological effects of the inks. In typical printing processes, invariably, the ink is cohesively split upon deposition onto a substrate, or onto an offset roll, from a patterned design surface, i.e., screen, gravure plate, etc. This results in a non-uniform surface which can only partially be alleviated by leveling. Excessive leveling causes loss of edge definition.
It is in this area of dot cross-sectional shape that the collector process potentially has another significant advantage over other printing processes. When the ink is initially deposited on the transfer roll, a typical triangular cross-section can be anticipated. The ink is partially cured to a semi-viscous, tacky state upon the transfer roll. In this state, it is compressed between the transfer roll and collector. It is subsequently compressed again between the collector and final substrate. This double compression of the semi-cured ink results in a flattening of the triangular cross-sectional shape.
If this in itself is insufficient to achieve the desired cross-section, it is possible to cure the ink during its compressed condition between the offset rolls, or between the collector roll and the final substrate. This is accomplished by light exposure through a transparent offset roll, or through the transparent substrate as ilustrated in FIG VI. Transparent offset rolls can be constructed by using transparent silicones, bonded onto a transparent glass or plastic core, as the offset surface. Of course, in these cases the materials must be transparent to light in the wavelengths necessary to cure the inks. This has been demonstrated by using photoinitiators which respond in the visible or near UV range.
Curing the ink in the compressed state will, of course, slow the printing rate. However, for an article such as an LCD color filter, very high printing rates are not required to realize economic advantages over current photolithographic procedures. Thus, it has been demonstrated that light-curable inks can be successfully printed via this procedure.
Thicknesses within the range of 5 microns or less can be achieved. In this thickness range, it has also been demonstrated that print speeds of at least 6 cycles per minute can be achieved while curing the ink under compression in the nip between the transfer roll and receiving surface. In addition to reduced print thickness, curing the ink in the compressed state has the further potential for a print that is improved in uniformity, and that exhibits smooth surfaces on both sides.
Another key element, in meeting the requirements for color filter printing with a collector process, is the offset rolls themselves. It is desirable to utilize higher durometer offset blankets, particularly for the collector, to minimize distortion during transfer. Even if repeatable, distortion can be a problem due to the need to register to the ITO electrodes. Consequently, offset blankets need to be constructed to minimize distortion. At the same time, they must still provide for satisfactory ink pick-up and release.
The cohesive strength in the radiation-curable inks is much higher than is feasible with thermoplastic inks. This enables the transfer roll and collector to employ less releasing surfaces in the process. It has also led to the potential for use of a non-silicone surface, such as a fluorocarbon polymer, as the collector surface. This has a distinct advantage in that no silicone will be on the top of the printed color filter pattern on the glass. Thus, rejection problems are avoided when overcoating the printed filter with a polyimide planarization layer. Significant rejection problems have been reported in the literature when silicone release surfaces were utilized in color filter manufacture via conventional techniques.
While the silicone film problem is amenable to being solved, the ability to use a non-silicone collector is regarded as a distinct advantage. It has, therefore, been demonstrated that the present inks can be transferred from silicones to fluorocarbons, and then to the glass substrate.
Fluorocarbon materials were tested as collector surfaces for thermoplastic inks, but were found to be unsatisfactory. The fluorocarbon materials accepted the thermoplastic inks from the silicone transfer rolls; however, consistent 100% release to a glass substrate was not achieved. In contrast, the fluorocarbon materials have been found capable of providing 100% release when using radiation-curable inks. The reason for the superior functioning of the radiation-curable inks is their higher cohesiveness after a partial cure. To attain 100% release, ink cohesion must be greater than adhesion of the ink to its releasing surface.
In addition to the nature of the collector surface, actual structure of the collector should be such that surface distortion is minimal or non-existent. This will result if the collector exhibits a relatively rigid surface, such as a fluorocarbon film backed by an elastomer layer to allow compensation for substrate warpage. This is expected to become more critical as the substrate size increases.
As noted earlier, it has been proposed to print a color pattern on film, to inspect the pattern, and, if satisfactory, to transfer the film and pattern to a substrate. Our process can be viewed as producing a color pattern on film in situ, followed by immediate transfer to a substrate. Inspection, prior to transfer, is feasible. Thus, transfer to a substrate can be avoided if the printed filter does not meet specification. Our apparatus has cleaning rolls which remove the ink from the collector when printing to ware is not desired. This ability to inspect the color filter, prior to application to the glass, provides us with the advantage of the film process while avoiding the disadvantage of the film cost.
We may use either gravure or screening for printing onto the transfer roll or first offset surface. We have also demonstrated a flexographic process wherein the first offset roll is replaced with a flexographic roll supplied with ink from an inking plate or roll. We may also employ a rigid typographic printing plate or roll to replace the transfer roll in the process. The use of a typographic printing technique not only eliminates the need for a first offset surface, but also allows single step curing of the ink under compression. This would occur during transfer to a transparent substrate by exposure from a light positioned beneath the substrate. Successful transfer and curing in this manner has been demonstrated.
The invention is further described with respect to specific apparatus embodiments for practicing the invention.
FIG. II is a perspective view of an apparatus 30. Apparatus 30 is designed to apply the process illustrated in FIG. I to production of a four-color pattern on a glass substrate.
Apparatus 30 embodies four rolls 32, 34, 36, and 38. Rolls 32-38 are shown as being suitably suspended, gravure type rolls. Each roll is associated with an ink source 40 and a doctor blade 42. Ink source 40 may be supplied with an appropriate colored ink in known manner.
Apparatus 30 further embodies an assembly that includes a transfer roll 44, a collector roll 46, and a cleaning roll 48. Associated with roll 44 is a source of radiation 50, for example, a UV lamp. The assembly is adapted to synchronized movement in conjunction with a support slide 52 which carries a flat glass substrate 54. Slide 52 has a recessed area 56 in its upper surface in which substrate 54 is securely held in a fixed position, for example, by a vacuum hold. This provides a continuous flat surface across the upper side of substrate 54 and support slide 52. Support slide 52 is carried by, and moves on, a main slide 58 mounted on a base 60.
In operation, the assembly moves in conjunction with slide 58 and substrate 54. As a result, transfer roll 44 visits roll 32 and receives a single color pattern therefrom. This pattern may be cured to a tacky state on transfer roll 44 and transferred to collector roll 46. In like manner, transfer roll 44 sequentially visits each of rolls 34, 36 and 38 to receive the unique color pattern of each roll. Each pattern is transferred to collector roll 46 to assemble a complete four-color pattern on roll 46. This pattern may then be inspected at an inspection unit 62. If rejected, the pattern may be removed by cleaning roll 48. If accepted, the complete pattern is transferred from collector roll 46 to substrate 54.
This ability to inspect the pattern before transfer to the substrate is an important feature of the invention. In some products, such as LCD panels, the glass substrate is a relatively expensive component that is lost when a defective pattern is printed. While it has been proposed to avoid that loss by use of a plastic film as an intermediate, the present process obviates the need for an intermediate. In addition, the disposal of rejected product, and the cost of glass cleaning for recycling, are minimized.
FIG. III is a partial side view of FIG. II. It shows the arrangement as transfer roll 44 visits roll 32 to receive the initial ink pattern for transfer to collector roll 46. It will be appreciated that this operation is repeated serially as the assembly moves along main slide 58. This permits transfer roll 44 to visit each of rolls 34, 36, and 38 and pick up an ink pattern therefrom.
FIG. II shows rolls 32-38 as gravure rolls. It will be appreciated that typographic or lithographic rolls might be substituted. In that case, a different ink source might be provided, and doctor blade 42 omitted, in customary manner. Use of a gravure roll or a screening mechanism requires offset roll 44 as well as collector roll 46. Otherwise, in producing a multi-color pattern, a previous color will tend to transfer back to the gravure roll or screen. A typographic roll does not require an offset roll since there is no contact except in the print areas on the roll. Likewise, a lithographic roll does not require an offset roll since the non-print areas do not accept ink.
Also, a combination of different type rolls is contemplated. For example, in printing a pattern involving red, green, and blue color dots within a black linear framework, the black framework might be printed initially. In that case, roll 32 might be a gravure roll. Rolls 34, 36, and 38, which would provide the three color dot patterns, might be typographic or lithographic rolls.
It is also contemplated that the initial ink patterns may be formed on traditional gravure or etch plates. While these may be heated, it is a feature of the present process, and more particularly the inks employed, that a pattern may be transferred at ambient temperature. This is normally desired in order to avoid possible registration problems due to temperature variations within a plate, or between successive plates. It also avoids effects on ink rheology.
FIG. IV, like FIG. II, is a perspective view of an apparatus generally designated 70. FIG. IV illustrates use of the process with gravure plates. These plates may be of the etched or intaglio type, or may be of the sensitized, flat plate type. Both types are commonly used in the decorating art.
Apparatus 70 embodies four gravure plates 72, 74, 76, and 78. Each plate is provided with a doctor blade 80 and a source (not shown) of the particular colored ink required for its pattern. In operation, a supply of an appropriate ink will be applied to each plate. The ink pattern is formed by moving doctor blade 80 across the plate.
Apparatus 70 further embodies an assembly 82. The same elements are included as shown in the assembly of FIG. II, but arranged rather differently. Thus, assembly 82 includes a transfer roll 84 and a collector roll 86, but collector roll 86 is positioned above transfer roll 84. This is the reverse of the arrangement in FIGS. II and III. Likewise, main slide 88 is positioned above support slide 90, and substrate 92 is held in a recess 94 on the underside of slide 90.
Apparatus 70 further embodies a radiation source 96, a cleaner roll 98 and an inspection unit 100. As explained earlier, the ability to inspect the complete pattern prior to printing, and the provision of a simple means of cleaning a defective pattern from a roll without printing, are important advantages of the invention.
The operation of apparatus 70, and particularly assembly 82, is essentially similar to that of apparatus 30. However, the arrangement of components is reversed. Thus, assembly 82 moves in conjunction with main slide 88 and substrate 92. In this way, transfer roll 84 serially visits plates 72-78 and receives a pattern from each. Each ink pattern is cured to a tacky state and transferred to collector roll 86 before transfer roll 84 proceeds to the next plate. After each individual pattern is collected on collector roll 86, the complete multi-color pattern is then inspected at unit 100. It is then either transferred in total to substrate 92 or removed by cleaner roll 98.
FIG. V is a partial side view of FIG. IV. Doctor blade 80 is removed to better illustrate the operation. FIG. V shows the arrangement of assembly 82 as transfer roll 84 visits plate 72. There, it receives the initial ink pattern for transfer to collector roll 86. The operation is repeated as assembly 82 moves from plate to plate. This permits transfer roll 84 to pick up the ink pattern from each plate and transfer it to collector roll 86.
It will be observed that operation of apparatus 70, as depicted in FIGS. V and VI, embodies a single forward motion of roll pair 84 and 86 to accomplish all of the required functions. This provides the ultimate in registration consistency. FIG. VI illustrates an enlarged view of FIG. V, showing ultraviolent radiation sources 99a, 99b and 99c in the transfer roll 84, collector roll 86, and behind the substrate 92, respectively.
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A method and apparatus for printing a multi-color ink pattern on a substrate surface which comprises arranging a series of patterned surfaces with each patterned surface having a pattern that is unique to one of the colors and that corresponds to the pattern of that color in the multi-color pattern, supplying to each patterned surface a radiation-curable ink formulation, having an appropriate colorant to form an ink pattern thereon, transferring individually the color pattern from each patterned surface to a collector roll, increasing the cohesiveness of the ink sufficiently to permit complete transfer of the pattern, forming a composite of the color patterns on a collector roll, and transferring the composite pattern in its entirety to the substrate surface.
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FIELD OF THE INVENTION
This invention relates to a foot valve assembly for water intakes that are placed along the bottom of a river or lake. More particularly, it relates to a foot valve that is incorporated into a portable intake stand suited for use at cottages that is intended to reduce the uptake of bottom sediments when water is pumped from a lake or river.
BACKGROUND OF THE INVENTION
A foot valve is a one-way check valve located at the intake end of a pipe leading to a suction pump. The function of a foot valve is to prevent the loss of priming water when the pump is not in operation. Typical foot valves have a surrounding screen to prevent the intake of large articles that would damage a pump. Such valves are also usually of the same diameter as the pipe to which they are to be connected, rendering them suitable for use at the bottom, or "foot" of a well hole.
Water intake stands for introducing water into a pipe are intended to minimize the intake of sediment and debris from river and lake bottoms. A concern respecting water intake stands is that they should locate the intake near, but not at the bottom of the water body, and they should not protrude substantially above the bottom to an extent that makes them vulnerable to being upset by currents, or by fisherman's lines or anchors.
A basic known way of supporting and stabilizing a water intake is to fasten the intake end of a pump pipe to a box with a perforated lid filled with gravel that is sunk to the bottom of a river or lake bed. This fastening is effected along the upper edge of the box thereby causing the pump pipe to trail downwardly to the bottom as it proceed towards the shore where a suction pump is located. Such an elevated pipe section is vulnerable to being snagged by fishermen's lines or anchors, risking detachment from, or up-ending of, the box.
A simple known commercial stand is that produced by Wally Weights Inc. of Kenora, Ontario, Canada. In one version, the Wally Weight (™) stand consists of a plastic "wheel" with the water intake occurring at the axle location. With a rigid length of intake pipe extending as an axle, the wheel lies on the lake bottom with the intake orifice elevated above the bottom. Provision is made at the intake opening in this stand for a foot valve to be attached. In use, the foot valve would be oriented at an angle between the horizontal and vertical positions.
A second version of a water intake stand from the same source provides for a cone that rises to the pipe intake at its center point. The cone and intake pipe are perforated to allow water to pass therethrough and enter a submersible pump located in the vertically extending central pipe portion of the stand. Such pumps do not always need a foot valve, although one may optionally be present.
Another company selling water intakes is the Big Foot. Manufacturing Co. of Cadillac Mich. U.S.A. The Big Foot(™) intake is in the form of two concentric perforated cylinders having an annulus therebetween. This annulus is filled with pea-sized gravel to strain water passing through to the core where the intake orifice is located.
While these prior art water intakes are able to function as intended, neither fully address the desirable objectives of providing an assembly for supporting a foot valve in conjunction with a water intake stand which is readily portable prior to installation, is relatively stable and anchored once installed along a lake or river bottom and provides a positioning means for locating the intake orifice above the actual bottom of the water source. It is with the objective of providing such a combination of benefits that the invention described hereafter has been conceived.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SUMMARY OF THE INVENTION
The invention in one of its broader aspects comprises a container having a bottom and sidewalls, there being positioned therein an intake conduit for conveying water that has upper and lower ends. The lower end of the intake conduit passes through and is anchored to the side wall of the container at a location proximate to the container bottom. The lower end terminates in an external coupling means for connection to a water pump intake pipe. The upper end of the intake conduit is positioned above the bottom of the container, at a distance spaced therefrom sufficient to provide for a ballasting mass to be placed within the container, over the container bottom and beneath the upper end of the conduit. To the upper end of the conduit may be attached by way of coupling means on the conduit, a check valve, such as a foot valve, held in a vertical orientation to receive water that is not being drawn from adjacent the river or lake bottom where sediments will be present.
In a preferred variant the container has a removable lid which, when in place, is pierced by the upper end of the intake conduit preferably at a central location, stabilizing the conduit in its position within the container.
In a preferred configuration, the container is a bucket with a handle that permits suspension of the bucket in an upright orientation from a single suspension point, as by a lifting line.
As further variants, the upper end of the intake conduit may be fitted with an encircling screen mounted above the upper rim of the container, containing the foot valve, to provide screening means to prevent the intake of pieces of solid matter. Fabric filter bags may further be fitted over this screen to reduce the size of particles entering the pump intake.
As a further convenience, the bottom of the container may be perforated to allow for flooding and drainage when the container is introduced into or removed from the water.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
SUMMARY OF THE FIGURES
FIG. 1 is a depiction of a prior art box of gravel to which is fastened a water pump intake pipe;
FIG. 2 is a schematic depiction of a Wally Weight company "wheel"-type water intake stand;
FIG. 3 is a schematic depiction of a second Wally Weight intake stand with a vertically oriented intake pipe;
FIG. 4 is a cross-sectional exploded side view of a water intake stand according to the invention;
FIG. 5 is a depiction of the water intake stand with a fabric bag-filter fitted in place; and
FIG. 6 is a pictorial view of the water intake stand of the invention being positioned on a lake bottom, adjacent to a dock.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 along a river bottom 1 a box 3 containing gravel 4 is fastened through a hole 6 in the box wall to a water pump intake pipe 5. Water enters the pipe 5 above the gravel 4 beneath a perforated lid 2, at a position located above the river bottom 1. This is a prior art arrangement that has the disadvantage that a trailing portion 7 of the pipe 5 is elevated above the bottom 1, where it can be accidentally snagged.
In FIG. 2 the prior art Wally Weight "wheel" configuration is depicted. A wheel 8 with perforations 9 has the pipe 5 connected at its axial location 10. Weights 11 endeavour to hold the pipes to the bottom 1, shortening the length of elevated pipe 12. A foot valve (not shown) may be connected to the pipe 5 at the open end of the axial location.
In FIG. 3, the second prior art Wally Weight configuration is shown. The "wheel" 13, which may be cone shaped, has a vertical perforated pipe 14 attached thereto into which may be slid a pump intake 5 or even a down-hole pump (not shown). Again, a portion 20 of pipes is elevated above the bottom 1.
In FIG. 4 a water intake according to the invention is shown. A container in the form of a plastic bucket 22 has a bottom 23 and sidewall 24. An intake conduit 25 generally positioned within the bucket 22 has lower 26 and upper 27 ends.
The lower end 26 passes through the sidewall 24 being held in place by a collar 19. This lower end 26 terminates with a coupling means 28, such as a thread, for connecting to a water pump intake pipe 5.
The upper end 27 of the intake conduit 25 is centrally positioned above the bottom 23, sufficiently elevated to permit a portable ballast 29 such as stones to be placed below it. Preferably, a lid 30 fitted over the bucket 22 is pierced centrally by the upper end 27 of the conduit 25. This lid not only serves to contain the ballast 29 if the bucket 22 tips but also provides structural support and stabilization to the conduit 25. A collar 31 at the upper end 27, in turn supports the lid 30.
A check valve 32 of the foot valve type may be attached to the upper end 27 of the intake conduit 25. This may optionally be provided as part of the product at the time of sale, or be attached by the purchaser using the coupling means, e.g. threaded end 16, provided at the upper end 27 of the conduit 25.
A basket 33 with straining openings 34 is fitted over the bucket 22 to strain-out coarse particles, conveniently engaging with the lid 30 near the rim 35 of the bucket 22 through use of attachment flanges 17. The diameter of the bucket's rim 35 permits a large basket 33 to be employed, providing a substantial area for straining and entry of water. The basket 33 encloses entirely the foot valve 32 protecting it from being struck directly, as by an anchor.
As shown in FIG. 5, a fabric filter in the form of a hood or bag 15 can be attached over the basket 33, held in place by a tied cord 18 fastened around the container rim 35. Such hood 15 if made of a fine material will provide further filtration and screening of particles to prevent their entry into the pump intake pipe 5.
The bucket 22 preferably has a hooped handle 36 as by a cord or wire that permits it to be suspended in a vertical orientation by a line 37, as shown in FIG. 6. Perforations 38 in the bottom 23 of the bucket 22 allow it to flood and drain readily, maintaining its vertical orientation. The fact that the pipe 5 is connected to the bucket 22 near its bottom 23 also contributes to maintaining this orientation.
The water intake stand of the invention is conveniently portable, being of reduced weight until ballast is added. The actual intake end of the water pump intake with the foot valve in place can be positioned 12 to 15 inches off of the river bottom. Significantly, the water pump intake pipe approaches and enters the water intake stand at the base of the bucket, adjacent the river bottom. This reduces the prospects of this pipe being inadvertently snagged.
Once positioned properly on the river bed 1, the bucket 22 will be stabilized in its orientation by the ballast 29 contained therein and the fact that the intake pipe enters the bucket 22 near its bottom end.
Conclusion
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invention in its broadest, and more specific aspects, is further described and defined in the claims which now follow.
These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
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An improved foot valve assembly for use with a water intake includes a bucket with an internal conduit having a connector for attachment to a water pump intake pipe at the base of the bucket. Ballast weight added to the bottom of the bucket provides stability. The intake of water occurs at the upper end of the internal conduit, through a vertically supported foot valve. A basket-fitted over the foot valve may support a fabric bag-filter.
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This is a division of application Ser. No. 575,918 filed May 9, 1975, now U.S. Pat. No. 4,006,233, which in turn is a continuation-in-part of co-pending application Ser. No. 511,961, filed Oct. 4, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to certain tricyclicdicarboximides which representatively are characterized in that they are the Diels-Alder condensation products of a cyclic diene and an N-substituted maleimide. Such tricyclicdicarboximides (Structure I, below) and their pharmaceutically acceptable salt, ester and amide derivatives are useful as minor tranquilizing and anti-convulsant agents. This invention also relates to processes for the preparation of such tricyclicdicarboximides, to pharmaceutical compositions comprising such compounds, and to methods of treatment comprising administering such compounds and compositions.
Structure I, below generically depicts the compounds of the present invention which are hereinafter collectively referred to as "tricyclicdicarboximides": ##STR1## Wherein: R 1 , R 2 , R 3 and R 4 are selected from the group consisting of hydrogen, halogen, alkyl, aminoalkyl, carboxyalkyl, aralkyl, cycloalkyl, haloalkyl, acyloxy, alkenyl, and dialkylaminoalkyl;
X is --CH 2 --(in which case the cyclic diene reactant necessary for the preparation of I is a bond isomer of cycloheptatriene or a substituted derivative thereof), or --CH═CH--(in which case the cyclic diene reactant necessary for the preparation of I is a bond isomer of cyclooctatetraene or a substituted derivative thereof);
R is selected from the group consisting of: ##STR2## wherein Y is hydrogen, halogen, lower alkyl, aminoalkyl, carboxyalkyl, alkoxy, carbalkoxy, carbamoyl and haloalkyl; and R 5 is acylamino, and amino.
Thus, it is an object of the present invention to provide tricyclicdicarboximides of the above general description (I). It is also an object of this invention to provide pharmaceutical compositions comprising such tricyclicdicarboximides and their non-toxic, pharmaceutically acceptable salt, ester and amide derivatives. Lastly, it is an object of the present invention to provide methods of treatment comprising administering the compounds and compositions of the present invention in situations where a minor tranquilizer is indicated.
DETAILED DESCRIPTION OF THE INVENTION
The tricyclicdicarboximides of the present invention are most conveniently prepared by the Diels-Alder condensation of a polycyclic diene (i.e., as previously indicated the bond isomer of cycloheptatriene or cyclooctatraene) and an N-substituted maleimide: ##STR3## wherein all substituents have previously been defined.
Alternately the tricyclicdicarboximides of the present invention may be prepared by reacting a substituted amino compound H 2 N--R, with the Diels-Alder product obtained by reacting either cycloheptatriene (or substituted derivatives thereof) or cyclooctatetraene (or substituted derivatives thereof) with maleic anhydride. ##STR4## wherein all substituents are as previously defined.
In Reaction I (above) the reaction is preferably carried out in a solvent such as pyridine, glyme, toluene, xylene and the like at a temperature in the range of from about 0° C. to the reflux temperature. However, there is no undue criticality as to the identity of the reaction solvent and reaction temperature. In Reaction II the reaction solvent is preferably pyridine, benzene, 2-propanol and the like and the reaction temperature is in the range of from about 0° C, to the reflux temperature. However, there is no undue criticality as to the condition of reaction. The Diels-Alder reactant in Reaction II is prepared by conventional procedures such as by contacting the dienophile (e.g. maleic anhydride) with an excess of the diene (cyclooctatraene or cycloheptatriene) at a temperature of from about 0° C. to about 200° C.; alternately a solvent such as benzene, toluene, xylene and the like may be used at a temperature of from about 0° C. to about 200° C.
The tricyclicdicarboximide (I) resulting from either Reaction I or Reaction II is predominately in the endo configuration, and this form is preferred for practice of the present invention.
Non-toxic pharmaceutically acceptable salt, ester and amide derivatives of the tricyclicdicarboximides of the present invention are prepared by conventional procedures. Preferred N-addition salts are those such as derived from hydrochloric acid, hydrobromic acid, and the like. For those embodiments of I which possess a carboxylic acid group preferred salts are those obtained from the alkali and alkaline earth metals; suitable amides are those obtained from bases such as methylamine, N,N-dimethylethylenediamine and the like; suitable esters may be prepared by conventional means from the free acid form of I, and may, for example, be selected from the group consisting of methyl, ethyl and the like.
The preferred tricyclicdicarboximides of the present invention are those wherein R 1 , R 2 , R 3 , and R 4 are hydrogen; and X and R are as previously defined.
In the method of treatment aspect of the present invention, the instant minor tranquilizer tricyclicdicarbodicarboximides are capable of producing anxiety relief without causing excessive sedation or sleep at a unit dosage level of from about 0.001 to about 8.00 mg. per kg. of body weight, or at a daily dosage level of from about 0.004 to about 32.00 mg. per kg. of body weight. Of course, it is understood that the exact treatment level will depend upon the case history of the animal or human individual being treated and in the last analysis the precise treatment level falling within the above guidelines is at the routine discretion of the therapist.
Also included within the scope of the present invention are pharmaceutical compositions comprising such tricyclicdicarboximides. Preferably these compositions are in unit dosage forms such as tablets, pills, capsules, powders, granules, sterile parenteral solutions or suspensions, and the like. For preparing solid compositions such as tablets, the principal active ingredient is mixed with a pharmaceutical carrier, i.e., conventional tableting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate, dicalcium phosphate, gums, and other pharmaceutical diluents, e.g., water, to form a solid preformulation composition containing a homogeneous mixture of a tricyclicdicarboximide of the present invention, or a non-toxic pharmaceutically acceptable salt, ester or amide derivative thereof. When referring to these preformulation compositions as homogeneous, it is meant that the active ingredient, i.e., the tricyclicdicarboximide, is dispersed evenly throughout the composition so that the composition may be readily subdivided into equally effective unit dosage forms such as tablets, pills, capsules, and the like. This solid preformulation composition is then subdivided into unit dosage forms of the type described above containing from 0.1 to about 500 mg of the active ingredient of the present invention. The tablets or pills of the novel composition can be coated or otherwise compounded to provide a dosage form affording the advantage of prolonged action of the instant tricyclicdicarboximide. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids or mixtures of polymeric acids with such materials as shellac, shellac and cetyl alcohol, cellulose acetate, and the like.
The liquid forms in which the novel composition of the present invention may be incorporated for administration orally or by injection include aqueous solutions, suitably flavored syrups, aqueous or oil suspensions, flavored emulsions with edible oils such as cottonseed oil, sesame oil, coconut oil, peanut oil and the like, as well as elixirs and similar pharmaceutical vehicles. Suitable dispersing or suspending agents for aqueous suspensions include synthetic and natural gums such as tragacanth, acacia, alginate, dextran, sodium carboxymethylcellulose, methylcellulose, polyvinyl-pyrrolidone, gelatin and the like.
The pharmaceutical tricyclicdicarboximide formulations of the present invention can be administered orally, parenterally, or rectally. Orally, they may be administered in tablets, capsules, suspensions or syrups, the preferred dosage form being a compressed tablet containing from 0.1 to about 500 mg. of the active ingredient. The optimum dosage depends of course on the dosage form being used and the type and severity of the condition being treated. In any specific case, as previously mentioned, the appropriate dosage selected will further depend on factors of the patient which may influence response to the drug, for example, general health, age, weight, and the desired effect.
The following Examples representatively illustrate, but do not limit, the product, process, method of treatment, or compositional aspects of the present invention.
EXAMPLE 1
N-(4-Acetamidophenyl)-anti-tricyclo-[3.2.2.0 2 .4 ] non-8-ene-endo-6,endo-7-dicarboximide
Method I
A mixture of N-(4-acetamidophenyl)maleimide (1.61 g., 0.007 mole), 1,3,5-cycloheptatriene (0.64 g., 0.007 mole), and xylene (50 ml.) is refluxed for 22 hours. The resulting hot yellow solution is decanted from a gummy precipitate and cooled. The yellow solid that separates is collected and air-dired, 1.57 g., (70%). Recrystallization from isopropyl alcohol yields N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 .4 ]non-8-ene-endo-6,endo-7-dicarboximide, m.p. 229°-231°.
Analysis Calc. for: C 19 H 18 N 2 O 3 : Calc.: C, 70.79; H, 5.63; N, 8.69. Found: C, 70.92; H, 6.00; N, 8.78.
Method II
A mixture of anti-tricyclo[3.2.2.0 2 .4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (4.11 g., 0.022 mole), 4'-aminoacetanilide (9.73 g., 0.065 mole), and pyridine (28 ml.) is heated under reflux for 18 hours. The solvent is removed at 25° C., water (50 ml.) is added and the mixture is acidified by the addition of concentrated hydrochloric acid (15 ml.). The solid that separates is collected, washed with water, 0.1N hydrochloric acid, water and dried to constant weight, 6.66 g. (96%), m.p. 229°-231° C. Repeated recrystallization from ethanol gives N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 .4 ]non-8-ene-endo-6,endo-7-dicarboximide, m.p. 230°-231.5° C.
Analysis Calc. for: C 19 H 18 N 2 O 3 : Calc.: C, 70.79; H, 5.63; N, 8.69. Found: C, 71.09; H, 5.54; N, 8.68.
EXAMPLE 2
N-(4-Acetamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.01 mole), 4'-aminoacetanilide (1.50 g., 0.01 mole), and pyridine (20 ml.) is refluxed for 20 hours. The pyridine is removed "in vacuo" to yield the product as a tan solid, 3.05 g. (0.0091 mole, 91% yield), m.p. 225°-236° C. Two recrystallizations from isopropyl alcohol yields N-(4-acetamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide as an off-white solid, 1.65 g., m.p. 223°-235° C.
Analysis Calc. for: C 20 H 18 N 2 O 3 : Calc.: C, 71.84; H, 5.43; N, 8.38. Found: C, 72.01; H, 5.61; N, 8.21.
EXAMPLE 3
N-(3-Acetamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.01 mole), 3'-aminoacetanilide (1.50 g., 0.01 mole), and pyridine 20 ml.) is refluxed for 24 hours. The pyridine is removed in vacuo to yield the product as a tan solid, 3.20 g. (0.00955 mole, 95.5% yield), m.p. 260°-265° C. Recrystallization from acetonitrile yields N-(3-acetamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide as an off-white solid, 2.0 g., m.p. 264°-266° C.
Analysis Calc. for C 20 H 18 N 2 O 3 : Calc.: C, 71.84; H, 5.43; N, 8.38. Found: C, 71.92; H, 5.66; N, 8.52.
EXAMPLE 4
N-(6-Benzoxazolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]-dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (0.67 g., 0.0033 mole), 6-aminobenzoxazolin-2-one (0.49 g., 0.0033 mole) and pyridine (10 ml.) is heated under reflux for 16 hours. The reaction mixture is cooled (25° C.), diluted with water (100 ml.) and the solid that separates is collected and dried, 0.95 g. Recrystallization from ethanol gives N-(6-benzoxazolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]-dec-3,9-diene-endo-7,endo-8-dicarboximide, m.p. 306°-309° C.
Analysis Calc. for: C 19 H 14 N 2 O 4 : Calc.: C, 68.25; H, 4.22; N, 8.38. Found: C, 68.35; H, 4.41; N, 8.33.
EXAMPLE 5
N-(6-Benzoxazolinyl-2-one)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide
Following the procedure of Example 4 and using anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (0.95 g., 0.005 mole), 6-aminobenzoxazolin-2-one (0.75 g., 0.005 mole) and pyridine (10 ml.) there is obtained 1.45 g, of solid, m.p. 265.5°-267° C. (dec.). Recrystallization from 2-propanol provides N-(6-benzoxazolinyl-2-one)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,-endo-7-dicarboximide, m.p. 283°-284.5° C. (dec.).
Analysis Calc. for: C 18 H 14 N 2 O 4 : Calc.: C, 68.25; H, 4.22; N, 8.38. Found: C, 68.33; H, 4.31; N, 8.34.
EXAMPLE 6
N-(5-Benzoxazolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.01 mole), 5-aminobenzoxazolin-2-one (1.50 g., 0.01 mole) and pyridine (20 ml.) is heated under reflux for 6 hours. The cooled solution (25° C.) is diluted with water (200 ml.) and the precipitate is collected by filtration, 2.60 g., m.p. 252°-257° C. Recrystallization from 2-propanol provides N-(5-benzoxazolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide, m.p. 287.5°-290° C.
Analysis Calc. for C 19 H 14 N 2 O 4 : Calc.: C, 68.25; H, 4.22; N, 8.38. Found: C, 68.33; H, 4.31; N, 8.34.
EXAMPLE 7
N-(5-Benzoxazolinyl-2-one)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide
Following the procedure of Example 6 and using anti-tricyclo[3.2.2.0 2 ,4 ]non-8ene-endo-6,endo-7-dicarboxylic anhydride (1.90 g., 0.01 mole), 5-amino-benzoxazolin-2-one (1.5- g., 0.01 mole) and pyridine (20 ml.), there is obtained 2.65 g. of yellowish solid, m.p. 252°-257° C. (dec. with eff.). Recrystallization from 2-propanol give N-(5-benzoxazolinyl-2-one)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide, m.p. 256°-258° C.
Analysis Calc. for C 18 H 14 N 2 O 4 : Calc.: C, 67.07; H, 4.38; N, 8.69. Found: C, 67.05; H, 4.49; N, 8.63.
EXAMPLE 8
N-(2-Acetamido-5-pyrimidinyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (1,21 g., 0.006 mole), 2-acetamido-5-aminopyrimidine (0.92 g., 0.006 mole), and pyridine (20 ml.) is heated under reflux for 24 hours. The pyridine is removed in vacuo to yield, after washing with water, 2.0 g. (0.006 mole, 100% yield), m.p. 232°-245° C. Two recrystallizations from isopropyl alcohol produces N-(2-acetamido-5-pyrimidinyl)-anti-tricyclo[4.2.2.0 2 ,5 ]-dec-3,9-diene-endo-7,endo-8-dicarboximide as a white crystalline solid, 1.14 g., m.p. 246.5°-249.5° C.
Analysis Calc. for: C 18 H 16 N 4 O 3 : Calc.: C, 64.27; H, 4.80; N, 16.66. Found: C, 64.21, H, 4.79; N, 16.56.
EXAMPLE 9
N-(Propargyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,-endo-7-dicarboximide
A mixture of anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (5.70 g., 0.03 mole), mono-propargylamine hydrochloride (2.76 g., 0.03 mole), and pyridine (60 ml.) is heated under reflux for 6 hours. The pyridine is removed in vacuo, and the residue triturated with water (50 ml.) to yield 6.5 g. (0.028 mole, 93%) of the crude product. Recrystallization from hexane produce N-(propargyl)-anti-tricyclo[3.2.2.0 2 ,4 ]-non-8-ene-endo-6,-endo-7-dicarboximide as a white crystalline solid, 5.1 g., m.p. 108°-110° C.
Analysis Calc. for C 14 H 13 NO 2 : Calc.: C, 73.99; H, 5.77; N, 6.16. Found: C, 73.90; H, 6.09; N, 6.30.
EXAMPLE 10
N-(3-Chloro-4-valeramidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]-dec-3,9-diene-endo-7,endo-8-dicarboximide
Step A: 2'-Chloro-4'-nitrovaleranilide
Valeryl chloride (12.06 g., 0.10 mole) is added dropwise to a cooled stirred solution of 2-chloro-4-nitroaniline (17.26 g., 0.10 mole) in pyridine (100 ml.). The mixture is warmed to ambient temperature, then heated (80°-100° C.) for 24 hours. The cooled solution is poured into cold 1 N hydrochloric acid (500 ml.) with stirring. The precipitated solid is collected, washed well with water and dried, 25.1 g., m.p. 80°-95° C. Recrystallization from cyclohexane yeilds mater al (19.75 g.) of m.p. 95°-97° C.
Step B: 4'-Amino-2'-chlorovaleranilide
2'-Chloro-4'-nitrovaleranilide (13.0 g.) is dissolved in warm glacial acetic acid (100 ml.) and iron powder (14 g.) is added portionwise to maintain gentle boiling. The resulting reaction mixture is refluxed for 1/2 hour and filtered. The filtrate is evaporated under reduced pressure and the residue is triturated with water. The solid that forms is collected (11.5 g.) and recrystallized from cyclohexane to yield 7,5 g., m.p. 96.5°-99° C.
Step C: N-(3-Chloro-4-valeramidophenyl)-anti-tricyclo-[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of 4'-amino-2'-chlorovaleranilide (2.27 g., 0.01 mole) anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2,02 g., 0.01 mole) and pyridine (20 ml.) is heated under reflux for 24 hours. The solvent is removed in vacuo and the residue (4.35 g., m.p. 120°-136° C.) is recrystallized from butyl chloride to give N-(3-chloro-4-valeramidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide, m.p. 157.5°-159° C.
Analysis calc. for: C 23 H 23 ClN 2 O 3 : Calc.: C, 67.23; H, 5.64; N, 6.82. Found: C, 67.16; H, 5.45; N, 6.87.
EXAMPLE 11
N-(4-Valeramidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
Step A: 4'-Nitrovaleranilide
Valeryl chloride (12.06 g., 0.10 mole) is added dropwise to a cooled stirred solution of 4-nitroaniline (13.81 g., 0.10 mole) in pyridine (100 ml.). The resulting mixture is stirred at ambient temperature for 1 hour then heated (80°-100° C.) for 24 hours. The cooled solution is poured into cold 1 N hydrochloric acid (500 ml.) with stirring. The precipitated solid is collected, washed with water and dried, 21.4 g., m.p. 107°-116° C. Recrystallization from butyl chloride provides material of m.p. 115°-118° C.
Step B: 4'-Aminovaleranilide
A solution of 4'-nitrovaleranilide (13.33 g., 0.06 mole) in absolute ethanol (750 ml.) is hydrogenated over 10% palladium on charcoal (2 g.) until the theoretical absorption is achieved. The catalyst is removed and the solvent is removed in vacuo. The residue is recrystallized from butyl chloride to yield 9.0 g., m.p. 81°-83° C.
Step C: N-(4-Valeramidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of 4'-aminovaleranilide (1.92 g., 0.01 mole), anti-tricyclo-[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.01 mole) and pyridine (25 ml.) is heated under reflux for 24 hours. The solvent is removed in vacuo and the residue, 3.75 g. m.p. 214°-218° C., is recrystallized from butyl chloride to give N-(4-valeramidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide, 2.8 g., m.p. 219°-220° C.
Analysis calc. for: C 23 H 24 N 2 O 3 : Calc.: C, 73.38; H, 6.43; N, 7.44. Found: C, 73.41; H, 6.54; N, 7.45.
EXAMPLE 12
N-(2-Thiazolyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide
A mixture of tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (1.90 g., 0.010 mole), 2-amino-thiazole (1.0 g., 0.010 mole) and pyridine (20 ml.) is refluxed for 24 hours. The cooled solution is diluted with water (200 ml.) and the solid that separates is collected, washed well with water, and dried, 2.12 g. Recrystallization from butyl chloride yields N-(2-thiazolyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide, m.p. 154°-156° C.
Analysis calc. for C 14 H 12 N 2 O 2 S: Calc.: C, 61.74; H, 4.44; N, 10.29. Found: C, 61.88; H, 4.44; N, 10.28.
EXAMPLE 13
N-(4-Aminophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of N-(4-acetamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide (0.90 g.), benzylamine (1 ml.) and methyl cellosolve (10 ml.) is heated under reflux for 18 hours. Benzylamine (1 ml.) is added and heating is continued for an additional 24 hours. The solvent is removed in vacuo, butyl chloride is added and the solid that separates is collected, 0.65 g. Recrystallization from 95% ethanol gives N-(4-aminophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide, m.p. 321°-324° C. (dec.).
Analysis calc. for: C 18 H 16 N 2 O 2 : Calc. C, 73.95; H, 5.52; N, 9.58. Found: C, 73.04; H, 5.74; N, 9.50.
EXAMPLE 14
N-(5-Indolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of anti-tricylco[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.010 mole), 5-aminoindolin-2-one (1.48 g., 0.01 mole) and pyridine (20 ml.) is heated under reflux for 20 hours. The cooled reaction mixture is diluted with water (200 ml.) and the solid that separates is collected, washed with water, and dried, 2.50 g. Recrystallization from 2-propanol yields N-5-indolinyl-2-one)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide, m.p. 279°-283° C.
Analysis calc. for: C 20 H 16 N 2 O 3 . Calc.: C, 72.28; H, 4.85; N, 8.43. Found: C, 72.08; H, 5.03; N, 8.26.
EXAMPLE 15
N-(3-Acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide
A mixture of anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (1.90 g., 0.01 mole), 3'-aminoacetanilide (1.50 g., 0.010 mole) and pyridine (20 ml.) is heated under reflux for 24 hours. The solvent is removed in vacuo and the residue is recrystallized from 2-propanol to give N-(3-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide, 1.85 g., m.p. 251.5°-252.5° C.
Analysis Calc. for: C 19 H 18 N 2 O 3 : Calc.: C, 70.79; H, 5.63; N, 8.69. Found: C, 70.63; N, 5.77; N, 8.47.
EXAMPLE 16
N-(3-Aminophenyl)-anti-tricylco[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide
A mixture of anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboxylic anhydride (0.95 g., 0.0005 mole), 1-(3-aminophenyl)urea hydrochloride (0.94 g., 0.005 mole), and pyridine (30 ml.) is heated under reflux for 24 hours. The cooled reaction mixture is diluted with water (200 ml.) and the solid that forms is collected and dried, 1.0 g., m.p. 204°-210° C. Recrystallization from butyl chloride yields N-(3-aminophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide as a white solid, m.p. 212°-214° C.
Analysis calc. for: C 17 H 16 N 2 O 2 : Calc.: C, 72.84; H, 5.75; N, 9.99. Found: C, 72.71; H, 5.90; N, 9.72.
EXAMPLE 17
N-(4-Propionamidophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (2.02 g., 0.01 mole), 4'-aminopropionanilide (1.64 g., 0.01 mole) and pyridine (20 ml.) is heated to reflux for 24 hours. The cooled reaction mixture is diluted with water (350 ml.) and the solid that separates is collected and dried, 3.4 g., m.p. 218°-221.5° C. Recrystallization from benzene gives N-(4-propionamidophenyl)-anti-tricyclo[4.2.2.0 2 ,4 ]dec-3,9-diene-endo-7,endo-8-dicarboximide with m.p. 223°-224° C.
Analysis calc. for: C 21 H 20 N 2 O 3 : Calc.: C, 72.39; H, 5.79; N, 8.04. Found: C, 71.38; H, 5.70; N, 7.92.
EXAMPLE 18
N-(4-Acetamido-3-chlorophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide
A mixture of 4'-amino-2'-chloroacetanilide (0.92 g., 0.005 mole), anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboxylic anhydride (1.01 g., 0.005 mole) and pyridine (20 ml.) is heated under reflux for 20 hours. The cooled solution is diluted with water (200 ml.) and the solid that forms is collected and dried, 1.4 g., m.p. 195°-207° C. Recrystallization from butyl chloride givesN-(4-acetamido-3-chlorophenyl)-anti-tricyclo[4.2.2.0 2 ,5 ]dec-3,9-diene-endo-7,endo-8-dicarboximide (0.75 g.) with m.p. 207°-208° C.
Analysis calc. for: C 20 H 17 ClN 2 O 3 : Calc.: C, 65.13; H, 4.65; N, 7.60. Found: C, 65.22; H, 4.64; N, 7.72.
EXAMPLE 19
Tablet Preparation
Tablets containing 1.0, 2.0, 25.0, 26.0, 50.0 and 100.0 mg., respectively of N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide are prepared as illustrated below.
______________________________________TABLE FOR DOSES CONTAINING FROM 1-25MG. OF THE TRICYCLICDICARBOXIMIDE COMPOUND Amount - mg.______________________________________N-(4-Acetamidophenyl)anti-tri-cyclo[3.2.2.0.sup.2.4 ]non-8-ene-endo-6,endo-7-dicarboximide 1.0 2.0 25.0Microcrystalline cellulose 49.25 48.75 37.25Modified food corn starch 49.25 48.75 37.25Magnesium stearate 0.50 0.50 0.50______________________________________
______________________________________TABLE FOR DOSES CONTAINING FROM 26-100MG. OF THE TRICYCLICDICARBOXIMIDE COMPOUND Amount - mg.______________________________________N-(4-Acetamidophenyl)anti-tri-cyclo[3.2.2.0.sup.2.4 ] non-8-ene-endo-6,endo-7-dicarboximide 26.0 50.0 100.0Microcrystalline cellulose 52.0 100.0 200.0Modified food corn starch 2.21 4.25 8.5Magnesium stearate .39 0.75 1.5______________________________________
All of the N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide, cellulose, and a portion of the corn starch are mixed and granulated to a 10% corn starch paste. The resulting granulation is sieved, dried and blended with the remainder of the corn starch and the magnesium stearate. The resulting granulation is then compressed into tablets containing 1.0 mg., 2.0 mg., 25.0 mg., 26.0 mg., 50.0 mg., and 100.0 mg. of N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide per tablet.
Following the procedure of Example 19, tablets comprising N-(propargyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide are prepared when the N-(4-acetamidophenyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide of Example 19 is replaced by an equivalent amount of N-(propargyl)-anti-tricyclo[3.2.2.0 2 ,4 ]non-8-ene-endo-6,endo-7-dicarboximide. Other tablets are prepared using the same procedures and the equivalent amounts of excipients along with equivalent amounts of the tricyclicdicarboximide compounds of the present invention prepared in accordance with the procedures of Examples 1-18 inclusive.
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Tricyclicdicarboximides representatively prepared by the Diels-Alder condensation of a cyclic diene such as cycloheptatriene, cyclooctatetraene and the like with a dienophile such as substituted N-phenylmaleimide and the like are disclosed having pharmaceutical utility as minor tranquilizers and anti-convulsants. Also disclosed are processes for the preparation of such tricyclicdicarboximides; pharmaceutical compositions comprising such compounds and their salt, ester and amide derivatives, and methods of treatment comprising administering such compounds and compositions.
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LICENSE RIGHTS
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 Grant No. B391-2R awarded by Rehabilitation Research and Development Service of the Department of Veteran Affairs.
BACKGROUND OF THE INVENTION
Lumbar muscle function is considered to be an important component of chronic lower back pain (LBP). It has been found that individuals with endurable back muscles and general physical fitness have fewer incidences of back problems than deconditioned cohorts. Complementary studies have documented compromised muscle function in patients with LBP. Although the mechanism associating muscle insufficiency to LBP is not clearly understood, it is commonly held that the passive tissues of the spine are increasingly stressed with increasing functional muscle insufficiency. The high incidence of back injury among workers exposed to fatiguing manual tasks and whole body vibration lend support to this concept. To further understand the relationship of muscle function to LBP, more effective assessment procedures need to be developed and tested for clinical use.
Most techniques presently available to assess muscle deficiencies are either nonobjective or they lack rigorous clinical validation and reliability. One technique that does provide objective data entails electromyographic (EMG) spectral analysis of lower back muscles. Although providing advantages over other techniques, prior EMG systems have suffered certain deficiencies resulting primarily from treatment of individual muscle groups as a continuous muscle mass and exclusive reliance on the amplitude of EMG signals. Improved but less than fully satisfactory techniques utilizing EMG spectral measurements are disclosed in Gilmore L. D., DeLuca D. J.; Muscle fatigue monitor: Second generation. IEEE Trans Biomed Eng BME-32: 75-78, 1985. Prior disclosures of EMG spectral analysis of LBP include Roy, S. H., DeLuca, C. J., Gilmore, L. D.: Computer Aided Back Analysis System. IEEE Engineering in Medicine and Biology Society--10th Annual International.
The object of this invention, therefore, is to provide an improved system for analyzing muscle fatigue associated with LBP.
SUMMARY OF THE INVENTION
This invention is a muscle function analysis system including a base; a restraint device supported by the base and shaped and arranged to receive and immobilize a human body portion retaining a muscle group concurrently activatable to produce a body function; and a support apparatus supported by the base and shaped and arranged to support other portions of the body, the support apparatus adapted to substantially isolate activity in the muscle group from muscle activity in the other body portions. Also included are an electrode array adapted for coupling to the muscle group so as to receive myoelectric signals generated by muscle activity therein and a processing system coupled to the electrode array and adapted to process the myoelectric signals. By isolating muscle activity in a particular muscle group, more useful data is obtained for evaluating muscle dysfunction in the group.
According to one feature of the invention, the one body portion includes a body joint, the muscle group is activatable to produce torque at the joint, and the restraint device establishes a predetermined angular orientation of the joint. Muscle activity isolation is enhanced by selectively establishing a particularly desirable joint orientation.
According to another feature of the invention, the one body portion of a human body is the pelvis, and the joint is between the pelvis and the torso. Immobilization of the pelvis facilitates an analysis of LBP.
According to yet another feature of the invention, the restraint device comprises plural molds adapted to envelop the one body portion and adjustable connector means for selectively fixing the relative positions between the plural molds. The provision of adjustable plural molds enhances use of the system with diverse test subjects.
According to still other features of the invention, the support apparatus includes a knee support adapted to maintain the body's knee joints in flexion, and a foot support adapted to maintain the body's ankle joints in plantarflexion. The knee and foot supports enhance operation by establishing a postural position with the thigh muscles at rest.
According to a further feature of the invention, the restraint device is adapted to permit establishment of an adjustable posterior pelvic tilt. The posterior pelvic tilt combines with partial knee flexion established by the knee support to substantially reduce or actually inhibit use of hamstring muscles during back extension.
According to an additional feature of the invention, the system includes a force constraint supported by the base and adapted to engage and prevent movement of the body's torso during extension thereof. The constraint permits a test subject to introduce contraction of the muscles in the lower back.
According to still other features of the invention, the base includes a substantially vertical standard and a pedestal adapted to support the body's feet; and the restraint device includes a first coupling providing a given spacing between the standard and an upper portion of the molds, a second coupling providing a predetermined spacing between the standard and a lower portion of the molds, and an adjustment means for selectively adjusting the predetermined spacing relative to the given spacing. This arrangement facilitates the desirable establishment of a posterior pelvic tilt.
According to additional features of the invention, the knee support is supported by the standard and defines knee support surfaces forming an acute angle with the standard so as to maintain the body's knee joints in flexion; and the foot support is supported by the pedestal and defines a surface inclined at an acute angle with respect to the horizontal so as to maintain the body's ankle joints in plantarflexion. This arrangement facilitates desired postural orientation with a test subject in a desirable upright position.
DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a block circuit diagram illustrating a back muscle analysis system according to the invention;
FIG. 2 is a perspective view of a postural positioning device employed with the system shown in FIG. 1;
FIG. 3 is a schematic diagram depicting a test subject restrained in the device shown in FIG. 2;
FIG. 4 is a diagram illustrating electrode placement on back muscles of a test subject;
FIG. 5 is a diagram illustrating orientation of an electrode over a muscle;
FIG. 6 is a diagram in which median frequency of myoelectric signals is plotted as a function of muscle contraction duration;
FIGS. 7-9 are diagrams in which the initial median frequency of myoelectric signals is plotted as a function of % maximum voluntary contraction (MVC) forces produced by the system of FIG. 1; and
FIGS. 10-12 are diagrams in which the mean slope of the median frequency of myoelectrical signals is plotted as a function of % MVC forces produced by the system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A back muscle analysis system 11 includes a postural control device 12, an EMG detecting electrode array 13, a visual applied-force feedback system 14 and a signal processing system 15. After being immobilized in the postural control device 12, a test subject 16 generates desired isometric back muscle activity, parameters of which can be monitored by the applied force feedback system 14. Resultant EMG signals are detected by the electrode array 13 and fed into the signal processing system 15. An analysis of back muscle dysfunction is obtained by analyzing various parameters of the EMG signals determined by the processing system 15.
As shown in FIG. 2, the postural control device 12 includes a base unit 20 consisting of a pedestal 21 and a vertical standard 22. Also included in the control assembly 12 is a subject restraint assembly 23, a subject support assembly 24 and a force constraint harness 25 all supported by the base 20. The restraint assembly 23 consists of a mold assembly 26 secured to the standard 22 by a coupling assembly 27. Forming the mold assembly 26 are a posterior mold portion 28 and a pair of anterior mold portions 31, 32. A plurality of adjustable straps 33 secure the anterior molds 31, 32 to the posterior mold 28 in an adjustable configuration. Forming the coupling assembly 27 is a first coupling consisting of a bar 35 extending transversely from the standard 22 and having opposite ends attached to, respectively, an upper portion of the posterior mold portion 28 and a vertically adjustable collar 36 on the standard 22; and a second coupling consisting of a rod 38 extending transversely from the standard 22 and having one end engaging a lower portion of the posterior mold portion 28 and an opposite end attached to a vertically adjustable collar 39 on the standard 22. A nut 41 engaged with the threaded rod 38 permits horizontal adjustment thereof relative to the standard 22.
The subject support assembly 24 includes a knee support assembly 42 having right and left knee pads 43, 44 extending transversely from the standard 22 and supported thereon by a vertically adjustable collar 45. The right and left knee pads 43, 44, define, respectively, knee support surfaces 46, 47 oriented at an acute angle to the standard 22. Also included in the subject support assembly 24 is a foot support block 48 having an inclined foot support surface 49 also oriented at an acute angle to the vertical standard 22.
The force constraint harness 25 consists of a flexible strap 51 having opposite ends 52, 53 secured to a vertically adjustable mount 54 on the standard 22. Connecting the ends 52, 53, respectively, to the mount 54 is a pair of load detecting transducers 55, 56 such as conventional load cells. A pad 58 is attached to a central portion of the flexible strap 51. Extending transversely from an upper end of the standard is a support bracket 60 that supports a video display 61.
After placement of the electrode array 13 in the manner described hereinafter, the subject 16 is immobilized in the control device 12 as illustrated in FIG. 3. A body portion retaining the lower back muscles of the subject 16 is received and immobilized by the restraint assembly 23. Specifically, the posterior and anterior mold portions 28, 31 and 32 are adjusted and secured by the connective straps 33 to conform to and envelop the hip, upper thigh, buttocks and anterior pelvic regions of the subject's body. Selective rotation of the nut 41 adjusts the effective length of the rod 38 and a predetermined spacing established thereby between the standard 22 and a lower portion of the posterior mold 28. The predetermined spacing is adjusted with respect to the given spacing established by the first coupling bar 35 between the upper portion of the posterior mold portion 28 and the standard 22. In that manner, the normal anterior pelvic tilt of the subject 16 is changed to a full posterior tilt of desired value as illustrated in FIG. 3. The knees of the subject 16 are placed in engagement with the pads 43, 44 which provide patellar tendon bearing surfaces and maintain the subject's knee joints in flexion at an angle φ preferably between 10° and 35°. Supporting the feet of the subject 16 is the inclined surface 49 of the block 48 that maintains the subject's ankle joints at an angle θ preferably between ±10° plantarflexion. That orientation prevents the feet from slipping posteriorly during a contraction of the back. Finally, the force restraint harness 25 is activated by placing the flexible strap around the subject 16 with the pad 58 engaging the subject's upper back portion. The mount 54 and the collars 36 and 45 are adjusted to establish desired vertical positions for, respectively, the force constraint harness 25, the restraint assembly 23 and the knee support assembly 43 as determined by the specific physical characteristics of the subject 16.
Prior to positioning the subject 16 in the postural control assembly 12, the electrode array 13 coupled to the processing system 15 is carefully arranged over the subject's lower back region as shown in FIG. 4. The array 13 consists of a first set of surface electrodes 63-65 and a second set of surface electrodes 66-68 bilaterally placed over specific muscles of the subject's lower back. In a preferred application, the electrodes 63, 66 are bilaterally located over the multifidus muscle at the L5 spinal level, the electrodes 64, 67 are bilaterally located over the iliocostalis lumborum muscle at the spinal level L2 and the electrodes 65, 68 are bilaterally placed over the longissimus thracis muscle at the spinal level L1. Preferably each of the electrodes 63-68 is adapted for surface attachment over a muscle and includes a pair of elongated, substantially parallel detection surfaces 71, 72 as illustrated in FIG. 5. Surface electrodes of a type suitable for use in the system 11 are disclosed in Gilmore, L. D. and DeLuca C. J.: Muscle Fatigue Monitor: Second generation, IEEE Trans Biomed Eng. BME-32: 75-78, 1985.
To isolate myoelectric activity detected by the electrode 63 to that produced in the specific muscle 75 over which it is placed, and to thereby minimize "cross-talk" produced by muscle activity in adjoining muscles, the detection parallel surfaces 71, 72 are preferably oriented substantially perpendicular to the muscle fibers as shown in FIG. 5. In addition, the electrode 63 is placed in a position spaced substantially from the innervation zone (motor point) 76 at the end of a nerve 77 associated with the muscle 75 and substantially spaced from the tendons 78, 79 attached to the muscle 75. The other electrodes 64-68 are similarly positioned to enhance detected signal quality. During strategic placement of the electrodes 63-68, the specific muscles to be covered thereby are electrically stimulated and palpitated to accurately determine fiber orientation and motor point locations.
After being positioned in the postural control device 12, the subject 16 exerts a posterior force (i.e. trunk extension) against the constraint harness 25 producing a static (isometric) contraction of the lower back muscles being monitored by the electrodes 63-68. The EMG signals detected by the electrodes 63-68 are fed into the processing system 15 and analyzed to determine certain parameters thereof. Those parameters can then be used to access muscle dysfunction in the manner described hereinafter. In addition, the constraint harness 25 separates the force generated by the subject 16 into two components F1, F2 that are sensed by the load cells 55, 56. Outputs produced by the sensors 55, 56 are applied to a force monitoring section 80 which produces inputs to the video display 61. In response to the displays provided by the video 61, the subject 16 is able to maintain applied force at desired levels and to control symmetry between F1 and F2.
Included in the processing system 15 are an amplifier section for amplifying the EMG signals, a recorder 82 for recording signal values, a muscle fatigue monitor (MF) 83 for monitoring the signals, a computer 84 and a printer-plotter unit 85. Also included is the force monitoring section 80 including a differential amplifier that receives the outputs of the transducers 55, 56 and a display section 88 providing an input to the video 61. A further description of the processing system 15 can be found in Gilmore, L. D., DeLuca, C. J.: Muscle Fatigue Monitor: Second generation, IEEE Trans Biomed Eng BME-32: 75-78, 1985 and Gilmore, L. D., DeLuca, C. J.: Muscle fatigue monitor (MFM): An IBM-PC based measurement system. Presented at the 9th annual meeting of the IEEE-EMBS, Boston, Mass., Nov. 14, 1987.
The six channels of EMG signals provided by the electrodes 63-68 are amplified in the amplifier section 81 to achieve an output amplitude of 2 to 3 V peak-to-peak. This data is recorded by the tape recorder 82. In addition, the outputs of the transducers 55, 56 are recorded by the recorder 82. The MFM calculates the median frequency (MF) and the root-mean-squares (RMS) of each received EMG signal in real-time using analog circuitry. Median frequency is defined as the frequency that separates the power density spectrum into halves of equal power. This parameter provides a reliable, consistent, and unbiased measure of the frequency shift of the EMG signal associated with muscle fatigue during sustained, constant-force contractions. In addition, the computer 84 utilizes input from the transducers 55, 56 to calculate for each subject a maximum voluntary contraction (MVC) by averaging force values over an adjustable window. The MVC force value is stored and can be used to set the visual display 61 to the desired percentage of the MVC. The feedback display helps the subject maintain a constant level of contractile force.
During each test of a subject, back muscle endurance characteristics are measured by assessing how rapidly the muscle groups monitored by the electrodes fatigue. This is followed by an assessment of how capable the muscles are of recovering to their pre-fatigued state. Fatigue is induced by having the subject contract their back muscles to produce a static (isometric) contraction at a specified force level which is a percent of MVC. This contraction is sustained for a specified period of time (for example, 15 seconds to 1 minute) or else repeatedly (on-and-off) for a specified duty cycle (e.g. 10 seconds of contraction followed by 5 seconds of rest repeated for 1 hour). The contraction levels can be specified at a pre-determined % MVC depending on the desired intensity of the fatigue task. Both the "static" and "dynamic" trials result in a state of fatigue in the lower back muscles which are measured by the EMG. Following the fatigue state, the ability of the muscle(s) to return to their rested or baseline level is monitored by having the subject rest (usually 1, 2, 5 or 10 minutes) and then retested briefly (10 second duration) to monitor the EMG parameters at specific times into recovery.
Following each test, the EMG signals provided by the electrodes 63-68 are individually processed by analog circuitry using the muscle fatigue monitor (MFM) 83 to compute the MF value of the signal. This parameter and the force data from the transducers 55, 56 are further amplified and simultaneously digitized by the computer 84. A sampling rate of 10 Hz is used to satisfy the Nyquist criterion, since the fluctuations of the MF and force are below 4 Hz due to the characteristics of the MFM.
The digitized MF records for each of the six electrodes 63-68 are simultaneously plotted in the section 85 as a function of time (FIG. 6). The software algorithm uses a moving average filter with a 2-second window (200 samples) to reduce high-frequency fluctuations in the data. These high-frequency fluctuations are due to the stochastic nature of the EMG signal and are not of interest when observing the time-dependent changes of the MF associated with fatigue. The plot is divided into two sections, corresponding to outputs of the electrodes 63, 64, and 65 on the left side of the back and the outputs of the electrodes 66, 67 and 68 on the right side of the back. The vertical axis represents the MF and the horizontal axis represents time. Quantitative measurements of the time rate of change of the MF of the individual curves is also provided. Linear regression using the method of least squares is used to compute the rate of decrease of the MF. A linear fit to the unfiltered data is chosen since it most consistently represents the time-dependent change of the MF as monitored from the back extensor muscles. The following parameters are investigated by the computer 84: 1) The initial median frequency (IMF) of the curve. This value is obtained by calculating the y-intercept of a straight line regression fit by a "least-squares" method to the MF data. 2) The slope of the regression line for the MF-time function, calculated over the duration of a muscle contraction.
In a preferred application of the analysis system 11, a suitable number of control subjects are first sequentially analyzed in the manner described above to provide a normative control data base. Subsequently, that data base is compared with EMG signal parameters determined by the signal processing system 15 during analysis of a test subject to locate dysfunctional lower back muscles.
In a specific example, twelve patients with a history of chronic back pain were evaluated and compared with a control group of 12 healthy subjects. All participants were male and right-handed. Grouping was determined by the presence or absence of a documented history of chronic back pain. Chronicity was defined as persistent or frequently recurring pain over a period of at least one year. The average duraction of a LBP history was 5.2 years for the patient group (range 1.5-13 years). Patients with acute exacerbation of back pain were excluded. Those subjects with previous back surgery or radiographic evidence of structural disorders of the spine also were excluded.
Following the determination of each subject's MVC and a 5-minute rest, the subject performed three constant-force contractions at 40% MVC, 60% MVC, and 80% MVC for a duration not to exceed 1 minute. A 15-minute rest period between contractions allowed for full recovery of the MF parameters. The summary statistics for IMF and MF slope measures were plotted as shown in FIGS. 7-9 and 10-12, respectively. Each contains data for the longissimus (L1), iliocostalis (L2) and multifidus (L5) muscle detection sites. In each plot, the data from the left and right sides of the back are further subdivided, as are the force levels of the contraction. This graphical representation identifies a number of important results, which are summarized below:
1) The IMF decreases for increasing levels of contractile force. This relationship was present for all muscle groups tested and in both LBP subjects and control subjects.
2) Left-right differences are present in both LBP and control subjects for each of the parameters studied.
3) For any given contraction force level, the average IMF and MF slope are greater at the L5 detection site than at either the L1 or L2 detection sites for both LBP and control subjects.
4) The IMF is significantly lower for LBP subjects compared with control subjects across all force levels of left and right longissimus, L1 electrode location.
5) Low-back pain subjects exhibit significantly higher MF slope values than control subjects at 80% MVC for the L2 and L5 recording sites.
After establishing a data base, the system 11 is used diagnostically to identify by quantifiable and objective methods whether an individual test subject has a muscular component to their low back pain problem. This task involves a comparison of the data base with the results obtained during a test of the test subject in the manner described above. The quantifiable technique also provides a measure of the degree of certainty of the diagnosis. This is accomplished by analyzing the EMG spectral parameter data from a fatigue test using discriminant analysis procedures. This statistical procedure establishes a formula that best separates the data into a Low Back Pain and non-Low Back Pain group. The formula can then be used to determine whether a specific test result is indicative of a muscular disorder associated with a particular low back pain syndrome or whether it is consistent with muscle behavior of the normal, pain-free population. The EMG values from this test are entered into the formula and this formula categorizes the results as either low back pain or non-low back pain based on the data base used to develop the formula. A categorization of "low back pain" would mean that the subject's test resulted in measures of fatigability and muscle dysfunction that are typical of muscle disturbances in specific categories of back pain disorders (e.g. chronic low back pain, herniated intervertebral disc, other structural spinal disorders, etc.). The analysis procedure would also indicate to what degree of accuracy it was classifying a test result.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, in addition to the disclosed technique for determining LBP, the system is readily applicable to evaluating muscle performance in most any situation in which multiple muscle groups (synergists or agonists/antagonists) are concurrently active to produce torque across a joint. The electrode array 13 would be applied to the different superficial muscle groups that function together during a particular fatigue-inducing task. The task would be defined and controlled in exactly the same way as in a back muscle evaluation. That is, the body part being tested would be constrained in a postural restraint device designed specifically for the body segment being tested. Force feedback and timing would be specified. All of the same parameters and methods of EMG and force analysis described for the BAS would be applied to evaluating the pattern of concurrent activity in the muscle groups being monitored. It is to be understood, therefore, that the invention can be practiced otherwise than as specifically described.
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A muscle function analysis system including a base; a restraint device supported by the base and shaped and arranged to receive and immobilize a human body portion retaining a muscle group concurrently activatable to produce a body function; and a support apparatus supported by the base and shaped and arranged to support other portions of the body, the support apparatus adapted to substantially isolate activity in the muscle group from muscle activity in the other body portions. Also included are an electrode array adapted for coupling to the muscle group so as to receive myoelectric signals generated by muscle activity therein and a processing system coupled to the electrode array and adapted to process the myoelectric signals. By isolating muscle activity in a particular muscle group, more useful data is obtained for evaluating muscle dysfunction in the group.
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TECHNICAL AREA
This invention relates to bushings for guiding rotating members such as drills into a workpiece, and more particularly to the extraction of chips from such bushings.
BACKGROUND OF THE INVENTION
Guide bushings play an important role in precision drilling and reaming operations. Typically, guide bushings are annularly shaped elongate elements formed of steel. They are usually fitted into a drill plate that is designed to be securely held adjacent to the workpiece that is to be drilled or reamed. The bore of the bushing acts to ensure straight entry and exit of the rotating member, typically a twist drill or reamer. (While the rotating member is hereinafter referred to as a twist drill or drill, it is to be understood that a bushing made in accordance with this invention could also be utilized with a reamer.)
Shavings of the workpiece are formed by the shearing action of a rotating drill as it advances through a workpiece. These shavings are most commonly referred to as chips. The chips are sometimes continuous, but often in the form of several pieces, depending upon the material being drilled or the design of the drill. During a drilling operation using a guide bushing, problems are encountered when chips rising through the flutes of the drill become compacted in the guide bushing. Compaction of chips in the guide bushing leads to compaction of chips in the workpiece which results in an undesirably rough surface finish of the hole being drilled. The compacting of chips in the bushing has a binding effect on the drill. The binding effect of the chips increases the amount of torque that must be applied to the drill and can lead to drill stalling, excessive drill and bushing wear, or drill breakage. Wearing of the guide bushing results in difficulties positioning the drill in order to form the precise hole required.
Methods currently used in attempts to solve the chip compaction problem generally include backing the drill out of the guide bushing to allow the chips to fall away from the drill and the bore of the bushing, or modifying the drill by altering the dimensions of the drill lands and flutes. Another alternative is to configure the drill plate that holds the bushing so that the bushing is spaced away from the workpiece. The space between the bushing and the workpiece allows most chips to separate and fall off the drill before entering the bushing. The disadvantage of such a drill plate configuration is that a space between the workpiece and the bushing is detrimental to precision drilling. Precise drilling operations require that the bushing be placed in direct contact with the surface of the workpiece for best control of the drill as it enters the workpiece.
In addition to the foregoing attempts to solve the chip compaction problem in guide bushings, attempts have been made to design bushings that avoid the problem. U.S. Pat. No. 1,612,215 issued to Muth describes a bushing that is intended to avoid compaction problems by breaking up chips so that they may either be directed upward or fall down out of the way of the bushing. Again, in order to fall out of the way of the bushing, there must be a space between the bushing and the workpiece, resulting in the previously discussed diminished drilling precision. Muth uses a bushing having a groove extending nearly vertically from one end of the bushing to the other. As the drill is rotated within the bushing, a scissor-like action is created between the leading edges of the drill lands and the bushing groove. This action causes the chips to be chopped or broken up into smaller pieces. The major problem with the Muth bushing is that the chips that are chopped or broken by the groove tend to compact and bind in the flutes of the drill located within the wall of the bushing. This binding impedes the upward movement of the chips through the bushing causing further compacting and binding. Chips are especially prone to bind in the Muth bushing if the bushing is held--as it should for precise drilling--in contact with the workpiece. In this case, all of the broken chips must be forced through the bushing since they are unable to fall away before entering the bushing. Thus, Muth does not completely solve the chip compaction problem of earilier bushings. Furthermore, the above-described scissor-like action between the groove and the drill will cause rapid wearing of the drill.
For precision drilling it is also to use as long a bushing as possible since a longer bushing provides greater control of a drill positioned within the bushing's bore. The previously mentioned compaction problem limits the length of bushing that can be utilized since the longer the bushing the greater the chance that compaction will occur as the chips travel up the length of the bushing. Most bushings commonly used today utilize a bore length that is approximately two to three times the internal diameter of the bore. This length is selected so that the bushing can adequately guide the drill in a straight line, without being so long as to aggravate the chip compaction problem.
This invention provides a bushing that effectively removes the chips from the workpiece while avoiding the compaction problems just described. Due to the effectiveness of the chip removal capability of a bushing made in accordance with this invention, the bushing may be placed in direct contact with the workpiece and be significantly longer than currently used bushings. Additionally, the bushing of this invention obviates the need for the time consuming process of backing the drill out of the bushing during the drilling operation.
SUMMARY OF THE INVENTION
In accordance with this invention, a bushing is provided for guiding a rotating member into a workpiece. The bushing includes a housing having a substantially cylindrical, longitudinal bore. The bushing has a first end that defines a plane substantially perpendicular to the longitudinal axis of the bore. The first end is designed to be placed adjacent to the workpiece during operation of the rotating member. A groove is scored in the wall of the bore and extends through the bore from the first end to the second end of the bushing in a counterclockwise helix. The slope of the groove with respect to the circumference of the bore is less than 50%.
In accordance with other aspects of this invention, the width of the groove is between 25%-50% of the product of the slope and the circumference of the bore.
In accordance with still other aspects of this invention, the cross-sectional shape of the groove is defined by a first surface and a second surface, the plane of the first surface at any given point along the circumference of the bore being substantially perpendicular to a plane that is tangent to the circumference at that given point, the plane of the second surface at any given point along the circumference of the bore obliquely intersecting a plane that is tangent to the circumference of the bore at that given point, at any given point along the groove the first surface is oriented between the second surface and the first end of the bushing.
In accordance with further aspects of this invention, the interior wall of the bushing is chamfered at the first end of the bushing to eliminate any sharp edges that are formed by the groove near that end.
This invention further provides a bushing where the internal groove is sloped to avoid any scissor-like action between the rotating drill and the groove, while guiding the chips through the bushing away from the workpiece without the undesirable chopping or breaking of the chips. The bushings made in accordance with this invention will work in conjunction with any standard drill, thus obviating the need for modification of the drill. Furthermore, since the chips are moved up and through the bushing instead of dropping out of it, there is no need to space the bushing a distance away from the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages of this invention will become more readily appreciated as the same becomes better understood from the following detailed description when considered in combination with the accompanying drawings, wherein:
FIG. 1 is an isometric view, partially in section, of bushing made in accordance with the invention;
FIG. 2 is a longitudinal cross-sectional view of a bushing formed in accordance with the invention; and
FIG. 3 is an enlarged detail of a part of the cross-section illustrated in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While, as illustrated in FIG. 1, a bushing 12 formed in accordance with the invention may have a housing that is cylindrical in shape, it is to be understood that the exterior shape of the bushing housing does not form part of the invention. Rather, the exterior configuration of the bushing housing can take on any desired shape as determined by the environment in which the invention is to be utilized. The bushing 12 includes a bore 20 that extends through the entire length of the bushing from a first end 22 to a second end 24. The wall 30 of the bushing that is defined by the bore 20 has a continuous groove 18 that extends from the first end 22 to the second end 24. The groove 18 is in the configuration of a counterclockwise helix extending from the first end 22 to the second end 24. Thus, the groove has a positive slope with respect to the circumference of the bore. The direction and slope of the groove in the bore can best be appreciated by scrutiny of FIG. 1, wherein traveling from any point such as A on the groove 18 in a counterclockwise direction (with respect to the first end) to the point B on the same groove will result in point B being slightly more distant from first end 22 than is point A. This positive increase in distance divided by the distance between points A and B will result in a measurement of the slope of the groove (a dimensionless parameter) with respect to the circumference of the bore. The significance of the slope characteristics of the groove is discussed in detail below.
FIG. 2 shows bushing 12 mounted in an opening in a drill plate 14. The bushing is mounted such that its first end 22 impinges on a workpiece 16 when the drill plate is positioned against the workpiece. A drill 10 having a diameter approximately equal to the diameter of the bore 20 is positioned within the bore 20. The drill is a conventional twist drill with flutes 33 and lands 35. The leading edges 32 of the lands 35 slide around the interior wall of the bushing as the drill is rotated in a clockwise direction.
In the preferred embodiment, the cross-sectional shape of the groove 18 (see FIG. 3) is defined by first and second surfaces 26 and 28. The first surface 26 of the groove defines an inclined plane which, at any given point along the circumference of the bore (e.g., point C in FIG. 3), is substantially perpendicular to a plane that is tangent to the circumference at that given point. The second surface 28 defines an inclined plane which, at any given point along the circumference of the bore (e.g., point C' in FIG. 3), obliquely intersects a plane that is tangent to the circumference of the bore at that same point. The first surface 26 and the second surface 28 intersect at a point 27 away from the interior wall 30 of the bushing. The angle of intersection between these surfaces is designated in the drawing as α. The first and second surfaces are arranged with first surface 26 being positioned between the second surface 28 and first end 22 at any point on the groove 18. The radial distance between the interior wall 30 and the point 27 in the groove defines the depth "d" of the groove.
The distance between any two longitudinally aligned points on the groove (points C and D in FIG. 3) is defined by the selected slope of the groove 18 multiplied by the circumference of the bore. The multiplicative inverse of the actual value of this distance is commonly known as the "pitch" of the groove in terms of grooves per unit of length.
The width of the groove (i.e., the distance between points C and C' in FIG. 3) is defined by the selected values for angle α and the depth of groove d. The width of the groove can also be conveniently stated in terms of the pitch described above. The preferred values for the above parameters are discussed shortly.
As the drill 10 is rotated it shaves chips (not shown) from the workpiece 16. As the chips travel up the flutes 33 of the drill, the centrifugal force created by the rapid rotation of the drill tends to propel the chips outwardly from the drill. Portions of the chips are propelled into the groove 18 by the rotating drill causing the entire chip to be urged upwardly along the length of the groove 18 by the positively sloping surface 26 of the groove.
Preferably, the slope of the groove 18 lies between 1.3% and 4.5%. While this range of groove slope is preferred, acceptable chip extraction is accomplished by grooves with slopes as great as 50%. Beyond a 50% slope, the first surface 26 of the groove 18 approaches a parallel relationship with the leading edge 32 of the drill lands 35. When this relationship occurs, the chips are chopped between that leading edge 32 and the first surface 26 of the groove 18. As noted earlier, chopped or broken chips tend to rapidly compact in the bushing, binding the drill. This is avoided by a bushing made in accordance with this invention, i.e., a bushing made in accordance with the invention does not chop or break up drill chips. Rather, the gradually inclined surface of bushings formed in accordance with the invention guide chips through the bushing as the drill rotates.
It is necessary to score the interior wall of the bushing with the groove 18 so that a certain portion of the interior wall 30 remains intact for proper guiding of the drill. In the preferred embodiment, intersection angle α and groove depth d are selected so that the width of the groove will be approximately 40% of the distance between two corresponding points (C and D in FIG. 3) on longitudinally aligned portions of the groove 18. That is, the groove width is selected to be 40% of the product of the slope and the circumference of the base. As noted earlier, the desired groove width can also be defined as 40% of the multiplicative inverse of the value of the groove's pitch. Thus, 60% of the area of interior wall 30 of the bushing will remain for precise guiding of the drill. The actual values of α and d will vary depending upon the slope chosen and the diameter of the bushing used. While 60% is preferred, the amount of the interior wall surface area remaining after the groove is scored can vary considerably without interfering with the chip extraction properties of the bushing.
While the groove can extend completely to the first end 22 of the bushing, preferably, the first end 22 of the bushing is chamfered to provide a continuous beveled surface 34 between the workpiece 16 and the groove 18. The chamfering eliminates any sharp blade-like edges that are formed when a groove is allowed to taper completely to the edge of the bushing in which it is formed. Elimination of such edges reduces the possiblity of a sharp groove edge cutting into a chip. Thus, chamfering enhances the guiding (as opposed to chopping) characteristics of the groove.
While a preferred embodiment of the invention has been illustrated and described, it is understood that various alterations, substitutions and equivalents and other changes can be made without departing from the spirit and the scope of the invention, which is defined by the appended claims.
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Disclosed is a bushing (12) for guiding a rotating member such as a drill (10) into a workpiece (16). Scored in the interior wall of the bushing bore is a groove (18) in the form of a counterclockwise helix having size and slope characteristics that provide effective removal of the shavings or "chips" from the interior portion of the bushing bore as the drill cuts into the workpiece.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates to dispensers for volatile materials such as insect control agents, scents and the like. In particular, the invention relates to dispensers that simultaneously dispense a volatile from a burnable coil and provide illumination.
There are a number of known dispensers for volatile ingredients that provide the additional feature of lighting the surrounding area. For example, U.S. Pat. No. 6,033,212 discloses a lantern that burns fuel for light. The flame is contained in a glass, transparent globe that is covered at its top. The cover has a slot that receives a pad impregnated with a volatile material having an insect control agent. The waste heat from the burning fuel exits the globe through the slot, which heats the pad and releases the volatile.
WO 00/78135 is another approach for mounting an insect repellent impregnated pad adjacent a flame. However, the types of pads used with these designs can be somewhat costly to produce, and in some cases place constraints on the type of active that can be used.
Citronella candles also provide both light and an insect repellent, and do so relatively inexpensively. However, exposed candle flames can be snuffed by the wind, and not all actives can survive being directly exposed to the candle flame when the candle wax is burnt.
Insect (e.g. mosquito) coils are also well known. They are typically a spiral coil of compressed, largely pulp material which has been impregnated with an insect control active. The coils can alternatively (or in addition) contain other active ingredients having different characteristics, such as aromatics or disinfectants. These coils are extremely inexpensive, and due to their slow burn rate provide overnight protection. They are particularly desirable because of their ability to disperse a variety of very effective insecticidal actives, at low cost.
However, these coils can be snuffed out if they are exposed to too much wind. Thus, it has been proposed to house them in apertured pots that can prevent outside gusts from directly reaching the coil. See e.g. U.S. Pat. No. 6,061,950. These pots also have the benefit of inhibiting persons from accidently bumping into these coils while they are burning. However, these pots dispense active at a slower rate than a coil that is directly open to the air, thus requiring them to be started somewhat earlier before using an area that might be insect infested.
Some other structures have been proposed to dispense insecticidal control agents by mounting materials containing them adjacent a heat source. See e.g. U.S. Pat. Nos. 692,075, 2,742,342 and 3,279,118. However, to date the art has not proposed a way to mount a mosquito coil in a lamp in a way in which the lamp flame assists in the dispersion of the vapors from the coil, without causing the entire coil to start burning out of sequence. Thus, there is still a need for an improved combined lamp and volatile dispensing device.
SUMMARY OF THE INVENTION
In one aspect the invention provides a lamp for dispensing a volatile material. There is a flame source, a chimney mounted around the flame source, a support mounted to the chimney above the flame source, and a burnable coil having a volatile material. The coil is positioned above the flame source so as to be exposed to heat therefrom.
In preferred forms the support is a plate having an opening (preferably a plurality of openings) there through. The support may also have a raised element (a spade) for supporting the coil, with the coil being mounted adjacent an upper opening of the chimney, vertically above the flame source. The chimney can have a radially inwardly extending ledge on which the support rests.
There is also preferably a skirt-like base upon which the flame source and chimney are mounted, an upper surface of the base having a recess for receiving a lower edge of the chimney. The base includes a plurality of openings positioned radially outside of the recess and a plurality of openings positioned radially inward of a radially outer edge of the recess. Air may pass inward through the radially outside openings, and then up through the chimney via the radially inward openings.
In other preferred forms, the recess includes a central depression for receiving the flame source, the flame source is a cup containing a candle, and the cup has a bottom with a recess sized to receive an upwardly extending mounting post of the cover. The support can optionally have a collector tray suspended below a top wall opening of the support so as to collect ashes, and/or the support top wall can include a recessed central section having no vertical openings there through, and a radially outward section having an opening there through.
The additional heat which builds up due to air flow through outer peripheral openings can be taken advantage of. There can be a faster release of active near the outside of the coil (as that portion is exposed to more heat). This enables an area to be adequately treated very soon after the device is lit. If desired, this effect can be enhanced by providing a higher concentration of active (per unit mass) near the outer periphery, and/or two different types of active (the more potent being on the outer periphery).
In another aspect, the invention provides a kit providing a replacement coil and candle for lamps of the above kind. A cup for housing the candle (e.g. one which interfits with the base) may also be supplied with the kit.
Still another aspect of the invention provides a method for controlling flying insects. One provides a lamp of the above kind, lights the coil and the flame source, and permits volatizable material to pass from the coil and out the chimney so as to expose an area to the volatizable material. The volatizable material is an insect control agent.
Preferred insect control agents are insecticides, repellents, and insect growth regulators. A wide variety of insect control agents of this type are known. The preferred ones are those which have previously been incorporated into mosquito coils, such as d-cis/trans allethrin.
Because the lamp provides both light and insect control, and does so even in windy environments, it is particularly suitable for use during a backyard barbecue, around sunset. The device is designed to utilize extremely inexpensive consumables (e.g. standard conventional burnable coils; standard wax candles).
The flame source serves multiple purposes. It provides light, while also creating convection to draw outside air past the burning coil. The air/volatile mix is then propelled out the top of the chimney to widely and quickly disperse the active.
The foregoing and other advantages of the present invention will appear from the following description. In that description, reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration preferred embodiments of the invention. These embodiments do not represent the full scope of the invention. Rather, reference should be made to the claims for interpreting the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away perspective view of a lamp of the present invention;
FIG. 2 is a cross sectional view thereof, taken along line 2 — 2 of FIG. 1;
FIG. 3 is a partial exploded perspective view thereof, with a portion of the chimney cut away;
FIG. 4 is a partial cross sectional view, similar to FIG. 2, albeit of an alternative embodiment;
FIG. 5 is a cut-away perspective view of another alternative embodiment; and
FIG. 6 is a cross sectional view thereof taken along line 6 — 6 of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-3 of the present application, a lamp 10 includes a base 12 supporting a removable, open-ended chimney 14 and a removable candle 16 . The chimney 14 can be made of glass or, preferably, a heat-resistive plastic, such as a V-O flame rated polycarbonate, commercially available under the name “Makrolon® 6455” from Bayer Corporation. The chimney 14 can be translucent to allow light to pass there through while obscuring the inside of the chimney, or alternatively could be transparent.
The chimney 14 attaches to the base 12 with bayonet style locking tabs/legs 18 formed on the lower edge of the chimney 14 that mate with locking slots 20 formed in the top of the base 12 . The legs 18 have bent feet 22 (see FIG. 2) that pass through an enlarged area of each slot 20 , but cannot pass through a narrow area of each slot 20 . Thus, the chimney 14 is locked to the base 12 when the legs 18 are rotated into the narrow area of the slots 20 .
The base 12 has a skirt 24 extending around its periphery and having a plurality of outer ventilation openings 26 spaced apart around the wall 24 . The base 12 also has a recessed top wall 28 with a plurality of spaced inner openings 30 . Thus, the outer openings 26 are open to the outside air and the inner openings 30 are at the interior of the chimney 14 so that air can pass into the base 12 and up into the chimney 14 . The top wall 28 is formed with a circular shelf 32 against which rests the bottom of the chimney 14 . At the center of the top wall 28 , and thus the base 12 , is an upwardly extending mounting post 34 for mounting the candle 16 .
The candle 16 is contained in a candle cup 36 having a floor 38 and a cylindrical wall 40 defining an open top. The candle cup 36 is preferably made of a V-O flame rated polycarbonate material. The candle 16 is preferably a conventional cylindrical paraffin wax candle having a wick 42 held at the bottom by a wick clip 44 disposed in a depression 46 in the cup floor 38 to restrict movement of the candle 16 . A downwardly opening cylindrical socket 48 extends from the center of the cup floor 38 as does a cylindrical cup support member 50 at the periphery of the cup floor 38 . The support member 50 is at least as tall as the socket 48 to allow the candle cup 36 to sit upright on top of the base 12 . The cup socket 48 engages the mounting post 34 to grip the candle cup 36 to the base 12 so that the candle 16 does not tip over or move with respect to base 12 . The lower half of lamp 10 is preferably identical to the FIGS. 16-20 embodiment of WO 00/78135. Thus, further details regarding its preferred construction can be obtained by reading that publication.
In accordance with the present invention, the chimney 14 preferably includes a circular ledge 52 extending radially inwardly into its interior on which rests a coil support 54 supporting a burnable coil 56 . The burnable coil 56 is impregnated with (e.g. the material is mixed with, coated with or otherwise carries) a volatile material. Our preferred insect control active is d-cis/trans allethrin. The coil 56 is conventional (e.g. has a spiral configuration and is otherwise of the type disclosed in U.S. Pat. No. 6,066,950, e.g. see U.S. Pat. No. 5,657,574), the disclosures of which are incorporated by reference herein.
The coil support 54 that is shown is a disk-shaped body having a circumferential lip 58 extending radially outward beyond an annular skirt 60 . The lip 58 rests on the chimney ledge 52 to mount the coil support 54 near the top opening of the chimney 14 . The coil support 54 has a top wall 62 with a spade 64 extending up from its center. The spade 64 is sized to fit in a recess 66 in a mounting end 68 of the coil 56 . The spade 64 thus can support the coil 54 spaced off the top wall 62 to reduce the occurrence of a burning coil 54 being inadvertently snuffed out during use due to losing heat to the support.
The wall 62 also has a plurality of ventilation openings 70 there through allowing air to pass through the coil 56 and exit the chimney 14 . The coil support 54 is preferably made of metal.
The lamp 10 is used by removing the chimney 14 temporarily to light the candle 16 . The chimney 14 then re-attached to the base and the coil 56 is placed onto the spade 64 and its free end is lit. A convective air flow is generated by the heat from the candle 16 , which pulls outside air into the base 12 through the openings 26 and up through openings 30 into the chimney 14 , past the candle 16 . The air stream is then drawn up through the chimney 14 and through the openings 70 in the coil support 54 past the burning coil 56 , where the air stream mixes with the volatile material released from the burning coil 56 . The volatile laden air then passes out through the top of the chimney 14 to the surrounding outside air.
The openings 26 and 30 in the base 12 increase air flow through the chimney 14 to provide the proper ventilation to the candle 16 and the coil 18 . The chimney draft does not extinguish the coil 18 , in part due to the heat from the candle vapors transferred to the coil through the coil support 54 .
The outside air pulled through the base 12 is cool relative to the air surrounding the open flame of the candle 16 . Thus, the surrounding lower wall of the chimney 14 is cooled by the air flow from below.
FIG. 4 shows a partial cross-sectional view of an alternate embodiment of the dispenser lamp. Elements of this embodiment similar to those described above are referred to herein with similar reference numerals, albeit with the suffix “A”. The elements of this embodiment are identical to the embodiment described above, except for an ash catcher tray 100 . Specifically, the dispenser lamp 10 A includes a base (not shown) mounting a candle (not shown) and a translucent chimney 14 A. The chimney 14 A has an inner ledge 52 A extending into its interior on which rests the coil support 54 A supporting a burnable coil 56 A of the type described above.
The disk-shaped coil support 54 A has a circumferential lip 58 A extending radially outward beyond an annular skirt 60 A. The lip 58 A rests on the chimney ledge 52 A to mount the coil support 54 A near the top opening of the chimney 14 A. The coil support 54 A has a top wall 62 A with a spade 64 A extending up from its center supporting the coil 54 A off the top wall 62 A. The top wall 62 A has a plurality of ventilation openings 70 A there through allowing air to exit the chimney 14 A and pass through the coil 56 A.
The catcher tray 100 is suspended beneath the openings 70 A in the top wall 62 A by a hanger member 102 .
The tray 100 has a circular bottom 104 and an upwardly extending peripheral wall 106 . The tray 100 can catch and contain partially burnt segments of the coil 56 A that may fall through the openings 70 A in the top wall 62 A.
The tray 100 reduces mess and more importantly prevents coil cinders from falling onto the candle. The tray 100 can be molded integrally with the hanger member 102 and top wall 62 A (as shown), or these elements can be separately formed and then connected in any suitable manner, such as a snap fit or threaded fastener. If separately formed, the hanger and/or the tray could be made of metal. In any event, the tray 100 will also serve to disrupt the flow path of the air stream though the chimney 14 A. In particular, it will force the air column in the center of the chimney 14 A to flow outwardly to pass around its periphery. The air will then flow back toward the center of the chimney 14 A, up through the openings 70 A in the coil support 54 A and out of the chimney 14 A. This mixes the heat effect across the radius of the chimney opening, thereby providing for more uniform heating.
FIGS. 5 and 6 illustrate another alternate embodiment of the dispenser lamp. Elements of this embodiment similar to those described above are referred to herein with similar reference numerals, albeit with the suffix “B”. The elements of this embodiment are identical to the embodiment described above, expect for the coil support. Specifically, the dispenser lamp 10 B includes a base 12 B mounting a candle 16 B and a translucent chimney 14 B identical to that of the first described embodiment. The chimney 14 B has an inner ledge 52 B extending into its interior on which rests the coil support 54 B supporting a burnable coil 56 B of the type described above.
The support 54 B forms a shallow tray having a bottom 110 and an upwardly extending annular wall 112 from which extends radially outward an annular flange 114 that rests on the chimney ledge 52 B to mount the coil support 54 B near the top opening of the chimney 14 B. The bottom 110 has a spade 64 B extending up from its center supporting the coil 54 B in the air. The tray can catch and contain burnt segments of the coil 56 B that fall to reduce mess and prevents embers from falling onto the candle. The flange 114 has a plurality of ventilation slots 70 B there through allowing air to exit the chimney 14 B and pass around the periphery of the coil 56 B. The tray will force the air column in the center of the chimney 14 B to flow outwardly to the slots 70 B past the periphery of the coil 56 B and out of the chimney 14 B.
The invention thus provides a device particularly suitable for use as a combined outdoor lantern and insect control device. The lantern utilizes conventional burnable coils, and in a preferred form inexpensive candles. Given the exposure of the coil to the flame heat, coil burning is somewhat more rapid than is conventional for coils. Thus, this device provides quicker coverage, but may be more suitable for use at a four hour cookout rather than as an overnight camping light.
The candle is preferably made of paraffin wax by a process of bonding small wax granules in a compression mold. This technique is well known for producing candles with consistent dimensions and densities. The preferred candle weighs from 15 to 20 grams with a diameter of about 37 mm and has an overall height of about 20 mm at its center. A candle of this size will burn for about 4 hours.
Exhausted coils are replaced by removing any remaining non-burnt section of the coil, emptying the ash and attaching the mounting end of the replacement coil from the kit to the spade of the coil support. Exhausted candles are replaced by removing the chimney from the base, removing the old candle cup and attaching the replacement candle from the kit to the base by pressing the socket onto the mounting post. In a preferred form of the kit, the candle will also have a candle cup which houses it.
Preferred embodiments of the invention have been described above. However, these embodiments are intended to be illustrative, and not exhaustive. For example, while the dispenser is shown and described for use with an insect control active, it could instead be used to dispense aromatics, disinfectants or other volatiles. Thus, the claims should be looked to in order to assess the full scope of the invention.
INDUSTRIAL APPLICABILITY
The present invention provides an apparatus providing illumination and dispensing volatiles useful, among other things, to repel insects.
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A lamp dispenses a volatile material, such as an insecticide, from a burnable coil. There is a flame source mounted on a base, a chimney, a coil support, and a burnable coil supported on the coil support above the flame. The flame provides light, heats the coil to some extent, and provides convection for dispersal of the volatile. A kit for replacing the candle and coil consumed during use is also disclosed, as are methods of use of such lamps.
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This application is a continuation of application Ser. No. 09/184,621, now U.S. Pat. No. 6,062,275, filed on Nov. 2, 1998, the disclosure of which is incorporated fully herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to vehicular maintenance and, more particularly, to systems and methods for replacing transmission fluid.
For the past several years, substantial attention has been directed to the field of transmission fluid changers. Such systems are useful, for example, in draining the oil from a vehicle transmission system in order to replace the transmission filter and/or to completely replace the old transmission fluid with new fluid. Existing transmission fluid changers such as those described in U.S. Pat. Nos. 5,447,184, 5,472,064, 5,318,080 and 5,370,160 require substantial human intervention during the fluid exchange process.
However, there is an intense need within the industry to provide a more efficient, less time consuming and a more user-friendly system for transmission fluid replacement that substantially reduces human intervention.
In view of this necessity, it is believed that those skilled in the art would find automated systems and methods for draining, filling and changing of transmission fluid to be quite useful.
SUMMARY OF THE INVENTION
In a first separate aspect, the present invention is directed to an apparatus for replacing waste fluid with clean fluid. The apparatus includes a waste tank for receiving the waste fluid from a first port, a clean tank containing the clean fluid, a processor coupled to first and second sensors, and a pump coupled to the processor for pumping the clean fluid into a second port. The processor measures the waste fluid level via the first sensor and measures the clean fluid level via the second sensor. Based on these measurements, the processor controls the pump's speed.
In a second separate aspect, the apparatus of the first separate aspect may also include a solenoid switch that includes first and second ports and a plurality of paths for transferring the clean and waste fluids.
In a third separate aspect of the invention, the paths in the solenoid switch of the second separate aspect may be selected via the processor by measuring the fluid pressure at each solenoid switch port.
In a fourth separate aspect, the apparatus of the first separate aspect may also include a disposal pump coupled to the processor for pumping the waste fluid from the waste tank into a disposal tank.
In a fifth separate aspect, the present invention is directed to a method of replacing waste fluid with clean fluid. The method comprises the step of providing a waste tank for receiving the waste fluid from a first port and a clean tank containing the clean fluid. The method further includes the step of coupling a processor to a first sensor, a second sensor and a pump for pumping the clean fluid into a second port. The method also includes the steps of measuring the waste fluid via the first sensor using the processor and measuring the clean fluid via the second sensor using the processor. And the method includes the step of controlling the pump using the processor based on the measuring steps.
In a sixth separate aspect, the present invention is directed to a method of replacing waste fluid in a system with clean fluid. The method includes the steps of draining a portion of the waste fluid from the system into a waste tank, measuring the amount of the drained fluid with a processor, and replacing the drained fluid with clean fluid from a clean tank using a pump that is controlled by the processor.
In a seventh separate aspect, the method of the sixth separate aspect may include the steps of withdrawing the remaining portion of the waste fluid plus the clean fluid in the system into the waste tank, gauging the amount of the withdrawn fluid using the processor, feeding the system with the clean fluid using the pump, gauging the amount of fluid in the feeding step using the processor, and controlling the pump such that the withdrawing step proceeds at substantially the same rate as the feeding step.
In an eighth separate aspect, the method of the seventh separate aspect may include the step of terminating the process when the clean fluid reaches a low level in the clean tank.
In a ninth separate aspect, the method of the seventh separate aspect may include the step of pumping an extra amount of the clean fluid into the system.
Accordingly, it is an object of the present invention to provide apparatus and method of replacing one fluid with another in a system, such as a vehicle transmission system.
Other objects and features of the present invention will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an automated system for replacing transmission fluid;
FIG. 1A is an exploded view of a solenoid switch of the system of FIG. 1;
FIG. 2 is a pictorial view of a control panel of the system of FIG. 1; and
FIG. 3 is a pictorial view of the system of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning now to the drawings, FIG. 1 provides a schematic illustration of a fluid changer system 100 according to a preferred embodiment of the present invention. As shown, the system 100 includes a clean fluid tank 110 , a waste fluid tank 120 , a clean pump 130 , a waste pump 140 , a solenoid switch 160 , a disposal tank 170 and a printed circuit board (PCB) 150 with an on-board microprocessor (not shown), a clean tank pressure sensor 151 and a waste tank pressure sensor 152 .
The clean tank 110 contains fresh fluid that is supplied to a vehicle transmission system (not shown). The clean tank 110 also includes a clean tank tube 112 with one end inside the clean tank 110 and the other end extending out and being connected to a clean fluid pump 130 . As shown, the clean tank tube 112 includes a filter 116 for purifying the fresh fluid before reaching the clean pump 130 .
The clean pump 130 pumps the fresh fluid out of the clean tank 110 through the clean tank tube 112 and filter 116 into the clean pump outlet tube 132 . The clean pump outlet tube 132 transports the fresh and purified fluid to the solenoid switch 160 , the operation of which is discussed below.
Turning back to the clean tank 110 , the clean tank 110 further includes a port 115 for withdrawing fluid from or adding fluid to the clean tank 110 . The clean tank 110 also includes a clean sensor tube 114 that extends out of the tank 110 and is coupled to the PCB 150 , so the on-board microprocessor can measure the fresh fluid pressure in the clean tank 110 .
As illustrated, the PCB 150 also receives a waste sensor tube 124 from the waste tank 120 for the purpose of measuring the waste fluid pressure in the waste tank 120 . The waste tank 120 also includes a waste tank tube 122 which extends out of the waste tank 120 and a waste filter 126 to reach a waste pump 140 for pumping out the waste fluid. The waste fluid is passed through the filter 126 so to prevent the impurities of the waste fluid from interfering with the proper operation of the waste pump 140 .
As seen in FIG. 1, the waste pump 140 pumps the waste fluid out via the waste tube 122 and pumps the waste fluid into the disposal tank 170 via a disposal tube 145 .
Referring back to the waste tank 120 , the waste tank 120 receives the waste fluid through a waste inlet port 127 connected via a waste inlet tube 128 to the solenoid switch 160 .
In a preferred embodiment, the solenoid system 160 comprises three solenoid valves (not shown) that are controlled via the PCB 150 microprocessor in accordance with the modes of operation described below. The three solenoid valves are set or reset according to each mode of operation to create the desirable fluid paths, such as fluid paths 161 , 163 , 165 , 166 and 167 , as shown in FIG. 1 A.
In addition to the clean pump outlet tube 132 and the waste inlet tube 128 , the solenoid switch 160 is also connected to a first hose 162 and a second hose 164 for receiving the waste fluid from the vehicle and replacing the waste fluid with fresh fluid from the clean tank 110 . Connected to the first hose 162 is a first hose pressure sensor 168 that is electrically connected to the PCB 150 via the first sensor wire 154 . Similarly, connected to the second hose 164 is a second hose pressure sensor 169 that is electrically connected to the PCB 150 via the second sensor wire 153 .
In a preferred embodiment, the cooler line (not shown) of the vehicle is disconnected and reconnected at one end through the first hose 162 and at the other end through the second hose 164 . For example, when the recirculating path 167 is established within the solenoid system 160 , the transmission fluid may flow from one end of the cooler line through the first hose 162 through the recirculating path 167 and the second hose 164 to reach the other end of the cooler line. While the vehicle engine is operating, the vehicle transmission pump (not shown) pumps the transmission fluid through the cooler line. The transmission fluid, depending upon the fluid flow direction, enters either from the first hose 162 or the second hose 164 . Regardless of the fluid direction, however, the vehicle's transmission fluid circulates through the path 167 and back to the vehicle system.
To utilize the system 100 for replacing the waste fluid, the vehicle cooler line is disconnected while the vehicle's engine is off. The cooler line is connected to the first hose 162 at one end and the second hose 164 at the other end. At this point, the system 100 is powered on. The default setting for the solenoid system is the recirculating path 167 . Accordingly, when the vehicle engine starts, the transmission fluid is pumped through the solenoid system 160 .
Now, referring to FIG. 2, a computer control panel 200 of a preferred embodiment is shown. In a preferred method of replacing the waste fluid, the process may begin by pressing the drain button 220 . The drain pan function drains the waste fluid from the vehicle so the vehicle transmission pan (not shown) can be dropped in order to change the transmission filter (not shown).
By pressing the drain button 220 , the on-broad microprocessor begins the process by turning on the drain LED 222 to indicate that the drain process has begun. If the vehicle's engine is off, the on/start LED 212 blinks to indicate that the engine must be turned on so the vehicle's transmission pump starts pumping the waste fluid through the solenoid system 160 . Once the engine is turned on, the on/start LED 212 stops blinking and stays on continuously.
At this point, the on-board microprocessor determines the transmission fluid direction in the first and second hoses 162 and 164 in order to set up the solenoid valves and select the proper path inside the solenoid system 160 . This task is accomplished by sensing the fluid flow in the first and second hoses 162 and 164 via their respective pressure sensors 168 and 169 . According to the sensed pressures, the microprocessor determines the waste fluid circulation direction in the cooler line. Also, based upon the pressures sensed from the pressure sensor tubes 114 and 124 , the microprocessor determines the amount of fluid in each tank. The waste tank 120 being substantially empty has a lower fluid pressure than the clean fluid tank 110 containing fresh fluid to be pumped in.
Having determined the fluid flow direction and the location of the tanks 110 and 120 , the solenoid valves are set such that the proper path is taken. For example, if the fluid enters the solenoid system 160 through the first hose 162 , the path 161 is set up such the waste fluid is directed into to the waste tank 120 through the waste inlet tube 128 through the waste inlet port 127 . On the other hand, if the fluid flow direction is from the second hose 164 , the solenoid switch is set up such that the path 166 is selected.
Before directing the waste fluid to the waste tank 120 , using the pressure sensor 152 the present fluid level of the waste tank 120 is captured by the microprocessor for future determination of the amount of drained waste fluid. In a preferred embodiment, the fluid pressure in the waste tank 120 is checked every seven seconds to determine whether the waste fluid is flowing and whether the waste tank 120 is being filled. If the waste tank 120 is not being filled, the drain LED 222 goes off, the solenoid switch valves are set to assume the recirculate path 167 , the engine off/stop LED 214 turns on, the engine on/start LED 212 flashes, and the sounder sounds until the stop button 270 is pressed.
However, if these error conditions do not occur, the transmission fluid is sufficiently drained so the vehicle's transmission pan (not shown) can be dropped. The solenoid valves are set such that no more fluid flows from the first and second hoses 162 and 164 , and the low vehicle fluid LED 224 is turned to indicate that the drain process is complete.
At this step, the vehicle transmission pan may be dropped and the transmission filter may be changed without transmission fluid flowing from the transmission system. After the filter has been replaced and the drain pan is placed in its original position, the drained waste fluid may be replaced by pressing the fill button 240 on the control panel 200 .
At the fill step, the PCB 150 determines the volume of the drained waste fluid based on the captured fluid level in the waste tank 120 at the start of the drain process and the current fluid level in the waste tank 120 . Those of ordinary skill recognize that the fluid level may be calculated based on the sensed pressure via the pressure sensor 152 . Knowing the drained volume, the PCB 150 activates the clean fluid pump 130 to pump an equal volume of fresh liquid from the clean fluid tank 110 to the transmission system. In other words, enough clean fluid is pumped out such that pressure sensors 151 and 152 reach the same pressure balance as before the drain process started.
The PCB 150 also sets up the solenoid valves such that the fluid carried via the clean pump outlet tube 132 is routed correctly. If the first hose 162 was determined to be the in-hose—as determined at the beginning of the draining process—the solenoid system 160 is set up to select path 165 so the clean fluid reaches the first hose 162 and from there into the transmission. On the other hand, if the second hose 164 is the in-hose, the path 163 is taken so the clean fluid reaches the second hose 164 .
When the fill button 240 is pressed, the fill indicator LED 242 goes on indicating that a fill process is in progress. If the fill button 240 is pressed only once, an amount equal to the drained fluid volume is pumped back into the transmission system. However, each additional time that the fill button 240 is pressed the system is instructed to pump an extra half a quart of fluid into the transmission system.
Accordingly, if the fill button 240 is pressed twice instead of once, the +½ LED in box 246 comes on indicating that an extra half a quart will be pumped into the transmission system. If the fill button 240 is pressed three times, the +1 LED in box 246 comes and one extra quart is pumped in. If the fill button is pressed eight times, the three LEDs +½, +1 and +2 in box 246 come on and 3.5 extra quarts of fluid will be pumped in. The fill indicator LED 242 goes off when the fill process is complete.
The next step of the process may begin by pressing the change fluid button 230 on the control panel 200 . At this step, the system 100 pumps clean fluid into the vehicle at substantially the same rate as pumping waste fluid out of the transmission system. Before the change fluid button 230 is pressed the first and second hoses 162 and 164 must be connected to the cooler line of the vehicle. The solenoid system is in its default state, i.e., the recirculation path 167 is in effect.
Once the change fluid button 230 is pressed, the change fluid process starts. If the clean fluid level in the clean tank 110 is low, the low clean fluid LED 244 starts flashing and the sounder starts sounding until the stop button 270 is pressed. Also, if the waste tank 120 is over ¼ full, the empty waste LED 260 starts flashing and the sounder sounds until the stop button 270 is pressed. If the preliminary conditions are correct, the fluid levels in the clean tank 110 and the waste tank 120 are measured via the pressure sensors 151 and 152 , respectively. In case the low clean fluid LED 244 is on, the clean fluid tank must be filled.
According to the flow direction-sensing process explained above, the system 100 determines the in-hose and the out-hose directions between the first and second hoses 162 and 164 , and also determines the clean pump outlet tube 132 and the waste inlet tube 128 via pressure sensors 168 , 169 , 151 and 152 , respectively. Once the flow direction is determined the solenoid valves in the solenoid system 160 are properly set to pump in the clean fluid and receive the waste fluid. For example, if the second hose 164 is the out-hose, path 163 is selected so that clean fluid flows from the clean fluid outlet tube 132 to the second hose 164 and into the transmission system. In this case, path 161 is also selected so the waste fluid being pumped by the vehicle engine flows from the first hose 162 through path 161 into the waste inlet tube 128 and the waste inlet port 127 .
However, if the first hose 162 is the out-hose, path 165 is selected so the clean fluid flows from the clean fluid outlet tube 132 into the first hose 162 and into the transmission system. Naturally, path 166 is also selected so the waste fluid flows from the second hose 164 to the waste inlet tube 128 and into the waste tank 120 .
Once the proper paths are selected, the clean fluid pump 130 pumps out clean fluid from the clean fluid tank 110 via the clean fluid tube 112 and through the clean fluid filter 116 . From there, clean fluid is pumped through the clean pump outlet tube 132 into the solenoid switch 160 and into the transmission system through the pre-selected path. As for the waste fluid, the vehicle transmission pump (not shown) also pumps the transmission fluid as the engine is running. Waste fluid flows from either the first hose 162 or the second hose 164 and takes the pre-selected path to reach the waste inlet tube 128 and the waste tank 120 .
In a preferred embodiment, every seven seconds during the change fluid process, the microprocessor on the PCB 150 monitors the flow rate based on pressure values obtained from the waste tank pressure sensor 152 and the clean tank pressure sensor 151 . The change in pressure in the clean tank 110 is calculated by simply subtracting the current pressure from previous pressure. The change in pressure in the waste tank 120 is calculated by subtracting the previous pressure from the current pressure.
If the change in pressure in the waste tank 120 is higher than the change in pressure in the clean tank 110 , it means that the waste tank 120 is being filled more quickly than the clean tank 110 is being emptied. In that case, the clean pump's 130 speed must be increased by a value proportionate to the difference in pressure changes in the clean tank 110 and the waste tank 120 .
However, if the change in pressure in the clean tank 110 is higher than the change in pressure in the waste tank 120 , it means that the waste tank 120 is being filled less rapidly than the clean tank 110 is being emptied. Accordingly, the clean pump's 130 speed must be reduced by a value proportionate to the difference in pressure changes in the clean tank 110 and the waste tank 120 .
The automatic flow rate control and its timing are important features since pumping the clean fluid faster than the vehicle's transmission pump is pumping the waste fluid will cause a fluid overflow in the transmission system. On the other hand, slow pumping of the clean fluid would cause a fluid underflow in the transmission system which may damage the vehicle and would also require the vehicle's engine be stopped from time to time to allow the clean tank pump 130 to catch up with the vehicle's transmission pump's faster speed. Therefore, those of ordinary skill in the art would appreciate such properly timed flow control that substantially eliminates human intervention during the change fluid process.
If the clean tank 110 becomes empty during the fluid change process, the sounder starts sounding and the solenoid system 160 reverts back to its default recirculating path 167 . In such event, more fluid may be added to the clean fluid tank 110 providing the waste tank level is below ¼ tank full and the change fluid button 230 may be pressed so the system 100 restarts the process from the last point. If LED 162 is lit, waste fluid must be emptied before proceeding.
In a preferred embodiment, once the fluid level in the clean fluid tank 110 reaches the low-level line 111 , the change process is complete and the complete LED 252 comes on to indicate the end of process. At the completion of the fluid change process, the solenoid system reverts to its default recirculating path 167 and the transmission fluid circulates through the solenoid switch.
At this point, the system 100 may be used to add extra fluid to the transmission system by pressing the fill button 240 , as explained above.
At the final stage, the vehicle engine is stopped and the cooler line is disconnected from the first and second hoses 162 and 164 and reconnected in its original form. Pressing the empty waste button 260 on the control panel 200 may also empty the waste tank 120 .
Once the empty waste button 260 is pressed, the empty waste LED 262 comes on indicating that the waste tank 120 is being emptied out into the disposal tank 170 . The waste fluid is pumped out the waste tank 120 using the waste fluid pump 140 and via the waste fluid tube 122 , through the waste fluid filter 126 and from there to the disposal tube 145 and the disposal tank 170 . Once the waste tank 120 is emptied, the empty waste LED 262 turns off. The process may also be stopped at any time by pressing the stop button 270 .
Turning to FIG. 3, a pictorial representation of a transmission service system 10 is shown. As shown, the service system 10 includes the fluid changer system 100 and the control panel 200 . In addition, the service system includes a fluid port 12 corresponding to the clean tank port 115 for adding or draining fresh fluid. The service system 10 also includes a clean fluid level meter 16 and a waste fluid level meter 14 for visually determining the fluid level in the clean fluid tank 110 and the waste fluid tank 120 , respectively.
Those skilled in the art will appreciate that, while the system 100 provides for processes such as draining, filling, changing fluid and emptying waste fluid, it would be possible in accordance with the present invention to design a system that allows for only one or more of the above-described processes.
While the present invention is susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims.
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Apparatus and method of replacing old fluid in a transmission system by feeding clean fluid into the system from a clean fluid tank using a pump and draining the old fluid into a waste tank and using a processor to monitor the clean fluid pressure in the clean tank and the old fluid pressure in the waste tank and adjusting the pump's speed using the processor such that the old fluid is drained at substantially the same rate as the clean fluid is fed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/671,646, entitled “Enhanced Adserving Metric Determination” and filed Jul. 13, 2012, which is hereby incorporated in its entirety as if it were fully set forth herein.
[0002] This application is related to U.S. Pat. No. 7,904,520, granted Mar. 8, 2011, entitled “First Party Advertisement Serving,” which is incorporated herein by reference for all purposes.
TECHNICAL FIELD
[0003] Implementations described herein relate generally to systems, methods, and processes for counting the unique viewers of internet ads. For example, implementations relate to determining whether a single user has been exposed and/or interacted with an ad one or more times from a single or multiple devices (work computer, home computer, tablet, smartphone, etc.) and/or multiple locations (work, home, other). Additionally, reports can be generated that demonstrate how many of the customers of that advertiser don't accept or regularly delete cookies.
BACKGROUND
[0004] Advertising via the Internet continues to grow and evolve at a rapid pace. Internet browser technology has evolved to encompass security and privacy concerns as well as new device extensions. Internet advertising counting methodologies have generally relied on internet cookies to track the users to determine how many times they have been exposed to ads. More specifically, the counting methodologies have generally relied on third-party internet cookie tracking because the vast majority of tracking companies utilize cookies within their own domain to serve internet ads and track the performance. In many cases, information from an advertiser site domain is transferred to the ad server site domain via the third-party cookies to be used for ad targeting purposes. Internet users are becoming increasingly aware of the data transfer and object to the transfer without their knowledge and permission. For example, if you visit www(dot)Domain1(dot)com you will get various third-party cookies set by the Domain1.com advertising and tracking partners as well as many Domain1.com first-party cookies set by their site partners and internal systems. In response, browser makers have enhanced access to cookie controls to enable the user to: 1) block all cookies; 2) block third-party cookies; 3) allow all cookies. Some mobile browsers are set by default to block third-party cookies and only allow first-party cookies. Standard internet advertising practices use third-party cookies to count internet ad exposure as well as the reach and frequency of those exposures. A problem encountered in counting ad views using third-party cookies is that third-party cookies can be blocked or deleted by the browser, secondary programs or users themselves. When the third-party cookies are blocked or deleted, the reach and frequency counting accuracy can be significantly over/understated, respectively. Interestingly, first-party cookie counting is less susceptible to automated cookie blocking and deletion than third-party cookie counting because users are more comfortable with cookies from companies they know and trust. Additionally, automated cookie deletion programs such as anti-spyware programs are focused on known tracking companies and generally leave first-party cookies alone.
[0005] The proliferation of digital devices and the emergence of new First-Party only browsers set a trend that limits the effectiveness of traditional third-party measurement techniques and the vendors in the eco-system that rely on them because they have no control over the upstream systems. Studies have consistently shown a rising trend in measurement deficiency—now greater than three times over traditional reach and frequency. The same factors that impact the measurement techniques are also impacting performance measurement—the association of responses to display advertising at similar rates.
SUMMARY
[0006] Due to enhanced privacy concerns, newer internet browsers and anti-spyware products are making it easier for users to control the acceptance and deletion of internet cookies on their browsers. For example, internet browsers can be set to:
1) accept all cookies; 2) reject third-party cookies but accept first-party cookies; 3) reject all cookies.
[0010] Internet advertisers use reach to determine how many users have seen their ads for Return on Investment (ROI) calculations.
[0011] Reach calculations for third-party cookies as described by the Interactive Advertising Bureau (IAB) Audience Reach Measurement Guidelines Version 1 Dec. 8, 2008, which is incorporated by reference herein in its entirety, are becoming more and more unreliable due to the volatility of third-party internet cookies due to the issues described herein.
[0012] First-Party cookies can get rejected or deleted by the browser but are less likely to get deleted because they are associated with a specific advertiser rather than an unknown company or third-parry ad server.
[0013] In one implementation, a process to provide reach and/or frequency calculations is provided. In one particular implementation, for example, a multiple-step process successively refines a reach calculation by adding:
1) A User ID; 2) An alternate user ID to the log file and; 2) A user registration ID from an advertiser registration system.
[0017] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more particular written Detailed Description of various implementations and implementations as further illustrated in the accompanying drawings and defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates an example ad serving operating environment.
[0019] FIG. 2 , collectively including each of sub- FIGS. 2A through 2C , is a flow chart of scenarios of browser security settings.
[0020] FIG. 3 is a comparison of first-party ad server setup (domain) to third-party ad server setup (domain).
[0021] FIG. 4 , collectively including each of sub- FIGS. 4A through 4D , has example reports with the data collected and potential charts depicting the path analysis of a user on different devices and across different locations.
[0022] FIG. 5 illustrates a general purpose computing system in which various operations described herein may execute.
[0023] FIG. 6 illustrates example operations used for determining one or more metrics related to advertisement serving.
[0024] FIG. 7 shows an example implementation of an ad serving environment in which a plurality of identifiers are used in targeting an advertisement to be provided to a user.
[0025] FIG. 8 shows another example implementation of an ad serving environment in which a browser and/or device fingerprint identifier is used in targeting an advertisement to be provided to a user.
[0026] FIG. 9 shows another example implementation of an ad serving environment in which a pixel firing measurement is performed.
DETAILED DESCRIPTION
[0027] U.S. Pat. No. 7,904,520 entitled “First Party Advertisement Serving” issued Mar. 8, 2011 to Neal et al. describes various first-party advertisement serving techniques and is incorporated by reference herein in its entirety. As described herein, these techniques can be useful in improved measurement of advertisement serving, such as determinations of advertisement reach and frequency. Ad counts based on cookies set in the first-party domain of the advertiser, for example, can be used in determining various measurements related to advertisement serving.
[0028] While in many instances, a First-Party measurement system may be much less likely as impacted by cookie blockings or deletions as third-party measurement systems, a measurement model is provided that, in one implementation, comprehends systematically a normalized measurement capability as the measurement landscape becomes increasingly challenging.
[0029] In some implementations, a model that comprehends one or more factors that impact measurement accuracy and provides advertisers one or more robust and empirical ways to understand performance of their advertising, make effective attribution and media investment decisions is provided. In one implementation, for example, a production validation methodology provides normalized measurement across the following response dimensions:
Reach & Frequency Media Overlap Device Overlap Closed Loop Measurement and Response Attribution
[0034] Generally accepted counting practices (Interactive Advertising Bureau (IAB), MMA) use a new/old cookie technique to track users for reach and frequency counting. In this technique, if no cookie is present, a new cookie is set and the impression and reach are counted, but the technique does not look for a previous impression to link for multi-impression tracking. If a cookie is present, however, the cookie's status is changed to old and then the impression and the reach is counted. The technique also looks back in the log files for a previous ad exposure for multi-impression counting. This technique enables an ad serving company to track ad exposure and frequency to a specific browser to allow for strategic ad rotation as well as Return on Investment (ROI) calculations by a publisher site. If cookies are blocked or deleted by any one of the above mentioned processes, the reach numbers will be much higher because new cookies look like unique users and frequency numbers will be understated because it appears that ads are displayed to multiple users not just one. For example, one person that has their browser set to reject cookies seeing the same ad twice in two different internet surfing sessions will be counted as being two people (reach) seeing the add one time each (frequency) whereas they should be counted as one person with a frequency of two.
[0035] In one implementation, the flawed standard new/old cookie setting and reach calculation process is supplemented by including the addition of:
1) Identification numbers added to log files of a first-party cookie; 2) ID values set by secondary advertiser site based systems to count ads more accurately in the following scenarios:
A) Users with a browser set to block or delete cookies or anti-spyware software that does the same; B) Users on different devices (computer, tablet, smart phone); C) Users at different locations.
DEFINITIONS
[0041] The following identification values are merely examples of values that may be used within one or more systems or processes described herein.
[0042] A user identifier (e.g., User_ID) is a standard cookie with an ID set on a browser by an ad server. In one implementation, for example, the user identifier (User_ID) comprises a combination of a server number and a sequence ID generated by an algorithm in each server.
[0043] An alternate user identifier (e.g., Alt_User_ID) is provided to a client device (e.g., by TCP/IP communications in conjunction with HTTP headers) and is created in one or more log files (e.g., from an IP address and a user agent string (e.g., operating system, browser brand and version)). In one implementation, for example, the alternate user identifier may include a device and/or browser “fingerprint” that includes information that can be used to identify a device and/or browser in use on the device. Non-limiting information that may be used to assemble a “fingerprint” for the device and/or browser, for example, may include information such as a user agent (including browser type (e.g., Internet Explorer, Chrome, Apple Safari, Firefox, etc., version, operating system), plug in(s) present, fonts, screen resolution, color depth (e.g., 16, 32 bit, etc.), computer settings, Internet Protocol address, MAC address, or other information that can be obtained or derived from the device and/or browser.
[0044] A registration identifier (e.g., Registration_ID) is set by one or more site-side systems as a first-party cookie and is read/writeable by the other systems in the First-Party domain space. In one implementation, for example, a Customer Management System (CMS) leverages user registration information to create a cookie with a unique customer identifier.
Scenarios (FIG. 1 )
[0045] FIG. 1 shows an example ad serving operating environment. In this environment, one or more devices 100 , such as but not limited to the work computer, home computer, tablet and smart phone devices shown, connect to various web sites on a network (e.g., the Internet) via a browser 150 operating on the one or more devices 100 . The devices 100 , for example, may connect to a publisher web site 200 , an ad server web site 250 and/or an advertiser web site 300 via the browser 150 .
[0046] Where a user is a registered user of the advertiser website, for example, the browser may provide registration information data to the advertiser web 300 site to establish credentials when accessing the advertiser web site 300 . The registration information data may be used, for example to log in or otherwise inform the web site of the identity of the user and/or establish credentials with the web site.
[0047] As described above, the browser 150 may be set at various privacy settings, such as accept all cookies, reject third party cookies but accept first party cookies or reject all cookies.
[0048] In one scenario a user has their browser set to accept all cookies ( 101 ) and the user already has a User_ID ( 102 ). An Alt_User_ID is then created in a log file ( 103 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 105 ); 2) Alt_User_ID reach and frequency reports ( 106 ); 3) User Device reports ( 107 ); 4) user cookie deletion reports ( 108 ). A subsequent check is made for a Registration_ID ( 109 ). If one is found, the Registration_ID is added to the log file ( 110 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 113 ); 2) User Device Reports ( 114 ); 3) User Location reports ( 115 ); 4) user cookie deletion reports ( 116 ).
[0049] In another scenario a user has their browser set to accept all cookies and the user already has a User_ID ( 102 ). The Alt_User_ID is then created in the log file ( 103 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 105 ); 2) Alt_User_ID reach and frequency reports ( 106 ); 3) User Device reports ( 107 ); 4) User cookie deletion reports ( 108 ). A subsequent check is made for the Registration_ID ( 109 ). If one is not found, nothing happens ( 117 ) unless the user visits the advertiser site ( 111 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 112 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 113 ); 2) User Device Reports ( 114 ); 3) User Location reports ( 115 ); 4) user cookie deletion reports ( 116 ).
[0050] In another scenario a user has their browser set to accept all cookies and the user does not have a User_ID ( 102 ). The User_ID cookie is set and the Alt_User_ID is then created in the log file ( 104 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 105 ); 2) Alt_User_ID reach and frequency reports ( 106 ); 3) User Device reports ( 107 ); 4) Cookie Deletion report ( 108 ). A subsequent check is made for the Registration_ID ( 109 ). If one is found, the Registration_ID is added to the log file ( 110 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 113 ); 2) User Device Reports ( 114 ); 3) User Location reports ( 115 ); 4) user cookie deletion reports ( 116 ).
[0051] In another scenario a user has their browser set to accept all cookies and the user does not have a User_ID. The User_ID cookie is set and the Alt_User_ID is then created in the log file and the following reports are generated: 1) User_ID reach and frequency reports; 2) Alt_User_ID reach and frequency reports; 3) User Device reports. A subsequent check is made for the Registration_ID ( 109 ). If one is not found, nothing happens unless the user visits the advertiser site ( 111 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 112 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 113 ); 2) User Device Reports ( 114 ); 3) User Location reports ( 115 ); 4) user cookie deletion reports ( 116 ).
[0052] In another scenario user has their browser set to reject third-party cookies ( 101 ). If the User_ID exists ( 202 ), the Alt_User_ID is created in the log file ( 203 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 205 ); 2) Alt_User_ID reach and frequency reports ( 206 ); 3) User Device reports ( 207 ); 4) Cookie Deletion reports ( 208 ). A subsequent check is made for the Registration_ID ( 209 ). If one is found, the Registration_ID is added to the log file ( 210 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 213 ); 2) User Device Reports ( 214 ); 3) User Location reports ( 215 ); 4) user cookie deletion reports ( 216 ).
[0053] In another scenario user has their browser set to reject third-party cookies ( 101 ). If the User_ID exists ( 202 ), the Alt_User_ID is created in the log file ( 203 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 205 ); 2) Alt_User_ID reach and frequency reports ( 206 ); 3) User Device reports ( 207 ); 4) Cookie Deletion reports ( 208 ). A subsequent check is made for the Registration_ID ( 209 ). If one is not found nothing happens ( 217 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 212 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 213 ); 2 ) User Device Reports ( 214 ); 3 ) User Location reports ( 215 ); 4 ) user cookie deletion reports ( 216 ).
[0054] In another scenario user has their browser set to reject third-party cookies ( 101 ). If the User_ID does not exist ( 202 ), the Alt_User_ID is created in the log file ( 204 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 205 ); 2) Alt_User_ID reach and frequency reports ( 206 ); 3) User Device reports ( 207 ); 4) Cookie Deletion reports ( 208 ). A subsequent check is made for the Registration_ID ( 209 ). If one is found, the Registration_ID is added to the log file ( 210 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 213 ); 2) User Device Reports ( 214 ); 3) User Location reports ( 215 ); 4) user cookie deletion reports ( 216 ).
[0055] In another scenario a user has their browser set to reject third-party cookies ( 101 ). If the User_ID does not exist ( 202 ), the Alt_User_ID is created in the log file ( 204 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 205 ); 2) Alt_User_ID reach and frequency reports ( 206 ); 3) User Device reports ( 207 ) 4 ) Cookie Deletion reports ( 208 ). A subsequent check is made for the Registration_ID ( 209 ). If one is not found, nothing happens unless the user visits the advertiser site ( 211 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 212 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 213 ); 2) User Device Reports ( 214 ); 3) User Location reports ( 215 ); 4) user cookie deletion reports ( 216 ).
[0056] In another scenario user has their browser set to reject all cookies ( 101 ). If the User_ID exists ( 302 ), the Alt_User_ID is created in the log file ( 303 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 305 ); 2) Alt_User_ID reach and frequency reports ( 306 ); 3) User Device reports ( 307 ); 4) Cookie Deletion reports ( 308 ). A subsequent check is made for the Registration_ID ( 309 ). If one is found, the Registration_ID is added to the log file ( 310 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 313 ); 2) User Device Reports ( 314 ); 3) User Location reports ( 315 ); 4) user cookie deletion reports ( 316 ).
[0057] In another scenario user has their browser set to reject all cookies ( 101 ). If the User_ID exists ( 302 ), the Alt_User_ID is created in the log file ( 303 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 305 ); 2) Alt_User_ID reach and frequency reports ( 306 ); 3) User Device reports ( 307 ); 4) Cookie Deletion reports ( 308 ). A subsequent check is made for the Registration_ID ( 309 ). If one is not found nothing happens ( 317 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 312 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 313 ); 2) User Device Reports ( 314 ); 3) User Location reports ( 315 ); 4) user cookie deletion reports ( 316 ).
[0058] In another scenario user has their browser set to reject all cookies ( 101 ). If the User_ID does not exist ( 302 ), the Alt_User_ID is created in the log file ( 304 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 305 ); 2) Alt_User_ID reach and frequency reports ( 306 ); 3) User Device reports ( 307 ); 4) Cookie Deletion reports ( 308 ). A subsequent check is made for the Registration_ID ( 309 ). If one is found, the Registration_ID is added to the log file ( 310 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 313 ); 2) User Device Reports ( 314 ); 3) User Location reports ( 315 ); 4) user cookie deletion reports ( 316 ).
[0059] In another scenario a user has their browser set to reject all cookies ( 101 ). If the User_ID does not exist ( 302 ), the Alt_User_ID is created in the log file ( 304 ) and the following reports are generated: 1) User_ID reach and frequency reports ( 305 ); 2) Alt_User_ID reach and frequency reports ( 306 ); 3) User Device reports ( 307 ) 4) Cookie Deletion reports ( 308 ). A subsequent check is made for the Registration_ID ( 309 ). If one is not found, nothing happens unless the user visits the advertiser site ( 311 ) and gets an Registration_ID in which case the Registration_ID is added to the log file ( 312 ) and the following reports are generated: 1) Registration_ID reach and frequency reports ( 313 ); 2) User Device Reports ( 314 ); 3) User Location reports ( 315 ); 4) user cookie deletion reports ( 316 ).
[0060] FIG. 3 provides a comparison of a first-party ad serving system to a third-party ad serving system. A distinction between first party and third party systems is that a first-party ad server ( 550 ) acts on behalf of the advertiser ( 600 ) and can read and write cookies in the advertiser domain (Domain1.com) or sub-domain (ad.Domain1.com). In the third-party ad serving model the third-party ad server ( 850 ) sets cookies in their own domain (Domain3.com) and does not work on behalf of the advertiser ( 900 ). Third-party cookie ad servers are targeted by many anti-spyware programs for deletion and are susceptible third-party cookie blocking and rejection in browsers.
[0061] The methods described herein facilitate the workflows of the individual players as well as the workflows between and among the advertiser and/or agency, e.g., TPAS, and the publishers. A campaign reporting system includes users surfing the web, ads served to their browsers, cookies accepted, rejected or deleted by/from their browsers, a database that logs files with the associated user cookie and ad information and a reporting system that uses cookies to track users and report on the reach and frequency of those ads.
[0062] Within the user's browser there are privacy controls that enable the user to Reject all cookies, reject only third-party cookies, and/or accept all cookies. There are also anti-spam and spyware programs that identify third-party data collection cookies and schedule them for deletion.
[0063] Internet Ads are typically controlled by cookies placed on the browser and enable the ad serving company to control which ads are viewed by the user. Internet browsers continue to evolve and new devices continue to be introduced that can take advantage of internet access. Cookie-type functionality is also evolving into files and databases as evidenced, but not limited to, the growing popularity of companies using Adobe Flash™ Local Shared Objects and Microsoft Silverlight™ “Isolated Storage” capabilities. Generally accepted advertising principals like frequency of ad exposure can be applied through these technologies to ensure that the user isn't exposed to the same ad too often thus reducing the possibility of ad burn-out.
[0064] On the reporting side, the process of the ad being served captures the unique cookie ID along with other user system data (IP Address, Browser Type, etc.) and the ad information (ad name, campaign, site, width/height, site section, etc.). The log files are processed to generate reports to show how many ads were served and then the reach of those ads (unique users) and frequency of those ads to the users as well as the actions by the users (click through, purchase, etc.). Cookies can be used to control the reach and frequency of the ads to help optimize the mix and increase the ROI of the campaign. If cookies are rejected or deleted it makes the reach and frequency reporting less accurate because many new cookies are served and subsequently counted as first impressions and unique users. Third-party cookies tend to get rejected and/or deleted more often than first-party cookies. First-party cookie technology, however, can be used to produce more accurate reach and frequency reports and can extend the process to include additional attributes to make the process even more accurate.
[0065] An exemplary implementation ( FIG. 3 ) may be understood in the context of a user visiting a website like Domain1.com that has a first-party advertising relationship with a first-party ad server. The first-party relationship enables the first-party ad server to read and write cookies in the first-party mode (ad.Domain1.com) to take advantage of relationship data that the advertising company may store in their cookies (ad.domain1.com=high_value) to serve relevant ads on their behalf. When the user visits the Domain1.com website and logs-in they receive a Domain1.com registration cookie (i.e. Domain1.com=RegID=1234). When the user then surfs the web and lands on a site where the first-party ad server is serving ads on behalf of Domain1.com, the first-party ad-server will receive the contents of the Domain1.com cookie jar and can take advantage of any data stored in the cookie on behalf of Domain1.com. In this scenario, the campaign served from the first-party ad-server may serve a specific ad to the user knowing that they are a registered high-value registered user of the advertiser site. If the user is concerned about online privacy they may have their browser set to:
1) reject all cookies; 2) reject only third-party cookies; 3) accept all cookies.
Reject All Cookies
[0069] If the user rejects all cookies they will get sent a new cookie request every time from first-party the ad-server (ad.domain1.com) or Domain1.com and the first-party ad server log files will capture a new User_ID each time but construct the same Alt_User_ID as long as the user is logging in from a consistent IP Address and Browser. In this case it's possible to track that this user is returning and the ad server or advertiser could actually generate a report on user location, operating system and browser type and the amount of users that are not accepting or are regularly deleting cookies.
Reject Only Third-Party Cookies
[0070] If the user rejects third-party cookies but accepts first-party cookies there are a few scenarios: 1) when the user visits the Domain1.com website the user will receive a first-party cookie. 2) When the user visits a different domain site the user will be viewed as a third-party and will be able to read the first-party Domain cookie (Ad.domain1.com) but any cookie writing will be rejected. The log files will capture a “new” cookie when the cookie is set on the first-party domain and continue to count accurately for each third-party ad serve on the external domain. If the external domain is the first time the user is seen, the Domain1.com cookie will not be set because it will be viewed as a third-party cookie to the external domain. This difference can be significant because if the cookies are set in the first-party domain (ad.Domain1.com) they can be read in the third-party domain ( 200 ) even if the browser is set to not accept third-party cookies. The log files will also be updated with new->old cookies and reach will be counted correctly in this scenario, making the first-party ad serving process more accurate for reporting and optimization purposes.
Accept All Cookies
[0071] If the user accepts all cookies then the third-party ad serving and counting process and the first-party ad serving and counting process will be similar but there could be counting discrepancies when the user accesses the web from different locations or devices. For example, a user may login from work ( 110 ) and then surf the web and view ads and then go home, login and view ads on a separate computer ( 120 ), tablet ( 130 ), or smartphone ( 140 ). In this scenario the standard reach and frequency counting process would count a reach of 2 and a frequency of one even though the same ad was viewed on both systems and should be counted as a reach of one and frequency of two.
[0072] In various implementations, however, a first-party system using the Alt_User_ID would see different User_ID's and different Alt_User_ID's but the same Registration_ID and could link the user across locations (IP addresses) and systems (work computer, home computer, tablet or smartphone). In this scenario, an enhanced counting process could correctly count the reach and frequency while standard third-party counting techniques could be significantly different.
[0073] In various first-party implementations, a new reach and frequency counting process works in a first-party cookie mode and captures multiple data points to help counting accuracy whether the user has their browser set to accept or reject cookies, there is a cookie deletion action by a the user or an anti-spam/spyware system or they use different forms of access such as work computer, home computer, tablet and smartphone.
Exemplary Operations
[0074] FIG. 1 depicts an example ad serving environment. In this implementation, an advertisement serving system works on behalf of an advertiser and generates ad tags that are then placed by a publisher advertising system into purchased media inventory. When a user surfs with their browser ( 150 ) to a web page, the web page can have many calls to different servers for content. When the ad tag is requested, the browser sends a request to the advertisement server ( 250 ) along with a number of headers. These headers help the browser and the hosting server determine the best way to provide the requested information. The user agent string is included in one of the headers provided from the browser. The user agent string from Microsoft Internet Explorer 9, by default, provides the following information to the server:
1) Application name and version (“Mozilla/5.0”) 2) Compatibility flag (“Compatible”) 3) Version Tokens (“MSIE 9.0”) 4) Platform Tokens (Windows NT 6.1″) 5) Trident Token (“Trident/5.0”) (User-Agent: Mozilla/5.0 (compatible; MSIE 9.0; Windows NT 6.1; Trident/5.0).
In many browsers it is possible to change the user agent string but the user needs to be technically proficient or run a program to make the changes. In general, the vast majority of users don't know these use agent strings exist and will never change them. In a typical web surfing process a user will visit a webpage from one of their systems (work computer ( 110 ), home computer ( 120 ), tablet ( 130 ), smartphone ( 140 ), etc.) ( 100 ), a Publisher website ( 200 ) will send HTTP headers that may include ad tags which will direct the browser to send its HTTP header information to the Advertisement deployment server ( 250 ) and request an ad. Since the ad tag had the “Host: media.Domain1.com”, the browser will send along the user agent and any cookies in the cookie jar for Domain1.com which can be used for counting, reach and frequency calculations.
[0080] FIG. 6 shows example operations of a process 600 for determining data related to advertisement serving operations. The process 600 , for example, may be performed to determine statistics such as, but not limited to, impression frequency, reach, site overlap, path analysis and the like. In the implementation shown in FIG. 6 , for example, the process generates source data logs in operation 602 . The source data logs, for example, may include all or a subset of transaction data collected in an advertisement serving process, such as for a campaign or within a particular domain. The transaction data, for example, comprises all or a subset of impressions, clicks, and pings. The data may further include name value pairs from the raw data. The source data logs can then be loaded into an analysis system, such as into staging tables, in operation 604 . In one particular implementation, for example, the data is organized into sets for analysis. The sets, for example, may be organized around one or more advertising campaigns (e.g., by a campaign ID), an advertisement serving domain, such as for first party advertisement serving, (e.g., by a domain ID), around a start date, an end date and/or a date range, or by any other set organization useful for analysis.
[0081] The analysis system analyzes the source data logs (e.g., from the staging tables) in a variety of manners. In operation 606 , for example, the analysis system performs the data analysis against a cookie, such as described above with respect to the standard new/old cookie paradigm. In operation 608 , the analysis system performs data analysis against alternate user ID data (e.g., data that can be used to identify a user by browser or client device as described above). In operation 610 , the analysis system performs data analysis against registration identification information (e.g., a Registration ID) that is readable and/or writeable in the first party domain space within a first party advertisement scheme.
[0082] The results of operation 606 are then compared to the results of operations 608 and/or 610 to create a normalized data set in operation 612 . The normalized data set, for example, can be used to identify instances in which cookies (or other persistent browser information) may have been blocked or deleted. The normalized data, thus, provides improved measurement over standard new/old cookie analysis schemes.
[0083] It is important to note that either operation 608 or operation 610 may be performed in isolation or both operations 608 and 610 may be performed and the results compared to the results of operation 606 . Thus, the results of a standard cookie analysis (operation 606 ) may be compared to an analysis performed using alternate user information (operation 608 ) and/or an analysis performed using registration identification information (operation 610 ).
[0084] FIG. 7 shows an example implementation of an ad serving environment in which a plurality of identifiers are used in targeting an advertisement to be provided to a user. For example, the ad serving environment may use two or more of the user identifier, the alternate user identifier and the registration user identifier described herein as well as any number of other identifiers, including derivatives of those or other identifiers. In the example shown in FIG. 7 , for example, one or more devices 100 A, such as but not limited to the work computer, home computer, tablet and smart phone devices shown, connect to various web sites on a network (e.g., the Internet) via a browser 150 A operating on the one or more devices 100 A. The devices 100 A, for example, may connect to a publisher web site 200 A, an ad server web site 250 A and/or an advertiser web site via the browser 150 A.
[0085] In this particular example, a rendering engine executing on rendering server 450 A provides a placeholder tag in the browser 150 A of one or more of the devices 100 A. First party information (cookie or other data elements), if present at the device 100 A (e.g., in browser 150 A), are identified and provided to an ad server 400 A. The ad server 400 A accesses memory cache server 250 A (or other data storage device such as a database, disc storage or the like) to match one or more elements of the first party information and a unique (or semi-unique) browser fingerprint detail.
[0086] The memory cache server 250 A and/or the ad server 400 A identify and/or selects two or more identifiers, such as a user identifier, an alternate user identifier (e.g., a browser fingerprint) and/or a registration information identifier, to use to identify one or more advertisements from an advertiser database 300 A or other external data provider data sets 350 A to provide to the ad server 400 A for targeting engine/creative selection decisioning as well as measurement counting accuracy. The ad server 400 A determines whether to provide any additional or replacement identifiers and/or first party data elements back to the browser 150 A to be used for relatively more relevant and/or accurate targeting information for targeting and creative selection to serve advertisements.
[0087] FIG. 8 shows another example implementation of an ad serving environment in which a browser and/or device fingerprint identifier is used in targeting an advertisement to be provided to a user. As described herein, the fingerprint identifier may be used alone or with one or more other identifiers. In the example shown in FIG. 8 , for example, one or more devices 100 B, such as but not limited to the work computer, home computer, tablet and smart phone devices shown, connect to various web sites on a network (e.g., the Internet) via a browser 150 B operating on the one or more devices 100 B. The devices 100 B, for example, may connect to a publisher web site 200 B, an ad server web site 250 BA and/or an advertiser web site via the browser 150 B.
[0088] In this particular example, a rendering engine executing on rendering server provides a placeholder tag in the browser 150 B of one or more of the devices 100 B as described above with respect to FIG. 7 . Browser and/or device fingerprint elements are used to create a unique (or semi-unique) fingerprint key (e.g., a universal key) for the browser 150 B and/or device 100 B. The fingerprint key, for example, may be stored in the browser 150 B or the elements may be provided to an ad/meta data server 250 B, which can use the elements to create on or more keys for use in an ad serving process. The fingerprint key may be a universally unique key or sufficiently distinct to statistically sufficiently distinguish a wide sampling of devices and/or browsers for the purpose of serving ads.
[0089] In addition to the fingerprint key or fingerprint elements, first party data elements (e.g., cookie or other data), if present, may be forward to the ad/meta data server 250 B as well. The ad/meta data server 250 B selects universal key or fingerprint key records for targeting from an advertiser database 300 B or from any other third party data provider 350 B. New targeting information (e.g., based on fingerprint selections) is provided back to the ad server 250 B for targeting and creative selection to serve an advertisement as well as for measurement determination. As described above with respect to FIG. 7 , the ad server 250 B may also determine whether to provide any additional information such as identifiers and/or first party data elements back to the browser 150 B to be used for relatively more relevant and/or accurate targeting information for targeting and creative selection to serve advertisements.
[0090] FIG. 9 shows another example implementation of an ad serving environment in which a pixel firing measurement is performed. In the example shown in FIG. 9 , for example, one or more devices 100 C, such as but not limited to the work computer, home computer, tablet and smart phone devices shown, connect to various web sites on a network (e.g., the Internet) via a browser 150 C operating on the one or more devices 100 C. The devices 100 C, for example, may connect to a publisher web site 200 C, an ad server web site and/or an advertiser web site via the browser 150 C.
[0091] In this particular example, a rendering engine executing on rendering server 450 C provides a placeholder tag in the browser 150 C of one or more of the devices 100 C. First party information (cookie or other data elements), if present at the device 100 C (e.g., in browser 150 C), are identified and provided to an ad server 400 C. Browser and/or device fingerprint elements are also identified and provided to the ad server 400 C. The ad server 400 C accesses memory cache server 250 C (or other data storage device such as a database, disc storage or the like) to match one or more elements of the first party information and a unique (or semi-unique) browser fingerprint detail. As described above, the fingerprint key or detail may be a universally unique key or sufficiently distinct to statistically sufficiently distinguish a wide sampling of devices and/or browsers for the purpose of serving ads.
[0092] The memory cache server 250 C and/or the ad server 400 C identify and/or select one or more identifiers, such as a user identifier, an alternate user identifier (e.g., a browser fingerprint) and/or a registration information identifier, to use to identify one or more advertisements from an advertiser database 300 C or other external data provider data sets 350 C to provide to the ad server 400 C for pixel management and measurement details. For example, memory cache server 300 C can identify appropriate pixel(s) to fire on a browser 150 C (either advertiser, publisher, or other) to ensure accurate counting and measurement via using an appropriate primary key set and closing a loop. The ad server 400 C receives decisioning pixel identifiers to send back to the browser 150 C one or more instructions to fire one or more determined measurement pixel(s).
Exemplary Computing System
[0093] FIG. 5 is a schematic diagram of a computing device 1000 upon which a creatives management or deployment system may be implemented. As discussed herein, implementations include various steps. A variety of these steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, the steps may be performed by a combination of hardware, software, and/or firmware.
[0094] FIG. 5 illustrates an exemplary system useful in implementations of the described technology. A general purpose computer system 1000 is capable of executing a computer program product to execute a computer process. Data and program files may be input to the computer system 1000 , which reads the files and executes the programs therein. Some of the elements of a general purpose computer system 1000 are shown in FIG. 5 wherein a processor 1002 is shown having an input/output (I/O) section 1004 , a Central Processing Unit (CPU) 1006 , and a memory section 1008 . There may be one or more processors 1002 , such that the processor 1002 of the computer system 1000 comprises a single central-processing unit 1006 , or a plurality of processing units, commonly referred to as a parallel processing environment. The computer system 1000 may be a conventional computer, a distributed computer, or any other type of computer. The described technology is optionally implemented in software devices loaded in memory 1008 , stored on a configured DVD/CD-ROM 1010 or storage unit 1012 , and/or communicated via a wired or wireless network link 1014 on a carrier signal, thereby transforming the computer system 1000 in FIG. 5 into a special purpose machine for implementing the described operations.
[0095] The I/O section 1004 is connected to one or more user-interface devices (e.g., a keyboard 1016 and a display unit 1018 ), a disk storage unit 1012 , and a disk drive unit 1020 . Generally, in contemporary systems, the disk drive unit 1020 is a DVD/CD-ROM drive unit capable of reading the DVD/CD-ROM medium 1010 , which typically contains programs and data 1022 . Computer program products containing mechanisms to effectuate the systems and methods in accordance with the described technology may reside in the memory section 1008 , on a disk storage unit 1012 , or on the DVD/CD-ROM medium 1010 of such a system 1000 . Alternatively, a disk drive unit 1020 may be replaced or supplemented by a floppy drive unit, a tape drive unit, or other storage medium drive unit. The network adapter 1024 is capable of connecting the computer system to a network via the network link 1014 , through which the computer system can receive instructions and data embodied in a carrier wave. Examples of such systems include SPARC systems offered by Sun Microsystems, Inc., personal computers offered by Dell Corporation and by other manufacturers of Intel-compatible personal computers, PowerPC-based computing systems, ARM-based computing systems and other systems running a UNIX-based or other operating system. It should be understood that computing systems may also embody devices such as Personal Digital Assistants (PDAs), mobile phones, gaming consoles, set top boxes, etc.
[0096] When used in a LAN-networking environment, the computer system 1000 is connected (by wired connection or wirelessly) to a local network through the network interface or adapter 1024 , which is one type of communications device. When used in a WAN-networking environment, the computer system 1000 typically includes a modem, a network adapter, or any other type of communications device for establishing communications over the wide area network. In a networked environment, program modules depicted relative to the computer system 1000 or portions thereof, may be stored in a remote memory storage device. It is appreciated that the network connections shown are exemplary and other means of and communications devices for establishing a communications link between the computers may be used.
[0097] In accordance with an implementation, software instructions and data directed toward operating the subsystems may reside on the disk storage unit 1012 , disk drive unit 1020 or other storage medium units coupled to the computer system. Said software instructions may also be executed by CPU 1006 .
[0098] The implementations described herein are implemented as logical steps in one or more computer systems. The logical operations are implemented (1) as a sequence of processor-implemented steps executing in one or more computer systems and (2) as interconnected machine or circuit modules within one or more computer systems. The implementation is a matter of choice, dependent on the performance requirements of a particular computer system. Accordingly, the logical operations making up the embodiments and/or implementations described herein are referred to variously as operations, steps, objects, or modules. Furthermore, it should be understood that logical operations may be performed in any order, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language.
[0099] The implementations described herein are implemented as logical steps in one or more computer systems. The logical operations are implemented (1) as a sequence of processor-implemented steps executing in one or more computer systems and (2) as interconnected machine or circuit modules within one or more computer systems. The implementation is a matter of choice, dependent on the performance requirements of the computer system being used. Accordingly, the logical operations making up the implementations described herein are referred to variously as operations, steps, objects, or modules. Furthermore, it should be understood that logical operations may be performed in any order, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language.
[0100] The above specification, examples and data provide a complete description of the structure and use of exemplary implementations of the invention. Since many implementations of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different implementations may be combined in yet another implementation without departing from the recited claims.
[0101] In some implementations, articles of manufacture are provided as computer program products. One implementation of a computer program product provides a transitory or non-transitory computer program storage medium readable by a computer system and encoding a computer program. Another implementation of a computer program product may be provided in a computer data signal embodied in a carrier wave by a computing system and encoding the computer program.
[0102] Furthermore, certain operations in the methods described above must naturally precede others for the described method to function as described. However, the described methods are not limited to the order of operations described if such order sequence does not alter the functionality of the method. That is, it is recognized that some operations may be performed before or after other operations without departing from the scope and spirit of the claims.
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A user can view creative from multiple locations (same laptop) and multiple devices (work computer, home computer, tablet, smartphone). The user can also adjust their privacy settings on their browser to accept or reject cookies and/or have anti-spam/spyware software that regularly deletes cookies. An enhanced counting method uses first-party cookie technology to track users across access channels and across privacy settings on their browser. The non-acceptance and deletion of cookies causes the accuracy of the traditional third-party cookie calculated reach and frequency calculations to vary widely. First-party cookies reduce this variability but are still subject to non-acceptance or deletion so additional actions need to be taken to provide the opportunity for accurate reports. Additional steps to increase the accuracy of reach and frequency reporting are provided.
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BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in drilling, particularly in drilling in rock formations.
Conventionally, a drill bit is situated at the bottom end of a drill string and rotation is supplied to the entire drill string and drill bit from the ground surface. Pressure is applied to the drill bit not only by the weight of the drill string but also by additional weight such as that applied by weight collars around the string just above the drill bit at the bottom of the hole.
This conventional method requires considerable weight and is relatively slow in operation and, if downward pressure is applied mechanically, considerable mechanism is required.
Furthermore, the drill string is basically suspended from the rig in order to prevent buckling of the drill string due to the static weight thereof.
Devices exist which eliminate the heavy collars used to increase the downward force exerted upon a drill bit, and which use hydraulic pressure to force a section of the drill string above the drill bit into contact with the sides of the drill hole. All of these require that the portion of the string or pipe in contact with the hole remain stationary, while some other device is used to push against this part of the drill string thus exerting a downward force upon the drill bit.
However, these devices require a totally different method of operation for the drill bit and cannot be adapted for use with conventional, rotatable drill strings.
SUMMARY OF THE INVENTION
The present invention overcomes these disadvantages by providing a drill bit on the lower end of a drill string, with means just above the drill bit to urge the drill bit downwardly as the drill bit is rotated.
In general, I provide one or more arms extending from the drill string just above the drill bit which bear against the wall of the drill bore and which include means which are angled downwardly so that a screw thread effect is obtained thus applying downward pressure to the drill bit, and means are also provided to apply pressure upon the wall engaging ends of the arms to urge them into contact with the walls.
This not only reduces the necessity of additional weight and downward pressure but also applies the pressure immediately above the drill bit rather than at the top of the drill string which can then be almost fully supported from the upper end thereof.
Although the device is generally designed to be secured to the drill pipe just above the drill bit, nevertheless more than one unit may be utilized in a drilling operation as for example, every thousand feet of drill pipe may incorporate one of the devices to assist in the provision of the necessary downward pressure to the drill bit.
Although in certain circumstances, pressure from the top of the hole can be eliminated, in the majority of cases the use of the present device enables the pressure to be reduced considerably.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan schematic view of a drill bore showing the device therein.
FIG. 2 is a schematic side view of one embodiment of the device.
FIG. 3 is a schematic side view of the embodiment of the device shown in FIG. 1.
FIG. 4 is an isometric view of the device per se.
FIG. 5 is an isometric view of one of the piston and roller assemblies per se.
FIG. 6 is a fragmentary vertical section of one of the piston and cylinder assemblies.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Proceeding therefore to describe the invention in detail, reference character 10 illustrates the side wall of a drill hole or bore formed in the ground by a conventional drill bit 11 which is secured to the lower end of a conventional drill string or pipe 12 extending downwardly from the ground surface (not illustrated). Drilling fluid (not illustrated) under pressure passes down through the drill pipe or string to the bit 11 to cool the bit and wash away or remove the chips, debris, etc. This drilling fluid is then returned to the surface by any one of a variety of conventional means (not illustrated).
The device collectively designated 13 consists of one or more assemblies 14 extending outwardly from the drill pipe or string 12 just above the drill bit 11.
Each assembly 14 includes a pipe or tube 15 mounted to the wall of the drill pipe by any conventional means and extending radially therefrom. A plunger or piston 16 is telescopically mounted within each pipe or tube 15 and hydraulic means are provided normally to urge the plunger outwardly in contact with the wall 10 of the drill hole or bore as will hereinafter be described.
The distal end of the plunger 16 is provided with a roller assembly 18 to facilitate rotary movement against the wall of the hole, said roller assembly being mounted for rotation upon a pin 17 extending between pins 17A formed on the end of the plunger 16.
It is desirable that the roller bearing 18 be inclined relative to the vertical axis of the hole so that rotary movement of the drill pipe or string causes the bearing assemblies to take up a slightly spiral movement in the form of a screw threading action thus applying pressure to the drill bit 11, when the drill bit is rotated in the direction of arrow 19 (see FIG. 1).
Conversely, of course, when the rotation of the drill string is reversed, the devices 13 assist in withdrawing the drill string by taking the weight of the drill bit and urging the drill string upwardly so that each section of drill pipe can be removed as it clears the surface.
As will be seen from the details of the drawings, the pipes or tubes 15 are preferably supported from the wall of the drill pipe by means of diagonal flanges 20 and, if necessary, by the ring flanges 21. Needless to say, other support methods can be provided, if desired.
The individual pistons 16 within the tubes or cylinders 15 are restricted insofar as outward motion is concerned and drawings 5 and 7 show the preferred method.
A spring loaded stopper key or piston ring 22 surrounds the piston 16 adjacent the inner end thereof and this rides in an annular channel 23 formed within the cylinder 15 by the annular flange 24 on the outer end of the cylinder and the inner flange 25 on the inner end thereof.
Springs 26 may react between the base of the piston ring or key groove 27 and the key or ring 22 to urge same outwardly as shown in FIG. 7. This prevents over-extension of the piston 16 or collapse into the center of the drill rod.
Alternatively, the spring loaded stopper key or ring can be set into the cylinder with a suitable groove being cut into the piston. This is shown in FIG. 7 in phantom and includes a longitudinally extending groove 28 within the wall of the piston 16 with a pin or stopper 29 engaging through an apertures within the wall of the cylinder with spring 30 reacting between the pin 29 and a screw 31 engaging within a boss 32 formed in the wall of the cylinder. The particular advantage of this embodiment is the fact that it maintains the angle of inclination of the cylinder and hence the roller at the desired degree of between, for example, 5° and 10° from the vertical thus assisting in the screw threading action hereinbefore described.
Hydraulic pressure to urge the pistons outwardly may either be provided by a separate hydraulic system extending from the surface (not illustrated) or, from the pressure of the drilling fluid passing downwardly through the drill string and being restricted as to release thereof by the conventional discharge aperture normally formed within the drill bit so that the drilling fluid within the drill string is always maintained at a pre-determined pressure which may act through apertures 33 formed within the drill string wall as clearly shown in FIG. 6.
Preferably, two pairs of diametrically situated assemblies 14 are provided, one in one horizontal plane and the other at right angles thereto in a horizontal plane spaced therefrom as illustrated in FIG. 4.
Although only one set of rollers is shown, nevertheless, a plurality of sets could be provided in a length of drill stem immediately above the drill bit.
In operation, a series of extendable rollers are fixed above a conventional drill bit and are used to exert force against the side wall of the drill hole and by having the rollers mounted at an angle to the longitudinal axis of the drill string, any rotational motion applied to the drill string from the surface, yields extra downward force upon the rock surface below the drill bit.
The rollers are readily retracted back into the drill string by releasing the hydraulic pressure so that the whole apparatus can be lifted or repositioned in the bore hole. It will be appreciated that the device requires that the whole shaft be in constant rotation so that the force is continuously bearing upon the drill bit as it proceeds through the rock so that it is adapted for use with rotational drill bits only and not percussive drill bits.
As drilling fluid under high pressure is normally required to remove the debris of drilling, this fluid can also be used to activate the extension of the roller assemblies.
As mentioned previously, other patents exist for devices which allow downward pressure to be exerted upon a drill bit, but these are stationary and do not rotate with the drill string.
Although the present description and drawings illustrate a drill bit operated from the surface by means of a drill string, nevertheless it will be appreciated that the rotational force may be supplied to the drill string immediately above the drill bit and above the present devices by means of a source of power either hydraulic or electric which may be lowered by cable or the like. However, once again, similar principles may be used in that the downward pressure is supplied by devices extending from the drill pipe and rotating therewith.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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A plurality of piston and cylinder assemblies extend radially from the wall of the drill tube above the drill bit. A roller assembly is journalled in the distal ends of the pistons and engages the wall of the bore hole. The pistons are urged outwardly by fluid pressure to engage the wall and they are inclined approximately 10° from the longitudinal axis of the drill string so that when the drill string is rotated, the engagement of the inclined rollers against the wall urges the drill bit downwardly thus assisting in applying the required pressure to the rotating bit.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority to Korean Patent Application No. 10-2010-0125527 filed in the Korean Intellectual Property Office on Dec. 9, 2010, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an exhaust gas post processing system that raises the temperature of the exhaust gas at an early stage of the engine operating and prevents the temperature of the exhaust gas from being excessively raised.
2. Description of Related Art
Generally, so as to purify the exhaust gas of the diesel vehicle, a diesel oxidation catalyst (DOC) and a diesel particulate filter (Diesel particulate filter) are applied and the DOC oxidizes a carbon monoxide and a hydrocarbon to eliminate them.
Further, the diesel particulate filter traps particulate matters of the exhaust gas, if the trapped PM exceeds a predetermined value, a fuel is post injected, the temperature of the exhaust gas is raised by the fuel oxidation heat in the DOC, and the trapped PM is burned in the diesel particulate filter.
Meanwhile, there is a problem that the exhaust gas purification catalyst (DOC, DPF, LNT, HC-SCR, and so on) is not activated from a low temperature of the exhaust gas in a condition that the engine is in an early stage of the operating. In addition, there is a problem that the catalyst is over heated by the exhaust gas passing the catalyst.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY
Various aspects of the present invention are directed to providing an exhaust gas post processing system having advantages of quickly raising the temperature of the catalyst at an early stage of the engine operating so as to activate the catalyst and cooling the exhaust gas when the temperature of the exhaust gas is raised to the high temperature so as to protect the catalyst from the high temperature.
An exhaust gas post processing system, may include an exhaust pipe in which an exhaust gas from an engine passes, a catalyst that may be disposed at the exhaust pipe so as to decrease a harmful material of the exhaust gas, and a water jacket that may be formed around an exhaust pipe that may be disposed at an upstream side of the catalyst of the exhaust pipe, wherein a coolant may be selectively supplied into the water jacket such that the water jacket cools down the exhaust gas passing the exhaust pipe and thus the catalyst does not be over heated.
A supply line supplies the coolant to the water jacket of the exhaust pipe at an upstream side of the catalyst and a return line exhausts the coolant from the water jacket.
A supply control valve and a return control valve may be disposed at the supply line and the return line respectively so as to control the flow of the coolant.
The supply line may be fluid-connected to an upper portion of the water jacket and the return line may be fluid-connected to a lower portion of the water jacket.
A control portion selectively closes the supply control valve and the return control valve according to a temperature of he exhaust gas.
The control portion closes the supply control valve and opens the return control valve when the temperature of the exhaust gas may be lower than a predetermined value at an early stage of the engine operating such that the coolant within the water jacket may be exhausted.
The control portion opens the supply control valve and the return control valve such that the coolant circulating the water jacket cools down the exhaust gas when the temperature of the exhaust gas passing the catalyst may be higher than a predetermined value after the engine may be warmed up.
The exhaust pipe may have a double pipe structure in which an inner pipe may be inserted into an outer pipe and the water jacket may be formed between the outer pipe and the inner pipe.
As stated above, in the exhaust gas post processing system according to the present invention, the coolant that flow the exhaust pipe prevents the temperature of the exhaust gas from being over heated such that the catalyst is not deteriorated beforehand. Further, the coolant is exhausted from the water jacket around the exhaust pipe at an early stage of the engine operating to achieve the heat insulation effect such that the temperature of the exhaust gas is quickly raised.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an exhaust gas post processing system according to an exemplary embodiment of the present invention.
FIG. 2 is a control flowchart for a low temperature of an exhaust gas in an exhaust gas post processing system according to an exemplary embodiment of the present invention.
FIG. 3 is a control flowchart for a high temperature of an exhaust gas in an exhaust gas post processing system according to an exemplary embodiment of the present invention.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
FIG. 1 is a schematic diagram of an exhaust gas post processing system according to an exemplary embodiment of the present invention.
Referring to FIG. 1 , an exhaust gas post processing system includes an engine 100 , a control portion 110 , an exhaust pipe 150 , a diesel particulate filter 120 , a temperature sensor 130 , a diesel oxidation catalyst 140 , a coolant supply line 180 , a supply line valve 170 , a coolant return line 190 , and a return line valve 195 . Further, a water jacket 160 is formed along an outside surface of the exhaust pipe 150 .
The exhaust pipe 150 has a double pipe type and the water jacket 160 is formed between the exterior circumference of one pipe and the interior circumference of another pipe. The diesel oxidation catalyst 140 and the diesel particulate filter 120 are sequentially disposed at a downstream side of the water jacket 160 .
As shown, the water jacket 160 is formed at an upstream side of the diesel oxidation catalyst 140 and this is one of exemplary embodiments, and the water jacket 160 can be formed at any portion of the exhaust line.
The coolant supply line 180 supplies the coolant to an upper side of the water jacket 160 and the coolant return line 190 receives the coolant from a lower portion of the water jacket 160 .
The supply line valve 170 is disposed at a portion of the coolant supply line 180 through which the coolant is supplied and the return line valve is disposed at a portion of the coolant return line 190 through which the coolant is withdrawn.
The temperature sensor 130 detects the temperature of the exhaust gas flowing the exhaust pipe 150 and transfers the detected temperature signal to the control portion 110 .
100321 The control portion 110 controls an opening rate of the supply line valve 170 and the return line valve 195 according to a temperature signal transferred from the temperature sensor 130 and an operating condition of the engine 100 .
For example, if the control portion 110 opens the supply line valve 170 and the return line valve 195 , the coolant is supplied through the coolant supply line 180 and the supply line valve 170 , and the coolant is exhausted through the return line valve 195 and the coolant return line 190 .
Further, if the control portion closes the supply line valve 170 and opens the return line valve 195 , the coolant in the water jacket 160 is exhausted through the return line valve 195 by the weight of oneself.
As shown, because the coolant return line 190 is connected to a lower end portion of the water jacket 160 and the coolant supply line 180 is connected to an upper end portion of the water jacket 160 , if the supply line valve 170 is closed and the return line valve 195 is opened, the water jacket 160 is drained by its own weight and the air fills the water jacket 160 .
FIG. 2 is a control flowchart for a low temperature of an exhaust gas in an exhaust gas post processing system according to an exemplary embodiment of the present invention.
Referring to FIG. 2 , the control portion 110 determines whether the temperature of the exhaust gas is lower than a predetermined value or not through the temperature sensor 130 in a S 200 .
The control portion 110 closes the supply line valve 170 in a S 210 and the control portion 110 opens the return line valve 195 in a S 220 . Accordingly, the coolant is exhausted from the water jacket 160 through the coolant return line 190 in a S 230 such that the air within the water jacket 160 achieves the insulation effect in a S 240 , the temperature of the exhaust gas is quickly raised in a S 250 , and the heating period for activating the catalyst (DOC, DPF) is reduced in a S 260 .
FIG. 3 is a control flowchart for a high temperature of an exhaust gas in an exhaust gas post processing system according to an exemplary embodiment of the present invention.
Referring to FIG. 3 , the control portion determines whether the temperature of the exhaust gas is larger than a predetermined value through the temperature sensor 130 in a S 300 .
If the temperature value is larger than that, the control portion 110 opens the supply line valve 170 in a S 310 , and the control portion 110 opens the return line valve 195 in a S 320 .
Accordingly, the coolant circulates the coolant supply line 180 , the water jacket 160 , and the coolant return line 190 in a S 230 , the temperature of the exhaust gas descends by the coolant circulating the water jacket 160 in a S 340 , and it is prevented that the catalyst (DOC, DPF) is over-heated in a S 350 .
For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner” and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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An exhaust gas post processing system may include an exhaust pipe in which an exhaust gas from an engine passes, a catalyst that may be disposed at the exhaust pipe so as to decrease a harmful material of the exhaust gas, and a water jacket that may be formed around an exhaust pipe that may be disposed at an upstream side of the catalyst of the exhaust pipe, wherein a coolant may be selectively supplied into the water jacket such that the water jacket cools down the exhaust gas passing the exhaust pipe and thus the catalyst does not be over heated.
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BACKGROUND
[0001] Various encoding schemes are known for encoding a video or sequence of pictures. The video may include a plurality of pictures, each picture sub-divided into a plurality of slices. Each slice includes a plurality of 8×8 pixel blocks. For example, encoding schemes may be discrete cosine transform-(“DCT”) based, which transforms blocks into 8×8 matrices of coefficients. The DCT coefficient matrix for each block is then quantized with a quantizer parameter, reducing some coefficients to zero. The quantized coefficient matrix is scanned in a pre-defined pattern, and the result is stored in a one-dimensional array.
[0002] The one-dimensional array is encoded with standard run-level encoding, where each group of consecutive zeros and subsequent non-zero value in the array is replaced with a run-level code. Additional encoding may be applied, resulting in a bit stream. The bit stream can be transmitted and decoded into a sequence of pictures similar to the encoded sequence of pictures. Because coefficients were quantized in the quantization step, some picture information is lost and not recovered in the decoding process.
[0003] Entropy encoders are known in the art. For example, Golomb-Rice and exponential Golomb codes are families of entropy codes that are indexed by a non-negative integer value (called an “order”). Both code families include non-negative integers as their symbol alphabets. Furthermore, both code families output codewords consisting of three parts: a unary prefix consisting solely of zero bits, a separator consisting of a single one bit and a binary suffix. If the prefix has q bits, the separator is a single bit and the suffix is k bits, the length of an individual code is q+k+1.
[0004] To encode a non-negative integer n using a Golomb-Rice code of order k, known coders first calculate the quotient and remainder of n with respect to 2 k , q=floor(n/2 k ) and r=n mod 2 k . These calculations are trivial: r corresponds to the k least-significant bits of the binary representation of n, and q corresponds to the other, most-significant, bits. Then the codeword for n consists of q zero bits, a single one bit, and k bits containing the binary representation of r; the length of the codeword is clearly q+1+k.
[0005] The exponential Golomb codes have a slightly more complex structure. For these the number of zero bits in the code prefix is q=floor(log 2 (n+2 k ))−k, where again n is a non-negative integer being encoded and k is the code order. The length of the suffix is q+k. As it happens, rather than specifying its suffix, the codeword is most easily obtained directly as the binary representation of the sum n+2 k , zero-extended by q bits for a total codeword length of q+1+q+k=2q+k+1. In these calculations, floor(log 2 (n+2 k )) is not difficult to compute; if the minimal-length binary representation of n+2 k requires b bits, then floor(log 2 (n+2 k )) is simply b−1.
[0006] Golomb-Rice codes and exponential Golomb codes are each well-suited for distinct source distributions. However, a need exists for a structured coding scheme that can efficiently encode source distributions that cannot be efficiently encoded by either Golomb-Rice or exponential Golomb codes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a procedure for encoding a bit stream according to an embodiment of the present invention.
[0008] FIG. 2 illustrates an encoder according to an embodiment of the present invention.
[0009] FIG. 3 illustrates a syntax according to an embodiment of the present invention.
[0010] FIG. 4 illustrates a picture division scheme according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0011] An improved coding scheme reduces a size of the bit stream associated with an encoded video. Thus, the bit stream may be transmitted with less bandwidth, or the video may be encoded with less quantization while still requiring the same bandwidth (thereby improving video quality). A method and system are provided to minimize the size of bit streams associated with encoded frames by using a new codebook scheme. An entropy encoding unit receives a one-dimensional array from a scanning unit after the DCT coefficient matrix has been quantized, scanned, and run-level encoded. The entropy encoding unit then encodes small values with Golomb-Rice codes and large values with exponential Golomb codes.
[0012] FIG. 1 illustrates a procedure for encoding a bit stream according to an embodiment of the present invention. The procedure may be executed on an entropy encoding unit of an encoder as depicted in FIG. 2 . At start, the procedure may receive a one-dimensional array of integers from a scanning unit, the one-dimensional array representing a bit stream to be further encoded. For example, the one-dimensional array may be a result of run-level encoded two-dimensional array of quantized coefficients that were scanned in a pre-defined pattern.
[0013] The one-dimensional array of integers received by the entropy coding unit is compressed with a combination code based on the Golomb-Rice and exponential Golomb codes. For small values in the array, Golomb-Rice codes are used. For large values, exponential Golomb codes are used. Switching among the code families is impliedly signaled between an encoder and a decoder according to codewords produced by encoding previous data. Within the encoder and decoder, each unit manages selection of appropriate code families using three parameters: an order of an associated Golomb-Rice code (called “kRice” herein), an order of an associated exponential Golomb code (called “kExp”), and a switch value indicating when to switch between the two types of codes.
[0014] In 100 , a threshold value is calculated as FirstExpN=(lastRiceQ+1) * 2 kRice , where lastRiceQ is the largest value of q for which the Golomb-Rice code still applies. For example, lastRiceQ may be chosen to maximize compression efficiency of the encoding scheme with regards to a source distribution.
[0015] In 102 , the entropy encoding unit tests whether n is smaller than FirstExpN. A value n to be encoded is selected from the one-dimensional array, for example, a first un-encoded value. Values less than FirstExpN are encoded with a Golomb-Rice code. Values greater than or equal to FirstExpN are encoded with a modified exponential Golomb code.
[0016] If yes, n is a small value to be encoded with a Golomb-Rice code and the procedure proceeds to 104 . If no, n is to be encoded with an exponential Golomb code and the procedure proceeds to 110 . In FIG. 1 , the left side of the flowchart indicates a sub-procedure to encode n with a Golomb-Rice code. The right side of the flowchart indicates a sub-procedure to encode n with an exponential Golomb code.
[0017] Steps 104 , 106 , and 108 are a sub-procedure for encoding n with a Golomb-Rice code. In 104 , a quotient q is calculated with respect to 2 k , q =floor (n/2 k ). In 106 , a remainder r is calculated as r=n mod 2 k , r corresponds to the k least-significant bits of the binary representation of n, and q to the remaining most-significant bits. In 108 , the codeword C representing n consists of q zero bits, a single one bit, and k bits containing the binary representation of r. The length of C is q+1+k.
[0018] Steps 110 , 112 , and 114 are a sub-procedure for encoding n with an exponential Golomb code. In 110 , x is calculated as x=n−FirstExpN. In 112 , the number of zero bits in the code prefix is calculated as q=floor (log 2 (x+2 k ))−k, where k is the code order. If the minimal-length binary representation of x+2 k requires b bits, then floor (log 2 (x+2 k )) is simply b−1. In 114 , the codeword C is (lastRiceQ+1+q) zero bits followed by (q+k+1) bits containing the binary representation of x+2 k .
[0019] In 116 , the entropy encoding unit tests whether all values from the one-dimensional array have been encoded. If yes, the procedure ends and each codeword C representing a corresponding encoded n is outputted to a channel as a bit stream. If no, the procedure returns to 100 , where a next value n will be encoded.
[0020] It will be appreciated that during decoding, a crossover point where the coding scheme changes can be calculated as follows: if an encoded value begins with lastRiceQ or fewer zero bits, an order-kRice Golomb-Rice codeword is decoded. If not, the first lastRiceQ+1 zero bits are ignored, then an order-kExp exponential Golomb codeword is decoded, and FirstExpN is added.
[0021] There are several ways for the decoder to know what codebook (kRice, firstRiceQ, and kExp) to use. The codebook can be fixed and built in the system, so both encoder and decoder use the same codebook. The codebook can also be sent as side information from the encoder to the decoder. Finally, if both encoder and decoder follow the same adaptation rule, the codebook to use for the next codeword is a function of previous codewords, which the decoder has already decoded.
[0022] FIG. 2 illustrates an encoder according to an embodiment of the present invention. The encoder 200 may be implemented in hardware or software and receives a source image 202 , a digital image. For example, the source image 202 may be a picture from a frame as described below. It should be understood that the encoder 200 may also receive a video, where each picture making up the video will be encoded.
[0023] The source image 202 is first transformed by a discrete cosine transform (“DCT”) unit 204 . The transform converts spatial variations into frequency variations and produces an array of transform coefficients associated with the source image 202 .
[0024] A quantization unit 206 then quantizes (e.g., divides) the array of coefficients produced by the DCT unit 204 by a quantization parameter such as a quantizer, producing an array of quantized coefficients. For example, high frequency coefficients are generally small and may be quantized to zero, making encoding quantized coefficients as (run, level) pairs more efficient than encoding them symbol by symbol. A plurality of quantization units may be available within the encoder 200 .
[0025] A scan unit 208 then scans the array of quantized coefficients and converts it into a string of run and level values. Typically, many high frequency coefficients are quantized to zero. By starting in the low frequency corner of the matrix, then zigzagging through the array, the coefficients are combined into a string with the zero-valued ones grouped together.
[0026] An entropy encoding unit 210 may then further encode the string, as described in FIG. 1 . The resulting bit stream may be outputted into a channel 212 . From the channel 212 , the bit stream may be transmitted or stored.
[0027] The process described above may be reversed in a decoder, where the decoder includes a run-level decoding unit 214 , an inverse scan unit 216 , an inverse quantization unit 218 , and an inverse DCT unit 220 . Each unit performs the inverse of its counterpart in the encoder 200 , producing a decoded image 222 . The inverse quantization unit cannot recover coefficients perfectly because they have been quantized. Therefore, the compression process is lossy. The decoded image 222 is a close approximation of the source image 202 .
[0028] It will be understood that a plurality of encoders may be available and operating in parallel.
[0029] FIG. 3 illustrates a syntax according to an embodiment of the present invention. An encoded video 300 may include a sequence of encoded frames.
[0030] An encoded frame 302 may include a plurality of fields. A size field 304 indicates the size of the encoded frame in bytes. A frame header field 308 includes header information, such as frame dimension, color information, frame structure, and the like. An encoded picture field 310 includes information sufficient to decode a picture. A second encoded picture field 312 , which includes information sufficient to decode a second picture, may be present. Typically a second encoded picture field is only present in an interlaced video frame. A stuffing field 314 may be included to guarantee the frame 302 is of a predetermined size.
[0031] An encoded picture 320 may include a plurality of fields. A picture header field 322 includes header information, such as metadata related to the picture. A slice table field 324 may contain a slice table indexing all slices stored in the picture. A plurality of slice fields 326 , 328 , and 330 may contain individual slices. It will be appreciated that any number of slice fields may be included in the picture 320 .
[0032] A slice 340 may include a plurality of fields. A slice header field 342 includes header information, such as metadata related to the slice. A Y data field 344 includes luminance information of the slice. A Cb data field 346 includes blue chrominance information of the slice. A Cr data field 348 includes red chrominance information of the slice.
[0033] FIG. 4 illustrates a picture division scheme according to an embodiment of the present invention. For example, a picture 400 may be 720 pixels horizontally and 486 lines vertically. Each pixel may be associated with display property data (luminance, blue chrominance, and red chrominance).
[0034] The picture is further divided into macroblocks, with each macroblock including an array of 16×16 pixels. Any number of macroblocks may be combined into a slice. For example, a plurality of eight macroblocks 42 may be combined into a first slice. Similarly, a plurality of four macroblocks 404 may be combined into a second slice. As described in FIG. 3 , a slice may contain display property data of its associated pixels, where the pixels are organized by macroblock. Optionally, macroblock data may be organized into sub-macroblock partitions (e.g., 8×8 blocks) for coding.
[0035] Although the preceding text sets forth a detailed description of various embodiments, it should be understood that the legal scope of the invention is defined by the words of the claims set forth below. The detailed description is to be construed as exemplary only and does not describe every possible embodiment of the invention since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the invention.
[0036] It should be understood that there exist implementations of other variations and modifications of the invention and its various aspects, as may be readily apparent to those of ordinary skill in the art, and that the invention is not limited by specific embodiments described herein. It is therefore contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principals disclosed and claimed herein.
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A method and system are provided for encoding a plurality of integers with variable-length code tables constructed by combining a plurality of structured code tables. Each code table has an associated set of integer values; the sets are disjoint and exhaustive, so that every integer appears in exactly one set. An integer is encoded using the codebook associated with the set in which the integer appears.
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BACKGROUND OF THE INVENTION
The invention described herein was made in the course of, or under, Contract No. EX-76-C-01-2356, with the U.S. Department of Energy.
The invention relates to rotary valves, particularly to a drive mechanism for rotary valves, and more particularly to a sequenced drive for such valves which provides both quasi-linear and rotary motions to the movable element of the valve.
The benefits of applying rotary and linear motions to the movable sealing element of a valve are well known: linear motion when engaging with or disengaging from the seat minimizes wear or damage due to scrubbing of the element against the seat, while rotary motion, used to swing the element out of the flowpath, leaves the flowpath unobstructed. Prior known mechanisms which provide this sequential motion usually have drawbacks such as dependence on delicate members that rely on friction or wedging actions, exposure to the flow medium, and complications arising from asymmetrical deflections and backlashes.
SUMMARY OF THE INVENTION
The present invention is directed to an improved sequenced drive for rotary valves which provides the advantages of rotary and linear motion to the movable sealing element, but overcomes the drawbacks of prior known sequenced drive mechanisms. This is accomplished by a shaft and linkage arrangement which smoothly and effectively provides linear translation and rotary movement of the sealing element with minimized damage to the valve seat and without obstructing the flowpath through the valve.
Therefore, it is an object of this invention to provide an improved sequenced drive for rotary valves.
A further object of the invention is to provide a mechanism capable of applying rotary and linear motions to the movable sealing element of a valve.
Another object of the invention is to provide a sequenced drive which includes a linkage and shaft mechanism which provides rotary and linear motions to the movable valve element which minimizes valve seat damage and flowpath obstruction.
Other objects of the invention will become readily apparent to those skilled in the art from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of a valve incorporating the sequenced drive of the inventions with the movable element in the seated position;
FIG. 2 illustrates the movable element of the FIG. 1 valve in the translation mode;
FIG. 3 illustrates the FIG. 1 valve with the movable element in the rotation mode;
FIG. 4 shows an embodiment of the sequence drive mechanism of the invention for a valve, similar to FIG. 1, but of opposite direction of rotation, as translation on the movable element commences;
FIGS. 5 and 6 illustrate the sequence drive mechanism of the invention of FIG. 4 as it commences and completes, respectively, rotation of the movable element;
FIG. 7 is a view partially in cross-section of an embodiment of a rotary valve to be driven by the sequenced drive of the invention; and
FIGS. 8 and 9 illustrate end and side views, respectively, of the linkage for the rotary valve of the FIG. 1 embodiment to provide symmetry of the sequenced drive.
DETAILED DESCRIPTION OF THE INVENTION
The invention involved an improved sequenced drive mechanism for rotary valves which provides linear and rotary motions to the movable sealing member. The drive mechanism minimizes wear or damage due to scrubbing action with the valve seat, and minimizes flowpath obstruction. The sequenced drive mechanism of this invention overcomes the above-mentioned drawbacks of the prior known drive mechanisms for rotary valves.
The operating sequence of the valve, as illustrated in FIGS. 1-3, is as follows:
1. With the movable sealing element C in the seated position on valve seat D of housing E, as shown in FIG. 1, the mechanism, illustrated in FIGS. 4-6 and described hereinafter, rotates shaft A while restraining shaft B from rotation. Because element C is fixed to shaft B, restraint of shaft B prevents rotation of element C.
2. As rotation of shaft A occurs, element C translates away from seat D, as shown in FIG. 2, because of the eccentric mounting of shaft B in shaft A.
3. At the desired time, shaft B is rotated, thus swinging element C out of the flow path, as shown in FIG. 3.
The sequence, above described, is reversed to close the valve wherein element C is again positioned on seat D as shown in FIG. 1.
The linkage and shaft arrangement of the sequenced drive mechanism for a rotary valve similar to that illustrated in FIGS. 1-3 is illustrated in FIGS. 4-6 showing the translation and rotation sequence of the drive mechanism which provides the operating sequence of the valve as above described, but in opposite rotational direction compared to that of FIGS. 1-3; the sequence being as follows:
1. To open the valve element C. link 1 (the driving link), attached at one end to a driveshaft 2, indicated by legend, and connected at the other end via a cam follower or pin 3 to a link 4 fixedly connected to shaft A, link 4 having a slot 5 therein. Link 1 is rotated by drive shaft 2 in a counter-clockwise direction, as indicated by the direction arrow thereon, causing shaft A to be driven in a clockwise direction via cam follower 3. The rotation of the sealing element C is determined solely by the orientations of a cam follower or pin 6 (fixed in housing E) and shaft B. A link 7 is fixed to shaft B and consists of two arms 8 and 9, arm 8 having an open slot 10 in the end thereof which cooperates with cam follower 6, while arm 9 is provided with a slot 11 within which a cam follower or pin 12, fixed to link 1, is positioned, slot 11 having wide and narrow sections. If desired, slot 11 need not be closed as shown. Initial rotation of link 1 does not influence the rotation of element C because cam follower 12 (rigidly fixed to link 1) moves along the wide section of the slot 11 in arm 9 of link 7, whereby arm 9 is not moved. The result is that shaft B is restrained from rotation while shaft A is rotated (see FIG. 4). Therefore, element C moves away from seat D, translation position of FIG. 2, with essentially no rotation thereof.
2. Continued counter-clockwise rotation of link 1 results in simultaneous disengagement of slot 10 in arm 8 of link 7 from cam follower 6 and engagement of cam follower 12 with narrow section of slot 11 in arm 9 of link 7, as shown in FIG. 5, whereby element C commences clockwise rotation as indicated by the direction arrow. The rotation of element C is determined by the orientations of cam follower 12 on link 1, and shaft B. As link 1 continues to rotate, shaft B is rotated by cam follower 12 through arm 9 of link 7, and element C rotates to the position shown in FIG. 6 providing essentially an unrestricted flowpath through the opening F in valve body E.
3. Reseating of element C on valve seat D results from clockwise rotation of link 1 by driveshaft 2, and the reverse of the above sequence of the linkage movement.
The entire sequenced drive mechanism of FIGS. 4-6, except for element C and an exposed end of shafts A and B, may be isolated from the flow medium passing through opening F in the valve body. FIG. 7 illustrates such an isolated shaft arrangement and consists of the shaft assembly positioned in an opening G of the valve body E. The shaft assembly, in addition to shafts A and B, comprises a thrust washer 13 and is positioned about shaft B at the end thereof opposite element C, a radial bearing assembly generally indicated at 14 located intermediate shafts A and B, combination radial/thrust bearings 15 positioned about shaft A, and shaft seals 16 positioned about shaft A and B, respectively. The shaft assembly is retained in opening G by a threaded retainer means 17 which cooperates with helical threads 18 in valve housing or body E.
The linkage, illustrated in FIGS. 4-6, may be arranged as shown in FIGS. 8 and 9, and consists of two mirror-image sets of linkage, one on each side of the valve body, with their driving links jointed by a drive shaft 2' running external to the valve having a central drive point 19. This arrangement has the following advantages:
1. No internal driveshafts or yokes are required.
2. By driving the driveshaft centrally, the arrangement is entirely symmetrical. This makes torsional deflections and backlash symmetrical, to assure precise synchronization of the two sets of linkage. This avoids, among other things, any tendency to twist the seating element.
3. The actuator, not shown, can drive the drive shaft through spur gears, bellcranks, rack-and-pinion, chain-and-sprocket, worm-and-pinion, "V" belts and other friction devices, or other gear systems. The actuator can be mounted at virtually any angle with respect to the drive shaft. In fact, in any single valve-actuator assembly, provisions can be made for universal mounting of the actuator.
It has thus been shown that the present invention provides a sequenced drive mechanism for rotary valves which provides the benefits of linear and rotary motions to the movable sealing element without the drawback of the prior known drive mechanisms and without complications arising from asymmetrical deflections and backlashes.
While a particular embodiment of the invention has been illustrated and described, modifications will become apparent to those skilled in the art, and it is intended to cover in the appended claims all such modifications as come within the spirit and scope of the invention.
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A sequenced drive for rotary valves which provides the benefits of applying rotary and linear motions to the movable sealing element of the valve. The sequenced drive provides a close approximation of linear motion while engaging or disengaging the movable element with the seat minimizing wear and damage due to scrubbing action. The rotary motion of the drive swings the movable element out of the flowpath thus eliminating obstruction to flow through the valve.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/640,918, filed Dec. 31, 2004, the entire contents being incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to disposable pulpless absorbent articles including superabsorbent materials which absorb water and aqueous liquids and provide improved properties, in particular faster absorption time, while maintaining acceptable fluid capture and retention properties.
BACKGROUND OF THE INVENTION
[0003] For fit, comfort and aesthetic reasons and from environmental aspects, there is an increasing trend to make disposable absorbent articles smaller and thinner. Disposable absorbent articles often contain superabsorbent materials and fiber or fluff to improve liquid handling characteristics of the articles. One may propose that the physical size of such articles could simply be reduced by decreasing the content of the high volume fluff fiber within the articles. However, since fiber acts to quickly, but temporarily, absorb liquid insults prior to capture by the superabsorbent material, a reduction of fiber content may lead to unacceptable fluid handling characteristics, such as liquid leakage, slow liquid capture and gel blocking.
[0004] Superabsorbent refers to a water-swellable, water-insoluble, organic or inorganic material capable of absorbing at least about 10 times its weight and up to about 30 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride solution in water. A superabsorbent polymer is a crosslinked neutralized polymer which is capable of absorbing large amounts of aqueous liquids and body fluids, such as urine or blood, with swelling and the formation of hydrogels, and of retaining them under a certain pressure in accordance with the general definition of superabsorbent. The superabsorbent polymers that are currently commercially available are crosslinked polyacrylic acids or crosslinked starch-acrylic acid graft polymers, in which some of the carboxyl groups are neutralized with sodium hydroxide solution or potassium hydroxide solution. As a result of these characteristic properties, these polymers are chiefly used for incorporation into sanitary articles, such as babies' diapers, incontinence products and sanitary towels.
[0005] In future absorbent article constructions, it is expected that there will be less fiber material, or potentially none at all. The superabsorbent polymer of future diaper constructions must have a sufficiently high absorption rate to maximize the use of available capillary spaces and to compensate for the reduction or substantial elimination of typically fast absorbing fibers.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to disposable pulpless absorbent articles including superabsorbent materials which absorb water and aqueous liquids and provide improved properties, in particular faster absorption time while maintaining acceptable fluid retention properties. To offset a reduction in fiber levels an improved superabsorbent material may be necessary in order to provide acceptable fluid handling characteristics, such as equivalent total retention capacity of body fluids, etc.
[0007] Disposable absorbent articles according to the present invention have higher centrifugal retention capacity (CRC) values, higher absorbency rate index (ARI) values and/or higher percentage absorbency rate index (PARI) as compared to products manufactured with existing pulp-containing technologies.
[0008] It is therefore an object of the present invention to provide a disposable absorbent article having a superabsorbent composition with an increased rate of liquid absorption, particularly within the targeted insult region. It is another object is to maintain acceptable liquid handling properties and liquid retention characteristics even when the fiber content is reduced or eliminated and the amount of superabsorbent material is increased in percent by weight based on the absorbent structure. This may be achieved by increasing the absorption rate of the superabsorbent polymer. Additionally, the selective placement of superabsorbent material within the absorbent core may yield benefits.
[0009] Absorbent articles according to the present invention contain minimal or no fluff material in order to address the increasing trend to make sanitary articles smaller and thinner. To offset a reduction in fiber levels an improved superabsorbent material may be used to provide acceptable fluid handling characteristics, such as equivalent total retention capacity of body fluids.
[0010] The present invention is also directed to a method of manufacturing a pulpless disposable absorbent article having acceptable or better fluid handling capabilities as compared disposable absorbent articles containing fiber or fluff. These and other objects of the invention will be more readily apparent when considered in reference to the following description and when taken in conjunction with the accompanying drawings.
[0011] Still other embodiments of the inventive disposable article and their manufacturing methods will become readily apparent to those skilled in the relevant art from the following detailed description of the drawings, wherein the various embodiments of the invention are described by way of illustrating the best mode contemplated for carrying out the invention. The invention is capable of other and different embodiments, its several details are capable of modification and its several structural or processed details are capable of modification in various and obvious respects, all without departing from the spirit and the scope of the present invention. Accordingly, the following drawings and detailed description of the drawings are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the invention and the accompanying drawings wherein like numerals represent like elements, and in which:
[0013] FIG. 1 representatively shows a perspective view of an a disposable absorbent article of the present invention.
[0014] FIG. 2 depicts a top plan view of disposable absorbent article.
[0015] FIG. 3 depicts a top plan view of the disposable absorbent article of FIG. 2 .
[0016] FIG. 4 depicts top plan views of forms of disposable absorbent articles suitable for application of the present invention.
[0017] FIG. 5 is a graphical representation of the CRC values over time for the various samples of Table 1.
[0018] FIG. 6 is a graphical representation of the CRC values in percentage form for the various samples of Table 1.
DETAILED DESCRIPTION
[0019] The present invention concerns a disposable absorbent article having an absorbent core structure used to absorb and retain liquids, such as urine or blood. The absorbent core structure is typically, or forms typically part of, a disposable absorbent article, such as preferably diaper and training pants, sanitary napkins, panty liners, and adult incontinence products.
[0020] The absorbent core structure forms part of a disposable absorbent article which is adapted to be worn adjacent to the body of a wearer to absorb and contain various exudates discharged from the body. The absorbent article may be configured to closely conform to the body of the wearer to assist in effective containment of body exudates.
[0021] In one embodiment, an absorbent article of the present invention will be described in terms of a disposable diaper which is adapted to be worn about the lower torso of a child. It is understood that the articles and methods of the present invention are equally adaptable for other types of absorbent articles, such as adult incontinent products, training pants, feminine hygiene products, other personal care or health care garments, and the like.
[0022] FIG. 1 representatively shows one example of a disposable absorbent article generally indicated at 10 and incorporating aspects of the present invention. FIG. 1 illustrates a diaper in a perspective view as worn by a user.
[0023] The illustrated diaper 10 includes a body 12 which generally defines a front waist region 14 , a rear waist region 16 , and a crotch region 18 which extends between and connects the front and rear waist regions 14 and 16 . The body 12 further defines a pair of laterally opposed side edges 20 , a pair of longitudinally opposed waist edges 22 , an interior body facing surface 24 which is configured to contact the wearer, an outer garment facing surface 26 opposite the interior surface 24 which is configured to contact the wearer's clothing in use. The outer surface 26 may be defined by an outer cover layer 34 and the interior surface 24 may be defined by a body side liner 36 . Diaper 10 includes an absorbent core 38 which may be located between the outer cover 34 and the body side liner 36 .
[0024] The front waist region 14 comprises the portion of the diaper 10 which, when worn, is positioned on the front of the wearer while the rear waist region 16 comprises the portion of the diaper 10 which, when worn, is positioned on the back of the wearer. The crotch region 18 comprises the portion of the diaper 10 which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer. The laterally opposed side edges 20 of the diaper 10 generally define portions of the leg openings. The waist edges 22 of the absorbent body 12 of the diaper 10 are configured to encircle the waist of the wearer when worn and provide a waist opening when fastened that defines a waist perimeter dimension.
[0025] The disposable absorbent article according to the present invention provides a close fitting seal around the thighs of the user, thereby significantly improving its leakage prevention capability. The close fitting seal of the inventive garment is at least partially provided through addition of fastening element 40 . The fastening element 40 may include known adhesive elements or hook fastening devices. A hook fastening element may be selected so as to be engageable with the loops formed on the surface of a nonwoven fabric. Thus, the nonwoven material of the stretchband panel provides the loop element of a hook and loop fastening system similar to those generally known in the art. In further embodiments, a loop landing tape may be located near the front waist region of the outside face of the inventive article, and a pair of hook fastening elements may be located near the rear waist region. The loop landing tape may be constructed from a knitted, extruded, or non-woven material, as is generally known in the art. A variety of fastener systems and devices are known to those of ordinary skill in the art. A particular fastener choice would not otherwise alter the scope of the appended claims.
[0026] The diaper 10 may further include leg elastics, containment flaps, and waist elastics as are known to those skilled in the art. For example, the absorbent body 12 of the disposable diaper 10 may include a pair of containment flaps which are configured to provide a barrier to the lateral flow of exudates. The containment flaps may be located along the laterally opposed side edges 20 of the absorbent body 12 .
[0027] The disposable diaper 10 may further optionally include elastics at the waist edge 22 of the diaper 10 to further prevent leakage of body exudates. For example, the disposable diaper may further comprise elastic waist features that help provide improved fit and containment of body exudates.
[0028] A diaper 10 according to the present invention may also include a pair of leg elastic members which are connected to the laterally opposed side edges 20 in the crotch region 18 of the diaper 10 . The leg elastics are generally adapted to fit about the legs of a wearer in use to maintain a positive, contacting relationship with the wearer to effectively reduce or eliminate the leakage of body exudates from the diaper 10 . Materials suitable for use as the leg elastics and waist elastic are well known to those skilled in the art. Exemplary of such materials are sheets or strands or ribbons of a polymeric, elastomeric material which are adhered to the outer cover 34 in a stretched position, or which are attached to the outer cover 34 while the outer cover is pleated, such that elastic constrictive forces are imparted to the outer cover 34 . The leg elastics may also include such materials as polyurethane, synthetic and natural rubber. Leg elastics, containment flaps and waist elastics may include elastic foam materials, elastic films (apertured, woven and non-woven, for example), elastic scrim material, elastic non-woven materials, elastic composites, and selectively activated elastic materials.
[0029] The diaper 10 may be of various suitable shapes. For example, in the unfastened configuration, the diaper may have an overall rectangular shape, T-shape or an approximately hourglass shape. The various aspects and configurations of the invention can provide distinctive combinations of softness, body conformity, reduced red-marking of the wearer's skin, reduced skin hydration, improved containment of body exudates and improved aesthetics.
[0030] The various components of the diaper 10 may be integrally assembled together employing various types of suitable attachment means, such as adhesive, sonic and thermal bonds or combinations thereof. In the illustrated shown embodiments, for example, the outer cover 34 and body side liner 36 are joined to each other. Similarly, other diaper components, such as the leg elastics and primary fasteners, may be assembled into the diaper 10 by employing the above-identified attachment mechanisms. Desirably, the majority of the diaper components are assembled together using ultrasonic bonding techniques for reduced manufacturing cost and improved performance.
[0031] The outer cover 34 of the diaper 10 may suitably be composed of a material which is either liquid permeable or liquid impermeable. It is generally preferred that the outer cover 34 be formed from a material that is substantially impermeable to liquids. A typical outer cover can be manufactured from a thin plastic film or other flexible liquid-impermeable material. For example, the outer cover 34 may be formed from a polyethylene film. If it is desired to present the outer cover 34 with a more cloth-like feeling, the outer cover 34 may comprise a polyolefin film having a nonwoven web laminated to the outer surface thereof, such as a spunbond web of polyolefin fibers. For example, a stretch-thinned polypropylene film may have thermally laminated thereto a spunbond web of polypropylene fibers. Methods of forming such cloth-like outer covers are known to those skilled in the art.
[0032] Further, the outer cover 34 may be formed of a woven or nonwoven fibrous web layer which has been totally or partially constructed or treated to impart a desired level of liquid impermeability to selected regions that are adjacent or proximate the absorbent core 38 . Still further, the outer cover 34 may optionally be composed of a micro-porous “breathable” material which permits vapors to escape from the absorbent core 38 while still preventing liquid exudates from passing through the outer cover 34 . For example, the outer cover 34 may comprise a stretched microporous polyolefin film having a nonwoven web laminated to the outer surface thereof, such as a spunbond web of polyolefin fibers. The outer cover 34 can also be embossed or otherwise provided with a matte finish to provide a more aesthetically pleasing appearance.
[0033] The bodyside liner 36 suitably presents a bodyfacing surface which is compliant, soft feeling, and nonirritating to the wearer's skin. Further, the bodyside liner 36 may be less hydrophilic than the absorbent core 38 , to present a relatively dry surface to the wearer, and may be sufficiently porous to be liquid permeable, permitting liquid to readily penetrate through its thickness. A suitable bodyside liner 36 may be manufactured from a wide selection of web materials, such as porous foams, reticulated foams, apertured plastic films, natural fibers (for example, wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The bodyside liner 36 is suitably employed to help isolate the wearer's skin from liquids held in the absorbent core 38 .
[0034] Various woven and nonwoven fabrics can be used for the bodyside liner 36 . For example, the bodyside liner maybe composed of a meltblown or spunbonded web of polyolefin fibers. The bodyside liner may also be a bonded-carded web composed of natural and/or synthetic fibers. The bodyside liner may be composed of a substantially hydrophobic material, and the hydrophobic material may, optionally, be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. The bodyside liner 36 may further include a lotion or treatment applied thereto to which is configured to treat or be transferred to the wearer's skin.
[0035] The absorbent core 38 of the diaper 10 contains particles of a high-absorbency material commonly known as superabsorbent material. In a particular embodiment, the absorbent core 38 comprises superabsorbent hydrogel-forming particles. The superabsorbent particles may be selectively placed into desired zones of the absorbent core 38 to better contain and absorb body exudates. The concentration of the superabsorbent particles may also vary through the thickness of the absorbent core 38 . Alternatively, the absorbent core 38 may comprise a laminate of fibrous webs and superabsorbent material or other suitable means of maintaining a superabsorbent material in a localized area.
[0036] The high-absorbency material can be selected from natural, synthetic, and modified natural polymers and materials. The high-absorbency materials can be inorganic materials, such as silica gels, or organic compounds, such as crosslinked polymers. The term “crosslinked” refers to any means for effectively rendering normally water-soluble materials substantially water insoluble but swellable. Such means can include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations such as hydrogen bonding, and hydrophobic associations or Van der Waals forces.
[0037] Examples of synthetic, polymeric, high-absorbency materials include the alkali metal and ammonium salts of poly(acrylic acid) and poly(methacrylic acid), poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha-olefins, poly(vinyl pyrolidone), poly(vinyl morpholinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Further polymers suitable for use in the absorbent core include natural and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums, such as alginates, xanthum gum, locust bean gum, and the like. Mixtures of natural and wholly or partially synthetic absorbent polymers can also be useful in the present invention. Such high-absorbency materials are well known to those skilled in the art and are widely commercially available.
[0038] The high absorbency material may be in any of a wide variety of geometric forms. As a general rule, it is preferred that the high absorbency material be in the form of discrete particles. However, the high absorbency material may also be in the form of fibers, flakes, rods, spheres, needles, or the like. As a general rule, the high absorbency material is present in the absorbent body in an amount of from about 85 to about 100 weight percent based on total weight of the absorbent core 38 .
[0039] One superabsorbent material suitable for use in an embodiment of the present invention has a vortex time of approximately 30 seconds. Alternative superabsorbent materials having similar or higher vortex times may also be practicable. A range of vortex times for superabsorbent materials which may used to practice the present invention is between 10 and 120 seconds.
[0040] The superabsorbent material may be selectively placed within the absorbent core 38 so that more material is within the target zone or portions thereof as compared to portions of the core 38 outside of the target zone. Additionally, the amount of superabsorbent material or even the composition of a superabsorbent material may vary depending on the particular zone or portion of the core 38 .
[0041] The absorbent core 38 may have any of a number of shapes. For example, the absorbent core may be rectangular, I-shaped, or T-shaped. In the embodiment of FIG. 1 , the absorbent core is generally rectangular in shape. The size and the absorbent capacity of the absorbent core 38 should be compatible with the size of the intended wearer and the liquid loading imparted by the intended use of the absorbent article.
[0042] FIG. 2 illustrates a disposable absorbent article 10 including an absorbent core 38 divided into ten generally equally spaced sections or zones numbered one through ten. FIG. 3 discloses the target region of the article 10 defined between approximately Zone 2 through Zone 7. In this example, the target region of the absorbent article is generally defined as the portion between the 10% to 80% dimensions as measured from the front edge 44 of the absorbent core 38 . The absorbent article 10 of FIG. 3 is a general representation of an absorbent article and alternative sizes, shapes and features would be appreciated by those of ordinary skill in the art. For example, the side edges of an alternative embodiment of an absorbent article according to the present invention may be concave or otherwise non-linearly configured.
[0043] FIG. 4 illustrates various alternative embodiments of absorbent articles 10 and depicts target zones for these embodiments. As illustrated, the target regions of the products may be defined as a portion of the overall absorbent core 38 or even as the entire absorbent core 38 (as shown in adult incontinence pad 46 ). The insult target region is the primary region receiving liquid or fecal insults during product use. The target insult region may be defined, as shown in FIGS. 2 and 3 , to include multiple zones of the absorbent core 38 .
[0044] Table 1 includes Centrifugal Retention Capacity (CRC) data of various current absorbent products and a preferred embodiment of the present invention, referred to as “Working Product T3CM”. Less preferred embodiments utilizing aspects of the present invention are referred to as Experimental Products A and B. Referring again to FIG. 2 , the CRC data was compiled for various size 4 (10 kg-17 kg) diapers divided into ten equal length zones. The CRC was measured at 0.5, 1, 2, 4 and 30 minutes.
[0045] The CRC data of Table 1 was collected by experimentation according to the following test protocol.
[0046] Zoned Centrifuge Retention Capacity Test
[0047] Equipment and materials:
[0048] 1. Large plastic tray
[0049] 2. Hanging apparatus with clips
[0050] 3. Plastic weighing pans
[0051] 4. Measuring rule
[0052] 5. Fine tip, permanent marker pen
[0053] 6. Scissors
[0054] 7. Timer
[0055] 8. 0.9% saline solution
[0056] 9. Electronic top loading scale accurate to 0.01 gm.
[0057] 10. Centrifuge (1400 rpm) with drain
[0058] Procedure
1. Position the plastic tray under the hanging apparatus. Fill with an excess amount of 0.9% saline solution. 2. Weigh 14 diapers and record the weight of each diaper as WI. 3. Measure the length of the core of each diaper and divide into 10 sections of equal length. Using a permanent, fine tip marker pen, draw a line marking the longitudinal edge of each of the 10 sections. 4. Starting from the front of the diaper number the sections 1 through to 10, with 10 being the rearmost section. 5. Take two of the weighed and marked diapers and immerse in the saline solution for 30 seconds. Ensure that during this time the diapers are fully immersed. 6. After the allotted time, remove the diapers from the saline solution and immediately transfer to the centrifuge, placing the diapers in the centrifuge with the nonwoven against the centrifuge wall. Start the centrifuge and spin for 3 minutes. 7. Remove the diapers from the centrifuge, place the diapers in the tared weighing pans and record each weight as WF. 8. With the scissors carefully cut along the lines separating each of the ten sections of the diaper. Weigh each divided section of the diaper, gathering up any pieces of core material that may have dropped out of each section during cutting and including in these in the weight measurement. Record the weight of each section as Sn, where n is the section number. 9. Repeat steps 5 to 8 but successively increase the immersion time to 1 minute, 2 minutes, 4 minutes, 10 minutes and 30 minutes. 10. Finally, take two weighed, diapers and divide into the marked sections. Weigh each section to record the dry, unswollen weight of each section as Dn. 11. Perform calculations:
Overall centrifuge retention capacity CRC=WF−WI
Retention capacity per section at time t=Sn−Dn
[0070]
TABLE 1
Core profile and CRF absorbency rate per zone
Immersion
CRC
FRONT Centrifuge Retention Capacity per section (g) → REAR
Product
Time (min)
(g)
1
2
3
4
5
6
7
8
9
10
Experimental
0.5
67
4.7
7.8
7.6
8.2
7.8
7.6
7.6
4.5
4.5
3.6
product A
1
82
6.5
9.7
9.4
9.3
9.7
9.8
8.6
5.6
5.4
4.1
2
109
8.2
11.4
12.8
14.0
12.7
13.2
11.8
8.5
7.2
5.5
4
216
18.1
22.6
23.3
24.4
26.0
24.0
22.6
19.8
18.7
13.0
30
538
55.6
70.2
72.7
70.0
62.3
56.6
50.8
32.1
42.3
23.0
Pampers
0.5
83
9.6
9.1
9.5
10.8
11.3
7.7
5.7
5.8
5.7
6
Baby Dry
1
116
12.9
15.7
14.4
16.2
12.6
12.7
7.7
7.4
8.5
8
(10-17 kg)
2
111
12.3
12.9
12.9
14.3
14.3
12.4
6.7
7.1
8.2
8.1
4
152
15.5
20.8
20.6
15.8
21.9
18
11.3
9.5
8.9
8.7
30
281
33.2
36.6
37.9
36
33.7
29.5
22.5
12.4
16.2
21.2
Luvs - Ultra
0.5
91
7.8
10.7
8.2
10.7
11.2
11.4
9.3
7.2
7.3
6
Leakguard
1
103
9.2
10.5
12.8
12.9
10.6
11
9.5
8.8
7.7
7.8
(10-17 kg)
2
125
8.5
13.6
14.3
15.4
13.2
15.4
14
10.3
9.1
9.8
4
158
15.3
16.4
17.7
24.5
16.4
21.3
15
9.4
11.3
8.6
30
265
20.4
23.8
28.1
31.1
26.9
24.1
29.4
20.4
27.7
30.3
Huggies
0.5
125
11.1
13.2
14.9
12.8
12.3
15.9
12.8
11.3
10.3
9.4
Baby
1
146
11.1
16.8
15.5
14.3
15.5
16.5
17.2
13.4
13.3
10.7
Shaped
2
187
16
21.4
20.6
18.8
18.4
20.6
21.2
16.4
17.8
14
(10-17 kg)
4
234
18.6
28
30.7
29.2
22.1
28
22.5
18.3
19.2
16.8
30
266
20.5
32.9
33.5
33.4
25
29.8
28.4
24
19.9
16.7
White
0.5
127
12.1
16
14.4
14.1
12.2
14.8
13.4
10.2
9.3
9.5
Cloud
1
160
14.7
17.2
20.1
20.5
19.2
17.3
13.8
11.1
11.8
12.8
Diaper (10-17 kg)
2
188
17.6
16.9
19.2
20.6
22.7
19
18.4
15.1
17.7
18.9
4
208
22.3
21.6
24.8
23.1
20.3
20.5
20.9
15.8
16.7
19.6
30
330
35.3
35.8
39.9
35.7
36.5
36.5
27.4
26.4
24.9
27.2
Experimental
0.5
191
19.1
19.1
19.1
19.1
19.1
19.1
19.1
19.1
19.1
19.1
product B
1
251
25.1
25.1
25.1
25.1
25.1
25.1
25.1
25.1
25.1
25.1
2
294
29.4
29.4
29.4
29.4
29.4
29.4
29.4
29.4
29.4
29.4
4
350
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
35.0
30
420
42.0
42.0
42.0
42.0
42.0
42.0
42.0
42.0
42.0
42.0
Working
0.5
190
11.7
22.9
24.2
24.3
24.3
25.6
22.6
13.3
12.4
6.9
product
1
232
14.3
28.4
28.9
30.7
29.3
30.6
28.2
15.4
15.5
9.0
T3CM
2
308
17.1
35.7
39.9
39.1
40.2
40.1
36.5
22.4
20.2
18.1
4
374
23.9
40.8
48.8
48.5
48.2
47.4
43.1
24.8
32.4
14.5
30
483
46.4
52.7
59.9
62.7
54.9
57.3
54.0
39.4
43.4
14.4
[0071] Table 1 illustrates that Working Product T3CM had substantially greater CRC values for each zone as compared to currently available diapers. For example, the CRC value for zone 5 of the Working Product T3CM was 54.9 grams at 30 minutes while the CRC values of zone 5 of the Pampers Baby Dry, Luvs—Ultra Leakguard and Huggies Baby Shaped products were 33.7 grams, 26.9 grams and 25 grams, respectively.
[0072] It was determined through consumer use testing that a pulpless product (Experimental Products A & B) that has similar CRC values as current fluff/SAP products would have an insufficient lock up rate. The performance of the Working Product T3CM is achieved through selective zoning and use of a rapid vortex rate SAP.
[0073] One skilled in the art would recognize that a superabsorbent material with a fast vortex rate (less than 40 sec.) used in a conventional fluff/SAP core will lead to gel blocking and premature product failure. Whereas in the Working Product T3CM a fast vortex rate SAP yields acceptable performance without gel blocking.
[0074] Each of currently available products of Table 1 includes conventional pulp fibers acts (which act as temporary reservoirs to capture liquid prior to absorption by the superabsorbent material). In comparison, products according to the present invention are pulpless.
[0075] In another aspect of the invention, the absorbent core by weight contains between 0% to 15% pulp, 55% to 100% superabsorbent, 0% to 45% adhesive or binder or other additive, 0% to 45% nonwoven. A more preferred range of pulp is between 0% and 10% and a yet more preferred range of pulp is between 0% and 5%. As used herein, the term “pulpless absorbent core” is defined to mean an absorbent core having less than approximately 15% pulp. Pulp can include hydrophilic fibers such as: cellulose fibers, for example, mechanical pulp, chemical pulp, semichemical pulp, digested pulp, as obtained from wood; and artificial cellulose fibers, for example, rayon, acetates. Among the above-exemplified fibers, cellulose fibers are widely preferred in existing products. In addition, the hydrophilic fibers may comprise synthetic fibers such as polyamides, polyesters, and polyolefins. Pulp is not limited to the above-exemplified hydrophilic fibers.
[0076] Table 2 provides Absorbency Rate Index values for the tested product samples of Table 1. The Absorbency Rate Index (ARI) is defined as:
[0077] ARI (zone 2 to 7)=Sum of CRC (zone 2 to 7 at 0.5, 1, 2 and 4 minutes)
[0078] For example, the ARI of the Pampers Baby Dry product is the sum of: 54, 79, 74 and 108, or 315. In comparison the ARI of the Working Product T3CM is 828 (144+176+231+277). Table 2 provides minimum ARI values for a Target Desired Rate (720), a more preferred desired rate (756), and a yet more preferred desired rate (815).
TABLE 2 Core absorbency rate in Zone 2 to 7 (Sum of Zone 2 to 7 CRC) Even Pampers Luvs - Ultra Huggies More more Ex- Baby Dry Leakguard Baby White Cloud Working Target desired desired perimental (10-17 kg) (10-17 kg) Shaped Diaper Experimental product desired rate or rate or product A (US) (US) (10-17 kg) (10-17 kg) product B T3CM rate higher higher Immersion time (min) 0.5 47 54 62 82 85 115 144 135 138.6 150 1 57 79 67 96 108 151 176 150 159.6 180 2 76 74 86 121 117 176 231 195 205.8 225 4 143 108 111 161 131 210 277 240 252.0 260 30 383 196 163 183 212 252 341 320 325.0 330 Absorbency Rate Index 0 to 4 min 322 315 326 459 441 652 828 720 756 815
[0079] Table 3 provides comparison between a significantly larger diaper (15-18 kg) and the minimum ARI values for a Target Desired Rate (720), a more preferred desired rate (756), and a yet more preferred desired rate (815). Table 3 illustrates that a pulpless absorbent article according the present invention has an ARI value that is greater than the ARI of a substantially larger product, i.e., White Cloud Training Pant (15-18 kg).
TABLE 3 Core absorbency rate in Zone 2 to 7 (Sum of Zone 2 to 7 CRC) White Cloud Target Even more Training Pants desired More desired desired (15-18 kg) rate rate or higher rate or higher Immersion time (min) 0.5 139 135 138.6 150 1 150 150 159.6 180 2 196 195 205.8 225 4 205 240 252.0 260 30 293 320 325.0 330 Absorbency Rate Index 0 to 4 min 690 720 756 815
[0080] One important aspect of the present invention is the realization that the ARI of a pulpless product must be significantly greater than ARI values of prior absorbent articles which incorporated pulp within an absorbent core. For the conventional fluff/SAP core, additional, though temporary, fluid capacity is provided by the fluff. Whereas in a pulpless core, fluid capacity is achieved solely through the SAP material and not through the fluid capacity of the fluff, i.e., there is little or no temporary fluid storage for a pulpless core. Since a pulpless absorbent core may not effectively wick liquid, the insult target region absorbency rate of an article according to the present invention must be sufficient high in order to prevent premature leakage.
[0081] Zones 2 to 7 effectively define the target insult region of the typical absorbent article in diaper form. Since a pulpless absorbent does not effectively wick fluid, the absorbent product's target region absorbency rate must be sufficient high to prevent premature leakage. Table 2 shows that current conventional diapers all have substantially lower target zone CRC values than a product according to the present invention, e.g., Working Product T3CM. In a preferred embodiment, a pulpless absorbent article according to the present invention provides an ARI value of 700 grains or greater in order to prevent premature leakage.
[0082] Table 4 provides core absorbency rate data expressed in percentage form. For each sample, a percentage of absorbency at time intervals of 0.5, 1, 2 and 4 minutes was obtained by dividing the amount absorbed at a given time interval by the total amount absorbed at 30 minutes. For example, the core absorbency rate data expressed in percentage form for the Working Product T3CM at 0.5 minutes was calculated by dividing 144 (from Table 2) by 483 (from Table 1), or 30%. Continuing with this example, the core absorbency rate data expressed in percentage form at 4 minutes was calculated by dividing 277 (Table 2) by 483 (Table 1), or 57%.
[0083] Table 4 also contains the Percentage Absorbency Rate Index (PARI) from 0 to 4 minutes for the various samples where PARI is defined as the following;
[0084] PARI (zone 2 to 7)=Sum of percentage CRC (zone 2 to 7) at 0.5, 1, 2 and 4 minutes. For example, the PARI value of the Working Product T3CM is calculated as follows: PARI=30+36+48+57=171%.
[0085] Table 4 also discloses targeted preferred ARI and PARI values for embodiments of the present invention. As suggested by Table 4, a pulpless absorbent product according to the present invention would preferably have a PARI value of approximately 170% or greater in order to prevent premature leakage.
TABLE 4 Core absorbency rate in Zone 2 to 7 (Sum of Zone 2 to 7 CRC) expressed as a percentage of total absorbency Even Luvs - Huggies White More more Ex- Pampers Ultra Baby Cloud Working Target desired desired perimental Baby Dry Leakguard Shaped Diaper Experimental product desired rate or rate or product A (10-17 kg) (10-17 kg) (10-17 kg) (10-17 kg) product B T3CM rate higher higher Immersion time (min) 0.5 9% 19% 23% 31% 26% 27% 30% 32.1% 33.0% 35.7% 1 11% 28% 25% 36% 33% 36% 36% 35.7% 38.0% 42.9% 2 14% 26% 32% 45% 35% 42% 48% 46.4% 49.0% 53.6% 4 27% 38% 42% 61% 40% 50% 57% 57.1% 60.0% 61.9% 30 71% 70% 62% 69% 64% 60% 71% 76.2% 77.0% 78.6% Absorbency Rate Index 0 to 4 min 60% 112% 123% 173% 134% 155% 171% 171.4% 180.0% 194.0%
[0086]
TABLE 5
Free Swell absorption rate of entire product (zones 1-10)
Free Swell Capacity (g/diaper)
Product:
Pampers
Luvs - Ultra
Immersion
Experimental
Baby Dry
Leakguard
Huggies Baby
White Cloud
Experimental
Working
time (min)
product A
(10-17 kg)
(10-17 kg)
Shaped (US)
Diaper (10-17 kg)
product B
product T3CM
0.5
118
382
451
411
343
152
295
1
142
445
523
426
409
207
401
2
194
482
615
467
495
287
532
4
372
510
659
567
553
358
631
30
681
556
845
768
734
549
773
[0087] Table 5 provides free swell absorption rate data for the investigated products of Table 1. Table 5 shows that the Working Product T3CM has an free swell which offers comparable performance to currently available products. Even though the Experimental Products A and B have similar free swell capacity as compared to conventional fluff/SAP products, Products A and B failed to provide acceptable performance as indicated in consumer use testing.
[0088] FIG. 5 is a graphical representation of the CRC values over time for the various samples of Table 1. FIG. 4 also illustrates targeted desired rates for embodiments of the present invention.
[0089] FIG. 6 is a graphical representation of the CRC values in percentage form for the various samples of Table 1. FIG. 5 also illustrates targeted desired rates for embodiments of the present invention.
[0090] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A disposable absorbent article comprising a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core interposed between the topsheet and the backsheet. The absorbent member is defined by a pulp-less absorbent core having a superabsorbent material providing efficient fluid handling characteristics. The absorbent core may be defined by its fluid handling properties including, but not limited to, greater absorbency rate index (ARI) and greater percentage absorbency rate index (PARI) as compared to absorbent articles of conventional pulp-containing technology.
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BACKGROUND OF THE INVENTION
This invention relates to a silicon etch solution and method and more specifically to a silicon etch solution and method which is resistivity specific.
The principles involved in wet etching silicon wafers have been known since the late 1950's. Early interest centered on chemical wafer polishing or on developing etch pits to reveal crystal imperfections. Most widely used were solutions containing HF as a reducing agent, water and acetic acid as moderating or diluting agents, and one or more oxidizers such as HNO 3 , H 2 O 2 , Br 2 , and I 2 . These compositions had very high etch rates of 1 to 40 microns/min. An advantage of these etchants was the smoothness of the resulting wafer surface.
In the 1960's and 1970's, new chemical etchants for silicon were developed which added versatility and variety to silicon etching capabilities. For example, two new anistropic etchant systems, KOH/H 2 O and ethylene diamine/pyrochatechol (EDP), were explored for use in the fabrication of micromechanical devices. These etches attack the <100> plane 30 to 400 times faster than the <111> plane. New oxidizers such as CrO 3 were added to the HF/acetic acid/water system to reveal defects for the evaluation of epitaxial layers.
Interest in the HF/HNO 3 /acetic acid/water (HNA) system was renewed to develop etches for mesa diode fabrication where resistivity specific etch rates were desired. In the early 1970's it was reported that an etching solution composed of 1 part HF, 3 parts HNO 3 , and 8 parts CH 3 COOH by volume would etch highly doped (greater than 1×10 exp 17/cm 3 ) single crystal silicon much faster than lightly doped material. The etch rate was 0.7 to 3 micron/min. for silicon having a resistivity of less than 0.01 ohm-cm. When the silicon resistivity was higher than 0.068 ohm-cm, no etching occurred.
During the manufacture of certain semiconductor devices, it is usually necessary to etch a layer or layers of polysilicon which may be doped to various levels. For example, doped polysilicon films are used in the fabrication of VLSI chips where they may serve as gate electrodes for FET structures, as polysilicon base or emitter regions in bipolar devices, or as resistors. In every case, the use of polysilicon films is predicated on the ability to etch line patterns with high resolution and sharply defined edges. Various methods of plasma etching are commonly employed to form resist-defined patterns in polysilicon films. Directional ion etching gives excellent line resolution and edge definition. Furthermore, since the polysilicon film patterns to be etched may include SiO 2 films which are partly exposed to the etch, an anisotropic plasma etch will prevent undercutting in the SiO 2 region. However, in fabricating bipolar devices with a polysilicon base, the polysilicon film has to be removed from the region of the future emitter. This requires a reasonably high etch rate for the doped polysilicon film and either no attack or at least a very slow etch rate of the silicon crystal underneath. No plasma or ion etch method is presently known which satisfies such an "etch stop" requirement. Additionally, ion etching introduces a certain amount of surface damage which is generally detrimental to the characteristics of semiconductor devices made in such damaged regions. An example of the surface obtained when RIE is used to etch doped polysilicon overlying an intrinsic or lightly doped surface is shown in FIG. 1. The uneveness of the surface is a result of the lattice damage which has occurred. A further problem with plasma etching is that the etchants attack the walls of the stainless steel chamber, causing nickel and iron to enter the etch atmosphere. These elements can then inbed in the wafer and result in device leakage.
With these considerations in mind, a wet chemical etch could offer significant advantages in the fabrication of certain types of semiconductor devices. HNA in a 1:3:8 volume ratio is unsuitable for this purpose because of its extremely high etch rate. Its etch rate in doped polysilicon is as high as 350 Angstroms/sec and, therefore, it does not lend itself very well to controlled etching of thin films. The result is incomplete etching if the process is interrupted too early or severe undercutting if the time limit is exceeded. Diluting the etchant with water or acetic acid slows the etch rate, but results in spotty surfaces due to polysilicon residue. A second etch solution has been used to achieve a specular surface, but this results in an additional step which is undesirable because of the additional level of process control required and because of the additional possibility of contamination of the wafers in the second etch bath.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to improve the etchant and method for etching doped silicon.
It is another object of this invention to improve the etchant and method for the resistivity specific etching of doped silicon.
It is another object of this invention to etch doped silicon films at an etch rate low enough to allow for process control.
It is a further object of this invention to etch doped silicon without leaving silicon residue, creating a clean specular crystal surface that lends itself to further device processing.
It is another object of this invention to etch doped silicon much faster than SiO 2 .
The present invention provides an improved etchant composition and method for the resistivity specific etching of doped silicon films which overlie intrinsic or lightly doped crystal regions. The composition of the etchant is 0.2-6 mole % hydrofluoric acid, 14-28 mole % nitric acid, and 66-86 mole % acetic acid/water. The etchant leaves no silicon residue and provides for controlled etching with an etch stop at the lightly doped or instrinsic region.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a SEM at 10,000× magnification of a surface obtained when RIE is used to etch doped polysilicon overlying an intrinsic or lightly doped surface.
FIG. 2 is a log-log graph of etch rate (in Angstroms/sec) versus boron doping concentration (in atoms/cm 3 ) showing the etch rates of various HNA solutions as functions of boron concentration in polysilicon.
FIG. 3 is a SEM at 10,000× magnification of a surface obtained after a composition of 4.25 mole % HF, 6.8 mole % nitric acid, and 40.26 mole % acetic acid is used to etch doped polysilicon overlying an intrinsic or lightly doped surface.
FIG. 4 is a SEM at 15,000× magnification of a surface obtained after the preferred composition of the present invention is used to etch doped polysilicon overlying an intrinsic or lightly doped surface.
FIGS. 5A through 5E show the preparation of the test wafer used.
FIGS. 6A and 6B show the final layout of the test wafer.
FIGS. 7A and 7B show the method of determining the thicknesses of CVD oxide and doped polysilicon etched.
FIG. 8 shows the region of interest of the phase diagram of the HNA family of etches.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Terminology
Doped or highly doped: Doping levels in excess of 10 exp 18 atoms/cm 3 .
Lightly doped: Doping levels less than 10 exp 16 atoms/cm 3 .
Clear and Specular: Featureless up to a magnification of 10,000×.
Resistivity specific: A property of etchants whereby silicon within a given resistivity range is etched much faster than silicon within a different resistivity range. For any given silicon, this property can be correlated to doping level. (See FIG. 2)
2. Preparation and Use of the Etchant
The etchant according to the present invention was prepared using 49% aqueous hydrofluoric acid, 70% aqueous nitric acid, and 99% acetic acid as the starting reagents. The compositions were prepared using volume ratios and were constantly stirred during preparation. The stirring can be ultrasonic or a magnetic stirrer may be used. The hydrofluoric acid was placed in the mixing container first, then the nitric, and finally the acetic. The water portion of the etchant came from the aqueous portions of the acids. For the preferred composition according to the present invention, 1 volume part of HF was placed in the mixing container and to that were added 50 volume parts of nitric and 100 volume parts of acetic acid, respectively. The shelf life of the etchant should be equal to that of the acids used.
The wafers processed according to this invention were etched by immersing them in a constantly stirred bath of the etchant. All experiments were done at room temperature. Data on the temperature dependence of the etch rate or preferential etch properties were not obtained. However, satisfactory results should be obtained within the interval of 20-30 degree C. Stirring can be ultrasonic or by means of a magnetic stirrer. Alternatively, flow-through agitation or a spray-type etcher could be used. During use, the life of the etchant will be dependent on the quantity of wafers processed.
3. Description of the Test Wafers
The following description of the test wafers can best be understood by reference to FIG. 5.
Underlying substrate 11 was single crystal silicon having a <100> orientation, but <111> orientation could also be used. Substrate 11 was doped with arsenic to a level of 10 exp 16 atoms/cm 3 , although any level up to 10 exp 18 atoms/cm 3 could be used. Thermal oxide 12 was grown at 900 degrees C. in oxygen, HCl and steam in a dry/wet/dry cycle to a thickness of 1000 Angstroms, but could be thermally grown by any of various known methods. After deposition of thermal oxide 12 a resist mask which exposed the bottom third of the wafer was created. Thermal oxide 12 was then removed from the bottom third of the wafer with dilute HF and the resist was stripped. (See FIG. 5A).
Next 3100 Angstroms of in situ doped polysilicon 13 was deposited by the thermal decomposition of silane with a boron-containing gas at 625-650 degrees C. (See FIG. 5B.) The uniformity of this layer was ±6% and the doping level was greater than or equal to 10 exp 19 atoms/cm 3 as measured with secondary ion mass spectroscopy (SIMS). The resistivity was measured with a four-point probe and was 0.4 ohm-cm. Both arsenic and phosphorus doped polysilicon have also been used. After deposition of polysilicon 13 resist was deposited, exposed and developed to open a window across the middle third of the wafer. (See FIG. 5C). Polysilicon 13 was removed from this portion of the wafer with a CF 4 RIE etch, thermal oxide 12 was removed with dilute HF, and the resist was stripped.
Finally, 3000 Angstroms of low temperature/low pressure CVD silicon dioxide 14 was deposited at 435 degrees C. (See FIG. 5D.) A final resist mask was deposited and three windows were opened in the CVD oxide, one over each third of the wafer. (See FIG. 5E.) The CVD oxide lying beneath these windows was etched away with buffered HF and the resist was stripped. Therefore, the upper third of the wafer had a window 16 exposing doped polysilicon 13 overlying thermal oxide 12, the middle third of the wafer had a window 17 exposing the single crystal substrate 11, and the bottom third of the wafer had a window 18 exposing doped polysilicon 13 overlying single crystal substrate 11. (see FIGS. 6A and 6B.) The wafer was divided into strips and each strip was etched for a different amount of time.
4. Etch Rate Measurements
The initial thickness of the low temperature silicon dioxide was measured optically using either interferometry or ellipsometry (thickness A in FIG. 7A). After etching, the remaining low temperature silicon dioxide was measured the same way (thickness B in FIG. 7B). The step in the silicon dioxide and polysilicon was measured with a profilometer (thickness C in FIG. 7B). By subtracting thickness B from thickness C the amount of polysilicon etched was determined. Dividing this number by the etch time gave the etch rate. These measurements were performed on the bottom third of the wafer.
The upper third of the wafer was used to study the selectivity of the etchant to doped polysilicon overlying thermal oxide. The middle third of the wafer was used to determine the amount of attack on the underlying intrinsic or lightly doped substrate.
The resist used for the various processing steps can be an optically exposed AZ type or it can be an E-beam type, processed according to standard techniques. The resist should be baked and/or plasma hardened after exposure and development to ensure that the integrity of the resist mask will be maintained during etching. Likewise, the thickness of the resist should be such that it will withstand processing. A thickness of approximately 10,000 Angstroms was used on the wafers processed.
5. Experiments and Results
In general terms, the concentration dependent properties of HNA etches may be discussed using a ternary phase diagram. FIG. 8 shows the region of interest (A-B-C-D) of the phase diagram of the HNA family of etches. One vertex represents the mole percent of hydrofluoric acid to a maximum of 40%, another that of nitric acid to a maximum of 40%, and the third the sum of acetic acid and water to a maximum of 100%. The shaded region of the phase diagram represents those compositions capable of preferentially etching doped polysilicon films without leaving a polysilicon residue, but having etch rates less than 50 Angstroms/sec to allow for process control in accordance with the preferred embodiments of the present invention.
Initial attempts to produce a slower resistivity specific etch consisted of diluting the 1:3:8 HNA etch (Dash etch) with acetic acid while maintaining the molecular ratio of the oxidizing agent (HNO 3 ) to the reducing agent (HF) at a constant value of 1.61 as in Dash etch. Whereas dilution did reduce the etch rate as expected, it also had undesirable side effects. The etchant was too preferential and failed to etch the higher doped polysilicon at the interface between the polysilicon layer and the underlying intrinsic or lightly doped surface. This resulted in a polysilicon residue remaining after etch. Not only was the etching non-uniform, the solutions were plagued by variable incubation periods before the onset of etching. This resulted in variation in the time required to remove polysilicon films of constant thickness. The result of these experiments is summarized in Table I.
TABLE I______________________________________COMPOSITION (MOLE %) Etch RateHF HNO.sub.3 HAc H.sub.2 O (Ang/sec) Surface______________________________________9.02 14.53 42.82 33.63 350 specular4.25 6.83 40.26 48.67 20 spotty8.34 13.43 54.70 25.53 220 spotty7.75 12.49 64.90 14.85 150 spotty4.20 6.78 73.71 15.33 18 spotty7.25 11.67 73.77 7.31 65 spotty______________________________________
The search for a slow, selective etch was broadened to include compositions whose molecular ratio of oxidizer to HF was greater than 1.61. Etchants were obtained having moderately low, reproducible etch rates of polysilicon films without incubation periods as well as clean, specular crystal substrate surfaces. Repeated experiments with a wide range of etchant compositions have shown a compositional boundary at approximately 14 mole percent nitric acid. As shown on the phase diagram of FIG. 8, etch compositions lying above this line are characterized by uniformly smooth substrate surfaces, whereas those below it are non-uniform leaving polysilicon residues. FIG. 3 is a SEM of a surface after etching with a composition having a mole percent of nitric acid less than 14 mole %, while FIG. 4 is a SEM of a surface after etching with a composition having a mole percent of nitric acid greater than 14 mole %. Also shown on the phase diagram of FIG. 2 is a line defining etch compositions having an etch rate of 50 Angstroms/sec. This is shown on the phase diagram as -- . -- . -- ..sub. --. Compositions to the left of this line have etch rates above 50 Angstroms/sec and compositions to the right of this line have etch rates less than 50 Angstroms/sec.
Systematic tests were performed on several etches lying within the shaded region of the phase diagram of FIG. 8. The compositions and characteristics of some of the specific compositions tested are presented in Table II. All etch rates have been verified to be uniform and reproducible across photolithographically patterned wafers. SEM analysis of the substrate surfaces has shown them to be specular and clear.
TABLE II______________________________________COMPOSITION (MOLE %) Etch RateHF HNO.sub.3 HAc H.sub.2 O (Ang/sec) Surface______________________________________0.5 14.0 62.5 24.0 2.0 clear, specular 0.59 25.2 35.0 39.0 10.0 clear, specular 0.76 20.5 45.3 33.4 7.3 clear, specular1.6 17.0 52.0 29.0 10.8 clear, specular2.0 15.0 56.3 26.7 9.3 clear, specular______________________________________
The preferred etch composition according to the present invention is the third composition of Table II and is 1 part HF, 50 parts nitric acid, and 100 parts acetic acid by volume using the starting reagents specified above. This corresponds to 0.76 mole % HF, 20.5 mole % nitric acid, 45.3 mole % acetic acid, and 33,4 mole % water. This composition has an etch rate of 7.3 Angstroms/sec for doped polysilicon. For etchants according to the present invention, polysilicon etch rates which lie in the 7 to 12 Angstrom/sec range are at least 25 times, faster than that of the lightly doped substrate giving excellent selectivity. The etch rate of the preferred composition allows a 3100 Angstroms film of doped polysilicon to be removed in 71/2 minutes which is slow enough for process control. Other compositions might be preferred for applications involving thicker or thinner doped polysilicon films. For thin films (i.e. approximately 3000 Angstroms or less), etch compositions would probably be chosen from the region lying to the right of the 50 Angstroms/sec line on the phase diagram of FIG. 8. Thicker films would allow the use of compositions lying to th left of the 50 Angstroms/sec line.
6. Applications
The etchant according to the present invention can be used in any application requiring the removal of a highly doped polysilicon layer overlying intrinsic or lightly doped silicon. The intrinsic or lightly doped silicon need not be single crystal silicon, it can be intrinsic or lightly doped polysilicon. The particular composition chosen will be a function of the thickness of the polysilicon to be removed, and will allow a suitable etch rate for process control purposes. The etchant can also be used in applications where the underlying layer is silicon dioxide or silicon nitride or where a silicon dioxide or silicon nitride layer is otherwise exposed to the etchant for limited times.
An additional use for the etchant relates to electron microscopy. In making cross-sections of silicon device structures, it is often desirable to examine the spreading of diffused impurities. As shown in FIG. 2, the preferred composition according to the present invention displays a sharp decrease in etch rate at a doping level of approximately 10 exp 19 atoms/cm 3 . Iso concentration lines can be delineated by exposing cross-sections to the etchant. Since the etchant is specific to doping level or resistivity regardless of type of dopant, even n regions which abut n+ regions or p regions which abut p+ regions can be marked. This information is important in designing processes for silicon device structures.
While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention. As noted above, the etchant can be used for any application requiring the preferential removal of a highly doped silicon layer overlying a lightly doped or intrinsic layer. The thicknesses and arrangements of the various layers and the makeup of the substrate may vary from application to application.
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The present invention provides an improved etchant composition and method for the resistivity specific etching of doped silicon films which overlie intrinsic or lightly doped crystal regions. The composition of the etchant is 0.2-6 mole % hydrofluoric acid, 14-28 mole % nitric acid, and 66-86 mole % acetic acid/water. The etchant leaves no silicon residue and provides for controlled etching with an etch stop at the lightly doped or intrinsic region.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is based on and hereby claims priority to International Application No. PCT/EP2009/053844 filed on Apr. 1, 2009 and German Application No. 10 2008 019 864.1 filed on Apr. 16, 2008, the contents of which are hereby incorporated by reference.
BACKGROUND
The invention relates to a process for the electrochemical coating of a substrate by brush plating, in which process an electrolyte, in which particles are dispersed, is applied to the substrate using a carrier, wherein a metallic layer, in the matrix of which the particles are incorporated, forms on the substrate.
A process of the type mentioned in the introduction can be gathered, for example, from JP 01301897 A. This document proposes the use of a brush plating process for producing a layer in which particles are dispersed. Brush plating is to be understood as meaning an electrochemical coating process in which the substrate to be coated is not dipped into an electrolyte, but instead the electrolyte is applied to the substrate using a carrier referred to as a brush. More specifically, a brush does not have to be used in this process. Instead, the carrier has to have the properties which make it capable of transferring the electrolyte onto the substrate owing to superior capillary forces. By way of example, a brush is suitable for this purpose because capillary channels suitable for transporting the electrolyte are formed between the individual bristles. Examples of other structures suitable for transferring the electrolyte are sponge-like, i.e. open-pored, inherently elastic materials.
In order to make effective coating possible, the carrier is fed with electrolyte through a channel system, which is fluidically connected to the capillary channels of the carrier. Compared to conventional electrochemical coating, in which the substrate is dipped into the electrolyte, the significant advantage is that a high material throughput is made possible by the continuous feed of electrolyte. During electroplating, for example, correspondingly high deposition currents can accordingly be implemented, and rapid layer build-up is thereby possible. In contrast to electrolyte baths, the continuous flow of the electrolyte in brush plating makes it possible to prevent the establishment of a steady state, which limits the coating rate, in the electrolyte owing to a limited diffusion rate.
It goes without saying that it is also known to incorporate particles in electrochemically produced layers which have been coated in an electrochemical bath. By way of example, it is known according to U.S. Pat. No. 2007/0036978 A1 to incorporate CNTs (this abbreviation is used hereinbelow for carbon nanotubes) in electrochemically deposited layers. However, a factor which further limits the incorporation of the CNTs in this case is the fact that the CNTs can only be dispersed in the electrochemical bath to a limited extent. The production of stable dispersions, i.e. dispersions which also remain stable for a relatively long period of time of more than 24 hours, creates problems. Although it is possible to stabilize the dispersion by using wetting agents, the latter are then also deposited at least partially in the layers. However, an improvement in the conductivity is sought, for example, with the incorporation of CNTs in electrochemical layers. However, the presence of wetting agents, which primarily remain on the surface of the CNTs, restricts the desired effect of the incorporation of CNTs in the metallic matrix of the electrochemically deposited layer.
SUMMARY
One possible object of the invention is therefore to specify a process for the electrochemical coating of substrates by brush plating, in which process it is possible to achieve relatively high particle incorporation rates.
The inventors propose a process in which the carrier is fed via two fluidically independent supply systems, namely via a first conduit system for the electrolyte, in which the concentration of particles is at least reduced compared to the required concentration, or no particles are present, and a second conduit system for the particles, by which particles are added to the electrolyte until the required concentration of particles is achieved therein. The process has the advantageous effect that no stable dispersion of particles has to be produced in the electrolyte. Instead, use is made of the fact that the time which passes until the electrolyte fed into the carrier reaches the surface of the substrate to be coated is very short in brush plating. In addition, the electrolyte is guided via the capillary channels formed by the carrier, which make agglomeration in the electrolyte more difficult. Therefore, undesirable agglomeration of particles during the short time until the substrate is coated from the constituents of the electrolyte is very unlikely. This has the advantage that it is also possible to use particles such as CNTs, which are poorly dispersible per se in the available electrolytes. Another possibility for making meaningful use of this fact relates to the fact that it is possible to add the particles in relatively high concentrations, which are normally no longer stable as a dispersion in the electrolyte in question. This makes it possible to increase the rate of incorporation of particles in the layer which forms. The process window available for forming electrochemical layers with dispersed particles is therefore advantageously larger.
A further advantage of brush plating arises from the fact that the transfer medium is in contact with the substrate during the layer formation process. This counteracts dendritic layer growth, since the layer which forms is compacted immediately. Specifically, the introduction of CNTs would otherwise promote the formation of dendrites—with negative effects on the quality of the layer.
According to one particular refinement, the required concentration of particles in the electrolyte is at a value above a critical value for stability of the dispersion. The advantages of a resulting increased rate of incorporation of particles in the layer which forms have already been explained.
According to another refinement, the particles are supplied in the second conduit system as a dispersion. The dispersing agent used in this case may equally be a gas (formation of an aerosol), a liquid (formation of a suspension) or a solid (formation of a solid mixture). If a solid is used, a powder which can be handled, metered and produced more easily is preferably formed from particles larger than the particles to be dispersed in the layer to be formed. However, it is also possible to convey and meter the particles to be incorporated in the layer to be formed as a powder. However, the use of dispersions has the advantage that handling is generally simplified. The electrolyte itself is preferably also used as the liquid dispersing agent. The electrolyte fed in through the first conduit system and the electrolyte fed in through the second conduit system therefore merely differ in terms of the concentration of dispersed particles. The electrolyte in the first conduit system, which makes up the majority of the throughput, is advantageously not provided with a relatively large quantity of particles in this case, such that handling is advantageously simplified. Particularly if the electrolyte is used repeatedly, i.e. the electrolyte is collected after brush plating has taken place and returned into the supply unit from which the first conduit system is fed, it may be the case, however, that small quantities of particles are present in the electrolyte. However, these do not bring about the problems of agglomeration mentioned above since, if a critical concentration is reached, the particles already precipitate in the collection container after brush plating has taken place and are therefore not returned into the supply container.
On the other hand, the relatively small quantity of electrolyte fed in through the second conduit system can be mixed in each case briefly before it is used, and therefore long-term stability of this suspension is not required. Alternatively, the liquid dispersing agent used can also be a liquid in which it is easier to disperse the relevant particles. However, this dispersing agent must not have an undesirable influence on the coating process of the brush plating. This has to be taken into consideration accordingly when selecting the dispersing agent.
If a liquid or else a solid is supplied as the dispersing agent, these can advantageously be selected such that the dispersing agent evaporates or sublimates at the temperatures which prevail during the brush plating. It is thereby withdrawn from the brush plating process before it can be incorporated in the coating which forms. It may be necessary to ensure that there is a suitable collecting device, which prevents the gaseous dispersing agent from escaping into the surroundings. This makes it possible to avoid any possible risks to health and for the dispersing agent to be used for renewed dispersion formation.
According to another refinement of the process, agglomeration of the particles is prevented by the action of an energy, in particular ultrasound, in the second conduit system. Supercritical dispersions can thereby advantageously also be used, since the risk of the dispersed particles already agglomerating in the second conduit system can be reduced by the introduction of energy. Particularly if ultrasound is used, this can also be introduced into the carrier, such that agglomeration of the particles is prevented in this region too. These particles can thereby be incorporated individually in the matrix of the layer which forms.
A further advantageous refinement is obtained if the particles are nanoparticles, in particular CNTs. If nanoparticles are used, it is advantageously possible to produce particularly fine layer structures on the component to be coated. In addition, the above-mentioned mechanisms for preventing the agglomeration of nanoparticles before they are incorporated in the layer can be utilized particularly effectively. In particular, the incorporation of CNTs in a metallic matrix without the use of wetting agents, which disrupt the function of the coating, is advantageously made possible.
Furthermore, the inventors propose a device for the electrochemical coating of a substrate by brush plating, comprising a carrier through which liquid can pass for applying an electrolyte to a substrate to be coated, and a first conduit system for the electrolyte, which has outlets on the carrier.
A device of this type is described in JP 01301897 A, which has already been mentioned in the introduction. According to this document, the device for brush plating has a roller-shaped design, a sponge-like roller being used as the carrier. The interior of this roller is provided with the conduit system, which has the form of an elongate cylinder running in the center of the carrier. This tubular conduit system has a plurality of bores, which issue into the material of the carrier.
One possible object was to specify a device for the electrochemical coating of a substrate by brush plating, by which device it is possible to produce electrochemical layers, in which particles are dispersed, relatively effectively.
The inventors proposed the device having the second conduit system, which can be fed independently of the first conduit system and issues into the first conduit system or into the carrier. The device thereby provides a possible way of supplying the particles to be incorporated in the coating to be formed separately to the device. Depending on whether this second conduit system issues into the first conduit system, or issues directly into the carrier, it is possible to feed the particles to be incorporated in the coating into the coating electrolyte only just before the coating operation is carried out. This advantageously makes it possible to avoid the formation of a dispersion of the coating electrolyte and the particles to be incorporated. This makes it possible to incorporate particularly particles whose dispersion in the electrolyte is problematic as the dispersing agent in the electrochemically forming layer. By way of example, the use of wetting agents, which can have a negative influence on the layer result, can also be avoided, as already mentioned.
According to one refinement, the first conduit system and the second conduit system are combined in a conduit module, which is in contact with the carrier by way of its outlets. It is thereby possible to advantageously produce a particularly compact device, in which the paths which the electrolyte and the particles have to cover can be kept short. Agglomeration of the particles in the electrolyte can thereby advantageously be avoided as far as possible. In addition, the device advantageously has a simple design, so that it is possible, for example, to easily change the carrier.
According to another refinement, the second conduit system engages with a generator for ultrasound. The generator engages with the second conduit system by virtue of the fact that the ultrasound produced by the generator acts at least in the second conduit system. The ultrasound has the advantageous effect that particles conveyed in the second conduit system do not agglomerate. By way of example, a powder of particles conveyed in the second conduit system can also be kept in fluid form by the ultrasound. More precise details relating to how the ultrasound generator can be applied in the conduit system can be gathered, for example, from DE 10 2004 030 523 A1.
Additionally, it is advantageous if the points at which the second conduit system issues into the first conduit system or into the carrier are provided with metering valves, in particular piezo valves. This refinement, too, can be implemented by taking the details from DE 10 2004 030 523 A1, mentioned above, into consideration. Very precise metering of the particles to the electrolyte is advantageously possible owing to the use of the piezo valves, even if the particles are handled in the form of a powder.
It is particularly advantageous if the ultrasonic excitation acts not only on the second conduit system, but also on the first conduit system and/or on the carrier. It is thereby possible to avoid agglomeration of particles which may still be present in the electrolyte or agglomeration of the particles after they have been introduced into the electrolyte. In addition, mixing of the electrolyte with the particles is promoted by the influence of the ultrasound in the carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 schematically shows the course of an exemplary embodiment of the proposed process using an exemplary embodiment of the proposed device,
FIG. 2 schematically shows another exemplary embodiment of the device in the form of an isometric view, and
FIG. 3 is a cross-sectional view of a conduit module, as can be used in another exemplary embodiment of the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
The proposed device 11 has a carrier 12 and a conduit module 13 , to which the carrier 12 is connected. The carrier is a brush, which can be positioned on the surface 14 of a substrate 15 . As will be explained in more detail below, the device can be used to produce a layer 16 , in which particles (not shown in more detail) are dispersed, on the substrate 15 .
In order to produce the layer 16 , the substrate 15 is placed in a collection container 17 . Furthermore, the substrate 15 and the device 11 are connected to a voltage source, the substrate being connected as cathode. An electrolyte is fed from an electrolyte supply container 19 into the carrier 12 . This electrolyte contains ions of the coating material, which will form the metallic matrix (not shown in more detail) of the layer 16 . In addition, there is a conduit from a particle supply container 20 , which contains a highly-concentrated suspension of the particles to be incorporated in the layer 16 , into the carrier 12 .
The conduit module 13 has a first conduit system 21 for the electrolyte and a second conduit system 22 for the particles. These are independent of one another, i.e. the first conduit system can be fed by the electrolyte supply container 19 and, independently thereof, the second conduit system 22 can be fed by the particle supply container 20 . The electrolyte is then mixed with the particles in the carrier, where a liquid having the composition of the electrolyte is preferably also used as the dispersing agent for the particles.
In order to form a layer 16 , the device 11 is then drawn over the surface 14 in the direction indicated (arrow). During this process, a continuous flow of particles and electrolyte is maintained. The layer 16 is formed relatively quickly owing to the applied voltage, excess electrolyte mixed with the particles being collected in the collection container 17 . A return conduit 23 leads from the latter to a separation device 24 , where the particles are separated again from the electrolyte. The electrolyte, which then only contains insignificant quantities of particles, is returned back into the electrolyte supply container 19 , and the particles, which are highly concentrated in the liquid of the electrolyte, are returned into the particle supply container 20 . The coating process can then be continued with the recovered electrolyte and the recovered particles. In this case, it has to be taken into consideration that the material conversion taking place on the surface 14 during the formation of the layer 16 has to be compensated for (not shown).
The device 11 according to FIG. 2 is suitable for coating a wire 25 , which in this respect functions as the substrate 15 according to FIG. 1 . The device therefore likewise has a tubular design. Initially, the carrier 12 , which is an open-pored, sponge-like structure, has a cylindrical shape and has a through-opening for the wire 25 in the center axis. The device can be guided back and forth on the wire in the direction of the indicated arrows.
In order to make it possible to obtain a coating, the conduit module 13 is arranged annularly around the carrier 12 , i.e. the conduit module forms a tubular sleeve. This is supplied with electrolyte via the first conduit system 21 . In this case, use is made of a central stub, where the electrolyte is guided through the carrier 12 , in the process also makes contact with the wire 25 and emerges at the ends of the tubular sleeve of the conduit module 13 .
Furthermore, the second conduit system 22 is formed in the wall of the conduit module 13 and has a plurality of issuing points 26 for feeding the particles into the carrier 12 . These issuing points are distributed uniformly over the length of the conduit module and also over the circumference thereof. Here, it is taken into account that the diffusion of the particles in the carrier 12 is limited compared to the electrolyte, and therefore uniform distribution in the carrier 12 is promoted by a relatively large number of issuing points 26 .
The particles are introduced into the second conduit system 22 via connection modules 27 (not shown in more detail). In addition, these each have a generator 28 for ultrasound. These generators 28 are dimensioned such that the ultrasound waves propagate throughout the conduit module 13 . The ultrasound counteracts agglomeration of the particles in the second conduit system 22 .
FIG. 3 shows a detail of the device, from which the interaction of the conduit module 13 and the carrier 12 can be gathered. The carrier 12 again has a sponge-like, elastic, open-pored structure, the pores 29 being visible. The conduit module has the first conduit system 21 , which forms outlets 30 adjoining the carrier 12 . The electrolyte can be pressed from the outlets into the pores 29 .
In contrast to the exemplary embodiment according to FIG. 2 , the second conduit system 22 is arranged parallel to the first conduit system 21 . The issuing points 26 of the second conduit system do not lead into the carrier 12 , but instead into the first conduit system 21 . In this case, the electrolyte is therefore already mixed with the particles in the first conduit system, and this has the advantage that here the diffusion operations required for mixing can still proceed relatively undisturbed. The path which the electrolyte dispersion thus produced still has to cover in the carrier is short, and therefore neither separation nor agglomeration of the particles can occur.
The particles can preferably be conveyed in the second conduit system as a powder. In order to prevent agglomeration, the generators 28 are arranged directly in the second conduit system 22 . By way of example, these can be formed by piezo crystals. Furthermore, metering of the powder located in the second conduit system 22 can be simplified by the provision of metering valves 31 at the issuing points 26 . These can be designed as piezo valves. A very compact design of the conduit module can advantageously be implemented by using piezo technology. The paths in the first and second conduit systems can therefore be kept short, in order to preclude agglomeration of particles as far as the surface to be coated.
The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004).
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A method for the electrochemical coating of a substrate uses brush plating. This is to take place with an electrolyte in that particles are dispersed, which are embedded into the developing layer. It is proposed to add the particles to the carrier for the electrolyte by way of a separate conduit system. The electrolyte is added by way of a conduit system. In this way it is achieved that an agglomeration of the particles in the electrolyte can be prevented because only a short time passes between when the particles are fed and the layer is formed. A device for electrochemical coating has two conduit systems provided for this purpose.
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CROSS REFERENCE TO RELATED APPLICATIONS
This document claims priority to French Application No. 03 10293, filed Aug. 29, 2003 and U.S. Provisional Application No. 60/501,822, filed Sep. 11, 2003, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to an applicator for a cosmetic product. The invention is particularly advantageous as an applicator for eye make-up such as mascara, to apply the mascara to eyelashes and eyebrows.
BACKGROUND OF THE INVENTION
Discussion of Background
In the field of mascara, the most commonly used applicators are formed from so-called “twisted” brushes. Such twisted brushes are made by placing a layer of bristles between two branches of a steel wire configured in the shape of a hairpin, then twisting the two branches of the steel wire about its axis. The steel wire thus twisted forms a spiral (actually, one spiral or helix for each strand of steel wire) in which the turns rise from left to right in relation to the direction of twist of the steel wire (when the brush is viewed in a vertical position) or from right to left. The first type of twisting produces a brush sometimes referred to as a “left-handed brush”. Such a brush is described in patent EP 0 611 170. The second type of twisting, hitherto the most frequently encountered, produces a brush referred to as a “right-handed brush”.
Such twisted brushes generally include a “bristled” part defining an applicator portion, extending into a “non-bristled” part of the steel wire, sometimes referred to as the “tail” of the brush. The non-bristled part serves to fix the device to a rod attached to an element used to grasp the device, with the element also providing a closure cap for the bottle containing the mascara.
The brush should be attached to the rod so that the brush does not axially fall out of the rod and is not thereby rendered unusable. The brush attachment should also have considerable rotational restraint so that the brush turns with the rod when the rod is rotated by the user to unscrew the cap from the bottle. The attachment must be especially firm when the mascaras used are mascaras that dry very quickly, i.e. mascaras having a relatively thick formulation and which therefore adhere strongly to the brush and to the bottle.
To attach the brush to the rod, the tail end of the brush is generally inserted into a hole fashioned in the rod, with the diameters of this hole and the tail of the brush being substantially equal. The attachment is secured by heating the metal tail of the brush and forcing it into the hole in the rod so that the plastic material of the rod melts locally in contact with the tail of the brush and conforms to the shape of the twist in the tail of the brush.
The brush is therefore securely restrained in that the rod, by conforming to the shape of the twist, forms a kind of female thread around the tail of the brush which constitutes a male thread. Thus, any axial movement becomes impossible without deforming the material of the rod or the brush. However, rotation in the direction tending to unscrew the tail from the brush remains easy in that there is no chemical adhesion between the plastic and the metal, and in that this movement involves no mechanical deformation. Thus, the rotational restraint remains low. The unscrewing movement of the brush relative to the rod can occur in the direction of opening or closing of the mascara.
To address this problem, a conventional approach is to locally crush the tail of the brush so as to render it locally flat and thus prevent the tail of the brush from unscrewing during the rotational movement. However, this flattening is only effective at fairly low rotational torque values, and is not sufficiently effective for mascaras of relatively thick consistency.
SUMMARY OF THE INVENTION
One of the objects of the invention is therefore to provide a cosmetic applicator that does not present the drawbacks of the prior art.
According to one object of the invention, an applicator is provided in which the brush has minimal or no risk of separating from the rod to which it is attached, even with products of relatively sticky consistency.
A further object of the invention is to provide an applicator which can be made in a simple manner and at a low cost.
According to the invention, these objects can be achieved, wholly or partially, by a cosmetic applicator, e.g., for mascara, with a twisted core which includes a first portion in which are trapped bristles arranged in a radial manner relative to the core, and a second portion fixed in a rod, with the second portion of the core being formed by at least two twisted zones of different direction and/or pitch. Various alternative features are possible in accordance with the invention.
By way of example, the twisted zone of the second portion of the core contiguous with the bristled portion can be twisted in the same direction as the bristled portion. Also, by way of example, the twisted zone of the second portion of the core contiguous with the bristled portion can be twisted with the same pitch as the bristled portion.
Further by way of example, the second portion of the core can be formed by a twisted zone with a first pitch and by a twisted zone with a second pitch different from the first.
Alternatively, the second portion of the core can be formed by a twisted zone having a progressively increasing, or decreasing, pitch between a first end of the second portion contiguous with the bristled portion of the core and a second end opposite the first.
By way of example, the core can be formed from two branches of a steel wire.
The bristled portion of the core can present a plurality of turns rising from left to right when the applicator is viewed in the vertical position. In this case, the brush is described as “left-handed”. Alternatively, the bristled portion of the core can present a plurality of turns rising from right to left when the applicator is viewed face on in the vertical position. In this case, the brush is described as “right-handed”.
Also, by way of example, the bristled portion of the core can be straight or rectilinear, or alternatively, curved. The rod can be integral with a grasping element. In addition, the bristles can form a brush of circular or polygonal transverse cross-section, for example, triangular, square or pentagonal.
One or more of the objects of the invention can also be achieved by a device for packaging and applying a product to keratinic fibers, such as the eyelashes or the eyebrows. The device includes a container holding the product, with the container delineating an opening in proximity to which is preferably disposed a wiper element, with the device equipped with an applicator as described above and described further herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become further apparent from the following detailed description, particularly when considered in conjunction with the drawings in which:
FIG. 1 illustrates a partial sectional view of a first embodiment of an applicator according to the invention;
FIG. 2 illustrates a partial sectional view of a second embodiment of an applicator according to the invention;
FIG. 3 illustrates a partial sectional view of a third embodiment of an applicator according to the invention;
FIGS. 4 and 5 illustrate variants of the applicator depicted in FIG. 1 ; and
FIG. 6 illustrates a packaging and application device using an applicator according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The applicator device 10 illustrated by way of example in FIG. 1 is designed to apply mascara. The device 10 includes a rod 30 carrying a brush 40 . In the illustrated example, the rod extends along an axis X. The brush has a circular cross-section, for example, extending transverse relative to the axis X.
The brush 40 includes a substantially straight twisted core 20 . The twisted core is obtained, for example, from a steel wire folded into a U shape, between the branches of which a sheet of bristles 41 is inserted before completing the twist operation. In response to the twisting movement, the bristles 41 are drawn in a spiral configuration to form a succession of turns spaced more or less widely apart. The bristles 41 in the illustrated example extend radially in relation to the support and are substantially rectilinear.
The sheet of bristles 41 forming the brush is trapped in a first portion 21 of the core 20 . A second portion of the core 22 , without bristles and also referred to herein as the tail of the brush, is fixed in the rod 30 . The end of the rod 20 opposite the brush 40 is generally connected to an element (shown in FIG. 6 ) that preferably forms both a grasping element for the brush 40 and a closure element for the container with which the brush is associated.
In this embodiment, the brush 40 is of the “right-hand brush” type, with the turns of the bristled portion 21 of the twisted core 20 rising from right to left when the brush 40 is viewed in the vertical position as shown.
The tail of the brush 22 , which is fixed into the rod 30 , includes two zones 22 a and 22 b twisted in two different directions. A first twisted zone 22 a , formed in the extension of the bristled portion 21 of the core 20 , has the same direction of twist and the same pitch as the bristled portion 21 of the core. A second twisted zone 22 b , extending beyond the first twisted zone 22 a , is in this instance twisted in the reverse direction relative to the first twisted zone 22 a of the tail of the brush.
The tail of the brush can have a length, by way of example, of approximately 2 cm. The two twisted zones at the tail end of the brush and the twisted portion carrying the bristles have a pitch, for example, of approximately 1 mm.
To make this applicator, after inserting the sheet of bristles between the branches of the steel wire folded into a U-shape, the branches of the steel wire are wound in a first direction so as to form the bristled portion 21 of the core 10 and the first twisted zone 22 a of the tail 22 of the brush. The two wires are then held at approximately 1 cm from the tip of the tail of the brush, and they are wound in the reverse direction so as to produce the second twisted zone 22 b at the tail end of the brush.
The tail thus obtained is then partially heated and inserted into a hole 31 pre-formed in the rod 30 . The plastic material of the rod melts slightly in contact with the tail and takes on the shape of the tail of the brush.
Thus, once the tail end of the brush, i.e. the zones twisted in both directions, has been inserted while hot into the hole in the rod, relative rotational movement of the brush in relation to the rod becomes impossible without severe deformation of the rod, because screwing in one part of the tail imparts an unscrewing action to the other part of the tail of the brush. The brush is thus very securely restrained from rotation relative to the rod. The presence of the twisted zone in the rod also provides effective axial restraint.
FIG. 2 illustrates a second embodiment of the applicator 10 according to the invention. In this embodiment, the length of the tail 22 of the brush is twisted in the same direction. However, the tail of the brush includes a first twisted zone 22 a having a first pitch, for example the same pitch as the bristled portion of the core, and a second twisted zone 22 b having a different pitch, with this pitch also being constant. The first twisted zone 22 a of the tail of the brush has a pitch approximately equal to 1 mm, for example, and the second twisted zone 22 b has a pitch of 1.5 mm, for example.
FIG. 3 illustrates a third embodiment of the applicator 10 according to the invention. In this embodiment, the length of the tail 22 of the brush is also twisted in the same direction. However, the tail 22 of the brush includes a first twisted zone 22 a having a first pitch, for example the same pitch as the bristled portion of the core. The second twisted zone 22 b of the tail in this instance has a pitch different from that of the first twisted zone but it is not constant over the full length of this zone. The pitch in this second twisted zone increases progressively from the first twisted zone up to the end of the core. Alternatively, the second twisted zone could decrease progressively from the first twisted zone to the end of the core. As a further alternative, the second portion of the core could include a portion in which the pitch increases and/or decreases progressively, so that the increasing or decreasing pitch provides the two zones with different pitches.
In the latter two embodiments, relative rotational movement of the brush in relation to the rod without severe deformation of the rod is also prevented, because the pitch of the twisted zone at the tail end of the brush is not constant, to thereby prevent unscrewing. Furthermore, the presence of the twisted zone in the rod also provides effective axial restraint. Here again, the brush is held very securely in the rod.
FIG. 4 illustrates an alternative embodiment of the applicator depicted in FIG. 1 . In this variant, the brush 40 is distinguished from the brush in FIG. 1 in that it is of the “left-hand brush” type, with the turns of the bristled portion 21 of the twisted core rising from left to right when the brush is viewed in the vertical position. With regard to the advantages afforded by a left-hand twisted core, reference may be made to U.S. Pat. No. 6,227,735, the contents of which are incorporated herein by reference.
The brush according to the variant in FIG. 5 is distinguished from the brush in FIG. 1 in that the bristled portion 21 of the twisted core 20 is curved, with the curvature corresponding substantially to the curvature of the line of the eyelashes on the eyelid. The tail of the core is preferably still straight.
FIG. 6 illustrates a packaging and application device 100 equipped with an applicator device 10 of the type described previously with reference to FIGS. 1 to 5 . The device 100 includes a container 50 holding a reserve of a cosmetic product, preferably an eye make-up such as mascara, and an applicator 10 . The applicator 10 includes an applicator device of the twisted brush type, preferably attached to the end of a rod 30 extending along axis X. The other end of the rod 30 is integral with a grasping element 60 which also forms a closure cap for the container 50 . The container 50 incorporates a wiper element 70 formed, in this instance by way of example, by a cylindrical sleeve of which one end terminates at a flexible annular lip 71 . When the applicator 10 is in the mounted position on the container 50 , the entire applicator device 10 is preferably located between the wiper lip 71 and the bottom of container. Other types of wiper elements can be used, for example a block of open-cell or semi-open cell foam, traversed axially by a slot or a passage of which the delimiting edges are substantially contiguous when no force is being exerted thereon.
To use the applicator, the user unscrews the cap formed by the grasping element 60 and withdraws the applicator 10 from the container 60 . In so doing, the applicator device 10 is caused to pass through the wiper element 70 , thereby regulating the quantity of product distributed on the bristles. The withdrawal movement of the applicator is substantially lengthwise relative to the axis X. After use, the user replaces the applicator in the container, again causing the applicator device 10 to pass through the wiper element 70 .
In the foregoing detailed description reference is made to preferred embodiments of the invention. It is evident that variants thereto can be proposed without departing from the invention as claimed herebelow. For example, the transverse cross-section of the brush perpendicular to the axis X can be of any shape other than circular, such as polygonal, or for example square, rectangular, triangular, pentagonal, etc. Similarly, the transverse cross-section of the bristles can be of different shapes, and the brush can include bristles having a single type of cross-section, or bristles having a combination of different cross-sections.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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An applicator is disclosed that is particularly advantageous for cosmetics such as mascara. The applicator includes a twisted core having: a first portion in which are trapped bristles arranged in a radial manner relative to the core, and a second portion fixed in a rod, with the second portion of the core being formed by at least two twisted zones having a different direction and/or pitch. A container or packaging arrangement including such an applicator is also disclosed.
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This invention was made with Government support under Contract No. DAAH04-87-C-1247 awarded by the Department of the Army.
BACKGROUND OF THE INVENTION
This invention pertains generally to guidance systems for cannon-launched projectiles, and particularly to mechanisms for protecting such a guidance system from the effects of high acceleration and deceleration during a launching phase.
It is known in the art that any guidance system intended to be used in a cannon-launched projectile must be capable of withstanding extremely large forces due to acceleration (and deceleration) experienced during the launching phase of such a projectile. For example, in the case of a projectile launched from a 155 millimeter cannon, an initial acceleration caused by firing results in a setback load in the order of 12,000 G (where G is the mass of the seeker) and then a deceleration (experienced when the projectile clears the barrel of the cannon) results in a setforward load in the order of 3000 G.
A so-called "strap-down" seeker presently is known to be a practical type of seeker capable of withstanding the setback and setforward loads experienced during the launching phase of a projectile fired from a cannon such as a 155 millimeter cannon. A "strap-down" seeker is characterized by the fact that the sensor in such a seeker is rigidly mounted within a projectile. As a result, a fixed field of view (relative to the centerline of the projectile) is provided. Consequently, unpredictable perturbations in the attitude of the projectile, i.e., coning due to precession or to nutation of the centerline of the projectile, cause the field of view similarly to change in an unpredictable manner. As a result, then, tracking of a desired target may become impossible.
SUMMARY OF THE INVENTION
With the foregoing background of this invention in mind, it is a primary object of this invention to provide a seeker for a cannon-launched projectile that is gyroscopically stabilized on gimbals within such projectile so that the field of view of the seeker may be changed as required with respect to the longitudinal centerline of such projectile.
Another object of this invention is to provide a simple but dependable mechanism to accomplish the primary object of this invention.
The foregoing and other objects of this invention are attained generally by providing a restraining mechanism having dogs formed integrally with the inner gimbal of a gyroscopically stabilized platform and a grooved latch, rotatably and slidably mounted on an inner surface of a cannon-launched projectile and coacting with the dogs so that: (a) the inner gimbal and any elements mounted on the inner gimbal are maintained in a substantially constant position along the longitudinal axis of the cannon-launched projectile prior to and during the firing cycle; and (b) the inner gimbal and any elements mounted on such gimbal are released after firing of the projectile by rotating the grooved latch out of contact with the dogs so that the inner gimbal may be gyroscopically stabilized during flight of the cannon-launched projectile after any loads due to setback or setforward load have been experienced.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference is now made to the following description of the accompanying drawings wherein:
FIG. 1 is a simplified cross-section according to this invention of the nose section of a cannon-launched projectile wherein a gimbal of a gimballed seeker is shown to be latched into a position to withstand setback and setforward forces during the launching phase of such projectile;
FIG. 2 is a simplified cross-section according to this invention of the forward end of a cannon-launched projectile after the launching phase of such projectile; and
FIG. 3 is an isometric view of the restraining mechanism in a condition corresponding to that shown in FIG. 1, the isometric view of FIG. 3 further showing the way in which the transition to a condition corresponding to that shown in FIG. 2 may be effected according to a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, it may be seen that the nose section 10 of a projectile (not numbered) is arranged so that a gimbal assembly 12 including a stabilized platform 12P and an infrared sensor 12S initially may be latched in place (see FIG. 1) with respect to the nose section 10 or later may be movably mounted (see FIG. 2) in such section.
It will be noted that the gimbal assembly 12 here illustrated shows the inner gimbals 12G of a two gimbal system. Thus, the outer gimbals of the two gimbal system (which outer gimbals are orthogonally disposed with respect to the inner gimbals 12G) are not visible in the crosssections of FIG. 1 and FIG. 2. It will be appreciated, however, by one of skill in the art that the outer gimbals coact with appropriate bearings (not shown) to position the two gimbal system within the nose section 10. The nose section 10 here is made up of a nose cone 14, here fabricated from a material such as sapphire, secured in any convenient manner to the forward end (not numbered) of the body 16 of the projectile. The inner portion of the forward end of the body 16 is shaped to provide: (1) a substantially spherical zone (not numbered) accommodating the facing surfaces of the gimbal assembly 12; (2) a first cylindrical section (not numbered) adjoining the substantially spherical zone to accommodate the facing surface of a latch 18; (3) a second cylindrical section (not numbered) counterbored with respect to the first cylindrical section to accommodate a spring 20 (sometimes referred to as a compression spring), the lower end of the latch 18 and an explosive squib assembly 22; and (4) a third cylindrical (but slotted as shown in FIG. 3) section interconnecting the first and second cylindrical sections as shown and serving as a journal bearing for the latch 18. A ledge 24 is formed inside the body 16 by appropriately sizing the first, second and third cylindrical sections and slotting the third cylindrical section as shown in FIG. 3. Projecting elements, referred to as gimbal standoffs 26, are attached, in any desired manner, to the bottom of the gimbal 12. To complete the assembly being described, a shear pin 28 is placed (as shown in FIG. 1) in an appropriate opening extending from the outside of the body 16 partially through the latch 18.
Referring now to FIG. 3, it may clearly be seen that dogs (not numbered) projecting outwardly from the free end of each one of the gimbal standoffs 26 initially mate (as shown in FIG. 1) with grooves (not numbered) formed in the latch 18. At the same time, contact is made between the lower surface of the grooved section of the latch 18 and the facing upper surfaces of the ledge 24. The spring 20 (FIG. 1) then is fully compressed between the lower surface of the ledge 24 (FIG. 1) and a flange 30 (FIG. 1) at the lower end of the latch 18. The shear pin (FIG. 1) then prevents any rotational motion of the latch 18 (and the engaged gimbal standoffs 26 and gimbal 12) relative to the body 16. When setback forces are applied to the gimbal 12 (and the gimbal standoffs 26), such forces are passed through the latch 18 and the ledge 24 to the body 16, thereby preventing longitudinal movement of the gimbal standoff 26 and gimbal 12 relative to the body 16. When setforward forces are extant (immediately after the body 16 clears the cannon barrel (not shown)), such forces are passed, through the projection from the flange 30 between the ledge 24 and the flange 30, to the body 16. Consequently, any relative motion between the body 16 and the latch 18, the gimbal standoffs 26 and the gimbal 12 is prevented during the time in which setforward forces are extant.
After the cannon-launched projectile enters into a ballistic trajectory, i.e., after setforward forces cease for all intents and purposes, the explosive squib assembly 22 is actuated in any convenient manner (not shown). A piston 22P projecting from the explosive squib 22 then is pushed against the projection 30A, to rotate the latch 18 (breaking the shear pin 28) so that the initially contacting grooved portions of the latch 18 are cleared of the dogs (not numbered) on the lower ends of the gimbal standoff 26 and the latch 18 is rotated into alignment with the slots in the third cylindrical section in the body 16 (FIGS. 1 and 2). The spring 20 then may expand, thereby forcing the latch 18 away from the gimbal standoff 26 and the gimbal 12 into the position shown in FIG. 2. The gimbal 12 then may be stabilized in any convenient manner.
Having described a preferred embodiment of this invention, it will now be apparent that changes may be made without departing from the inventive concept in the art of cannon-launched projectiles, of positively latching the inner gimbal of a gyroscopically stabilized seeker in a fixed position relative to the body of such a projectile during a firing sequence. Thus, it is evident that the number and shape of the latching elements may be varied so long as provision is made for both setback and setforward forces. It is felt, therefore, that this invention should not be restricted to its disclosed embodiment, but rather should be limited only by the spirit and scope of the appended claims.
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A restraining mechanism for a gimbal in a gyroscopically-stabilized seeker in a cannon-launched projectile is shown to consist of a movable latch, so shaped and disposed that relative longitudinal motion between the gimbal and the body of such projectile is prevented during the launching phase, and a release mechanism whereby the movable latch is cleared of the gimbal after the launching phase.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of burners and particularly to gas burners used in industrial heaters.
BACKGROUND OF THE INVENTION
[0002] It is well known in a variety of industries to use heaters having burner assemblies for a number of different applications, including kilns, drying apparatus, furnaces and for preventing freezing of tanks and pipelines. In the oil and gas industry, heaters are particularly used in regions where low ambient temperatures may result in freezing of storage tanks or in production and process pipelines. Further process heaters are used which may be used when knocking water out of oil and when heating salt baths and the like. Gas burner assemblies are typically arranged in a housing or firetube which extends into a storage or holding tank to be heated.
[0003] In prior art natural draft or “non-forced draft” situations, primary combustion air is drawn into a mixing chamber or mixer head of the gas burner assembly as a result of the velocity of the flammable gas entering the mixing chamber or venturi. The premixed gas/air fuel mixture exits the venturi at a burner nozzle, typically a rosebud nozzle, where the mixture is ignited. Secondary combustion air is drawn into the housing and around the burner assembly as a result of draft. The secondary air, intended to aid in combustion, may adversely affect the operation of the burner assembly. Large volumes of secondary air creating a large turbulent draft at the burner head may result in the flame being lifted from the burner nozzle or may blow out a flame at the nozzle. Attempts to reduce or dampen the amount of secondary air entering the burner can substantially shutoff the flow of secondary air which compromises the efficiency of the burner.
[0004] Further, variability in operation can adversely affect the consistency of ignition and flame sensing. Typically, burners may be operated in high-fire and low-fire situations. In a low-fire situation, the pressure of fuel entering the burner is relatively low compared to a high-fire situation. Conventional burners which are set to operate under low-fire conditions can experience lifting of the flame from the burner nozzle should they be used in a high-fire situation. Thus, in conventional burners, ignition and flame sensing, which are optimized for one flame characteristic, become problematic as the position of the flame alters. Use of a pilot has provided a consistent flame source and ignition sensing. In variable firing conditions, should the fuel/air ratio and secondary air flow be sufficiently unstable at the burner nozzle, remote lighting of the burner becomes difficult. As a result, the industry has typically relied on manual lighting of such burners which has resulted in significant hazard to personnel performing the task.
[0005] Additionally, freezing is a common problem with natural draft burner assemblies. Typically, areas of low pressure adjacent the orifice of the burner may result in freezing at the orifice or in the gas lines which feed the orifice. Low flow of fuel at pilot assemblies are even more prone to freezing
[0006] Clearly, there is interest in the industry to provide a reliable burner which remains lit under ambient conditions, is safe to ignite and operate and permits flame-sensing in both low fire and high fire situations, does not freeze in low ambient temperature and is efficient.
SUMMARY OF THE INVENTION
[0007] A burner assembly according to one embodiment of the invention comprises a pilotless ignition and flame sensing system and a burner head having a nozzle tip situated in a secondary air housing and which is equally operable at low and high fire. The nozzle tip discharges a mixture of primary air and gaseous fuel which is separated from the secondary air flowing therearound for stabilizing flame at the nozzle tip. A flame ionization sensor senses flame at the nozzle tip throughout low and high fire operation, obviating the need for a pilot. Secondary air is separated from the nozzle tip by directing the secondary air away from the tip such as through a conical ring situated on the burner head or by an air deflector ring which also serves to swirl the secondary air circumferentially in the housing or in a preferred embodiment, by a combination of both the low pressure ring and the deflector plate manufactured as a unitary structure with the nozzle head. More preferably, the burner assembly comprises a tubular barrel having a mixing chamber at the gas inlet end and a nozzle tip having a plurality of orifices at the burner head end. The mixing chamber can received aspirated primary combustion air, preferably through a plurality of air orifices, or through a forced air inlet.
[0008] In a broad aspect of the invention, a burner assembly is provided for mounting in a housing and forming an annular space therebetween, the burner assembly having a nozzle tip mounted in a burner head at a first distal end of a tubular barrel, the tubular barrel having a primary combustion air inlet and a fuel inlet at a second proximal end for providing a flow of primary combustion air and fuel in the tubular barrel directed toward the nozzle tip and a flow of secondary combustion air in the annular space directed towards the nozzle tip, the burner assembly comprising: a deflector for deflecting the flow of secondary combustion air in the annular space away from at least the nozzle tip for stabilizing at least a position of a flame thereon. Preferably, a conical low pressure ring is positioned circumferentially about the nozzle tip and extends radially outwardly from the burner head for substantially separating the flow of primary combustion air and fuel from the flow of secondary combustion air at the nozzle tip creating an area of low pressure at the nozzle tip relative to a pressure of the secondary air in the annulus whereby lifting of the flame from the nozzle tip is reduced.
[0009] In another embodiment, a pilotless burner assembly comprises the burner assembly as described above and further comprises an igniter supported in the air deflector for remotely igniting the burner assembly which is positioned adjacent the burner tip and therefore separated from the secondary air. Preferably the igniter further comprises flame sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic side view of a burner according to an embodiment of the invention and positioned for operation in a firetube or housing;
[0011] FIG. 2 a is a side view of the burner assembly removed from the housing for clarity;
[0012] FIG. 2 b is a plan view of a deflector plate positioned at a nozzle of the burner according to FIG. 1 , the housing being removed for clarity;
[0013] FIG. 3 is a bottom perspective view of a burner according to FIG. 1 positioned in the housing, an igniter and heat return tube removed for clarity;
[0014] FIG. 4 is a side view of a nozzle portion of the burner according to FIG. 1 , the housing removed for clarity and illustrating a heat return tube for preventing freezing of the burner by heat tracing;
[0015] FIG. 5 is a schematic side view of a mixer head according to FIG. 1 ;
[0016] FIG. 6 is a plan view of the mixer head according to FIG. 5 shown along section lines A-A;
[0017] FIG. 7 is a sectional view of the mixer head according to FIG. 5 shown along section lines B-B; and
[0018] FIG. 8 is a sectional view of the mixer head according to FIG. 5 shown along section lines C-C.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Having reference to FIGS. 1-8 , a burner assembly 1 according to an embodiment of the invention is shown.
[0020] As shown in FIG. 1 , the burner assembly 1 comprises a tubular barrel 2 which is mounted in the bore of a firetube or other such housing 3 , forming an annulus 5 therebetween. The tubular barrel 2 conducts primary fuel gas G from a gas inlet 6 at a base or proximal end 8 of the tubular barrel 2 to a burner head 1 2 at a distal end 11 of the tubular barrel 2 . The barrel 2 is typically of conventional configuration. The gas at the gas inlet 6 is fed at a first pressure P 1 through an orifice 50 to a mixer head 7 ( FIGS. 5, 7 and 8 ) at the proximal end 8 . Primary combustion air A p is drawn into the mixer head 7 via natural draft and the combined air A p and gas G are mixed therein and flow through the tubular barrel 2 at a second pressure P 2 to an orifice or plurality of orifices 1 0 in the burner head 12 . The air and gas discharge from the burner head 12 at a nozzle tip 13 and, when ignited, form a flame 15 .
[0021] Secondary combustion air A s is aspirated or drawn into the annulus 5 and flows therein toward the nozzle tip 1 3 at a third pressure P 3 , to mix with the primary air A p and fuel G and enhance combustion of the primary air A p and fuel G in a combustion zone C at the nozzle tip 13 and in the housing 3 extending outwardly therefrom. Depending upon the draft created by a pressure differential along the burner assembly 1 , the velocity of the secondary air A s is altered. A chimney effect in an exhaust stack for the heated system (not shown), aids in creating a draft.
[0022] In low pressure fuel or low-fire conditions, the velocity of secondary air A s is relatively low compared to a high-fire condition. If unrestricted, the flow of secondary air A s up the annulus 5 and past the nozzle tip 13 can adversely affect the flame 15 .
[0023] In order to stabilize at least a position of the flame 15 relative to the nozzle tip 13 , means are provided to deflect the flow of secondary air A s away from at least the nozzle tip 13 .
[0024] In a preferred embodiment, best seen in FIG. 4 , the means for deflecting the flow of secondary air A s is a radially outwardly extending low pressure ring 14 extending from the burner head 12 . The low pressure ring 14 is shaped such as an inverted, truncated frustrum of a cone and is positioned circumferentially about the nozzle tip 13 of the burner head 12 . A diameter of the low pressure ring 14 increases as it extends downstream and away from the nozzle tip 13 .
[0025] The secondary combustion air A s flowing through the annulus 5 from the proximal end 8 of the burner assembly 1 to the distal end 11 of the burner assembly 1 and approaching the nozzle tip 13 is deflected outwardly by the low pressure ring 14 , typically creating a turbulence pattern in the flow of the secondary air A s which aids in establishing a local area of low pressure P 4 at the nozzle tip 13 and particularly at the plurality of orifices 10 . The low pressure P 4 at the tip 13 is low relative to the pressure P 3 of the secondary air A s . Further, the low pressure ring 14 separates the flow of secondary air A s from the flow of primary air A p and fuel G exiting the orifices 10 at the nozzle tip 13 which further aids in maintaining the area of low pressure P 4 . The area of low pressure P 4 acts to minimize lifting of the flame 15 from the nozzle tip 13 , resulting in increased stability and reliability of the flame 15 regardless the pressure P 2 and velocity of the primary combustion air A p and fuel G in the burner assembly 1 and the draft in the housing 3 . Further, the low pressure ring 14 aids in preventing the flame from being extinguished by the secondary combustion air A s .
[0026] Preferably, the nozzle head 12 and the low pressure ring 14 are formed as a unitary structure.
[0027] Alternately, as shown in FIGS. 1-4 , the means for deflecting the flow of secondary air A s in the annulus 5 away from at least the nozzle tip 13 is included as part of an air deflector plate 20 which extends radially outwardly from the burner head 12 . The deflector plate 20 extends from the burner head 12 , such as from an underside 21 , and extends radially from the burner head 12 across the annulus 5 . The deflector plate has an inner mounting ring 29 adjacent the burner head and extending circumferentially therearound. Preferably, the inner ring 29 can act to restrict and deflect the flow of secondary combustion air A s away from and around the nozzle tip 13 .
[0028] As shown in FIGS. 2 a, 2 b and 3 , the air deflector plate 20 comprises a plate base 22 , preferably extending radially from the burner head 12 and across a diameter of the housing 3 . The burner head 12 can be conveniently supported concentrically in the housing 3 by the air deflector plate 20 .
[0029] A plurality of angled deflectors or vanes 23 are formed about the plate base 22 , each vane 23 being formed adjacent one of a plurality of radially extending openings 24 formed in the plate base 22 . The plate base 22 and the openings 24 act to dampen or reduce the pressure P 3 the secondary combustion air A s reaching the burner head 12 and nozzle tip 13 . Further, the angled vanes 23 act to direct the secondary combustion air A s outward and circumferentially to the walls of the housing 3 , creating a turbulence pattern therein which substantially fills the housing 3 at the combustion zone C for improved mixing of the primary air A p and fuel G therein. Preferably, angled vanes 23 also act to restrict and deflect the flow of secondary combustion air A s away from and around the nozzle tip 13 .
[0030] Thus, higher efficiency combustion is achieved as a greater amount of the available fuel G is burned in the housing 3 . Further, the deflection of at least a portion of the gas/air mixture to the outer walls of the housing 3 caused by the turbulence patterns as described establishes a flame pattern which extends to about the diameter of the housing 3 aiding in a more complete combustion of the gas/air mixture therein.
[0031] An angle of the vanes 23 of the deflector plate 20 may be adjustable so as to control the amount of secondary air A s reaching the housing 3 and the combustion zone C therein and thus the combustion efficiency of the burner assembly 1 . Controlling the rate of secondary combustion A s air further acts to control the draft of the burner assembly 1 which increases the retention time in the housing 3 and permits more efficient heat transfer therein.
[0032] Most preferably, as shown in FIGS. 1, 3 and 4 , the means for deflecting the flow of secondary air A s in the annulus 5 away from at least the nozzle tip 13 comprises both the low pressure ring 14 and the deflector plate 20 . In this embodiment, the nozzle head 12 , low pressure ring 14 and deflector plate 20 are preferably manufactured as a unitary nozzle structure.
[0033] As shown in FIGS. 1 and 2 a, aventuri sleeve 25 may be positioned within the tubular barrel 2 to accelerate the flow of primary combustion air A p and fuel G therein causing turbulence which results in enhanced mixing of the primary combustion air A p and fuel G prior to reaching the orifices 10 .
[0034] In an embodiment shown in FIG. 4 , at least a first port 30 is formed in the air deflector plate 20 to accommodate and support an ignition system, preferably a pilotless ignition system such as an igniter/flame rod 31 for igniting the primary fuel/air mixture exiting the plurality of orifices 10 in the burner head 12 . The flame/igniter rod 31 preferably incorporates flame sensing using flame ionization technology. Due to the isolation of the nozzle tip 13 from the direct flow of secondary air A s , a consistent flame 15 is maintained at the nozzle tip 13 and will be detected by the flame sensor regardless whether the burner assembly 1 is operated at low-fire or high-fire conditions. Thus, the burner assembly 1 can be reliably and remotely lit using the igniter/flame rod 31 . Incorporation of the igniter/flame rod 31 eliminates the need for a conventional pilot and additional troublesome components associated therewith which are conventionally subject to freezing.
[0035] Preferably, the igniter/flame rod 31 is arranged to pass along the housing 3 from the proximal end 8 of the tubular barrel 2 , through the air deflector plate 20 and to be positioned with a sparking tip 32 oriented at an optimal sparking distance (such as about ⅛″) from the nozzle tip 13 .
[0036] Also with reference to FIG. 4 , in another embodiment, at least one additional port 32 is formed in the air deflector plate 20 to support a heat return tube 40 . The heat return tube 40 , typically a flexible metal tube, extends from and is in communication with the mixer head 7 at the base 8 of the burner assembly 1 . An intermediate length of the heat return tube 40 extends along at least the fuel feed line 6 , along the gas inlet orifice 50 to the tubular barrel 2 and along the tubular barrel 2 to extend outward through the additional port 32 into the housing 3 adjacent the burner tip 13 , positioning a first intake end 41 adjacent or within the combustion zone C. The heat return tube 40 draws heated combustion gases from the housing 3 into the first intake end 41 of the heat return tube 40 and the heated combustion gases are communicated therealong to a second end 42 at the mixer head 7 to conduct heat and prevent freezing of the components of the burner assembly 1 which are adjacent the heat return tube 40 . A pressure differential between the mixer head 7 and housing 3 at the combustion zone C acts to draw the combustion gases into and along the heat return tube 40 .
[0037] As shown in FIGS. 5-8 , the mixer head 7 preferably comprises a tubular housing 60 having a solid base 61 through which a plurality of orifices 62 are formed. Primary combustion air is aspirated through the air orifices 62 . The air orifices 62 extend into a mixing chamber 63 formed in the tubular housing 60 . The mixing chamber 63 is positioned intermediate the air orifices 62 and the tubular barrel 2 which is connected thereto. The gas inlet orifice 50 is formed at a center of the base 61 through which fuel G is introduced to the mixing chamber 63 from the gas inlet 6 . Fuel/primary combustion air G/A p combined in the mixing chamber 63 are discharged into the tubular barrel 2 . The plurality of orifices 62 act to minimize or prevent gusts of primary combustion air A p from entering the mixer 7 which is particularly advantageous in low velocity fuel conditions.
[0038] An air shutter 26 is provided at the base 61 of the mixer head 7 for controlling the amount of primary combustion air A p entering the air orifices 62 . Preferably the air shutter 26 is threaded onto a gas inlet nipple 64 extending outward from the mixer base 61 . The air shutter 26 can be moved along the nipple 64 away from and toward the base 61 of the mixer 7 to permit more or less air to pass thereby into the air orifices 62 .
[0039] Preferably, the fuel orifice 50 is provided in a fuel orifice insert 65 which is threadably connected into the mixer base 61 . The size of the fuel orifice 50 can be altered by swapping the insert 65 for an insert 65 having a different size fuel orifice 50 .
[0040] Alternatively, in another embodiment of the invention as shown in FIGS. 5, 6 and 8 , the burner assembly 1 further comprises an auxiliary air inlet 51 in the mixer head 7 through which primary combustion air A p may be forced into the flow of fuel G in the mixer head 7 prior to entering the tubular barrel 2 . In this situation, the air shutter 26 at the base 8 of the burner assembly 1 can be closed completely and the flow of primary combustion air A p is controlled through the forcible addition of air through the auxiliary air inlet 51 . The flow of fuel gas G is controlled by adjusting the size of the fuel orifice 50 in the mixer head 7 . In this embodiment, the burner assembly 1 can operate as a forced draft burner assembly, which may be preferable in cases where a more precise control of the primary combustion air/fuel ratio A p /G is required. Secondary air A s continues to be aspirated as in the natural draft embodiment.
[0041] Applicant has found this unique burner assembly operates at efficiencies in the order of 7-10% more efficient than other natural draft burners and can operate efficiently at pressures ranging from about 0.25 psig to about 15 psig. Burners employing this unique design can be manufactured to range in size from about 1″×6″ to about 2″×24″. Those skilled in the art would appreciate these specifications are guidelines only and the burner of the present invention is not limited to these dimensions or pressure ranges.
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A burner assembly has a burner head and a deflector plate extending radially therefrom and across a firetube housing for supporting the burner assembly therein. The deflector plate has a plurality of angled vanes for re-directing secondary combustion air flowing through the housing. Secondary air is deflected away from a nozzle tip at the burner head to minimize lifting of the flame by the deflector plate or by a low pressure ring formed around the nozzle tip above the deflector plate for creating an area of low pressure. Preferably, a combination of the deflector plate and low pressure ring provides a stable flame positioned at the nozzle tip under low-fire and high-fire conditions enabling use of a pilotless ignition and flame sensing system which is consistent under low and high fire conditions. More preferably, the deflector plate supports the igniter and optionally a heat return tube for heat tracing of the freeze-prone burner assembly components.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application incorporates by this reference all subject matter contained in PCT Patent Application Serial No. PCT/IL2003/000545, as filed on 29 Jun. 2003, and entitled “GRIPPERS MALFUNCTION MONITORING”. This PCT application was published on 13 Jan. 2005 as International Publication No. WO 2005/002864 A1.
FIELD OF THE INVENTION
The field of the invention is printers and copiers, especially apparatus and methods for monitoring malfunctioning of grippers.
BACKGROUND OF THE INVENTION
Printers and copiers often have a photo-sensitive member which receives an image, and an intermediate transfer member, often with a heated blanket, which receives the image from the photo-sensitive member and transfers it to sheet of paper or other printing media on an impression roller. (The printing media will henceforth be referred to as “paper,” but any printing media should be understood.) The intermediate transfer member often has a delicate surface, for example the heated blanket may comprise a release surface with a soft conforming layer underneath, which allows the surface to press against the impression roller with uniform pressure. These characteristics of the intermediate transfer member produce good images on the printing media, but also mean that its surface may be damaged relatively easily, and such damage may require a time-consuming and expensive replacement of the member. Even for different structures, the intermediate transfer member (often in the form of a blanket) is subject to damage from excess pressure and/or from toner that is left on the release surface too long.
One cause of such damage is paper sticking to the blanket. Normally, paper is fed onto the impression roller and held there with grippers. If the paper is misfed for any reason, then the paper may stick to the blanket of the intermediate transfer member after the image is printed. The printer must then be stopped, opened up, the paper removed, and the ink on the blanket (which in normal operation gets completely transferred to the paper) must be cleaned off. Delay in removing the ink from the blanket may result in the ink drying onto the (generally heated) blanket, which must then be replaced. Ink may also remain on the intermediate transfer member if, as a result of the paper misfeeding, at least part of the intermediate transfer member presses directly against the surface of the impression roller, without any paper in between. If the paper is folded or wrinkled as a result of the misfeed, it may dent the blanket, also making it necessary to replace the blanket. If paper is not released on time from the impression roller, then two sheets of paper may end up on the impression roller, which can hurt the blanket.
Because paper misfeeds are potentially so damaging, it would be desirable to prevent any events which could cause a misfeed, even relatively rare events.
SUMMARY OF THE INVENTION
An aspect of an embodiment of the invention concerns an apparatus and method for preventing some misfeeds which can damage the blanket, by sensing when the grippers fail to open properly or fail to close properly. Optionally, this is done by two proximity sensors, for example capacitive, inductive or optical sensors, which sense the proximity of a target element which is in a different position depending on whether the grippers are open or closed. Alternatively, the state of the grippers is sensed directly, but sensing the proximity (or lack of proximity) of a target element potentially provides a simpler way to determine the state of the grippers, since the grippers are not generally accessible.
In an embodiment of the invention, the target element rotates with the impression roller. The target element changes its position as the impression roller rotates, while the sensors are fixed in place and sense the target element as it passes them, if the grippers are open. The first sensor is located in a position such that, in normal operation, the grippers would already be open when the target passes the first sensor, if the grippers are supposed to open on that cycle of the impression roller. The second sensor is located in a position such that, in normal operation, the grippers would already be closed when the target passes the second sensor (and hence the second sensor would not sense the target), if the grippers are supposed to close on that cycle of the impression roller. Alternatively, one or both of the sensors are instead located at a position such that they would sense the target only if the grippers were closed. Alternatively, only one of these sensors is present, and only one type of malfunction of the grippers (failure to open, or failure to close) is sensed.
Optionally, the target element is, or is attached to, an element which causes the grippers to open and close. For example, the target element is a cam follower, which follows a cam while rotating with the impression roller, opening and closing the grippers at the proper points in the cycle.
In printers where only one transfer to paper takes place at each print engine, the cam is often fixed in place. The grippers always open and close at the same points in the cycle of the impression roller, which picks up a sheet of paper during each cycle, and releases it before picking up the next sheet during the next cycle. In such a printer, the grippers virtually never fail to open or close properly. However, in printers which print more than one image on each sheet of paper, for example color printers which print several color separations on each sheet of paper, the grippers do not open and close on every cycle, and the cam is not fixed in place. Instead, as in the HP3000 Twister printer using a cam, there is a locking mechanism, in this example a hook which hooks onto the cam, which locks the cam in place when the grippers are supposed to open and close, to release a sheet of paper which is finished being printed, and to pick up the next sheet.
When the grippers are not supposed to open, for example when additional images are going to be printed on the sheet that is being held by the grippers, then the locking mechanism is released, and the cam rotates together with the impression roller and the cam follower. The grippers then remain closed, until the locking mechanism is re-engaged, and the cam follower starts to move relative to the cam again. This process is illustrated in FIGS. 2A-2I , and described in detail below.
In printers with a moveable and lockable cam, the grippers are much more likely to fail to open or fail to close at the proper time. This can occur, for example, if the locking mechanism fails to release, or fails to engage, or if the cam fails to rotate with the impression roller when the locking mechanism is released, or if the cam stops rotating at the wrong orientation when an attempt is made to engage the locking mechanism. While gripper malfunction is very rare, the consequences are harmful and it is desirable to sense gripper malfunction as soon as it occurs.
If the sensors sense that the grippers have failed to open, or failed to close, then optionally the printer is automatically stopped, before damage has been done to the blanket of the intermediate transfer member, and a diagnostic message is issued to the operator.
There is thus provided, in accordance with an exemplary embodiment of the invention, a system for printing an image on a printing media, comprising:
a) an impression roller; b) a gripper which receives the printing media when said gripper is open, closes to hold the printing media to the impression roller while the image is printed, and opens to release the printing media from the impression roller; and c) at least one sensor which senses whether the gripper is open or closed.
Optionally, the impression roller rotates on a rotation axis, the closing of the grippers occurs within a first angular range in the rotation of the impression roller, the opening of the grippers to release the printing media occurs within a second angular range in the rotation of the impression roller, and the at least one sensors comprise one or both of:
a) a first sensor which senses whether the gripper is open or closed at a first sensor angle in the rotation of the impression roller, which first sensor angle follows the first angular range and precedes the second angular range; and b) a second sensor which senses whether the gripper is open or closed at a second angle in the rotation of the impression roller, which second angle follows the second angular range and precedes the first angular range.
Optionally, the at least one sensors comprise only the first sensor.
Alternatively, the at least one sensors comprise only the second sensor.
Alternatively, the at least one sensors comprise both the first and second sensors.
In an embodiment of the invention, there is a sensor target which has a first position when the gripper is open and a second position when the gripper is closed, and at least one of the at least one sensors is a proximity sensor which detects the target only in one of the first and second positions.
Optionally, the proximity sensor detects the target only in the first position.
Optionally, the proximity sensor is an inductive sensor.
Alternatively, the proximity sensor is a capacitive sensor.
Alternatively, the proximity sensor is an optical sensor.
Optionally, the target is attached to a control element which controls the opening and closing of the gripper.
Alternatively, the target comprises a control element which controls the opening and closing of the gripper.
In an embodiment of the invention, there is a cam, and the control element comprises a cam follower which follows the perimeter of the cam, the grippers being open when the cam follower is on a first portion of said perimeter, and closed when the cam follower is on a second portion of said perimeter.
Optionally, there is a control rod attached to the gripper, and a lever joining the control rod to the cam follower, and the cam follower is on the first portion of the perimeter of the cam, the lever rotates the control rod into an orientation where the gripper is open, and when the cam follower is on the second portion of the perimeter of the cam, the lever rotates the control rod into an orientation where the gripper is closed.
Optionally, there is a cam stopper, the cam does not rotate when the cam stopper is engaged, and the cam rotates substantially in synchrony with the impression roller when the cam stopper is disengaged, thereby preventing the gripper from opening when the cam stopper is disengaged and the cam follower is on the first portion of the perimeter of the cam.
Optionally, friction keeps the cam rotating substantially in synchrony with the impression roller when the cam stopper is disengaged.
Alternatively or additionally, there is a cam attachment mechanism which attaches the cam to the impression roller when the cam stopper is disengaged, thereby keeping the cam rotating substantially in synchrony with the impression roller.
Optionally, the cam stopper comprises a first cam stopper element which is attached to the cam, and a second cam stopper element which is fixed in place, and the cam stopper elements engage each other to engage the cam stopper, and disengage to disengage the cam stopper.
Optionally, there is an actuator which moves one of the cam stopper elements into a first position where it engages the other cam stopper element, and into a second position where it disengages the other cam stopper element.
Optionally, the cam only stops at a stopping position, and the cam stopper element moved by the actuator does not interfere with the rotation of the cam when said element is in the first position, until the cam is substantially in the stopping position.
Optionally, one of the cam stopper elements is a hook.
There is thus also provided, in accordance with an exemplary embodiment of the invention, a method of preventing damage to an intermediate transfer member in a printer with a rotating impression roller, and a gripper which has an open position and a closed position, which gripper holds a printing media to the impression roller when the gripper is closed but not when the gripper is open, the method comprising:
a) feeding the printing media onto the impression roller when the gripper is open and the impression roller is oriented at a first range of angles in its rotation; b) closing the gripper to hold the printing media onto the impression roller when the impression roller is oriented at a second range of angles in its rotation; c) transferring an image from the intermediate transfer member to the printing media while the printing media is held onto the impression roller; d) opening the gripper to release the printing media from the impression roller after the image is transferred, when the impression roller is oriented at a third range of angles in its rotation; and e) sensing at least one of: a failure of the gripper to be open to receive the printing media, a failure of the gripper to close to hold the printing media, a failure of the gripper to stay closed until after the image is transferred, and a failure of the gripper to open to release the printing media.
Optionally, sensing comprises sensing, a failure of the gripper to be open to receive the printing media.
Alternatively or additionally, sensing comprises sensing a failure of the gripper to close to hold the printing media.
Alternatively or additionally, sensing comprises sensing a failure of the gripper to stay closed until after the image is transferred.
Alternatively or additionally, sensing comprises sensing a failure of the gripper to open to release the printing media.
In an embodiment of the invention, the method includes stopping the printer after at least one of the failures has been sensed, before said failure causes damage to the intermediate transfer member.
Optionally, sensing comprises sensing whether the gripper is open or closed when the impression roller is oriented at an angle that it reaches in its rotation after passing the second range of angles and before reaching the second range of angles, thereby sensing failure of the gripper to close and failure of the gripper to stay closed.
Additionally or alternatively, sensing comprises sensing whether the gripper is open or closed when the impression roller is oriented at an angle that it reaches in its rotation after passing the third range of angles and before reaching the first range of angles, thereby sensing failure of the gripper to open and failure of the gripper to be open.
Optionally, sensing whether the gripper is open or closed when the impression roller is oriented at an angle comprises detecting the proximity or lack of proximity of a target to a proximity sensor, and the target passes near the sensor only when the impression roller is oriented at said angle, and only when the gripper is in one of an open state and a closed state, but not when the gripper is in the other of said states.
BRIEF DESCRIPTIONS OF THE DRAWINGS
Exemplary embodiments of the invention are described in the following sections with reference to the drawings. The drawings are generally not to scale and the same or similar reference numbers are used for the same or related features on different drawings.
FIG. 1 is an exploded view of one end of an impression roller with grippers, showing a mechanism for opening and closing the grippers, according to an exemplary embodiment of the invention. The gripper 106 , gripper control rod 108 , bearing 109 , lever 110 , cam follower 112 , sensor target 114 , and sensors 120 and 122 are shown outside the impression roller 102 for clarity and to reveal details which would otherwise be concealed by the impression roller 102 .
FIGS. 2A-2I are a time sequence of schematic axial views showing the operation of the mechanism, according to the same embodiment of the invention; and
FIG. 3 is an axial view showing a situation in which the grippers fail to close, according to the same embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 shows one end of an impression roller 102 in a printer or copier, in accordance with an embodiment of the invention. The impression roller rotates continuously around an axis 104 during normal operation of the printer or copier. A gripper 106 is opened and closed by the rotation of a gripper control rod 108 , which is mounted in a bearing 109 that is attached to the impression roller. Optionally there are one or more additional grippers not shown in the drawing, located for example further to the left of the gripper shown, which are also opened and closed by control rod 108 . A lever 110 attaches control rod 108 to a cam follower 112 . When cam follower 112 moves radially outward from axis 104 , lever 110 causes control rod 108 to rotate in a direction which opens gripper 106 . When cam follower 112 moves radially inward, then lever 110 causes control rod 108 to rotate in the other direction, which closes gripper 106 . Alternatively, cam follower 112 , lever 110 , contrail rod 108 , and gripper 106 are configured so that moving cam follower 112 outward causes gripper 106 to close, and moving cam follower 112 inward causes gripper 106 to open. In describing the drawings, we will assume that moving cam follower 112 inward causes gripper 106 to close, but the appropriate changes in the description, if the reverse is true, will be obvious to one skilled in the art.
In an embodiment of the invention, a sensor target 114 is situated at or near the end of cam follower 112 , opposite the end of cam follower 112 that is attached to lever 110 . Optionally, sensor target 114 is not a separate element added to cam follower 112 , but is just the far end of cam follower 112 , made of the same material as the rest of cam follower 112 .
Cam follower 112 follows the surface of a cam 116 , as impression roller 102 rotates around axis 104 . Although cam 116 is shown some distance to the right of impression roller 102 , in FIG. 1 , for clarity, cam 116 is optionally directly in contact with the end of impression roller 102 . Cam 116 has a depression 118 on one side. When cam follower 112 moves into depression 118 , then gripper 106 closes, by the mechanism described above. When cam follower 112 moves out of depression 118 , then gripper 106 opens.
A first position sensor 120 is located directly to the right of, and somewhat above, depression 118 . When cam follower 112 falls into depression 118 , then sensor target 114 at the end of cam follower 112 will be located radially inward from sensor 120 , and sensor 120 will fall to detect target 114 . However, if cam follower 112 fails to fall into depression 118 , but remains at the same distance from axis 104 as it normally is when gripper 106 is open, then target 114 at the end of cam follower 112 will be located at the same radius as sensor 120 , which will detect target 114 as it sweeps by sensor 120 in the course of the rotation of impression roller 102 .
A second position sensor 122 is optionally located at the same radial distance from axis 104 as sensor 120 , but at a different azimuthal position. As cam follower 112 follows outside of cam 116 , target 114 will go past sensor 122 , which will detect it. However if, as will be described below, cam 116 and depression 118 rotate together with impression roller 102 , and cam follower 112 remains in depression 118 as impression roller 102 rotates, then target 114 will be too far inward radially to be sensed by sensor 122 , as cam follower 112 goes past sensor 122 .
Alternatively, sensor 120 and/or sensor 122 are located in positions so that they will only detect target 114 if cam follower 112 is in depression 118 when it passes the sensor.
Optionally, sensors 120 and 122 are inductive sensors. Alternatively, they are capacitive sensors, or optical sensors, or any other kind of proximity sensor known to the art. Optionally, the two sensors are not the same kind of sensor, although, using the same kind of sensor for both sensor 120 and sensor 122 has the potential advantage of making the design and operation of the apparatus simpler. Optionally, only one of sensor 120 and sensor 122 is present but having both sensors present has the potential advantage that the sensor can detect both failure of the grippers to open and failure of the grippers to close.
A rod 124 , attached to cam 116 , is restrained by a hook 126 , to keep cam 116 fixed in place while impression roller 102 rotates. Hook 126 is attached to an axle 128 , which is turned by a control motor 130 . The control motor brings hook 126 upward, where it catches rod 124 , to lock cam 116 in place, and brings hook 126 downward to a position where hook 126 does not interfere with rod 124 , to unlock cam 116 . Alternatively, any other actuator known to the art, for example a solenoid, is used instead of control motor 130 and axle 128 , to move hook 126 back and forth. Alternatively, another reversible attachment mechanism known to the art, such as a clamp or a latch, or a rod which fits into a hole, serves to keep cam 116 fixed in place instead of hook 126 and rod 124 . A potential advantage of using hook 126 and rod 124 over some other attachment mechanisms is that the hook can be moved into a position to catch rod 124 any time after rod 124 has passed by that position on the previous rotation of the cam, and the hook will stop the cam at the proper time, but will not interfere with the rotation of the cam until rod 124 reaches the hook.
Although rod 124 is shown at the bottom of cam 116 , optionally rod 124 , or whatever attachment mechanism is used, is located anywhere where it can conveniently hold the cam in place, and where it does not interfere with other elements, for example the cam follower.
When hook 126 is moved away from rod 124 , then cam 116 is free to rotate around axis 104 , and does rotate around axis 104 , in synchrony with impression rotor 102 . For example, friction between cam 116 and impression roller 102 keeps them rotating together when hook 126 does not prevent cam 116 from rotating. Alternatively, cam 116 is attached to impression roller 102 by another pin or a latch or any other reversible attachment mechanism, when hook 126 does not interfere with rod 124 . Alternatively, separate synchronized motors are used to drive impression roller 102 and cam 116 . Using friction to keep cam 116 and impression roller 102 rotating together has the potential advantage that it is not necessary to actively drive cam 116 , or to activate a separate attachment mechanism, but simply removing hook 126 from rod 124 makes cam 116 rotate together with impression, roller 102 . Alternatively, cam follower 112 and depression 118 are used to keep cam 116 rotating together with impression roller 102 , as described below.
The details of how impression roller 102 and cam 116 are mounted are not shown, for clarity. Optionally, impression roller 102 and cam 116 are both mounted on a common axle along axis 104 , for example, or any kind of rotary bearing known to the art is used. Similarly, the mechanism used to drive impression roller 102 is not shown in FIG. 1 , and may be any kind of rotary drive mechanism known to the art.
The normal operation of the cam and cam follower in an exemplary embodiment of the invention will be described with reference both to FIG. 1 , a side view, and FIGS. 2A through 2I , which provide a time sequence of axial views. The operation may be easier to understand by looking at both FIG. 1 and the series of FIGS. 2A-2I together. In the axial view of FIGS. 2A-2I , the outer surface of impression roller 102 is shown as a dashed circle surrounding cam 116 , although in fact, as seen in FIG. 1 , cam 116 is located at a different axial position than impression roller 102 . In FIGS. 2A-2I , gripper 106 is in an open state when it is oriented at an angle to the surface of impression roller 102 , and in a closed state when it is tangent to the surface of impression roller 102 .
In a first mode of operation, cam 116 is held in place by hook 126 when the impression roller is waiting for paper. This is shown in FIG. 2A , where hook 126 is shown hooked around rod 124 . Depression 118 in cam 116 is located at a position such that gripper 106 will be in the open position when paper is fed into gripper 106 , as in FIG. 2B , and gripper 106 then closes around the paper, as in FIG. 2C , holding the paper to impression roller 102 . Note that when cam follower 112 falls into depression 118 and gripper 106 closes, as in FIG. 2C , cam follower 112 does not pass next to sensor 120 , but passes below sensor 120 , and sensor 120 does not detect target 114 (not shown in FIGS. 2A-2I ) which is attached to cam follower 112 . Optionally, depression 118 is positioned so that gripper 106 closes shortly after the paper is fed into the gripper, and the paper does not have time to slip out of the gripper after it is fed in. Although FIGS. 1 , 2 A, and 2 B show depression 118 located on the top of cam 116 when cam 116 is held in place by hook 126 , the actual position of depression 118 need not be on the top of cam 116 when cam 116 is held in place by hook 126 .
Once gripper 106 closes around the paper, hook 126 starts to swing downward, away from rod 124 , releasing cam 116 , as shown in FIG. 2C , and cam 116 begins to rotate with impression roller 102 , as shown in FIGS. 2D , 2 E, and 2 F. Cam follower 112 thus remains in depression 118 , and gripper 106 remains closed around the paper, as impression roller 102 rotates. Note that, because cam follower 112 remains in depression 118 , cam follower 112 does not pass next to sensor 122 , but passes to the side of sensor 122 in FIG. 2E , and target 114 is not detected by sensor 122 , indicating that gripper 106 is closed.
A printed image is then transferred to the paper from the intermediate transfer member, not shown in the drawing. Optionally, this is done in a single rotation of the impression roller. Optionally, if only a single image is being printed on the paper, then hook 126 is not removed from rod 124 at all, so FIGS. 2D , 2 E and 2 F are skipped, and, the image is printed during, the fraction of a cycle when the grippers are closed. Alternatively, for example in color printing, two or more rotations of the impression roller are used in order to print the full image on the paper. Cam 116 continues to rotate synchronously with impression roller 102 , and gripper 106 remains closed around paper, while the image is printed. Optionally, the trapping of cam follower 112 in depression 118 is sufficient to keep cam 116 rotating in synchrony with impression roller 102 . Alternatively, other mechanisms are used, as described previously.
When the image has been printed and it is desired to remove the paper from the impression roller, then hook 126 swings back upward, as shown in FIG. 2F , until it is in position to catch rod 124 , as shown in FIG. 2G . Cam 116 then stops rotating and remains fixed in place with depression 118 at its original location, for example on top of cam 116 as shown in FIG. 2G . As impression roller 102 and cam follower 112 continue to rotate around axis 104 , cam follower 112 goes out of depression 118 and moves outward from axis 104 , as shown in FIG. 2H . This causes lever 110 to rotate control rod 108 , opening gripper 106 when impression roller 102 is in a proper orientation to release the paper. As impression roller 102 continues to rotate, cam follower 112 continues to follow the surface of cam 116 . This time, as shown in FIG. 2I , cam follower 112 passes right by sensor 122 , and sensor 122 detects target 114 on cam follower 112 , indicating that gripper 106 is open. Impression roller 102 and cam follower 112 return to the position shown in FIG. 2A , where gripper 106 is ready to receive the next piece of paper.
If hook 126 fails to catch rod 124 when impression roller 102 is in the position shown in FIG. 2G , then cam 116 will continue to rotate with impression roller 102 , as shown in FIGS. 2D , 2 E and 2 F, and gripper 106 will fail to open. This means that the paper will not be released, and that gripper 106 will not be able to receive the next sheet of paper. This condition will be detected because sensor 122 will fail to sense cam follower 112 , which will be positioned as in FIG. 2E , rather than as in FIG. 2I as it is supposed to be. The printer is then optionally stopped, before the next piece of paper can misfeed and possibly damage the blanket of the intermediate transfer member.
If hook 126 fails to disengage properly from rod 124 when it is supposed to, then cam 116 will not rotate with impression roller 102 , but will remain in the orientation shown in FIG. 2C . Then cam follower 112 will go out of depression 118 and gripper 106 will open prematurely, as in FIGS. 2H and 2I , rather than remaining closed as it is supposed to, as shown in FIGS. 2D and 2E . This could lead to the paper sticking to the blanket of the intermediate transfer member. It could also lead to the paper slipping out of place before all of the image has been printed on the paper, with the result that part of the image is printed directly on the impression roller. Since the impression roller may not absorb all of the ink from the intermediate transfer member, as the paper does, this can result in some of the ink remaining on the blanket of the intermediate transfer member and drying, damaging the blanket. The premature opening of gripper 106 will be detected because sensor 122 will detect target 114 when cam follower 112 passes by sensor 122 , as in FIG. 2I . The printer is then optionally stopped before any damage is done to the blanket. In the case of damage due to ink drying on the blanket, it is specially important to detect the problem quickly, so that the ink can be cleaned off the blanket before it dries. Using sensor 122 to detect the problem potentially allows the ink to be cleaned off the blanket in time. If the problem is not detected until a paper jam occurs later, for example, then it may be too late to save the blanket because on the ink on the blanket may already be dry.
FIG. 3 shows an example in which gripper 106 fails to close when impression roller 102 reaches the orientation, shown in FIG. 2C , at which gripper 106 is supposed to close. In FIG. 3 , cam follower 112 follows cam 116 , but cam 116 is oriented in the wrong direction, with depression 118 on the side instead of on top, when the grippers are supposed to close. For example, cam 116 stops rotating when it is at a wrong orientation for stopping, due to a problem with the bearing of cam 116 . Such a condition could also cause gripper 106 to open prematurely. The condition shown in FIG. 3 , where gripper 106 fails to close, could also be caused by a failure of hook 126 to hold cam 116 in place, causing cam 116 to start rotating with impression roller 102 before cam follower 112 has reached depression 118 . The failure of gripper 106 to close, or the premature opening of gripper 106 , can cause paper to misfeed or to stick to the blanket of the intermediate transfer member, possibly damaging the blanket.
The condition shown in FIG. 3 , whatever its cause, and whether it involves a failure of the gripper to close, or a premature opening of the gripper, will result in sensor 120 detecting target 114 as cam follower 112 passes sensor 120 , indicating that gripper 106 is open when it is supposed to be closed. The printer then optionally is stopped, before a paper misfeed does any damage.
Although this description and the claims refer sometimes to paper, the invention may also be used with any other printing media, and the claims cover the apparatus and the method when any printing media is used. Similarly, the term “printer” used in the description or the claims covers any apparatus which prints an image on a printing media, including a copier, for example. The invention has been described in the context of the best mode for carrying it out. It should be understood that not all features shown in the drawings or described in the associated text may be present in an actual device, in accordance with some embodiments of the invention. Furthermore, variations on the method and apparatus shown are included within the scope of the invention, which is limited only by the claims. Also, features of one embodiment may be provided in conjunction with features of a different embodiment of the invention. As used herein, the terms “have”, “include” and “comprise” or their conjugates mean “including but not limited to.”
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A system for printing an image on a printing media, comprising:
a) an impression roller; b) a gripper which receives the printing media when said gripper is open, closes to hold the printing media to the impression roller while the image is printed, and opens to release the printing media from the impression roller; and c) at least one sensor which senses whether the gripper is open or closed.
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RELATED APPLICATIONS
U.S. application Ser. No. 07/743,799, filed concurrently herewith by W. H. Dumbaugh, Jr. under the title HIGH ALUMINA, ALKALINE EARTH BOROSILICATE GLASSES FOR FLAT PANEL DISPLAYS, discloses glasses designed for use as substrates in flat panel display devices utilizing polycrystalline silicon thin film transistors. The glasses disclosed therein exhibited strain points higher than 625° C., liquidus temperatures below 1075° C., long term stability against devitrification, liquidus viscosities greater than 1.5×10 5 poises, and having compositions essentially free from alkali metal oxides and MgO while consisting essentially, in mole percent, of:
______________________________________SiO.sub.2 63-68 BaO 4.5-10Al.sub.2 O.sub.3 7.5-11 CaO + SrO + BaO 14-26CaO 9.5-16 B.sub.2 O.sub.3 1-7SrO 0-5______________________________________
U.S. application Ser. No. 07/743,800, filed concurrently herewith by W. H. Dumbaugh, Jr. under the title ALKALINE EARTH ALUMINOBOROSILICATE GLASSES FOR FLAT PANEL DISPLAYS, is directed to glasses designed for use as substrates in flat panel display devices utilizing polycrystalline silicon thin film transistors. The glasses disclosed therein exhibit strain points higher than 675° C., liquidus temperatures below 1125° C., long term stability against devitrification, and having compositions essentially free from alkali metal oxides while consisting essentially, in mole percent, of:
______________________________________SiO.sub.2 60-65 BaO 4.5-10Al.sub.2 O.sub.3 8-10 MgO + CaO + SrO + BaO 23-28CaO 11-24 B.sub.2 O.sub.3 1-4SrO 0-12 MgO 0-4______________________________________
BACKGROUND OF THE INVENTION
Glass has been chosen as a substrate in liquid crystal display devices for several reasons: (1) it is transparent; (2) it can withstand the chemical and physical conditions to which it is exposed during display processing; and (3) it can be manufactured at reasonable cost in thin sheets with precisely controlled dimensions. Liquid crystal displays are passive displays which are dependent upon external sources of light for illumination. They are fabricated as segmented displays or in one of two basic matrix configurations. The substrate needs of the two types differ. The first type is intrinsic matrix addressed, relying upon the threshold properties of the liquid crystal material. The second type is extrinsic matrix or active matrix addressed, in which an array of diodes, metal-insulator-metal devices or thin film transistors (TFTs) supplies an electronic switch to each pixel. In both designs, however, two sheets of glass form the structure of the display.
Intrinsically addressed liquid crystal displays are fabricated employing thin film deposition at temperatures of about 350° C., followed by photolithographic patterning. Because of the low temperature requirements involved in the process, soda lime silicate glass having a silica barrier layer thereon to prevent migration of Na+ ions has been used extensively as substrates therefor. A higher performance version of intrinsically addressed liquid crystal displays, termed the super twisted nematic, has an added substrate requirement of extremely precise flatness. That requirement has demanded that the soda lime silicate glasses employed in the displays be polished. Alternatively, Corning Code 7059 glass, a barium boroaluminosilicate glass marketed by Corning Incorporated, Corning, N.Y., which is precision formed into sheet requiring no surface polishing utilizing the downdraw fusion pipe, such as is described in U.S. Pat. Nos. 3,338,696 (Dockerty) and 3,682,609 (Dockerty) has been employed.
Extrinsically addressed liquid crystal displays can be subdivided into two categories: the first based upon metal-insulator-metal or amorphous silicon (a-Si) devices; and the second based upon polycrystalline silicon (poly-Si) devices. Devices formed from poly-Si are processed at substantially higher temperatures than those employed with a-Si thin film transistors. Those temperatures have demanded the use of glasses exhibiting higher strain points than soda lime silicate glasses and Corning Code 7059 glass to preclude thermal deformation of the sheet during processing.
The lower the strain point of the glass, the greater this dimensional change. One means for correcting this problem is to anneal the glass sheet after forming; a process adding significant cost. A more economical solution to that problem is to design glasses with high strain points so the dimensional change is minimal during device processing at about 600° C.
Contamination of thin film transistors by sodium migrating from the glass substrate is a major concern during processing. That problem has led to the use of a coating on the substrate glass to provide a barrier to the migration of the alkali.
Therefore, the principal objective of the present invention was to devise glass compositions operable as substrates in liquid crystal display devices utilizing poly-Si thin film transistors, the glass compositions being essentially free from alkali metal oxides, being relatively inert to the chemicals used in display processing, having a strain point higher than 625° C., and, most vitally, exhibiting long term stability against devitrification when in contact with platinum metal and high temperature refractory ceramic materials utilized in the downdraw fusion pipe referred to above for precision forming thin glass sheeting.
SUMMARY OF THE INVENTION
As has been indicated above, a most critica1 requirement which the inventive glass must satisfy is its resistance to the development of devitrification when exposed for very long periods to platinum metal and ceramic materials of high refractoriness at temperatures where the glass exhibits a viscosity of about 10 4 -10 6 poises. The drawing of glass sheet utilizing a fusion pipe does not impart the very fast quenching action of conventional pressing processes of shaping glass articles. By the very nature of the process, molten glass may remain in contact with the refractory component of the melting unit for as long as 30 days.
It is very difficult to evaluate in the laboratory the tendency of a glass to devitrify under the conditions present in drawing glass sheet. As a first approximation, a "liquidus" measurement is used. In reality, however, because of the method used in the laboratory, this measurement is not a true liquidus. Thus, the measuring technique involves placing crushed glass in a platinum boat which is then introduced into a gradient furnace having a temperature spread spanning the range wherein the liquidus is thought to be located. After 24 hours the boat is removed from the furnace, allowed to cool, the glass removed from the boat, thin sections prepared from the glass, and those thin sections examined microscopically. A measurement is made of the maximum temperature at which crystals are observed. The viscosity corresponding to this "liquidus" temperature provides the first estimate as to whether a particular glass is close to acceptability.
The critical viscosity for forming glass sheeting utilizing the downdraw fusion pipe process is about 1-3×10 5 poises. Accordingly, to better evaluate the devitrification proclivity of a glass for use in the process, a solid piece of the glass is heated to temperature well above the liquidus while in contact with platinum or a highly refractory ceramic material, such as alumina or zircon, depending upon the fusion pipe material most suitable for a given glass composition. Thereafter, the molten glass is cooled to a viscosity within the glass forming range and that temperature is held for seven days. The sample is thereafter visually examined for the presence of crystals. Because the inventive glasses are designed to be used in forming sheet via the downdraw fusion pipe process, the glasses will exhibit a viscosity at the liquidus temperature greater than about 1.5×10 5 poises.
Corning Code 7059 glass, consisting essentially, expressed in terms of weight percent on the oxide basis, of about 25% BaO, 10% Al 2 O 3 , 15% B 2 O 3 , and 50% SiO 2 , exhibits an annealing point of 639° C., a strain point of 593° C., and a linear coefficient of thermal expansion (25°-300° C.) of 46×10 -7 /°C. Because of its freedom from alkali metal oxide and its utility in forming thin glass sheet via the downdraw fusion pipe process, Corning Code 7059 glass has been used extensively as a substrate in a-Si devices. In an effort to devise glasses for use as substrates in poly-Si devices, a research program was initiated to develop glasses demonstrating higher strain points and other properties superior to Code 7059 glass, such as to render them applicable as substrates for liquid crystal displays utilizing polycrystalline silicon thin film transistors.
As a result of the above research program, a series of glasses was discovered in the strontium aluminosilicate system demonstrating annealing and strain points substantially higher than those exhibited by Corning Code 7059. Thus, the present inventive glasses demonstrate strain points over 675° C., annealing points above 725° C., and consist essentially, expressed in terms of mole percent on the oxide basis, of 15-26% SrO, 6-10% A 2 O 3 , and 65-75% SiO 2 . Maintenance of the individual components within the stated ranges is necessary to assure the development of the desired properties in the glass. For example, excess SiO 2 results in a glass which is too viscous; excess Al 2 O 3 raises the liquidus temperature too high; and excess SrO depresses the strain point to too low a value. The inclusion of minor amounts of BaO, CaO, and B 2 O 3 can be useful in improving certain of the physical properties displayed by the inventive glasses. To illustrate, up to 10% total BaO and/or CaO can act to reduce the liquidus temperature and up to 5% B 2 O 3 can be helpful in improving the meltability of the glasses. Nevertheless, the total of those and any other extraneous addition ought not to exceed about 12% to prevent a negative impact on the glass properties.
A very vital discovery derived from the research program was the need for excluding MgO from the glass composition. Thus, it was observed that more magnesium silicate precipitated out of the glass at a higher temperature than the other alkaline earth metal silicates, thereby, in effect, leading to greatly increased crystal growth. Consequently, not only will the inventive glass composition be essentially free from alkali metal oxides to prevent the migration of alkali metal ions, but also will be essentially free from MgO; that is, no substantive amount of an alkali metal-containing material or a magnesium-containing material will be included in the batch materials.
U.S. Pat. No. 4,634,684 (Dumbaugh, Jr.) discloses glasses especially designed for use as substrates for flat panel display devices, those glasses consisting essentially, in mole percent, of 9-12% SrO, 9-12% Al 2 O 3 , and 77-82% SiO 2 . As is immediately evident, those glasses contain less SrO and more SiO 2 than the present inventive glasses. The glasses of the patent demonstrated annealing points of at least 850° C., thus strongly recommending their utility as substrates in displays employing poly-Si thin film transistors. Unfortunately, however, batches for those glasses required melting temperature in the vicinity of 1800° C., thereby rendering them economically unfeasible in current commercial glass melting units.
Hence, the present inventive glasses are distinctive in exhibiting strain points in excess of 675° C., but yet having the capability of being melted at temperatures not exceeding about 1600° C., thereby enabling them to be melted in current commercial glass melting units. Measurements of liquidus temperatures have ranged between about 1100°-1325° C. and linear coefficients of thermal expansion (25°-300° C.) have ranged between about 45-62×10 -7 /°C.
The preferred glass compositions consist essentially, in mole percent, of:
______________________________________SiO.sub.2 67-70 CaO and/or BaO 0-10Al.sub.2 O.sub.3 7-9 B.sub.2 O.sub.3 0-5SrO 21-25 [CaO and/or BaO] + B.sub.2 O.sub.3 0-12______________________________________
Whereas it is not possible mathematically to precisely convert mole percent to weight percent, the following ranges represent approximations of the inventive glass compositions in terms of weight percent:
______________________________________SiO.sub.2 50-65 CaO and/or BaO 0-12Al.sub.2 O.sub.3 8-15 B.sub.2 O.sub.3 0-5SrO 22-38 [CaO and/or BaO] + B.sub.2 O.sub.3 0-14______________________________________
PRIOR ART
In addition to U.S. Pat. No. 4,634,684 discussed above, the following materials are cited as having relevance to the present inventive compositions.
U.S. Pat. No. 4,180,618 (Alpha et al.) reports the fabrication of electronic devices comprised of a thin film of silicon deposited upon a glass substrate, the glass exhibiting a linear coefficient of thermal expansion between 32-42×10 -7 /°C. and consisting essentially, in weight percent, of 55-75% SiO 2 , 5-25% Al 2 O 3 , and at least one alkaline earth metal oxide selected from the group in the indicated proportions of 9-15% CaO, 14-20% SrO, and 18-26% BaO. Not only is SrO merely an optional ingredient which is not present in the preferred compositions, but also the level thereof is below the minimum required in the instant inventive glasses.
U.S. Pat. No. 4,634,683 (Dumbaugh, Jr.) describes glasses especially developed for use as substrates in flat panel display devices. Those glasses displayed annealing points higher than 900° C., linear coefficients of expansion between 30-40×10 -7 /°C., and consisted essentially, in mole percent, of 68-80% SiO 2 , 18-26% Al 2 O 3 , and 2-6% BaO and/or SrO. As can be observed, the Al 2 O 3 concentrations are far higher and the SrO levels much lower than required in the present inventive compositions.
U.S. Pat. No. 4,824,808 (Dumbaugh, Jr.) also sets forth glasses particularly designed for use as substrates in liquid crystal display devices. The glasses exhibited linear coefficients of thermal expansion between 20-60×10 -7 /°C., strain points over 625° C. (no exemplary glass composition reported in the patent demonstrated a strain point above 650° C.), and consisted essentially, in cation percent, of 52-58% SiO 2 , 20-23% B 2 O 3 , 0-4% MgO, 0-6% CaO, 0-6% SrO, 1-9% BaO, 8-12% MgO+CaO+SrO+BaO, 0-3% ZnO, and 0-1% fining agent. Not only is the level of SrO far below that demanded in the instant inventive glasses, but also the B 2 O 3 concentrations are much greater than the maximum permitted in the subject inventive glasses.
Kh. Sh. Iskhakov, "Region of Glass Formation in a Strontium Oxide-Silicon Dioxide System", Uzb. Khim. Zh. 15 [1], 10-12 (1971) describes the preparation of glasses composed in mole percent, of 25-60% SrO, 5-30% Al 2 O 3 , and 35-65% SiO 2 . The very broad ranges marginally overlap those required in the present inventive glasses. Nevertheless, not only is there no mention whatever of the exceptional utility of glasses within the composition intervals of the instant invention as substrates for liquid crystal display devices, but also the publication cited no specific glass having a composition within the ranges required in the subject invention.
Moreover, Kh. Sh. Iskhakov in "Properties of Glasses in the Strontia-Alumina-Silica System", Uzb. Khim. Zh. 15 [2], 79-81 (1971) discusses several compositions of glasses having compositions within the ranges of the above Iskhakov literature reference. The author noted that the glasses exhibited coefficients of thermal expansion between 64-97×10 -7 /°C.; hence, higher than the thermal expansions in the present inventive glasses.
G. I. Zhuravlev, A. I. Kugnetsov, T. I. Semenova, and N. G. Suikovskaya, Glass, USSR SU870,365, Jan. 7, 1984, disclose the preparation of glasses demonstrating high softening points and special electrical resistivities, the glasses consisting, in weight percent, of 25-35% SrO, 11-20% Al 2 O 3 , and 41-63% SiO 2 . Not only is there no reference whatever to the special utility of SrO-Al 2 O 3 -SiO 2 glasses as substrates in liquid crystal display devices, but also no specific exemplary glass composition is provided which comes within the ranges of the present inventive glasses.
DESCRIPTION OF PREFERRED EMBODIMENTS
Table I below lists a number of glass compositions, expressed in terms of parts by weight on the oxide basis, illustrating the compositional parameters of the present invention. Because the sum of the individual components totals or very closely approximates 100, for all practical purposes the tabulated values may be considered as reflecting weight percent. The actual batch ingredients may comprise any materials, either oxides or other compounds, which, when melted together with the other batch materials, will be converted into the desired oxide in the proper proportions. For example, SrCO 3 and CaCO 3 can provide the source of SrO and CaO, respectively.
The batch ingredients were compounded, tumble mixed together thoroughly to aid in producing a homogeneous melt, and charged into platinum crucibles. After placing lids thereon, the crucibles were introduced into a furnace operating at about 1600° C. and the batches melted for about 16 hours. Thereafter, the crucibles were withdrawn from the furnace, the melts poured onto steel plates to yield glass slabs having dimensions of about 30 cm×15 cm×1 cm, and those slabs transferred immediately to an annealer operating at about 775° C. (The Examples labelled 7059, 1733, and 1724 have been inserted as comparative examples and refer to glasses commercially marketed by Corning Incorporated.)
Although the above description represents a laboratory melting procedure, it must be recognized that the inventive glasses are capable of being melted and formed utilizing large scale, commercial glass melting and forming equipment. Thus, it will be recalled that the subject glasses were designed to be drawn into thin glass sheet employing the downdraw fusion pipe. Also, whereas not employed in the laboratory melts, conventional fining agents, e.g., As 2 O 3 and Sb 2 O 3 , may be included in the batches in proper amounts where deemed desirable.
Table I also records measurements of several physical and chemical properties determined on the listed glasses in accordance with techniques conventional in the glass art. Hence, the annealing point (A.P), strain point (St.P) and internal liquidus temperature (Liq.) employing a platinum boat are tabulated in ° C. Also reported are the linear coefficient of thermal expansion (Exp.) over the temperature range of 25°-300° C., expressed in terms of ×10 -7 /°C., the density (Den.) in terms of grams/cm 3 , and the viscosity of the glass at the liquidus temperature (Vis.) in terms of poises. Finally, an evaluation of the resistance to attack by acids was determined by measuring the weight loss (W. L.) in terms of mg/cm 2 after an immersion for 24 hours in a bath of 5% by weight aqueous solution of HCl, the bath operating at a temperature of 95° C.
Table II records the glass compositions in terms of mole percent.
TABLE I______________________________________7059 1733 17241 2 3 4 5______________________________________SiO.sub.2 50.0 57.0 56.8 56.4 63.6Al.sub.2 O.sub.3 10.0 15.2 16.4 11.1 13.0SrO -- 3.6 -- 32.4 23.4CaO -- 3.9 7.8 -- --BaO 25.0 5.2 8.0 -- --B.sub.2 O.sub.3 15.0 12.4 4.7 -- --MgO -- 1.4 5.8 -- --A.P. 639 695 721 762 798St.P. 593 640 674 718 748Liq. 986 1041 1100 1100 1250Exp. 46 36.5 44 58.4 45.0Den. 2.76 2.49 2.64 2.94 2.726Vis. 1.8 × 10.sup.6 10.sup.6 10.sup.5 2.8 × 10.sup.5 --W.L. 12 4 0.25 0.03 0.01______________________________________6 7 8 9 10______________________________________SiO.sub.2 61.1 61.2 60.0 60.0 58.7Al.sub.2 O.sub.3 10.0 12.8 11.3 14.1 8.4SrO 28.9 26.0 28.7 25.9 32.8A.P. 764 782 771 789 753St.P. 715 732 724 740 707Liq. 1260 1215 1215 1321 1163Exp. 52.4 50.7 54.1 48.7 60.4Den. 2.839 2.788 -- -- 2.951W.L. 0.01 0.01 -- -- --______________________________________11 12 13 14 15______________________________________SiO.sub.2 58.8 58.8 57.6 56.4 56.4Al.sub.2 O.sub.3 11.2 14.0 11.2 9.7 11.1SrO 30.0 27.1 31.2 33.8 32.4A.P. 767 786 763 756 761St.P. 723 739 718 713 718Liq. 1201 1308 1155 1145 1100Exp. 55.6 51.2 57.1 58.5 58.4Den. 2.878 2.829 2.907 2.968 2.935Vis. -- -- -- -- 2.6 × 10.sup.5W.L. -- -- 0.01 0.02 0.03______________________________________16 17 18 19 20______________________________________SiO.sub.2 55.3 56.2 54.2 51.9 57.1Al.sub.2 O.sub.3 11.0 11.0 11.7 10.8 12.1SrO 33.6 34.8 34.2 37.2 26.8CaO -- -- -- -- 3.9A.P. 759 754 763 751 761St.P. 716 710 720 709 718Liq. 1145 1150 1160 1150 1205Exp. 59.1 62.0 59.3 64.5 55.9Den. 2.965 3.003 2.988 3.064 2.879W.L. 0.02 0.09 -- 0.17 --______________________________________21 22 23______________________________________SiO.sub.2 58.1 56.1 59.3Al.sub.2 O.sub.3 12.4 10.9 11.3SrO 22.3 24.9 27.4CaO 7.2 -- --BaO -- 8.2 --B.sub.2 O.sub.3 -- -- 1.9A.P. 759 750 741St.P. 717 705 698Liq. 1175 1120 1220Exp. 56.4 57.5 51.4Den. 2.83 -- 2.817W.L. -- -- 0.02______________________________________
TABLE II______________________________________(Mole %)______________________________________1 2 3 4 5 6 7 8______________________________________SiO.sub.2 63.5 65.5 62.6 69.0 75 73 73 72Al.sub.2 O.sub.3 7.5 10.3 10.7 8.0 9 7 9 8SrO -- 2.4 -- 23.0 16 20 18 20CaO -- 4.8 9.2 -- -- -- -- --BaO 12.5 2.3 3.5 -- -- -- -- --B.sub.2 O.sub.3 16.5 12.3 4.5 -- -- -- -- --MgO -- 2.4 9.5 -- -- -- -- --______________________________________9 10 11 12 13 14 15 16______________________________________SiO.sub.2 72 71 71 71 70 69 69 68Al.sub.2 O.sub.3 10 6 8 10 8 7 8 8SrO 18 23 21 19 22 24 23 24______________________________________17 18 19 20 21 22 23______________________________________SiO.sub.2 67 67 65 68 67.5 70 71Al.sub.2 O.sub.3 8 8.5 8 8.5 8.5 8 8SrO 25 24.5 27 18.5 15 18 19CaO -- -- -- 5 9 -- --BaO -- -- -- -- -- 4 --B.sub.2 O.sub.3 -- -- -- -- -- -- 2______________________________________
Example 15 constitutes the most preferred composition.
Whereas the present invention has been described in detail utilizing the inventive glasses as substrates in liquid crystal display devices, it will be understood that they can be employed in other flat panel display devices such as electroluminescent displays and plasma displays.
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The invention is concerned with glasses for use as substrates in flat panel display devices which use polycrystalline silicon thin film transistors. The compositions for these glasses are essentially free from alkali metal oxides and MgO and consist essentially, in mole percent, of:
______________________________________
SiO 2 65-75 CaO and/or BaO 0-10Al 2 O 3 6-10 B 2 O 3 0-5SrO 15-26 [CaO and/or BaO] + B 2 O 3 0-12______________________________________
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The present utility application hereby formally claims priority of U.S. Provisional Patent application No. 61/133,762 filed Jul. 2, 2008 “Yarn Made From A Blend Of Polyester And Silver Fibers And A Process For Manufacturing Thereof ” filed by the same inventor listed herein, namely, I. Michael Indiano, and said referenced provisional application is hereby formally incorporated by reference as an integral part of the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the general field of manufacturing of yarn made from various component materials, usually fibrous materials, and improved processes for manufacturing such yarns is such a manner that it is stable to facilitate weaving therewith and has unique antimicrobial characteristics and is substantially fire retardant. These yarns, made under such conditions, can be utilized for various purposes such as forming woven fabrics and other materials and can be formed with various characteristics depending upon the specific different fibers utilized in the process for making of the yarn. These processes can be used to make fine count yarns. More particularly, the present invention related to yarns used for making fabrics which are fire retardant as well as being capable of destroying or inhibiting the growth of various types of undesirable microorganisms.
2. Description of the Prior Art
A number of different yarn compositions and manufacturing processes for making yarns and carding machines used in these processes have been patented such as shown in U.S. Pat. No. 2,245,359 patented Jun. 10, 1941 to C. G. Perry on “Yarn Making”; and U.S. Pat. No. 3,251,178 patented May 17, 1966 to J. Stirling on an “Apparatus For Making Rope Strand Or Yarn”; and U.S. Pat. No. 3,347,727 patented to E. Bobkowicz et al on Oct. 17, 1967 and assigned to Emilian Bobkowicz; and U.S. Pat. No. 3,998,988 patented Dec. 21, 1976 to A. Shimomai et al and assigned to Teijin Limited on a “Conjugate Fiber, Fibrous Material And Fibrous Article Made Therefrom And Process For Production Thereof”; and U.S. Pat. No. 4,017,942 patented Apr. 19, 1977 to M. Clayton et al and assigned to The English Card Clothing Company on a “Textile Carding”; and U.S. Pat. No. 4,042,737 patented Aug. 16, 1977 to K. F. Forsgren et al and assigned to Rohm and Haas Company on a “Process For Producing Crimped Metal-Coated Filamentary Materials, And Yarns And Fabrics Obtained Therefrom”; and U.S. Pat. No. 4,388,370 patented Jun. 14, 1983 to V. S. Ellis et al and assigned to Imperial Chemical Industries Limited on “Electrically-Conductive Fibres”; and U.S. Pat. No. 4,756,941 patented Jul. 12, 1988 to F. P. McCullough et al and assigned to The Dow Chemical Company on a “Method And Materials For Manufacture Of Anti-Static Carpet And Backing”; and U.S. Pat. No. 5,234,720 patented Aug. 10, 1993 to R. D. Neal et al and assigned to Eastman Kodak Company on a “Process Of Preparing Lubricant-Impregnated Fibers”; and U.S. Pat. No. 5,372,739 was patented Dec. 13, 1994 to R. D. Neal et al and assigned to Eastman Chemical Company on a “Lubricant-Impregnated Fibers, Lubricant, And Processes For Preparation Thereof”; and U.S. Pat. No. 5,549,957 patented Aug. 27, 1996 to E. J. Negola et al on a “Bulked Continuous Filament carpet Yarn”; and U.S. Pat. No. 5,677,058 patented Oct. 14, 1997 to R. D. Neal et al and assigned to Eastman Chemical Company on a “Lubricant Impregnated Fibers And Processes For Preparation Thereof”; and U.S. Pat. No. 6,035,493 patented Mar. 14, 2000 to W. C. Carlton on a “Textile Carding And Relevant Apparatus”; and U.S. Pat. No. 6,723,428 patented Apr. 20, 2004 to S. W. Foss et al and assigned to Foss Manufacturing Co., Inc. on “Anti-Microbial Fiber And Fibrous Products”; and U.S. Pat. No. 6,815,060 patented Nov. 9, 2004 to Y. Yuuki and assigned to Asahi Kasei Kabushiki Kaisha on “Spun Yarn”; and U.S. Pat. No. 6,841,244 patented Jan. 11, 2005 to S. W. Foss et al and assigned to Foss Manufacturing Co., Inc. on “Anti-Microbial Fiber And Fibrous Products”; and U.S. Pat. No. 6,946,196 patented Sep. 20, 2005 to S. W. Foss and assigned to Foss Manufacturing Co., Inc. on “Anti-Microbial Fiber And Fibrous Products”.
SUMMARY OF THE INVENTION
The novel concepts set forth in the present patent application are used to form unique yarns capable of being both fire retardant as well as being antimicrobial. The composition of the fibers used for the yarn in this application combines the benefits of a polyester material component with a silver component. This unique combination of fibrous staple formed into yarn according to the process disclosed herein forms yarn from a fiber mixture including 94% polyester staple mixed with 6% silver staple. The fabric strength and fire retardancy are primarily provided by the polyester component and the antimicrobial characteristic is provided primarily by the silver component.
It is important that the polyester fiber chosen for yarn manufacturing herein have a high level of fire retardancy. One readily available high quality 100% polyester fiber is sold under the trade name, Trevira 350 CS FR provides this quality. This polyester fiber stable is sold with uniquely advanced levels of fire retardancy required in certain applications of products made from the yarn of the present invention, such as those items utilized in hospitals.
Initially the polyester fiber staple and silver fiber staple are physically mixed together at a ratio of 94% to 6%, respectively, in a large container. The contained mixture is then sprayed with a liquid ceramic which initially helps form a physical mixture of the component fibers with the liquid ceramic material.
This moderately mixed polyester and silver fibrous mixture is then removed from the container in batches each normally being approximately 20 to 100 pounds per batch of material. These batches of this ceramic coated fibrous mixture are then placed in a uniquely configured carding machine which has very large teeth for gently and slowly opening of the fibers of the polyester and silver components such that a completely homogeneous mixture of these two fibrous components and the liquid ceramic spray can be achieved. This mixing step forms the fully opened fibrous mixture into a completely homogeneous blend of the various components. Carding can often take as many as two individual carding steps and can take as long as a period of one to two hours or less to finally formed the fully opened and homogeneously blended staple mixture.
The machine used for carding utilizes a uniquely configured card, sold commercially under the trade name “Wolf card”, which utilizes unusually large teeth to prevent damaging of the individual component fibers and, in particular, prevents damaging of the silver fibers while at the same time achieving a fully opened and blended homogeneous final mixture of all the component fibers as required prior to spinning.
The opened and blended fiber mixture is then spun into yarn using a sequence of individual steps. The finally formed yarn is coated with a paraffin and ceramic wax mixture. The paraffin component of the mixture lubricates the spinning yarn to allow it to be easily used to make fabrics or other materials and also facilitates winding of this final yarn onto cones.
The ceramic material sprayed on the unblended fibers in the vat is defined herein as a first ceramic material and is quite different from the ceramic sprayed on the yarn after blending which is defined herein as the second ceramic. After final scouring or heating this first ceramic material chemically reacts with the second ceramic material responsive to heating thereof to form tiny platelets over the external surface of the polyester and silver fibrous blend for binding and sealing thereof by encapsulating it. Neither the first ceramic material nor the second ceramic material can be absorbed into the fibers due to the nature of the polyester and silver blended materials and, thus, they reacts together to molecularly bond and encapsulate the yarn in order to maintain the overall integrity of the structure of the yarn. This bonding between the first and second ceramic materials is activated by the subsequent hot scouring or steam heating of the finally formed yarn to a temperature of approximately 180 degrees in a heating chamber. This heating causes the first and second ceramic materials to bond together chemically into platelets encapsulating the yard and thus stabilizing the yarn structure.
It is an object of the present invention to provide a yarn made from a homogeneous blend of Trevira brand 350 CS FR 100% polyester fiber and silver fibers.
It is an object of the present invention to provide a yarn made from a unique combination of polyester and silver by a novel process not known heretofore.
It is an object of the present invention to provide a blend of individual fibers of 100% polyester and silver having a limited length normally between 30 and 60 millimeters individually.
It is an object of the present invention to provide a yarn made from a blend of Trevira 350 CS FR brand polyester staple and silver fiber staple at a ratio of 94 to 6, as well as a process for manufacturing thereof wherein the finally formed yarn is substantially capable of destroying or inhibiting the growth-of microorganisms while also being substantially flame retardant.
It is an object of the present invention to provide a unique process for making a uniquely formed yarn made from a novel carding machine utilizing a Wolf card with oversized teeth which allows for a slow and gentle processing of the fiber mixture for opening and blending of the individual component fibers to facilitate forming of a finally blended material which is completely homogeneous while at the same time preventing the damaging of the silver fiber staple component or other fibrous component thereof while also preventing the silver from agglomerating.
It is an object of the present invention to provide a yarn made from a blend of polyester and silver as well as a process for manufacture thereof wherein a paraffin and ceramic wax mixture is applied to the finally formed yarn to facilitate lubrication thereof and to facilitate encapsulating thereof to fix the structural integrity of the resultant yarn.
It is an object of the present invention to provide a yarn made from a blend of polyester and silver and a process for manufacturing thereof wherein the finally formed yarn is heat scoured with steam within the heating chamber to a temperature of as high as 180 degrees Fahrenheit to chemically bind a first ceramic component with a second ceramic component to encapsulated and stabilize the finally formed yarn structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a unique composition for a yarn composition made from a blend of polyester and silver, as well as a novel sequence of processing steps for the manufacturing thereof. This preferred embodiment describes herein is only a single example of the unique construction for yarn combining this above-described blend. This disclosure illustrates only a example of a novel type of processing that can be utilized for the manufacturing of such yarn. It should be appreciate that other similar steps can be included in other similar methods and still come within the general overall contemplated concept of the present disclosure herein for the method of producing yarn shown herein as well as for the composition of the yard so produced.
Usually the blend from which the yarn of the present invention is made will include polyester fiber staple which can be purchased in fiber lengths of approximately 30 to 60 millimeters in length. This specific length is preferred but other lengths somewhat outside of the range defined above will also provide usable. The choice of fiber length can be carefully chosen in order to be able to produce fine count yarn if required for a specific application. Silver stock fiber is then purchased in longer fiber lengths which is then cut to be complementary to the length chosen for the polyester staple. As such, normally the various component fibers used for form the yarn of this invention will include fibers all having approximately the same length, but this requirement can vary significantly depending upon the application and use for the finally formed yarn.
The polyester fiber staple used in the present invention will preferably comprise a commercially available Trevira brand 350 CS 100 polyester fiber that has high flame retardancy characteristics. This fibrous material is readily available and is extremely beneficial because it can be used in those applications that require advanced levels of fire retardancy such as hospitals.
In the preferred configuration of the present invention, the polyester Trevira brand fibers, otherwise known collectively as polyester staple, will comprise approximately 94% of the initial mixture of fibers used to ultimately form the yarn. These Trevira polyester fibers will preferably be chosen specifically due to the better flame retardant characteristics thereof. A silver staple component will then be added to an extent such as to comprise approximately 6% of the overall physical mixture of fibers. As such, the preferred overall ratio of polyester Trevira staple to silver staple in the initial mixture of fibrous components will be 94% to 6%, respectively.
The proper initial proportions of polyester staple and silver staple are initially physically placed within a container or large vat and are mixed to a limited extend. This physical mixing preferably is performed manually utilizing a hand tool such as a large wooden spatula, but it should be appreciated that any other means for physically mixing the fiber components together initially can be used. It should be understood that such physical mixing of the fibers has physical limitations due to the fibrous nature of the components and, thus, only a moderately thorough physical mixture can be achieved at this time in the process. Once this moderate mixing of the initial fibrous components within the vat has been completed, the entire content of the vat is then sprayed with a clear translucent liquid ceramic material which comprises a first type of ceramic material. This first ceramic material is quite similar to a paint without a pigment since it is both clear and translucent. This liquid ceramic spraying step coats all portions of the mixture of the fibrous materials throughout the container or vat. These fibrous materials which are now coated with the clear translucent liquid first ceramic spray will then physically be mixed again preferably manually with a wooden spatula in a similar manner as performed previously in order to further mix both the fibers with the liquid first ceramic material sprayed into the vat.
The next step in this process is to initiate the blending of this fiber mixture by opening of the fibers. Forming a homogeneous mixture of such fibrous material is only possible after the fibrous material is made substantially opened such as by carding thereof. Individual batches of any size but preferably 20 pounds to 100 pound of the fiber mixture are removed from the vat and placed into the blending chamber of a textile carding machine. The carding machine for the present invention, preferably, is a Wolf carding machine which uses a type of card having special coarse teeth for the purpose of very gently and slowly opening and blending this mixture of different fibers, some of which can be very delicate, especially the silver staple. This type of carding machine is utilized specifically to open such fibers in order that they can be homogeneously blended together. This opening and homogeneous blending occurs very slowly with the use of such a coarse card in the carding machine and, thus, requires a longer period of time with a number of individual passes of the batches of fibrous material used for effectively opening and blending the, mixture. As many as two individual carding steps may be required over a time period of as long as one to two hours may be needed in order to achieve full and complete homogeneous opening and blending of the fibrous mixture. This considerably long length of time is required due to the fact that a card that is being used for this carding process uses very coarse or open teeth as opposed to a fine toothed card which is normally utilized for other carding processes and achieves mixing and blending faster but treats the blended material more roughly. In the present invention it is important to appreciate that such a fine toothed card can not be utilized because such a card could cause clogging or agglomerating of the silver fibers together which would prevent the thorough mixing thereof homogeneously throughout the overall fibrous mixture.
The Wolf carding machine described in this invention is commonly used for carding other materials such as wool. By modifying the configuration of the teeth to be more coarse, it can be converted such it can be used to provide a slower carding process as needed for the present unique combination of polyester staple and silver staple. Once carding of the mixture in the vat is finalized, then all the fibers will be opened and the final mixture will be completely homogeneous. It is then possible to spin the blended fiber into yarn by a process of sequential steps.
At first the blended homogeneous fiber material is formed into a sliver form which is somewhat tighter than the initial final carded mixture. The consistency of the fibrous mixture is then made further tighter by placing it into a roving form. This roving is then wound onto roving spools or bobbins and it moves into a spinning frame to facilitate spinning directly into the final yarn form. The final spinning step takes the blended fiber which has been formed into sliver and roving and spins it into yarn.
At this stage the yarn needs to be lubricated to facilitate weaving characteristics thereof for forming of fabrics and material and to facilitate winding thereof onto cones. For this purpose a paraffin and ceramic wax mixture is applied onto the spinning yarn as it is wound onto the cones. The paraffin component of the wax mixture lubricates the yarn to enhance knitting characteristics thereof to facilitate use thereof in forming woven materials and products. The paraffin also facilitates the winding of the yarn upon cones. The ceramic component of this ceramic and paraffin coating is chosen to be a second ceramic material which is chosen to be a different type of ceramic as compared to the first ceramic material. The first ceramic material and the second ceramic material are specifically chosen such that when mixed together and heated, these two different types of ceramic material can chemically react to form platelets which will encapsulate the finally formed yarn for enhancing the structural integrity thereof.
The next step in the process to form the yarn is to steam heat the yarn or heat scour it within a heating chamber at a temperature of approximately 180 degrees Fahrenheit which will molecularly bond the first ceramic material to the second ceramic material together in the foil of tiny platelets encapsulating the yarn for stabilizing thereof. As such, the final yarn product is significantly strengthened by the combination of the heat treating of the first and second ceramic materials and is simultaneously lubricated by the paraffin component of the final coating step. In this manner the process of the present invention imparts an anti-microbial characteristic to any products made from the yarn while also maintaining the highly desirable elevated levels of fire and flame retardancy not known or available heretofore in combination with one another in a yarn material.
While particular embodiments of this invention have been described above, it will be apparent that many changes may be made in the form, arrangement, sequencing and positioning of the various elements of the combination of element subject to this patent application. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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A unique formulation for yarn from a novel combination of fibers of polyester and silver which is made by a special manufacturing process including proprietary individual steps. The formed yarn product is durable and useful and can be used to make various fabrics and/or materials and, most particularly, to make final products that possess highly advanced characteristics, particularly fire retardant properties and antimicrobial properties.
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CROSS REFERENCE TO PROVISIONAL APPLICATION
This application claims the benefit of the filing date of provisional patent application 60/759,649 filed Jan. 17, 2006.
BACKGROUND OF THE INVENTION
The invention relates to fabric for paper making machines and, more particularly, to a seam press fabric.
Paper is conventionally manufactured by conveying a paper furnish, usually consisting of an initial slurry of cellulosic fibers, on a forming fabric or between two forming fabrics in a forming section, the nascent sheet then being passed through a pressing section and ultimately through a drying section of a papermaking machine. In the case of standard tissue paper machines, the paper web is transferred from the press fabric to a Yankee dryer cylinder then creped.
Paper machine fabric or clothing is essentially employed to carry the paper web through these various stages of the papermaking machine. In the forming section, the fibrous furnish is wet-laid onto a moving forming wire and water is encouraged to drain from it by means of suction boxes and foils. The paper web is then transferred to a press fabric that conveys it through the pressing section, where it usually passes through a series of pressure nips formed by rotating cylindrical press rolls. Water is squeezed from the paper web and into the press fabric as the web and fabric pass through the nip together. Press fabrics generally comprise a batt of fibers needled to a base fabric. In the final stage, the paper web is transferred either to a Yankee dryer, in the case of tissue paper manufacture, or to a set of dryer cylinders upon which, aided by the clamping action of the dryer fabric, the majority of the remaining water is evaporated.
The base fabrics of press felts are woven endless, whether they are seamed or not, such that the yarns of the weft in the loom lie in the machine direction of the fabric on the paper machine. The weft yarns weave back and forth continuously between the laterally extending edges of the fabric and form a seam loop at the reversals on one side. The two ends formed are then joined together on the machine by means of a pintle wire.
Press felts consist of multiple layers which are secured together by needling. This works by mechanically locking the constituent batt fibers into various layers and in so doing holds them together. In addition, the batt fiber gives a homogenous paper support surface.
Thus, in the paper making industry, paper making felts or fabrics are used to carry the cellulosic material as it is formed into paper, and one such fabric is an endless woven base with a pin seam for securing the ends of the fabric together once the fabric is in place on the machine.
Numerous disclosures have been made in connection with manufacture of pin seam fabrics, including U.S. Pat. Nos. 6,283,165, 6,000,441, 3,283,388 and 4,495,680 as non-exhaustive examples. These teachings and others tend to be costly and slow, and the need remains in the industry for reduced cost and faster delivery time.
It is the primary object of the invention to provide a press fabric which meets these needs.
Other objects and advantages will appear below.
SUMMARY OF THE INVENTION
In accordance with the present invention, the foregoing objects and advantages have been attained.
According to the invention, a press fabric is provided which comprises a substantially flat inner sleeve having first and second ends; and an outer sleeve around the inner sleeve and comprising at least one machine direction yarn wound around the inner sleeve and defining first and second seam loops at the first and second ends of the inner sleeve.
Still further according to the invention, a method for making a press fabric is provided, which method comprises the steps of winding at least one machine direction yarn around an inner sleeve having first and second opposite ends so as to define first and second seam loops at the first and second opposite ends; flattening the inner sleeve; and joining the first and second seam loops.
According to the invention, the inner sleeve can be a woven or non woven base which is preferably formed into an endless loop upon which the machine direction yarns are wound to form an outer sleeve with seam loops. This is particularly advantageous since the seam loops are formed form yarns which are not woven with cross direction yarns, and there are therefore no cross direction yarn knuckles.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of preferred embodiments of the present invention follows, with reference to the attached drawings, wherein:
FIG. 1 shows a press fabric according to the invention;
FIG. 2 is a schematic sectional view of the outer sleeve seam portion of the fabric of FIG. 1 ; and
FIG. 3 shows starting material for an inner sleeve according to one embodiment of the invention.
DETAILED DESCRIPTION
The invention relates to press fabrics and more particularly to a seam press fabric and a method for making same.
FIG. 1 shows a press fabric 10 according to the invention. Fabric 10 is useful in paper making machines and is mounted in such machines to carry cellulosic material through the various stages of the machine as the material is being formed into paper. One such section is the press section of the machine, and the fabric of the present invention is particularly well suited for use as a press fabric.
As shown in FIG. 1 , fabric 10 has an inner sleeve 12 and an outer sleeve 14 .
Inner sleeve 12 can be any suitable substrate upon which outer sleeve 14 can be applied, and which will have the appropriate properties for use in a paper making machine fabric. Thus, inner sleeve 12 should be an open structure having void volume for accepting and holding water. One example of suitable material for inner sleeve 12 is an open scrim having machine direction components 16 and cross direction components 18 .
Outer sleeve 14 is defined according to the invention by winding machine direction yarn or yarns around inner sleeve 12 , preferably in a spiral fashion, such that outer sleeve 14 is formed primarily if not entirely of machine direction yarns 20 .
The machine direction is indicated in the drawings as MD, and refers to the direction in which the fabric will move when in use in a paper making machine.
The cross direction (CD in the drawings) is also a direction referred to herein, and refers to the direction transverse to the machine direction when the fabric is used on a paper making machine.
Batt material is typically attached to fabric 10 and can be positioned between inner sleeve 12 and outer sleeve 14 . After winding of outer sleeve 14 , it should be clear that inner sleeve 12 has two ends 22 , 24 , and batt material and any CD yarns in areas 22 , 24 can be removed to expose seam loops 26 , 28 formed from yarns 20 of outer sleeve 14 (See also FIG. 2 ). At this point, fabric 10 is structurally ready for mounting on a paper making machine, which typically involves feeding the fabric through the various rolls of the machine, preferably using a leader, until the fabric is on the machine with loops 26 , 28 substantially adjacent to each other as shown in FIG. 2 . These loops can then be pinned, for example using a pintle 30 schematically illustrated in FIG. 2 , to join the ends together and finish installation of fabric 10 onto a paper making machine.
It should be appreciated that manufacturing fabric 10 in this manner provides seam loops 26 , 28 from machine direction material which is not woven with cross direction material. This is desirable since the machine direction yarns are typically under tension, and when they are woven with cross direction yarns, cross direction knuckles can be formed which are not desirable as they adversely impact the paper product made on the machine.
The absence of cross direction yarns in outer sleeve 14 is compensated by the cross direction yarns or components of inner sleeve 12 . Thus, one desirable aspect of inner sleeve 12 is a good cross machine direction strength. one way to arrive at this structural strength is to start with a length of open material such as a scrim or the like which has a length that is about twice the length of the desired eventually fabric. This material 32 is shown in FIG. 3 as having a length 2L, that is, a length twice the desired length L of fabric 10 . Material 32 can be a woven or non-woven structure, and preferably has a greater number of cross direction threads or components than machine direction threads or components. This is schematically illustrated in both FIGS. 1 and 3 as the spacing between the schematically illustrated yarns or components of inner sleeve 12 in those drawings.
In order to make material 32 into inner sleeve 12 , material 32 is preferably wound around rollers or the like and ends 34 , 36 are pinned together. Thus, machine direction yarns or components of material 32 can also preferably be formed into inner sleeve seam loops 38 which can be joined to each other as described so as to provide inner sleeve 12 as shown in FIG. 1 . Of course, the actual method of preparation of inner sleeve 12 can vary, and although the disclosed embodiment is a particularly preferred embodiment, other materials and manufacturing methods could of course be used for inner sleeve 12 , well within the broad scope of the invention.
Suitable material for inner sleeve 12 includes but is not limited to open mesh scrim or screen, thin single layer woven fabric, joined spun bonded fibers, films and the like which preferably have cross direction stability. The material should have minimal machine direction, or warp, yarns. Suitable material could be a 0.005 inch PET, which has good stretch resistance. The machine direction yarns can preferably have a spacing of about 5-25 yarns per inch, preferably 10-15 yarns per inch. Cross direction yarns can be in the typical amounts normally used for such structures. Further, as an alternative and/or enhancement to pin seaming, inner sleeve 12 can be joined using an ultrasonic cutter or the like, and the joint can be reinforced with a thin perforated film or iron-on adhesive if desired.
Another alternative for inner sleeve 12 would be to provide same through a preferably low cost extruded netting process for making the scrim.
Once inner sleeve 12 is provided and formed into an endless loop, machine direction yarns of outer sleeve 14 can be applied.
Machine direction yarns 20 can, as one non-limiting example, be a single mono or plied monofil yarn. Winding of yarn onto inner sleeve 12 can be done from a creel, and reeds can be used to maintain spacing. After winding of the yarns of outer sleeve 14 , a batt material is attached to fabric 10 to lock inner sleeve 12 and machine direction yarns 20 of outer sleeve 14 together. The batt can be needle punched, and a low melt adhesive can be used as well.
The composite tube of inner sleeve 12 , outer sleeve 14 and batt material is then collapsed to substantially flatten the structure, and batt and any scrim material present at ends defined by the 180° opposite seam loops can be removed to clear the seam loops. Preferably after feeding onto a paper making machine, these loops are joined for example using a pintle. More batt fiber can then be needled into the structure as needed, and a batt flap can be attached to cover the seam if desired.
The final product is a four layer fabric, with two woven inner layers and two outer machine direction only layers. The final product is about half the length of the starting inner sleeve material, and has two superimposed, laminated endless bases. This structure produces excellent pressing uniformity, compaction resistance and void volume capability as well as good fiber bonding and wear resistance, all of which help to satisfy the above identified need in the industry.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
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A press fabric includes a substantially flat inner sleeve having first and second ends; and an outer sleeve around the inner sleeve and comprising at least one machine direction yarn wound around the inner sleeve and defining first and second seam loops at the first and second ends of the inner sleeve. A method for making the fabric is also disclosed.
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BACKGROUND
This application generally relates to automated methods and equipment for laying up plies of composite material, and deals more particularly with a method and apparatus for placing short courses of composite tape on a substrate during the layup process.
Composite structures such as those used in the automotive, marine and aerospace industries may be fabricated using automated composite material application machines, commonly referred to as automated fiber placement (AFP) machines. AFP machines may be used in the aircraft industry, for example, to fabricate structural components and skins by placing relatively narrow strips of composite, slit fiber tape or “tows” on a manufacturing tool. The tape may be placed on the tool in parallel courses that may be in substantially edge-to-edge contact to form a ply.
Known AFP machines employ a tape placement head that dispenses, cuts and compacts courses of tape onto the tool surface as a tape placement head is moved by a robotic device over the tool surface. These tape placement heads typically include a supply spool of tape, and a dispensing mechanism that draws the tape from the spool and guides the tape into a nip between a compaction roller and the tool surface. A cutter blade within the dispensing mechanism located upstream from the compaction roller cuts the tape to a desired course length. The minimum length of a tape course that can be placed by the tape placement head may therefore be governed by the distance between the point where the tape is compacted onto the tool surface and the point where the tape is cut by the blade.
In some applications, relatively short courses may be required which have a length less than the minimum course length that can be cut by known tape heads. In other words, a desired course length may be less than the distance from the compaction point to the point where the cut is made. Under these circumstances, it may be necessary to place courses that are longer than optimum course lengths, thereby adding weight and/or cost to the part, or prompting the need to trim the plies of excess tape, or to manually lay the short courses by hand, thereby adding undesired labor and expense to the manufacturing process.
SUMMARY
Accordingly, there is a need for a tape placement head and method for cutting courses of tape which allow placement of courses of shorter length.
The present application discloses various systems and methods to address the aforementioned challenges with existing tape heads.
In one example, an automated fiber placement (AFP) machine is disclosed for placing composite material on a substrate. The AFP machine comprises a first low-profile tow control module comprising one or more circular cutter blades, and a second low-profile tow control module comprising one or more circular cutter blades. The AFP machine further comprises a vee block coupled to the first and second low-profile tow control modules and located between the first and second low-profile tow control modules, the vee block comprising a plurality of air passages located therein. The AFP machine further comprises a plurality of air cylinders coupled to the vee block and nested between the first low-profile tow control module and the second low-profile tow control module, the plurality of air cylinders being aligned with the air passages located within the vee block.
The first and second low-profile tow control modules may have a height no greater than about ¾ inch. The circular cutter blades may have a height no greater than about ¾ inch. The AFP machine may further comprise a compaction roller having a diameter no greater than about ¾ inch. The circular cutter blades may be removably coupled to a cutter rocker arm configured to be rotated about an axle by a first, cutter extend piston and second, cutter retract piston. The substrate may comprise a flat or nearly-flat charge. The AFP machine may further comprise a control unit configured to access a file that includes computer readable instructions for fabricating a composite item. The AFP machine may further comprise one or more positioning devices configured to maneuver the substrate relative to a delivery head while the composite material is placed on the substrate. The positioning device(s) may comprise one or more NC machines, robotic arms, or mandrels.
In another example, a delivery head of an automated fiber placement (AFP) machine comprises a vee block having a plurality of air passages located therein, and a first tow control module coupled to the vee block. The first tow control module comprises a tow guide tray, a support frame, a cutter rocker arm with an attached cutter blade, and a pinch/feed rocker with an attached pinch roller. The cutter rocker arm is coupled to the support frame by a cutter rocker axle. The pinch/feed rocker is nested within the cutter rocker arm and is coupled to the support frame by a pinch/feed rocker axle. A plurality of pistons are positioned in cavities located within the vee block and coupled to the air passages, the pistons being aligned with the cutter rocker arm and the pinch/feed rocker.
The attached cutter blade may comprise a circular cutter blade. The pistons may comprise a first, cutter extend piston and second, cutter retract piston, which are configured to rotate the cutter rocker arm about the cutter rocker axle. The tow guide tray may define a plurality of tow guide paths, and the first tow control module may comprise a corresponding plurality of cutter rocker arms and pinch/feed rockers. The delivery head may be configured to place composite material on a flat or nearly-flat charge. The delivery head may further comprise a second tow control module coupled to the vee block, the second tow control module comprising substantially identical components as the first tow control module, located in complementary positions.
In another example, a method of placing a course of composite material on a substrate is disclosed using an AFP machine with a low-profile delivery head and a circular cutter blade. The method comprises feeding one or more tows of composite material through the delivery head by extending a feed piston to bring a pinch roller into contact with a feed roller, thereby causing the tow(s) of composite material to be pulled between the pinch roller and the feed roller along a tow guide channel. The method further comprises cutting the tow(s) of composite material to a desired length by extending a cutter extend piston and retracting a cutter retract piston, thereby causing a cutter rocker arm to rotate about an axis and lower the circular cutter blade through the tow guide channel. The method further comprises retracting the circular cutter blade by extending a cutter retract piston and retracting a cutter extend piston, thereby causing a cutter rocker arm to rotate about an axis and raise the circular cutter blade out of the tow guide channel.
The method may further comprise rotating the circular cutter blade to provide a new cutting edge. The method may further comprise clamping the tow(s) of composite material in place in the tow guide channel by extending a clamp piston at substantially the same time as the circular cutting blade is lowered. Extending the pistons may comprise supplying air pressure to the pistons through passages formed within a vee block. The substrate may comprise a flat or nearly-flat charge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of one example of an automated fiber placement (AFP) machine in accordance with the present application.
FIGS. 2A and 2B are schematic diagrams illustrating one example of an AFP machine in accordance with the present application.
FIG. 3 illustrates a partial cross-sectional view of one example of a delivery head for an AFP machine.
FIG. 4 illustrates an exploded view of one example of a delivery head for an AFP machine.
FIGS. 5A through 5D illustrate the positions of a pushrod/piston subassembly during various stages of the AFP process.
FIG. 6 is an illustration of a flow diagram of aircraft production and service methodology.
FIG. 7 is an illustration of a block diagram of an aircraft.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that various changes may be made without departing from the spirit and scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense.
The present application discloses a system for placing composite lamina plies to fabricate a composite item and a method of using this system. Specifically, the system provides for the short path course application of a composite lamina by reconfiguring the functional mechanisms of a fiber placement head. In some examples, the system includes an automated lamination device such as, for example, an automated fiber placement (AFP) machine. This lamination device includes one or more dispensing heads to place plies of composite material upon a mandrel, layup mold or tool. In addition, the lamination device includes a cutting device to cut the composite material. Additional details and variations regarding the configuration and operation of the system will be apparent to those of ordinary skill in the art, having the benefit of this disclosure.
FIG. 1 is a block diagram of one example of an automated fiber placement (AFP) machine 100 in accordance with the present application. In the example shown in FIG. 1 , the AFP machine 100 includes a placement head 105 that is positioned by a corresponding positioning device 110 . The placement head 105 is configured to place 115 composite material upon a substrate 120 . The substrate 120 includes the surface of a workpiece 125 , such as, for example, a mandrel, tool, layup model, or any other suitable surface on which composite material is placed. In addition, the substrate 120 may include any previously applied composite material, tackifier, and the like that is previously laid down on the workpiece 125 . The workpiece 125 is rotated or otherwise positioned by a drive apparatus 130 . The drive apparatus 130 and/or the positioning device 110 are controlled by a control unit 135 . The control unit 135 accesses a file 140 that includes computer readable instructions for fabricating a composite item.
FIG. 2A is a schematic diagram illustrating one example of an automated fiber placement (AFP) machine 200 in accordance with the present application. In general, the AFP machine 200 is configured to maneuver a substrate 210 , such as a tool or a flat charge layup mold, relative to a fiber placement head assembly, or delivery head 215 , while tows of composite material are placed on the substrate 210 . For instance, in the specific example illustrated in FIG. 2A , the AFP machine 200 comprises a numerical control (NC) machine 205 , such as a robotic arm, which is configured to manipulate the substrate 210 while the delivery head 215 remains stationary. In other cases, the AFP machine 200 may comprise an NC machine 205 that is configured to move the delivery head 215 while the substrate 210 either remains fixed or moves in one or more additional axes of motion. Beyond these examples, other alternative mechanisms may be utilized for moving the substrate 210 relative to the delivery head 215 , as will be appreciated by those of ordinary skill in the art.
The delivery head 215 is shown in greater detail in FIG. 2B . The AFP machine 200 further comprises a tow supply system 220 including a set of storage spools 225 , or creels, as well as a series of tow guides, e.g., redirect rollers 230 and redirect pulleys 235 , as well as a tension brake system 250 . For simplicity, the complete roller support framework for the AFP machine 200 is not shown in its entirety in FIGS. 2A and 2B . The AFP machine 200 may also comprise various standard control components, such as pneumatic cylinders, electro-servo actuators, control wires, hoses, etc. (not shown) that control the operation of the AFP machine 200 under the direction of a suitable control module, such as the control unit 135 shown in FIG. 1 .
In operation, the AFP machine 200 pulls tows 240 of a composite material, such as carbon fiber-epoxy, from the storage spools 225 around redirect rollers 230 , which function to maintain a predetermined tension onto the each fiber or tow 240 , and through redirect pulleys 235 to the delivery head 215 . Each tow 240 , in turn, is cut to the correct length by a cutting blade in response to a command from a control unit 135 , as the material course, also called a tow band, is laid over the substrate 210 . Each tow 240 has a corresponding cutting blade, however the number of blades may vary depending upon the number of tows 240 and the width of each tow 240 . As the tows 240 emerge from the delivery head 215 , they pass over a compaction roller 245 which applies and compresses the tows 240 onto the surface of the substrate 210 as it moves relative to the delivery head 215 . Heat may be applied to the tows 240 immediately before they are placed on the substrate 210 in order to increase the surface tackiness of the resin impregnated tow. Tension can be maintained on the tows 210 to assist in pulling them through the AFP machine 200 as sensed by redirect rollers 230 controlling the tension brake system 250 .
FIGS. 3 and 4 illustrate a partial cross-sectional view and an exploded view, respectively, of one example of a delivery head 215 . In the example shown in FIGS. 3 and 4 , the delivery head 215 comprises a “vee block” 350 having a plurality of air fittings 384 coupled to passages 352 located within the vee block 350 , through which air pressure can be ducted during operation. The air fittings 384 are compatible with conventional pneumatic valves configured to control the operation of the delivery head 215 per predetermined instructions from the control unit 135 . The delivery head 215 is comprised of a first, upper tow control module 354 A and a second, lower tow control module 354 B, which contain substantially identical components located in complementary positions. The tow control modules 354 A, 354 B guide the tows 240 through the delivery head 215 during operation, as described above. For simplicity, only the components of the upper tow control module 354 A are separated in the exploded view of FIG. 4 .
Each tow control module 354 comprises a tow guide tray 356 coupled to the vee block 350 , which establishes the configuration of the tow feed path as set by the tow channel dimensions 358 within the tow guide tray 356 . The total bandwidth output is defined by a plurality of tow guide channels 358 corresponding to the number of tows 240 for which the delivery head 215 is designed. For example, in the specific case illustrated in FIGS. 3 and 4 , both the upper tow control module 354 A and the lower tow control module 354 B include a tow guide tray 356 having three tow guide channels 358 each, meaning that the delivery head 215 is configured to place up to six tows 240 of composite material (three tows 240 from the upper tow control module 354 A and three tows 240 from the lower tow control module 354 B) simultaneously on the substrate 210 during each course in an aligned edge on edge pattern.
The delivery head 215 further comprises a plurality of pushrod/piston subassemblies 360 , corresponding to the selected number of tow guide channels 358 . Each pushrod/piston subassembly 360 comprises a first, cutter retract piston 360 A, a second, clamp piston 360 B, a third, feed piston 360 C, and a fourth, cutter extend piston 360 D. In the illustrated example, the cutter retract piston 360 A, clamp piston 360 B, feed piston 360 C, and cutter extend piston 360 D all include bias springs 362 . Each pushrod/piston subassembly 360 is located in a series of cavities 364 in the vee block 350 , which are aligned with a corresponding tow guide channel 358 .
Each tow control module 354 also comprises a support frame 366 coupled to the tow guide tray 356 , as well as a cutter rocker arm 368 with an attached cutter blade 370 and a pinch/feed rocker 372 with an attached pinch roller 374 for each tow guide channel 358 . Each cutter rocker arm 368 is coupled to the support frame 366 by a first, cutter rocker axle 376 A, on which the cutter rocker arm 368 pivots during operation. Similarly, each pinch/feed rocker 372 is coupled to the support frame 366 by a second, pinch/feed rocker axle 376 B, on which the pinch/feed rocker 372 pivots during operation. Although the first, cutter rocker axle 376 A is illustrated as a single, unitary member for all three cutter rocker arms 368 shown in FIG. 4 , in some cases, the first, cutter rocker axle 376 A may be subdivided into multiple members, each one corresponding to an individual cutter rocker arm 368 . Each tow control module 354 also comprises one or more blade covers 378 coupled to the support frame 366 , which are configured to cover the cutter blades 370 during operation.
The cutter rocker arms 368 and pinch/feed rockers 372 of the delivery head 215 are substantially symmetric, which may advantageously reduce twist and binding distortions in some instances. Each pinch/feed rocker 372 nests in a pocket of a corresponding cutter rocker arm 368 , except near the back end, where tabs extend for engagement by a feed piston 360 C. At the locations of the tabs in each pinch/feed rocker 372 , the corresponding cutter rocker arm 368 steps up to allow adequate rotation of the pinch/feed rocker 372 . Each cutter rocker axle 376 A is located high enough to allow the corresponding pinch/feed rocker 372 to rotate, and the tow control module 354 is preferably designed to substantially minimize the amount of overall rotation required.
The delivery head 215 further comprises a compaction roller 245 coupled to the vee block 350 configured to contact the substrate 210 where the vee block 350 forms a nip point at the intersection of the vee pattern fiber feed to a contact intersection point under the compaction roller 245 . In addition, the delivery head 215 comprises a first, upper feed roller 382 A and a second, lower feed roller 382 B coupled to one or more suitable drive mechanisms, such as a servo actuator. The feed rollers 382 A, 382 B form a nip compaction pull force when pinch roller 374 is activated by pistion 360 C acting on pinch/feed rocker 372 to contact feed roller 382 . The force acts to pull the tows 240 of composite material through the upper and lower tow control modules 354 A, 354 B, respectively, at a desired speed and for a desired time duration, under the direction of a suitable control module, such as the control unit 135 shown in FIG. 1 .
Unlike conventional AFP delivery heads, the delivery head 215 of the present application includes various distinctive features that optimize the delivery head 215 for short courses and flat or nearly-flat charges. For example, the total distance from the tow drop off or cutting point to the roller nip area is reduced by compaction roller 245 , which is substantially smaller in diameter than a conventional compaction roller, and additionally by the compact design of the tow cut add mechanism which places the cut off point to the nip point closer. Specifically, in some cases, the compaction roller 245 has a diameter of no more than about ¾ inch.
In addition, the delivery head 215 includes cutter blades 370 with a unique circular cutter geometry, rather than the traditional rectangular shape utilized in conventional cutter blades. The circular cutter blade design advantageously allows the delivery head 215 to utilize cutter blades 370 that are substantially shorter than conventional AFP cutters. Specifically, in some cases, the cutter blades 370 have a maximum length of no more than about ¾ inch. The circular cutter blade design also advantageously eliminates the need for blade guides, because the cutter blades 370 can cut equally well in every orientation. Additionally cutter life is extended by cutter rotation during use about the center cutter mounting point. The circular cutter blades 370 are also easily accessible, removable, and replaceable.
In conventional AFP machines, the pneumatic conduits and other equipment used to actuate the pushrods and pistons are typically coupled to the exterior of the tow control modules and the vee block. As a result, conventional AFP delivery heads can be bulky and cumbersome, making it difficult fabricate small composite parts with short course lengths. The delivery head 215 of the present application, by contrast, employs a unique design in which the air fittings 384 are nested between the upper and lower tow control modules 354 A, 354 B, and air pressure is ducted through passages 352 located within the vee block 350 to control the operation of the pushrod/piston subassemblies 360 . This compact configuration advantageously enables the delivery head 215 to utilize a low-profile design for the tow control modules 354 . Specifically, in some cases, the tow control modules 354 have a maximum height of no more than about ¾ inch.
FIGS. 5A through 5D illustrate the positions of a pushrod/piston subassembly 360 A- 360 D during various operational stages of the AFP process. In general, the pistons 360 A- 360 D are spring biased in a retracted position, and can be extended by supplying air pressure to the desired cylinder bore cavities 364 of the associated activation pistons 360 A- 360 D through the corresponding air fittings 384 and passages 352 . This can be accomplished with various control valves and other control equipment (not shown) using conventional techniques and control methods processed within control unit 135 that are well-known to those of ordinary skill in the art.
FIG. 5A illustrates the “tow feed” stage of the AFP process, during which a tow 240 of composite material is pulled through the delivery head 215 by the feed roller 382 . During this tow feed stage, as shown in FIG. 5A , the cutter retract piston 360 A is extended and the cutter extend piston 360 D is retracted, to prevent the front end of the cutter rocker arm 368 from lowering to engage the cutter blade 370 . In addition, the feed piston 360 C is extended, which lowers the front end of the pinch/feed rocker 372 and brings the pinch roller 374 into contact with the feed roller 382 in contact with pinch roller 374 as activated by feed piston 360 C. The clamp piston 360 B is retracted to ensure that the tow 240 of composite material can be pulled through the corresponding tow guide channel 358 under the control of the feed roller 382 , at the desired speed and for the desired duration.
FIG. 5B illustrates the “free run” stage of the AFP process, during which a tow 240 of composite material passes through the delivery head 215 as the desired material course is placed on the substrate 210 . During this free run stage, as shown in FIG. 5B , the feed piston 360 C is retracted, while all the other pistons remain in the same position as during the tow feed stage shown in FIG. 5A . The retraction of the feed piston 360 causes the pinch/feed rocker 372 to pivot around the pinch/feed rocker axle 376 B, lowering the back end and raising the front end of the pinch/feed rocker 372 . This rotation, in turn, causes the pinch roller 374 to disengage from the feed roller 382 , thereby allowing the tow 240 of composite material to pass freely through the tow guide channel 358 due to the movement of the substrate 210 and/or the delivery head 215 during the placement of the material course on the substrate 210 .
FIG. 5C illustrates the “tow cut” stage of the AFP process, during which a tow 240 of composite material is cut to a desired length by the cutter blade 370 . During this tow cut stage, as shown in FIG. 5C , the cutter retract piston 360 A is retracted and the cutter extend piston 360 D is extended, while all the other pistons remain in the same position as during the free run stage shown in FIG. 5B . The retraction of the cutter retract piston 360 A and extension of the cutter extend piston 360 D cause the cutter rocker arm 368 to pivot around the cutter rocker axle 376 A, thereby lowering the front end of the cutter rocker arm 368 and causing the cutter blade 370 to pass through the tow guide channel 358 and cut the tow 240 of composite material to the desired length.
FIG. 5D illustrates the “tow clamped” stage of the AFP process, during which a tow 240 of composite material is held in place in the delivery head 215 after being cut by the cutter blade 370 . During this tow clamped stage, as shown in FIG. 5D , the cutter retract piston 360 A is extended and the cutter extend piston 360 D is retracted to disengage the cutter blade 370 . During this step, the circular cutter blade 370 may rotate due to vibrations or other forces, thus advantageously providing a new cutting edge on the same cutter blade 370 for the next tow cut. At substantially the same time, the clamp piston 360 B is extended to exert a force on the tow 240 and hold it stationary in the tow guide channel 358 . Without this clamping step, the tow 240 may have a tendency to recoil after being cut due to the tension caused by the remaining length of tow material stored on the corresponding storage spool 225 . By holding the tow 240 stationary, however, the AFP machine 200 can accurately determine the location of the end of the tow 240 , and can thus accurately position the delivery head 215 for placement of the subsequent course of composite material on the substrate 210 .
In conventional AFP machines, the cutter blade is normally actuated by a single, dual-acting air cylinder, i.e., a single air cylinder that “pushes” the cutter blade to engage the cutter and “pulls” the cutter blade to disengage the cutter. In the AFP machine 200 of the present application, by contrast, the advance and retract functions of the cutter blade 370 are separated into two pistons (e.g., the cutter retract piston 360 A and the cutter extend piston 360 D). This configuration advantageously eliminates the need for at least one rod seal and simplifies the mechanism by using only pushrods with no “pull” requirement.
As a result of the features described above, the AFP machine 200 of the present application advantageously has a minimum cut length that is substantially shorter than the minimum cut length of a conventional AFP machine. For example, in some cases, the AFP machine 200 of the present application can cut tows 240 of composite material to lengths as short as about 1½ inches. As a result, the AFP machine 200 of the present application advantageously allows economical application of the AFP process to small composite parts, especially flat or nearly-flat charges. This may include certain composite parts (e.g., spars, etc.) in which an area being compacted by the AFP machine 200 is flat or nearly-flat locally, while the composite part(s) may have curved portions, e.g., a tight convex curvature at a radius from a web to a flange.
Referring to FIGS. 6-7 , the systems and methods of the present application may be implemented in the context of an aircraft manufacturing and service method 600 as shown in FIG. 6 and an aircraft 700 as shown in FIG. 7 . During pre-production, exemplary method 600 may include specification and design 602 of the aircraft 700 and material procurement 604 . During production, component and subassembly manufacturing 606 and system integration 608 of the aircraft 700 takes place. Thereafter, the aircraft 700 may go through certification and delivery 610 in order to be placed in service 612 . While in service 612 by a customer, the aircraft 700 is scheduled for routine maintenance and service 614 (which may also include modification, reconfiguration, refurbishment, and so on).
Each of the processes of method 600 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in FIG. 7 , the aircraft 700 produced by exemplary method 600 may include an airframe 720 with a plurality of systems 722 and an interior 724 . Examples of high-level systems 722 include one or more of a propulsion system 726 , an electrical system 728 , a hydraulic system 726 , and an environmental system 728 . Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosed embodiments may be applied to other industries, such as the automotive industry.
Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method 600 . For example, components or subassemblies corresponding to production process 606 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 700 is in service 612 . Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 606 and 608 , for example, by substantially expediting assembly of or reducing the cost of an aircraft 700 . Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 700 is in service 612 , for example and without limitation, to maintenance and service 614 .
Although this disclosure has been described in terms of certain preferred configurations, other configurations that are apparent to those of ordinary skill in the art, including configurations that do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Accordingly, the scope of the present disclosure is defined only by reference to the appended claims and equivalents thereof.
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A composite automation method and apparatus for the generation of short path course application of a composite lamina is realized by reconfiguring the functional mechanisms of the fiber placement head. Separating the fiber advance and retract functions, nesting the activation cylinders, and making use of push only activation results in a simplified, compact AFP delivery head. Uniform cutting is provided by a circular configuration fiber cutting blade, were at activation the blade both provides a progressive cutting force and rotates to providing a new cutting edge, and requires limited cutting edge guidance as all orientations cut equally well. The mechanism nested in functions and placed in close proximity to the compaction roller reduces the overall fiber course to the application point.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Canadian Patent Application No. 2,854,409 filed Jun. 14, 2014 entitled Quarter Turn Torque Anchor and Catcher. This application is also a continuation-in-part of United States patent application Ser. No. 14/311,322 filed Jun. 22, 2014 and entitled Quarter Turn Torque Anchor and Catcher, which is itself a continuation-in-part of U.S. patent application Ser. No. 13/716,075 filed on Dec. 14, 2012 and entitled Quarter Turn Tension Torque Anchor. The entire disclosures of these priority documents and all related applications or patents are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to tools for petroleum wells generally, including wells accessing heavy crude. In particular, the present invention relates to a tubing anchor catcher and its use in a system for reducing movement, which may be caused by a downhole pump, within in a well conduit.
BACKGROUND OF THE INVENTION
[0003] A tubing string is used within a petroleum well to position downhole tools proximal to one or more underground geological formations that contain petroleum fluids of interest. The tubing string may also be referred to as production tubing or a production string. The tubing string is made up of sections of individual pipe joints that are typically threadedly connected to each other. The tubing string extends within a bore of the well. The well bore is typically completed with casing or liners. The completed well bore may also be referred to as a well conduit. The tubing string can carry various downhole tools into the well conduit. For example, downhole tools can be used for various purposes including anchoring the tubing string within the wellbore at a desired location and to limit movement of the tubing string. Downhole tools can also be used to stimulate and capture production of petroleum fluids. The tubing string is also the primary conduit for conducting the petroleum fluids to the surface.
[0004] Known tubing anchors use either a combination of right and left hand threads, or are limited to one thread orientation. Examples of such tubing anchors are shown in U.S. Pat. No. 3,077,933 to Bigelow and in Canadian patent no. 933,089 to Conrad. Disadvantages of such tubing anchors include the expense of manufacturing the threaded portions, the threads may be susceptible to corrosion and the threads may be difficult to, or unable to, unset if they become filled with sand or corroded. With the new technology of fracing, the industry has adopted a heavier weight casing to be able to handle the bends and ‘S’ curves that are drilled today. A heavier weight casing wall makes the interior diameter of the casing smaller. This change in diameter, combined with the wells drilled with deviations and horizontal applications, makes the setting of the older design (multiple revolutions) tubing anchor catchers and packers hard to set as it is hard to feel, or detect, at surface when the tools is set due to the friction on the side walls and having to workout the tubing twist going around bends in the well bore.
[0005] Another type of tubing anchor shown in U.S. Pat. No. 5,771,969 and corresponding Canadian patent no. 2,160,647 to Garay avoids the aforementioned threads and instead uses a helical bearing to transform rotational movement into linear movement for setting and unsetting the tubing anchor. The helical bearing also accommodates shear pins for secondary unsetting if required. The use of one component, namely the helical bearing, to perform several functions has the advantage over the previous prior art of being less expensive to manufacture and less susceptible to seizing.
SUMMARY OF THE PRESENT INVENTION
[0006] The present invention provides a tubing anchor catcher that acts to reduce or stop movement of a tubing string within a wellbore. The tubing anchor catcher may also catch the tubing string and hold the tubing string in place if a part of the tubing string disconnects or fails above tubing anchor catcher.
[0007] One example embodiment of the present invention provides a tubing anchor catcher tool that is positionable within a well conduit for preventing movement of a tubing string. The tool comprises: a mandrel that is connectible at either end to the tubing string, the mandrel comprising a groove; a first cone element that is slidably mountable on to the mandrel, the first cone element comprising a first conical surface; a drag body that is slidably mountable on the mandrel, the drag body comprising a drag member that is sized for frictionally engaging an inner surface of the well conduit, a pin for engaging the groove, and a second conical surface; a biasing member that is slidably mountable on the mandrel adjacent the drag body for engaging the first cone element when the biasing member is compressed; and a slip cage that is slidably mountable on the mandrel, the slip cage comprising a slip that is adapted for engaging the inner surface of the well conduit when the mandrel is rotated a quarter turn relative to the drag body and the conical surface is disposed underneath the slip. Wherein when the second cone element is engaged, the second cone element is slidably moveable underneath the slip.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0008] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:
[0009] FIG. 1 is an elevation side view of an example embodiment of a tubing anchor catcher;
[0010] FIG. 2 is a mid-line cross-sectional view taken along line 2 - 2 in FIG. 1 ;
[0011] FIG. 3 is a mid-line cross-sectional view of FIG. 1 showing the tubing anchor catcher with its slips extended;
[0012] FIG. 4 is a perspective view of an example embodiment of a mandrel for use as part of the tubing anchor catcher of FIG. 1 ;
[0013] FIG. 5 is an enlarged view of an example embodiment of a groove that forms part of the mandrel of FIG. 4 , showing a pin from the tubing anchor catcher engaged in the groove, in a run-in position;
[0014] FIG. 6 is the view of FIG. 5 showing the pin in a set position;
[0015] FIG. 7 is a mid-line cross-sectional view of an example embodiment of a tubing anchor catcher, in the run-in position;
[0016] FIG. 8 is a mid-line cross-sectional view of the tubing anchor catcher of FIG. 7 , in the set position;
[0017] FIG. 9 is a side elevation view of an example embodiment of a tubing anchor catcher;
[0018] FIG. 10 is a mid-line, sectional view of the tubing anchor catcher of FIG. 9 ; and,
[0019] FIG. 11 is an exploded isometric view of the tubing anchor catcher of FIG. 9 .
[0020] FIG. 12 is an enlarged view of a portion of FIG. 12 .
[0021] FIG. 13 is a side elevation view of an example embodiment of a tubing anchor catcher positioned within a well bore.
[0022] FIG. 14 is a cross-sectional view taken along line 14 - 14 in FIG. 13 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] FIGS. 1 to 8 depict one example embodiment of a tubing anchor catcher 10 . The tubing anchor catcher 10 may be inserted within a well conduit 12 (see FIGS. 13 and 14 ), such as a wellbore casing. FIGS. 1 and 2 depict the tubing anchor catcher 10 in an unset, or “run-in”, orientation in which it can be run inside the well conduit 12 on a tubing string. Safety subs 14 A, B may be attached to a mandrel 20 of the tubing anchor catcher 10 having attachment means, such as an inner threaded lower end 22 and an outer threaded upper end 24 . In this embodiment, the tubing anchor catcher 10 may be run down the well conduit 12 while being threadedly connected within the tubing string in the downhole direction indicated by arrow 16 . Arrow 17 indicates the opposite direction within the well conduit 12 , namely the up-hole direction. It is noted, however, that terms such as “up”, “down”, “forward”, “backward” and the like are used to identify certain features of the tubing anchor catcher 10 when placed in a well conduit. These terms are not intended to limit the tubing anchor catcher's use or orientation. Further, when describing the invention, all terms not defined herein have their common art-recognized meaning.
[0024] The tubing anchor catcher 10 has an upper end 10 A and a lower end 10 B. The tubing anchor catcher 10 may comprise of a drag body 40 , a slip cage 60 and a biasing member 94 , all of which are mounted about the external surface of the mandrel 20 . The drag body 40 houses a drag means, in the form of one or more drag blocks 42 , for spacing the tubing anchor catcher 10 away from the inner wall 13 of the conduit 12 . The drag blocks 42 , for example three or four drag blocks 42 , may be generally evenly spaced circumferentially about the tubing anchor catcher 10 . Each drag block 42 has a drag spring to urge the outer surface 46 of the drag block against the well conduit's inner wall. Upper and lower drag retaining rings 48 , 50 keep the drag blocks 42 removably mounted within the drag body 40 . In addition to keeping the tubing anchor catcher 10 spaced from the well conduit 12 , the contact of the drag block surface 46 the well conduit's 12 inner wall or surface 13 causes friction that urges the drag body 40 to remain stationary while the mandrel 20 moves within the rest of the tubing anchor catcher 10 .
[0025] As will be discussed further, the drag body 40 is connected to the mandrel 20 by one or more pins 88 that extends inwardly from the drag body's 40 inner surface to engage an externally facing groove 80 that is on the outer surface of the mandrel 20 . As described further below, in one example embodiment, the pins 88 are made from a shearable material.
[0026] The slip cage 60 , which may also be referred to as a slip retainer, is also mounted on the mandrel 20 adjacent the drag body 40 . In particular, the slip cage 60 is mounted on the mandrel 20 above the drag body 40 (i.e. in direction 17 ). The slip cage 60 may house one or more radially, movable slips 62 . For example, three slips 62 are depicted as being evenly spaced about the slip cage 60 , although this is not intended to be limiting as the tubing anchor catcher 10 described herein may operate with one or more slips 62 . Each slip 62 has an outer surface with teeth 63 for gripping the inner wall 13 upon contact. The teeth 63 may comprise upward gripping teeth 63 B and downward gripping teeth 63 A. The slip 62 may also have an inner surface with opposed, outwardly inclined edges with an upper edge 64 A and a lower edge 64 B. A fastener in the form of a socket head cap screw 65 is fastened to the drag body 40 and is located within each of a plurality of associated elongate slots 66 that are defined by the slip cage 60 and spaced circumferentially thereabout, preferably between each slip 62 . The cap screw 65 is adapted to contact upper and lower shoulders 68 A, B at each end of the associated slots 66 , which forms a stop means to prevent the slip cage 60 , and the drag body 40 , from longitudinally separating.
[0027] A cone element 70 is mounted about the mandrel 20 at an upper end of the slip cage 60 . The cone element 70 comprises an upper edge 70 A and a lower edge 70 B. The lower edge 70 B forms a first conical surface whose inclined surface wedges under the slips 62 when the tubing anchor catcher 10 is moved into a set position. Likewise, an upper edge of the drag body 40 forms a second conical surface 54 whose inclined surface also wedges under the slips 62 when the tubing anchor catcher 10 is moved into a set position. However, the first and second conical surfaces 70 B, 54 may not actively contact the slips in the unset position. A slip spring 76 urges each slip 62 radially inwardly into the slip cage 60 and away from the well conduit 12 while in the unset position ( FIG. 2 ).
[0028] FIG. 3 depicts the tubing anchor catcher 10 in the set position with the slips 62 extended outwardly from the slip cage 60 for engaging the inner surface 13 of the well conduit 12 . The slips 62 are extended due to either or both of the conical surfaces 70 B, 54 moving underneath the slips 62 . For example, when the conical surface 54 moves underneath the slip 62 , the spring 94 may be compressed, from below due to the movement of the mandrel and the tension in the tubing string, and force the first conical surface 70 B underneath the slip 62 .
[0029] FIG. 4 depicts the mandrel 20 as including an upper end 20 A and a lower end 20 B. As described above, the upper and lower ends 20 A, B may each comprise threaded connections for connecting the mandrel 20 to the tubing string. As shown in FIG. 2 , the upper end 20 A comprises a box threading and the lower end 20 B comprises a pin threading. At least one groove 80 is formed on the mandrel's outer surface 26 , as best seen in FIGS. 4 to 6 . The groove 80 is dimensioned (width, depth) to slidingly accommodate a protruding portion of the pin 88 that extends therein threaded through a hole 56 in the drag body 40 . The lower retaining ring 50 retains the drag blocks 42 within the drag body 40 . The tubing anchor catcher 10 may comprise one or more sets of grooves 80 and pins 88 . For example, the tubing anchor catcher 10 may have three sets of grooves 80 and three sets of associated pins 88 that are generally evenly radially spaced about the mandrel 20 .
[0030] As depicted in FIGS. 5 and 6 , the groove 80 may comprise a C-shape with shoulders 82 and 86 defining a first arm 80 A of the groove 80 and shoulders 84 and 92 defining a second arm 80 B of the groove 80 . The two arms 80 A, B of the groove 80 are connected by central portion 80 C that is defined by walls 86 , 87 , 89 and 90 . Wall 90 separates the first and second arms 80 A, B.
[0031] As seen in FIGS. 5 and 6 , which is an enlarged view of groove 80 , a portion 88 a of the pin 88 protudes into the groove 80 and is seated against the shoulder 92 in the run-in (i.e. un-set) position with the slips 62 retracted within the sip cage 60 . To move the pin 88 to the set position at shoulder 82 , the tubing string can be manipulated at surface so as to move axially, i.e. by pulling or pushing, and rotationally, i.e. by turning, so as to similarly manipulate the mandrel 20 . The manipulation at surface may articulate the tubing anchor catcher 10 between the run-in position and a set position. Due to the drag blocks 42 frictionally engaging the inner surface 13 of the well conduit 12 , the drag body 40 and the slip cage 60 remain relatively fixed as the mandrel 20 and the rest of the tubing string, are manipulated from surface. As manderel 20 is pulled, for example about one inch, in direction 17 , the pin 88 slides relative to mandrel 20 in direction A so as to engage the shoulder 84 . Thereafter, the mandrel 20 can be lowered, for example about 6 to 7 inches, and turned, for example, a quarter turn to the left (i.e. about 90 degrees). The turning is about the longitudinal axis of the tubing string and, therefore, the tubing anchor catcher 10 . This manipulation causes the pin 88 to move from shoulder 84 , generally along walls 89 , 87 and 86 to rest in shoulder 86 of the first arm 80 A. When the pin 88 is in shoulder 86 , the tubing anchor catcher 10 is in a pre-set position. The tubing string, and the mandrel 20 can be turned freely to the left. Pulling the tubing string and, therefore, the mandrel 20 upwards, at least about an inch, in direction 17 will cause the pin 88 to move into shoulder 82 . When the pin 88 is in shoulder 82 , at least the conical surface 54 has moved under the slips 62 and the tubing anchor catcher 10 is set with the slips 62 extending outwards from the slip cage 60 to engage the inner surface 13 of the well conduit 12 .
[0032] In this embodiment, when viewed in vertical elevation with the top of mandrel 20 upwards, groove 80 is in the shape of a reverse “C”, although this is not intended to be a literal graphical description of shapes that will work, as other shapes will work other than exact C-shapes as may mirror images of the groove 80 .
[0033] To release the slips 62 , the tubing string and, therefore, the mandrel 20 can be manipulated at surface. For example, the mandrel 20 can be moved relative to the rest of the tubing anchor catcher 10 , so that the pin 88 moves out of shoulder 82 . As shown in FIG. 6 , the mandrel 20 can be pushed down so that the pin 88 moves along line F. With a quarter turn to the left the pin will move along line H and then a straight pulling up of the tubing string and mandrel 20 will cause the mandrel 20 to move so that the pin 88 ends up in shoulder 84 . When the pin 88 has moved out of the first arm 80 A of the groove 80 , the conical surface 54 moves out from under the slips 62 and the spring 76 will cause the slips 62 to retract back into the slip cage 60 .
[0034] When the tubing anchor catcher 10 is in the set position and in the event of a break in the tubing string, etc, which may cause the tubing string to fall down into the well (i.e., in direction 16 ), the tension in the tubing string is lost. This causes the weight of the tubing string to bear on the upper safety sub 14 A, which will bear on the biasing member 94 . The biasing member 94 will compress, from the weight of the tubing string above, and act against the upper edge 70 A of the cone 70 . This action causes the upper teeth 64 A to more directly engage and bite into the inner surface 13 of the well conduit 12 . For example, the greater the amount of tubing string weight that compresses the spring 94 , the harder, or more directly, the upper teeth 64 A will engage the inner surface 13 of the well conduit 12 . When the downwardly gripper teeth 64 A are more directly engaged into the inner surface 13 of the well conduit 12 , the upper teeth 64 A can hold the weight of the tubing string above the tubing anchor catcher 10 , for example, until such time that the tubing string can be recovered at surface.
[0035] If it is not possible to move pin 88 in the groove 80 so as to unset slips 62 , for example due to packing of sand or other materials into the groove 80 , the slips 62 may be unset by applying a sufficient upward tension on the tubing string and the mandrel 20 . In one embodiment, the upward tension is of a sufficient amplitude to shear the pins 88 , which form the primary connection between the drag body 40 and the mandrel 20 . Then the mandrel 20 may move upward (i.e. in the direction of arrow 17 ), relative to the drag body 40 , which causes the second conical surface 54 of the drag body 40 to move out from under the slips 62 . This allows the slips 62 to retract from contacting the inner surface of the well conduit. When the slips 62 are retracted, the tubing anchor catcher 10 may be pulled out of the well conduit 12 . For example, the pin 65 may engage the lower shoulder 68 B of the slot 66 so that the slip cage 60 , and the drag body 40 do not separate. Alternatively, or additionally, the lower edge of the catcher body 40 may engage the lower safety sub 14 b as the tubing string is pulled upwards towards the surface (i.e. in direction 17 ).
[0036] FIGS. 9 to 12 depict an alternative embodiment of a tubing anchor catcher 100 with an upper end 100 A and a lower end 100 b . The tubing anchor catcher 100 may comprise many of the same features as tubing anchor catcher 10 . For example, one difference between the two tubing anchor catchers 10 , 100 is that the pin 88 of the tubing anchor catcher 10 may be sheared as a secondary release mechanism, as described above. In contrast, the tubing anchor catcher 100 may comprise a pin 188 that is not designed to shear as a secondary release mechanism. The tubing anchor catcher 100 may comprise one or more shear pins 72 that are mounted on the lower cone 41 to drag body 40 . The shear pins 72 are made of a material that will shear in response to a lower shearing force than the shear force required to shear the pin 188 . The second conical surface 54 is formed on the upper end of cone 41 (see FIG. 12 ). Cone 41 slidably mounts about the external surface of the mandrel 20 so that conical surface 54 in combination with conical surface 70 B on cone 70 compress together along mandrel 20 to force slip 62 into the set position, as described above. The shear pins 72 provide a secondary release of slips 62 by the application of a sufficient pulling force to the tubing string so as to shear the shear pins 72 . When the shear pins 72 are sheared, the conical surface 54 can move from under the slips 62 and the slips 62 can retract away from the inner surface 13 of the well conduit 12 .
[0037] The tubing anchor catchers 10 , 100 are thus designed to anchor the tubing string from movement longitudinally along the well (in both directions, up and down the well) and from rotating. The anchoring is achieved by simple setting and release procedures that require relatively little movement of the tubing string. In this instance, setting is achieved by a small pull and left hand rotation of the mandrel 20 (via the tubing string) that is adequate for the pins 88 , 188 to travel the short distances within the groove 80 . Further, both tubing anchor catchers 10 , 100 can prevent a broken tubing string from falling into the well bore by the compression of the spring 94 causing the downward gripping teeth 63 A to grip the inner surface 13 of the well conduit 12 , as described above.
[0038] In one optional embodiment of the present invention, the slips 62 may be configured to center either or both of the tubing anchor catchers 10 , 100 within the well conduit 12 by radially extending from the slip cage 60 (see FIGS. 13 and 14 ). This may provide one or more by-pass spaces 78 between the tubing anchor catchers 10 , 100 and the inner surface 13 of the well conduit 12 , which may create high flow areas for fluids (e.g. gas) and solids (e.g. sand) to pass by the tubing anchor catchers 10 , 100 . The by-pass spaces 78 may also allow coil tubing to extend more easily past the tubing anchor catcher 10 , 100 . In the FIG. 14 , which is provided by way of example only, depicts by-pass spaces 78 with 1.0 inch (25.4 mm) radial clearance that are created between the 4.5 inch (114.3 mm) OD of the slip cage 60 and the 6.5 inch (165.1 mm) ID of the well conduit 12 .
[0039] This optional embodiment of the tubing anchor catchers 10 , 100 may permit capillary cable to be carried downhole via the large by-pass spaces 78 . In particular, the fact that the tubing anchor catchers 10 , 100 is set and unset by longitudinal motion and a limited, quarter turn, permits its use with the capillary cable since the tubing anchor catchers 10 , 100 may avoid wrapping of the cable around the tubing anchor catchers 10 , 100 . In contrast, prior art anchors that require multiple full (360 degree) rotations—between two to nine full rotations for setting and unsetting—cause an undesirable wrapping of the cable around the anchor, which can damage the cable. Alternately, the cables must be pre-wrapped when inserted with these prior art anchors, so that they unwrap as the anchor is twisted during setting, which is tedious and undesirable.
[0040] Optionally, the drag blocks 42 may be hardened, in comparison to prior art drag blocks, for a longer operational life. The slips 62 may optionally be made of solid high strength metal for superior durability and grip on the well conduit wall 13 , and Inconel™ type springs 76 are employed for improved resistance to H 2 S and CO 2 . Further, the surface of the mandrel 20 may optionally be coated with Teflon® for improved resistance to H 2 S and CO 2 , and to help maintain mandrel strength.
[0041] While the above disclosure describes certain examples of the present invention, various modifications to the described examples will also be apparent to those skilled in the art. The scope of the claims should not be limited by the examples provided above; rather, the scope of the claims should be given the broadest interpretation that is consistent with the disclosure as a whole.
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A torque anchor for anchoring well equipment in a well conduit to arrest movement in both longitudinal directions and rotation in a first direction, but not rotation in an opposed second direction. A mandrel connected to the equipment has one or more grooves for slideably receiving respective pins from a drag body on the mandrel. A slip cage on the mandrel houses slips for selectively engaging and disengaging the conduit. Manipulation of the mandrel at surface causes the pins to move within the one or more grooves on the mandrel and the drag body to move toward the slip retainer driving the slips outward to grip the conduit. Further pulling at surface maintains the set position. The anchor is unseta surface by releasing the pull, rotating the mandrel in the second direction, and pushing the mandrel to disengage the slips.
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PRIORITY
[0001] This application claims priority of U.S. provisional application No. 61/192,447 filed on Sep. 19, 2008.
SEQUENCE LISTING
[0002] This application contains sequence data provided on a computer readable diskette and as a paper version. The paper version of the sequence data is identical to the data provided on the diskette.
FIELD OF THE INVENTION
[0003] This invention is related to the field of plant molecular biology. More specifically the invention is related to the field of improving photosynthetic efficiency and reducing cell-damage caused by near ultraviolet light by transgenically integrating fluorescent protein encoding genes into algae and cyanobacteria.
BACKGROUND OF THE INVENTION
[0004] Bioreactors for photosynthetic organisms have been proposed for the production of pharmaceuticals, natural pigments, single cell proteins, secondary metabolites and more recently for mass culture of microalgae and cyanobacteria that contain high oil concentrations for producing biodiesel and for other uses, as well as other co-products. Many problems are to be overcome before bioreactors can be efficiently used for biodiesel production (Chisti 2007). Sunlight contains near-UV wavelengths that cause cell damage and can reduce biomass yield, as well as raise the temperature of the culture medium to above optimum temperature. Many cyanobacteria naturally synthesize compounds that can act as UV blockers (Sinha and Hader 2007), but these compounds dissipate the absorbed energy as heat, and thus do not enhance photosynthesis. Dyes absorbing light in the near UV wavelength region have been thought to be effective in enhancement of algal growth, but the dyes proved toxic to the algae. Despite these problems, Prokop et al. (1984) stated that incorporation of dyes into the media of algae suspensions does in fact provide additional light source and enhance growth.
SUMMARY OF THE INVENTION
[0005] In this disclosure we solve the problem of near-UV light causing cell damage and reducing biomass with a novel approach. Namely, our approach is to use proteinaceous fluorescent pigments that absorb light at wavelengths not used efficiently by the plants and emit light at favorable wavelengths for algal growth and photosynthetic yields. Endogenously including natural, biological pigments into a photosynthetic organism where they would be much more efficient has never been envisaged before.
[0006] Some organisms possess a great variety of compounds that absorb light of many colors and fluoresce the light at longer wavelengths. Their visual effects are either due to the intricate ultrafine physical organization of tissues that results in differential scattering of the incoming light, or to the display of specific colored molecules (pigments), or to the combination of both. The pigments are usually small molecules featuring extended conjugated pi-systems in their chemical structure, which endow them with chemical resonance of frequencies residing within the wavelength span of the visible spectrum (400 to 750 nanometers). The green fluorescent protein-like (GFP-like) family are the only known pigments that are essentially encoded by a single gene, since both the substrate for pigment biosynthesis and the necessary catalytic moieties are contained within a single polypeptide chain thus serving both as a substrate and an enzyme. The only external agent required to complete the pigment biosynthesis is molecular oxygen (Heim et al., 1994).
[0007] The prototypical GFP from the bioluminescent jellyfish Aequorea victoria and its derivatives and analogs have become important imaging tools in molecular and biological sciences where they are used as cell and protein labels, visible markers of gene expression both by themselves and as fusion proteins for use in cellular physiological studies. Recently, it was discovered that the majority of the bright colors of Anthozoa (i.e. reef corals, anemones and other related organisms) are determined by proteins homologous to GFP. These include fluorescent blue, green, yellow and red proteins and the lower wavelength—fluorescent, purple-blue hues. The discovery of GFP-like proteins in non bioluminescent organisms has greatly expanded multi-color labeling as well as other applications. A variety of fluorescent proteins ranging from cyan to red colors isolated from reef corals are now commercially available and novel varieties are being constantly discovered.
[0008] Corals have a symbiotic relationship with dinoflagellate microalgae (zooxanthellae) that live within their endodermal cells. Consequently, corals are highly dependent on sunlight for the photosynthesis of the zooxanthellae from which they derive much of their own energy requirements. By focusing on spectral, microstructural and eco-physiological studies of coral fluorescent proteins in vivo, Salih et al. (2000) proposed that they function in light optimization of coral tissues for photosynthetic requirements of their intracellular microalgal symbionts.
[0009] To improve the currently available systems, we use genes encoding native fluorescent proteins or genes encoding, native proteins that have been artificially modified to increase their stability, after they have been adapted to the codon usage of the algae/cyanobacteria used. They are overexpressed in each cell to create a unique and better light regime in the bioreactor. This is achieved by using a fluorescent protein that absorbs light in the near-UV region and emits light in the photosynthetic range of the recipient organism thus enhancing photosynthesis and preventing cell damage caused by short wavelength light. In addition, we also use other native or synthetic genes encoding other fluorescent proteins that absorb light in photosynthetically underutilized wavebands (such as the green wavelengths) and emit light in the photosynthetic range of the recipient organism. These genes are adapted to the codon usage of the algae/cyanobacteria used and overexpressed in each cell. These genes can be expressed in tandem with other genes or used in co-transformations and thereby also be used as selectable markers. Additionally, two or more fluorescent proteins can be introduced into the cells in order to reach optimal photosynthetic efficiency.
[0010] Accordingly, this invention provides a method to enhance algal and cyanobacterial photosynthesis and/or prevent cell damage caused by short wavelengths, by the over expression of naturally occurring or synthetic genes encoding fluorescent proteins within the cells. These genes are configured to match the preferred codon usage of the target organism used. The genes can be expressed alone or fused to a specific transit peptide or targeting protein that will lead them to specific locations within the cells. These transgenic algae/cyanobacteria can serve as a platform for further engineering of desired traits when also used as selectable markers.
[0011] The method according to this invention can be used for both freshwater and marine photosynthetic organisms.
A SHORT DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 . Action spectra of photosynthetic O2 evolution in Cryptophyta and Chlorophyta (thin black). Excitation spectra of fluorescent protein (thick grey). Emission spectra of fluorescent protein (thick black).
[0013] FIG. 2 . Plasmid map containing the DNA cassette used to transform the green algae C. reinhardtii, the eustigmatophyte Nannochloropsis oculata and the haptophyte Isochrysis sp. with the blue fluorescent protein (BFP)-azurite gene. The modified coding sequence of BFP-azurite gene was cloned into the BstBI/BamHI sites downstream to the Hsp70A/RbcS2 promoter and RbcS2 first intron and upstream to the 3′ RbcS2 terminator.
[0014] FIG. 3 . Schematic diagram of the DNA fragment used to transform the cyanobacterium Synechococcus PCC7002 with the blue fluorescent protein (BFP)-azurite gene. The modified coding sequence of BFP-azurite gene according to the Synechococcus PCC7002 codon usage was cloned into the BamHI site of pCB4 downstream to the RbcLS promoter.
[0015] FIG. 4 . UV LED (light emitting diode) spectrum used for excitation of fluorescent proteins (as specified by supplier, Nichia, Tokyo, Japan)
[0016] FIG. 5 . PCR screen for BFP containing Chlamydomonas reinhardtii transformants. PCR with BFP specific primers was performed on DNA extracted from 22 colonies grown on selectable medium. The specific primers were designed to amplify a 511 by product. M—marker; 1 to 22—transformants.
[0017] FIG. 6 . mRNA expression of BFP in Chlamydomonas reinhardtii transformants containing pSI-BFP-Pt. PCR was performed on cDNA synthesized from RNA extracted from 10 selected transgenic colonies. M—marker; -rt—control for DNA contamination; NTC—no template control. The specific primers were designed to amplify a 511 bp product.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Algae and cyanobacteria with biotechnological utility are chosen from among the following, non-exclusive list of organisms
[0019] List of Species:
[0020] Chlamydomonas reinhardtii, Pavlova lutheri, Isochrysis sp. CS-177, Nannochloropsis oculata CS-179, Nannochloropsis like CS-246, Nannochloropsis salina CS-190, Tetraselmis suecica, Tetraselmis chuii and Nannochloris sp. as representatives of all algae species. Synechococcus PCC7002, Synechococcus WH-7803, Thermosynechococcus elongatus BP-1 as representatives of all cyanobacterial species. The algae come from a large taxonomical cross section of species (Table 1)
[0000]
TABLE 1
Phylogeny of some of eukaryotic algae used
Phylogeny of eukaryotic algae used
Genus
Family
Order
Phylum
Sub-Kingdom
Chlamydomonas
Chlamydomonadaceae
Volvocales
Chlorophyta
Viridaeplantae
Nannochloris
Coccomyxaceae
Chlorococcales
Chlorophyta
Viridaeplantae
Tetraselmis
Chlorodendraceae
Chlorodendrales
Chlorophyta
Viridaeplantae
Phaeodactylum
Phaeodactylaceae
Naviculales
Bacillariophyta
Chromobiota
Nannochloropsis
Monodopsidaceae
Eustigmatales
Heterokontophyta
Chromobiota
Pavlova
Pavlovaceae
Pavlovales
Haptophyta
Chromobiota
Isochrysis
Isochrysidaceae
Isochrysidales
Haptophyta
Chromobiota
Phylogeny according to: http://www.algaebase.org/browse/taxonomy/
Note:
Many genes that in higher plants and Chlorophyta are encoded in the nucleus are encoded on the chloroplast genome (plastome) in the Chromobiota red lineage algae (Grzebyk, et al., 2003)
[0021] The General Approach for Algae and Cyanobacteria is as Follows:
[0022] De novo synthesized blue fluorescent protein (BFP)-azurite, A5cDNA (Mena et al., 2006) or other fluorescence proteins such as DsRed, for enhancing algal and cyanobacterial photosynthesis and/or preventing cell damage caused by short wavelengths were cloned under the control of the Hsp70-rbcS2 promoter or other constitutive promoters and 3′rbcS2 terminator for algae ( FIGS. 2 and 3 ). More than one fluorescent protein can be cloned in tandem to achieve stacking, leading to optimal utilization of the total light spectrum reaching the culture. Genes encoding more than one fluorescent protein can be functionally stacked in a sequential manner, or by co-transformation.
[0023] The methodologies used in the various steps of enabling the invention are described below:
[0024] Transformation of Chlamydomonas
[0025] Algae cells in 0.4 ml of growth medium containing 5% PEG MW6000 were transformed with, for example, 1 to 5 μg of the plasmid described in example 1, by the glass bead vortex method (Kindle, 1990). The transformation mixture was then transferred to 10 ml of non-selective growth medium for recovery and incubated for at least 18 h at 25° C. in the light. Cells were collected by centrifugation and plated at a density of 10 8 cells per 80 mm Petri dish. Transformants were grown on fresh TAP or SGII agar plates containing a selective agent for 7-10 days at 25° C.
[0026] Transformation of Marine Algae
[0027] I. Electroporation
Fresh algal cultures are grown to mid exponential phase in artificial seawater (ASW)+f/2 media. Cells are then harvested and washed twice with fresh media. After resuspending the cells in 1/50 of the original volume, protoplasts are prepared by adding an equal volume of 4% hemicellulase (Sigma) and 2% Driselase (Sigma) in ASW and are incubated at 37° C. for 4 hours. Protoplast formation is tested by Calcofluor white non-staining. Protoplasts are washed twice with ASW containing 0.6M D-mannitol (Sigma) and 0.6M D-sorbitol (Sigma) and resuspended in the same media, after which DNA is added (10 μg linear DNA for each 100 μl protoplasts). Protoplasts are transferred to cold electroporation cuvettes and incubated on ice for 7 minutes, then pulsed in an ECM830 electroporation apparatus (BTX, Harvard Apparatus, Holliston, Mass., USA). A variety of pulses is usually applied, ranging from 1000 to 1500 volts, 10-20 msec per pulse. Each cuvette is pulsed 5-10 times. Immediately after pulsing the cuvettes are placed on ice for 5 minutes and then the protoplasts are added to 250 μl of fresh growth media (without selector). After incubating the protoplasts for 24 hours in low light at 25° C. the cells are plated onto selective solid media and incubated under normal growth conditions until single colonies appear.
[0029] II. Microporation
A fresh algal culture is grown to mid exponential phase in ASW+f/2 media. A 10 ml sample of the culture is harvested, washed twice with Dulbecco's phosphate buffered saline (DPBS, Gibco, Invitrogen, Carslbad, Calif., USA) and resuspended in 250 μl of buffer R (supplied by Digital Bio, NanoEnTek Inc., Seoul, Korea, the producer of the microporation apparatus and kit). After adding 8 μg linear DNA to every 100 μl cells, the cells are pulsed. A variety of pulses is usually needed, depending on the type of cells, ranging from 700 to 1700 volts, 10-40 msec pulse length; each sample is pulsed 1-5 times. Immediately after pulsing, the cells are transferred to 200 μl fresh culture media (without selector). After incubating for 24 hours in low light at 25° C., the cells are plated onto selective solid media and incubated under normal culture conditions until single colonies appear.
[0031] III. Particle Bombardment
A fresh algal culture is grown to mid exponential phase in ASW+f/2 media. 24 hours prior to bombardment cells are harvested, washed twice with fresh ASW+f/2 and resuspended in 1/10 of the original cell volume in ASW+f/2. 0.5 ml of each cell suspension is spotted onto the center of a 55 mm Petri dish containing 1.5% agar solidified ASW+f/2 media. Plates are left to dry under normal growth conditions. Bombardment is carried out using a PDS 1000/He biolistic transformation system according to the manufacturer's (BioRad Laboratories Inc., Hercules, Calif., USA) instructions using M10 tungsten powder (BioRadLaboratories Inc.) for cells larger than 2 microns in diameter, and tungsten powder comprised of particles smaller than 0.6 microns (FW06, Canada Fujian Jinxin Powder Metallurgy Co., Markham, ON, Canada) for smaller cells. The tungsten is coated with linear DNA. 1100 or 1350 psi rupture discs are used. All disposables (unless otherwise noted) are supplied by BioRad Laboratories Inc. After transformation the cells are incubated under standard culture conditions for 24 hours, followed by transferring the cells onto selective solid media at a density of 10 4 cells per 90 mm diameter plates, and incubated under normal growth culture until single colonies appear.
[0033] Transformation of Cyanobacteria
[0034] For transformation to Synechococcus PCC7002, cells are cultured in 100 ml of BG-11 30 Turks Island Salts liquid medium (http://www.crbip.pasteur.fr/fiches/fichemedium.jsp?id=548) at 28° C. under white fluorescent light and subcultured at mid exponential growth. To 1.0 ml of cell suspension containing 2×10 8 cells, 0.5-1.0 μg of donor DNA (in 10 mM Tris/1 mM EDTA, pH8.0) is added, and the mixture is incubated in the dark at 26° C. overnight. After incubation for a further 6 h in the light, the transformants are selected on BG-11+Turks Island Salts agar plates containing a selection agent until single colonies appear.
[0035] Quantification of Transgenic Protein
[0036] For quantification of the transgene expression products, proteins are isolated from the algal cells utilizing a buffer containing 750 mM Tris pH 8.0, 15% sucrose (wt/vol), 100 μM β-mercaptoethanol and 1 mM phenylmethylsulfonylfluoride (PMSF). Samples are then centrifuged for 20 min at 13,000×g at 4° C., with the resulting supernatant used in western immunoblotting. Western immunoblotting is carried out as described by Cohen et al. (1998) using a rabbit anti-RCFP polyclonal Pan antibody that detects any of the entire panel of GFP-like reef coral fluorescent proteins (Clontech, Palo Alto, Calif., USA) and an alkaline phosphatase-labeled goat anti-rabbit secondary antibody (Sigma).
[0037] Proteins for in vitro BFP assays are prepared in the same fashion except that the crude lysate is centrifuged for 30 min at 40,000×g at 4° C. to remove contaminating thylakoids. Microtiter assays are carried out on volumes of 100 μl with samples diluted in protein extraction buffer. Protein concentrations are determined using Bio-Rad Protein assay reagent (Bio-Rad Laboratories Inc).
[0038] RNA Extraction, cDNA Synthesis and Quantitative RT-PCR Analysis
[0039] For screening for transgenes expressing high levels of BFP mRNA, total RNA is isolated using either QIAGENS's plant RNeasy Kit (QIAGEN, Hilden, Germany) or the Trizol reagent (Invitrogen, Carlsbad, Calif., USA). cDNA is synthesized using 3 μg total RNA as a template with an oligo-dT primer for algae and a specific 3′primer for cyanobacteria, and SuperScript™ II reverse transcriptase (Invitrogen, Carlsbad, Calif., USA) according to the manufacturer's instructions. Presence of BFP-azurite DNA was tested by PCR using BFP-azurite specific primers (Sequence in example 1). REDTaq DNA polymerase (Sigma) was used for the PCR amplification. A 1 kb DNA ladder was used as DNA size marker (Fermentas, Md., USA).
[0040] Photosynthetic Efficiency and Culture Growth
[0041] Fluorescent proteins transform high energy, damaging (near-UV) wavelengths into lower energy, longer, less damaging (blue to red) wavelengths. Fluorescent proteins with overlapping excitation and emission spectra, can convert light from any wavelengths (near-UV, green) poorly used by photosynthetic pigments into photosynthetically more active wavelengths. In order to test the hypothesis that cells expressing synthetic genes encoding fluorescent proteins will be more efficient using whole light spectra reaching the culture, cells expressing the BFP-azurite or any other type of fluorescent protein are compared to wild type cells. To assess the contribution of fluorescent proteins to cell photosynthetic efficiency, cells are illuminated with narrow band light with a peak at excitation wavelength of the fluorescent proteins. (e.g. a near-UV LED—light emitting diode) emitting at 375±5 nm ( FIG. 4 ). Photosynthetic activities of the transgenic algae are examined and compared to those of the wild types by measuring oxygen evolution in the light and oxygen consumption in the dark, using Clark type electrodes (Pasco Scientific, Roseville, Calif., USA).
[0042] A setup for comparative evaluation of oxygen evolution was built, allowing simultaneous measurements of 8 algal samples illuminated at different intensities and wavelengths. Temperature is maintained using a water-bath with circulator (Model CB 8-30e, Heto Lab Instruments).
[0043] Culture Conditions
[0044] Cells of eukaryotic marine cultures (e.g. Isochrysis galbana, Phaeodactylum tricornutum and Nannochloropsis sp.) and transformants thereof are cultured on artificial seawater (ASW) medium (Wyman et al., 1985) supplemented with f/2 (Guillard and Ryther, 1962). Marine cultures are grown at 22-25° C. with a 16/8 h light/dark period. Fresh water cultures (e.g. Chlamydomonas reinhardtii ) and transformants thereof are cultured photoautotrophically on in liquid medium, using mineral medium as previously described (Harris, 1989), supplemented with 5 mM NaHCO 3 , with continuous shaking and illumination at 22° C. Cells of marine cyanobacteria (e.g. Synechococcus PCC 7002) and transformants thereof are cultured in medium BG-11+Turks Island salts liquid medium (http://www.crbip.pasteur.fr/fiches/fichemedium.jsp?id=548). Cyanobacteria are cultured at 25° C. under continuous white light, with constant CO 2 -air bubbling.
[0045] In order to test the hypothesis that cells expressing synthetic genes encoding fluorescent proteins are more efficient than the wild type capable of using sunlight, we compare algae expressing fluorescent proteins to wild type cells in ambient sunlight.
[0046] For example, the growth rate of wild type and BFP-azurite transformants cultured in PAR (photosynthetically active radiation—i.e. 450-750 nm light) and PAR+near-UV is measured using direct cell counts. Culture density is measured daily for a period of ten days. The growth rate of wild type and DsRed transformants cultured in sunlight is measured using direct cell counts. Culture density is measured daily for a period of ten days.
[0047] Algae and cyanobacteria expressing fluorescent proteins have increased photosynthetic activity and growth rate compared to the wild type at the tested wider light spectrum containing near-UV.
[0048] The invention is now described by means of various non-limiting examples:
Example 1
Generation of Eukaryotic Algae Cells Expressing BFP-Azurite
[0049] The BFP-azurite sequence (Mena et al., 2006) was artificially synthesized using the published sequence (SEQ ID NO: 1) with modifications according to the codon usage of P. tricornutum (BFP-Pt) (SEQ ID NO: 2) and the green algae C. reinhardtii (BFP-Cr) (SEQ ID NO: 3) and with the addition of BstBI and BamHI restriction sites at its ends. The gene was cloned into pGEM-T vector (Promega, Madison, USA) and then ligated into the BstBI/BamHI restriction sites of pSI103 (Sizova et al., 2001) replacing the aphVIII selectable marker gene, generating the plasmid pSI-BFP. In this plasmid the BFP-azurite gene is under the control of the Hsp70A/RbcS2 promoter and 3′ RbcS2 terminator.
[0050] Parental strain C. reinhardtii CC-425 was co-transformed with the pSI-BFP-Pt plasmid and linearized plasmid pJD67, containing the structural gene (ARG7) of the argininosuccinate lyase to complement the arg2 locus (Davies et al. 1994, 1996). C. reinhardtii colonies were selected on TAP medium without arginine. Approximately 35 colonies that grew without arginine were transferred to liquid TAP medium and screened for pSI-BFP construct using PCR with primers ( FIG. 5 ):
[0000]
BFP-forward primer (SEQ ID NO: 4):
CTGGACGGAGATGTTAATGG
and
BFP-reverse primer (SEQ ID NO: 5):
TCGGAGTGTTCTGCTGATAG.
[0051] RNA was extracted from positive colonies containing the pSI-BFP construct for BFP expression monitoring by RT-PCR on cDNA using the primers BFP-forward and BFP-reverse ( FIG. 6 ). Colonies expressing the BFP transcript are then screened for BFP expression as described in example 5.
[0052] In addition, the pSI-BFP-Pt/Cr plasmid together with pSI-PDS plasmid containing the pds gene (conferring resistance to the phytoene desaturase-inhibiting herbicide flurochloridone) (SEQ ID NO: 6) are co-transformed to Nannochloropsis oculata CS-179 and Isochrysis sp. CS-177 using the transformation methods described above.
Example 2
Generation of Synechococcus PCC7002 Expressing the BFP-Azurite Gene Under the Control of the Cyanobacterial rbcLS Promoter
[0053] The BFP-azurite sequence (Mena et al., 2006) is artificially synthesized to enhance stability using the published sequence (SEQ ID NO: 1), but with modifications according to the preferred codon usage of Synechococcus PCC7002 (SEQ ID NO: 7) and with the addition of BamHI restriction sites at both ends. The gene is cloned into pGEM-T vector (Promega, Madison, USA) and then transferred into the BamHI site of pCB4 plasmid (Deng and Coleman, 1999) downstream to the Synechococcus PCC 7002 rbcLS promoter (SEQ ID NO:8) and upstream to rbcLS terminator.
[0054] Likewise, similar constructs, made based on codon usage of other cyanobacterial species are generated and transformed into these species.
Example 3
Generation of Eukaryotic Algae Cells Expressing DsRed
[0055] The DsRed gene is artificially synthesized using the published sequence (accession number BAE53441; SEQ ID NO: 9) with modifications according to the codon usage of the green algae C. reinhardtii (SEQ ID NO: 10) and with the addition of BstBI and BamHI restriction sites at its ends. The gene is cloned into pGEM-T vector (Promega, Madison, USA) and then ligated into the BstBI/BamHI restriction sites of pSI103 (Sizova et al., 2001) replacing the aphVIII selectable marker gene, generating the plasmid pSI-DsRed. In this plasmid the DsRed gene is under the control of the Hsp70A/RbcS2 promoter (SEQ ID NO:11) and 3′ RbcS2 terminator. The gene product fluoresces green light to red wavelengths.
[0056] The pSI-DsRed plasmid is co-transformed with pSI103 containing the paromomycin resistance gene to C. reinhardtii CW15 (CC-400) and with pSI-PDS plasmid containing the pds gene (conferring resistance to the phytoene desaturase-inhibiting herbicide flurochloridone) to marine algae using the transformation methods described above.
Example 4
Generation of Synechococcus PCC7002 Expressing the DsRed Gene Under the Control of the Cyanobacterial rbcLS Promoter
[0057] The DsRed gene is artificially synthesized using the published sequence (accession number BAE53441; SEQ ID NO:9) with modifications according to the codon usage of Synechococcus PCC7002 (SEQ ID NO: 12) and with the addition of BamHI restriction sites at both ends. The gene is cloned into pGEM-T vector (Promega, Madison, USA) and then transferred into the BamHI site of pCB4 plasmid (Deng and Coleman, 1999) downstream to the Synechococcus PCC 7002 rbcLS promoter (SEQ ID NO:8) and upstream to rbcLS terminator.
[0058] Likewise, similar constructs, based on codon usage of other cyanobacterial species are generated and transformed into these species.
Example 5
Screening for Algal/Cyanobacterial Transformants
[0059] BFP-azurite transformants are grown on fresh agar plates for 7 days at 25° C. Colonies are transferred at equal concentrations to 200 μl culture media (as described in the “culture conditions” section) in 96-well micro-well plates, and cultured under the conditions described in the “culture conditions” section, until they reach a substantial cell concentration (˜10 6 BFP fluorescence is excited at ˜380 nm and monitored at the emission of 450 nm. DsRed and other fluorescent proteins are monitored according to their specific excitation and emission spectra.
[0060] Cells from cultures producing the highest fluorescent signal are collected and cultured as single cell colonies under 380 nm near-UV light (duration and intensity are set at LD99% of wild type cells). Surviving cells are then transferred for future culturing and further examination.
Example 6
Screening for Transformants Expressing High Level of BFP, DsRed or other Fluorescent Proteins Using Western Immunoblotting
[0061] Proteins from transformed algae and cyanobacteria cells with detectable levels of blue or other fluorescence are isolated from algae/cyanobacteria cells utilizing a buffer containing 750 mM Tris pH 8.0, 15% sucrose (wt/vol), 100 μM β-mercaptoethanol and 1 mM phenylmethylsulfonylfluoride (PMSF). Samples are then centrifuged for 20 min at 13,000×g at 4° C., with the resulting supernatant used for western immunoblotting. Western immunoblotting is carried out as described by Cohen et al. (1998) using an anti-RCFP polyclonal Pan antibody primary antibody (Clontech, Palo Alto, Calif., USA) and an alkaline phosphatase-labeled goat anti-rabbit secondary antibody (Sigma). This polyclonal antibody recognizes the GFP-like family of proteins.
Example7
Enhanced Photosynthetic Activity
[0062] Experimental Design
[0063] One of the major goals in the field of production of photosynthetically generated materials (such as oils, proteins, pigments and pharmaceuticals and other co-products) is to utilize the whole spectrum of light reaching the photosynthetic cell, thus increasing photosynthetic efficiency and decreasing heating. In order to demonstrate that cells expressing synthetic genes encoding fluorescent proteins are more efficient using whole light spectra (PAR and near-UV, or full sunlight) reaching the culture, we compare photosynthetic efficiency of transformed algae or cyanobacteria expressing the BFP-azurite and/or any other single or multiple fluorescent proteins set to their respective wild type cultures.
[0064] To assess the contribution of fluorescent proteins to cell photosynthetic efficiency, cells are illuminated with a narrow band light with a peak at excitation wavelength of the specific fluorescent protein. Photosynthetic activity of the transgenic algae is examined and compared to that of wild type cells. Oxygen evolution in the light and oxygen consumption in the dark is measured using Clark type electrodes (Pasco Scientific, Roseville, Calif., USA).
[0065] Algae and cyanobacteria expressing BFP-azurite have increased photosynthetic activity as measured by oxygen evolution. Significant differences between oxygen evolution of algae and cyanobacteria expressing BFP-azurite and that of their respective wild type are observed when cells are illuminated with light at the excitation wavelength of BFP.
Example 8
Enhanced Overall Growth Rate
[0066] In order to test that cells expressing synthetic genes encoding fluorescent proteins are more efficient at outdoor light conditions namely, ambient sunlight we compare growth rates of cultures expressing the BFP-azurite to that of wild type cells.
[0067] Growth rate at ambient conditions is determined by measuring culture density daily for a period of ten days.
[0000] Growth rate is measured using:
[0068] Direct cell count
[0069] Optical density—at relevant wavelength (e.g. 750 nm)
[0070] Pigment/chlorophyll concentration.
[0000] Algae and cyanobacteria expressing BFP-azurite have increased photosynthetic activity and growth rate when compared to the wild type.
REFERENCES
[0000]
Chisti Y (2007) Biodiesel from microalgae. Biotechnol Adv 25: 294-306
Chow K, Tung W (1999) Electrotransformation of Chlorella vulgaris. Plant Cell Reports 18: 778-780
Cohen A, Yohn C B, Bruick R K, Mayfield S P (1998) Translational regulation of chloroplast gene expression in Chlamydomonas reinhardtii. Methods Enzymol 297: 192-208
Davies J P, Yildiz F H, Grossman A R (1994) Mutants of Chlamydomonas with aberrant responses to sulfur deprivation. Plant Cell 6:53-63
Davies J P, Yildiz F H, Grossman A R (1996) Sacl, a putative regulator that is critical for survival of Chlamydomonas reinhardtii during sulfur deprivation. EMBO 15: 2150-2159.
Deng M D, Coleman J R (1999) Ethanol synthesis by genetic engineering in cyanobacteria. Appl Environ Microbiol 65: 523-528
Gilmore A M, Larkum A W, Salih A, Itoh S, Shibata Y, Bena C, Yamasaki H, Papina M, Van Woesik R (2003) Simultaneous time resolution of the emission spectra of fluorescent proteins and zooxanthellar chlorophyll in reef-building corals. Photochem Photobiol 77: 515-523
Grzebyk, D., O. Schofield, P., Falkowski, and J. Bernhard (2003) The Mesozoic radiation of eukaryotic algae: the portable plastid hypothesis. J. Phycol. 39:259-267)
Guillard, R. R. and Ryther, J. H. (1962). Studies on marine planktonic diatoms. I. Cyclotella nana Hustedt and Detonula confervacaea (Cleve) Gran. Canadian Journal of Microbiology 8: 229-239
Heim R, Prasher D C, Tsien R Y (1994) Wavelength mutations and posttranslational autoxidation of green fluorescent protein. Proc Natl Acad Sci USA 91: 12501-12504
Kindle K L (1990) High-frequency nuclear transformation of Chlamydomonas reinhardtii. Proc Natl Acad Sci USA 87: 1228-1232
Mena M, Treynor T, Mayo S, Daugherty P (2006) Blue fluorescent proteins with enhanced brightness and photostability from a structurally targeted library. Nature Biotechnology 24: 1569-1571
Prokop A, Quinn M F, Fekri M, Murad M, Ahmed S A (1984) Spectral shifting by dyes to enhance algae growth. Biotechnol Bioeng 26: 1313-1322
Salih A, Larkum A, Cox G, Kuhl M, Hoegh-Guldberg O (2000) Fluorescent pigments in corals are photoprotective. Nature 408: 850-853
Sinha R P, Hader D-P (2007) UV-protectants in cyanobacteria. Plant Science 174: 278-289
Sizova I, Fuhrmann M, Hegemann P (2001) A Streptomyces rimosus aphVIII gene coding for a new type phosphotransferase provides stable antibiotic resistance to Chlamydomonas reinhardtii. Gene 277: 221-229
Wyman M, Gregory R P F, and Carr N G (1985) Novel role for phycoerythrin in a marine cyanobacterium, Synechococcus strain DC2. Science 230, 818-820.
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This disclosure provides a method to reduce cell damage caused by near UV light absorption of algal or cyanobacterial cultures. The algal or cyanobacterial cells are transformed to express one or more fluorescent proteins, that absorb the harmful UV or near UV wavelengths and emits wavelengths that are photosynthetically more active. The photosynthetic pigments of the transgenic algal or cyanobacterial cell culture will then absorb the photosynthetically active light emitted by the fluorescent proteins. Accordingly the harmful effects of the UV and near UV radiation are reduced and the photosynthetic activity of the algal or cyanobacterial cells is improved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation, under 35 U.S.C. §120, of copending International Application No. PCT/EP2006/000717, filed Jan. 6, 2006, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application DE 10 2005 000 890.9, filed Jan. 7, 2005; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a fiber layer, which is suitable for use in an exhaust system of a mobile internal combustion engine. The invention also relates to a particulate filter for the same use. Moreover, the invention relates to a method for removing particulates from the exhaust gas of an internal combustion engine having a gas-permeable filter layer. The invention furthermore relates to an exhaust system and a vehicle having the particulate filter.
It is known to use particulate traps which are constructed from a ceramic substrate in order to reduce the level of particulate emissions from exhaust gases from combustion processes. Those traps have channels, so that the exhaust gas which is to be purified can flow into the particulate trap. Adjacent channels are closed off on alternate sides, so that the exhaust gas enters the channel on the inlet side, is forced to pass through a ceramic wall and escapes again along an adjacent channel on the outlet side. Filters of that type achieve an efficiency of approximately 95% across the entire range of particulate sizes which occur.
In addition to undesirable chemical interactions between the particulates and additives and special coatings, the reliable regeneration of a filter of that type in the exhaust system of an automobile still causes problems. It is necessary to regenerate the particulate trap, since the increasing accumulation of particulates in the channel walls through which the exhaust gas is to flow causes the pressure loss across the filter or the back-pressure to rise continuously, which has adverse effects on the engine power. The regeneration generally includes brief heating of the particulate trap or the particulates which have collected therein, so that the particulates are converted into gaseous constituents. That can be achieved, for example, by briefly raising the temperature of the exhaust gas to levels which are sufficient to convert the particulates which have accumulated in the particulate trap, with the aid of an upstream exothermic reaction (e.g. oxidation of additional fuel injected into the exhaust pipe: “afterburning”). However, that high thermal loading of the particulate trap has adverse effects on the service life. Moreover, under certain circumstances it is necessary to monitor the extent of blockage of the particulate trap in order to ensure that a thermal regeneration of that nature should be initiated only at the required times.
In order to avoid such a discontinuous regeneration, which promotes thermal wear, a system (known as CRT: Continuous Regeneration Trap) for the continuous regeneration of filters or particulate traps has been developed. In a system of that type, the particulates are burnt at temperatures of well over 200° C. by oxidation with NO 2 . The NO 2 required for that purpose is often generated by an oxidation catalytic converter disposed upstream of the particulate trap. In that case, however, the problem arises specifically with a view toward use in motor vehicles using diesel fuel that there is only an insufficient level of nitrogen monoxide (NO) which can be converted into the desired nitrogen dioxide (NO 2 ) in the exhaust gas. In that respect, it may under certain circumstances be necessary to add substances or additives which yield NO or NO 2 (e.g. ammonia) so as to ultimately allow continuous regeneration of the particulate trap in the exhaust system.
Those fundamental considerations have given rise to a new filter concept, which has mainly become known under the name “open filter system” or “PM cat”. Those open filter systems are distinguished by the fact that there is no need for the filter channels to be constructed in such a way that they are closed off on alternate sides. In that context, it is provided that the channel walls are at least in part composed of porous material and that the flow channels of the open filter have diverting and/or guiding structures. Those internal fittings or microstructures in the channels cause the flow or the particulates contained therein to be diverted toward the regions made from porous material. In that context, it has surprisingly emerged that the particulates adhere to and/or in the porous channel wall as a result of interception and/or impacting. The pressure differences in the flow profile of the flow in the exhaust gas are of importance for that effect to occur. The divergence or microstructures additionally make it possible to generate local subatmospheric or superatmospheric conditions, which lead to a filtration effect through the porous channel wall since the above-mentioned pressure differences have to be compensated for.
In that case, the particulate trap, unlike the known closed screen or filter systems, is “open”, since there are no blind flow alleys and/or (at least almost) every channel has a cross section which, although it may vary, can ultimately still be flowed through freely. That property can also be used to characterize particulate filters of that type, which means that, for example, the parameter “freedom of flow” is suitable for descriptive purposes. A more extensive description of “open” filter elements of that type is to be found, for example, in German Utility Model DE 201 17 873 U1, corresponding to U.S. Patent Application Publication No. US 2004/0013580 A1; International Patent Application No. WO 02/00326, corresponding to U.S. Patent Application Publication No. US 2003/0097934 A1; International Patent Application No. WO 01/92692, corresponding to U.S. Patent Application Publication No. US 2003/0086837 A1; and International Patent Application No. WO 01/80978, corresponding to U.S. Patent Application Publication No. US 2003/0072694 A1, the contents of the disclosures of which are hereby incorporated in full in the subject matter of the present description and can also be used below for more detailed characterization of filter elements of that type in the context of the present invention.
The provision of suitable materials for the porous channel sections has to be matched to a large number of factors, in particular material, resistance to corrosion, thermal stability, manufacturing suitability, filter efficiency. By way of example, metallic fiber layers which have been configured with a protective sheath so as to comply with some of the factors required in the automotive industry have also been proposed. Those are described, for example, in German Published, Non-Prosecuted Patent Application DE 101 53 283 A1, corresponding to U.S. Patent Application Publication No. US 2004/0194440 A1 or International Patent Application No. WO 03/038248, corresponding to U.S. Pat. No. 7,128,772.
The known “open filter systems” or the filter layers used therein have already proven very successful. Important factors in that context are low pressure loss and the possibility of placing filter systems of that type relatively close to the internal combustion engine, where the particulate traps are usually exposed to an elevated temperature.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for removing particulates from exhaust gases, and a corresponding fiber layer, particulate filter, exhaust system and vehicle, which overcome the hereinafore-mentioned disadvantages of the heretofore-known methods and devices of this general type and which demonstrate a way of making the known particulate filters even more efficient in terms of their purifying action. Moreover, it is intended to provide a fiber layer or filter layer which can be produced at low cost even as part of series production and which is suitable for use in metallic particulate traps, so as to be able to withstand high thermal and dynamic loads in the exhaust system of an automobile for a prolonged period of time.
With the foregoing and other objects in view there is provided, in accordance with the invention, a fiber layer for use in an exhaust system of a mobile internal combustion engine. The fiber layer comprises an assembly of fibers, two opposite surfaces of the fiber layer defining a layer thickness extending between the surfaces, and at least one parameter selected from the group consisting of porosity, fiber diameter and fiber type content, for characterizing the fiber layer. The at least one parameter has a magnitude varying in direction of the layer thickness and the magnitude has an extreme at a distance from the surfaces of the fiber layer.
In the present context, the term “fibers” is to be understood as meaning elongate elements, the fiber length of which is a multiple of the fiber diameter. The fibers have been combined with one another to form a sheet-like layer. The assembly may be of ordered or random nature. Examples of ordered assemblies include knitted fabrics, woven fabrics, meshes. An example of a random assembly is a tangled layer. The fibers may be directly cohesively bonded, but it is also possible for the fibers to be connected to one another by technical joining through additional measures. The preferred manner of producing the technical joining connection is by brazing. However, a sintering process or even welding may be used as well. The fibers or fiber layers are made from a corrosion-resistant material which is able to withstand high temperatures, so that they are able to withstand the ambient conditions in an exhaust system for a prolonged period of time. Important variables for describing the fibers are fiber length, fiber diameter and fiber type content. It is preferable for the fiber length of fibers of this type to be in a range of from 0.05 to 0.4 mm (millimeters). The fiber diameter is usually in a range of less than 0.09 mm, preferably in a range of from 0.015 to 0.05 mm. The configuration of the fibers with respect to one another can be described, inter alia, by the porosity. In this context, the term porosity means the proportion of regions through which media can flow freely within a cross section of the fiber layer. The porosity is usually in a range of from 50% to 90%. The assembly of fibers generally forms cavities, openings or pores, the maximum extent of which is in the range of from 0.001 to 0.1 mm and can be selected on the basis of the particulates that are to be removed. A further parameter is what is known as the fiber type content, a term used to describe the proportion in which the fibers are present when different fiber types or configurations are used to form the fiber layer. For example, if the fiber layer includes a number of fibers (F small ) with a small fiber diameter, on one hand, and a number of fibers (F large ) with a larger fiber diameter, on the other hand, the fiber type content results from the ratio of F small or F large to (F small +F large ). The fiber type content of one type of fibers preferably varies in the range of at least 10%, in particular 20%, over the layer thickness.
In the case of the fiber layer proposed herein, at least one of the characteristic parameters varies in the direction of the layer thickness, with an extreme in the interior of the fiber layer. In this context, the term “fiber layer” is actually only to be understood as meaning the combination of fibers. It does not include additional components of other forms of material (such as for example sheet-metal foils) for producing a filter layer. This does not mean that components of this type may not be present, but rather that they are not taken into consideration in connection with the varying parameters. This has no effect on the configuration of the fiber layer with different types of fiber or fiber layers disposed adjacent one another, which are intended to set the desired fiber layer parameter. This means in particular that the fiber layer has a different construction in edge layers than in central layers.
The term “extreme” is to be understood as meaning a maximum value or a minimum value for the parameter under consideration. In this context, a variation in the magnitudes which is substantially symmetrical with respect to the middle or center of the layer thickness is preferred. This has the advantage that the fiber layer has the same effect from both sides in terms of its filtering action and is therefore easier to produce, transport and process further in terms of manufacturing technology aspects. It is very particularly preferable for the respective extremes to be disposed substantially in a common cross-sectional plane of the fiber layer, i.e., for example, all to be at approximately the same distance from the surface of the fiber layer.
The configuration of the fiber layer proposed herein produces different flow resistances to a gas stream flowing through and/or particulates entrained therein at different depths of the fiber layer. The result of this is that the gas stream advances into different layers or depths of the fiber layer in accordance with the external flow forces and/or pressure differences. This fact can be exploited in order to achieve more effective purification of the gas streams, with an undesirable rise in the pressure loss being avoided at the same time.
In accordance with another feature of the invention, the fiber layer includes metallic fibers. In this context, it is preferable to use iron materials which contain a proportion of at least one of the following alloying elements: aluminum, chromium, nickel. The material itself can preferably be sintered, which means both that the fiber itself is made from sinterable material or produced by the sintering process and that the fibers have been technically joined to one another using the sintering process.
In accordance with a further feature of the invention, the fiber layer has a plurality of subregions, in which at least one of the parameters is constant, in the direction of the layer thickness. In other words, this means that the fiber layer has a stratified or layered structure, with the parameter under consideration being substantially constant within one such stratum or layer. A stratified or layered fiber layer of this type may in principle also include a different fiber material, with the strata or layers ultimately being joined to one another. However, it is preferable to form a fiber layer from one material, in which case the fibers themselves and/or their configuration with respect to one another is configured in such a way that individual strata or layers are formed. This has the advantage of ensuring more stable and durable cohesion of the layers, which is not necessarily the case with strata or layers including different materials and/or strata or layers which are joined to one another by additional technical joining materials.
In accordance with an added feature of the invention, with a stratified or layered structure of the fiber layer of this nature, it is particularly advantageous for there to be an odd number of subregions, with a centrally disposed subregion having the extreme magnitude of the parameter. It is preferable for a fiber layer of this type to have three (or if appropriate five) subregions, with the parameters in the edge layers being selected to be substantially identical and with a differing magnitude of the parameter being present in the centrally disposed subregion. The parameter may, in this case, have a magnitude which changes suddenly or continuously in the boundary region between the individual subregions.
In principle, the layer thickness of a fiber layer or filter layer of this type is in a range of less than 3.0 mm, preferably in a range of from 0.1 mm to 2.0 mm. Fiber layers with a layer thickness in the range of from 0.3 mm to 0.5 mm have given good results for mobile use, with subregions with a thickness of approximately 0.1 mm being formed. The layer thickness may, but does not have to be, divided into subregions which form equal proportions of the overall thickness.
In accordance with an additional feature of the invention, if the fiber layer is configured with a varying porosity, the extreme represents a minimum value. In other words, this means that the porosity of the fiber layer is lowest in an inner, in particular central, region of the fiber layer, i.e. the highest flow resistance for a gas stream flowing through it is present there. This means that for complete flow through the fiber layer there must be a considerable pressure difference, whereas the flow of gases through the edge region can take place even at relatively low pressure differences. Moreover, it should be noted that experience has shown that these subregions of reduced porosity are the first to become blocked with solids or particles, which means that they may be partially blocked until the particulates have been converted into gaseous constituents and the fiber region has been regenerated. Nevertheless, the fiber layer usually still has some filtering action at these locations, since the exhaust gas or gas stream can still flow through the edge layers of the fiber layers and can therefore continue to be purified.
In accordance with yet another feature of the invention, if the fiber diameter is configured to be variable over the layer thickness of the fiber layer, it is preferably proposed that the extreme represent a minimum value. In other words, this means that fibers in an interior subregion of the fiber layer have a smaller fiber diameter than fibers in the edge layers. Tests have shown that the efficiency of the fibers in terms of their purifying action and/or their potential to accumulate particulates increases as the fiber diameter decreases. This therefore means that in this case there is a fiber layer which is particularly efficient in central regions, whereas edge regions are less efficient. By way of example, the fibers in the central region may, for example, be used with a fiber diameter of less than 50 μm (micrometers) or even less than 25 μm, whereas, for example, fibers with a fiber diameter in the range of from 50 μm to 100 μm may be present in the edge region.
In accordance with yet a further feature of the invention, by way of example, it is also possible for the fiber type content to be configured so as to vary across the layer thickness of the fiber layer, in which case fibers (F small ) with a smaller fiber diameter and fibers (F large ) with a larger fiber diameter are mixed or combined with one another. It is particularly preferable for the F small fibers to have a fiber diameter in the range from 20-25 μm (micrometers), whereas the F large fibers are constructed with a fiber diameter in the range of from 35-45 μm. The extreme of the fiber type content parameter in this case is preferably in the range of from F small =approximately 0.3-0.4 to F large =approximately 0.7-0.6. A fiber type content of this nature has given particularly advantageous results with regard to particulate separation if it is kept substantially constant across the layer thickness. However, further advantages can also be achieved if the fiber type content close to at least one edge region is in the range of from F small =0.0-0.2 to F large =1.0-0.8.
In accordance with yet an added feature of the invention, at least some of the fibers have a fiber diameter which varies over their fiber length. In other words, this means that the fiber layer does not have to be produced with fibers of different configurations, but rather at least some of the fibers themselves are provided with a varying fiber diameter. This considerably simplifies the production of fiber layers of this type having varying parameters, in particular in series production.
In accordance with yet an added feature of the invention, the magnitude of the fiber diameter represents an extreme, in particular a minimum value, in a central portion of the fiber. In other words, this means that fibers which have two thick ends and a slender middle portion are provided. These fibers can then be combined with one another in such a way that, for example, the portions of the fibers having the same fiber diameter are disposed adjacent one another (in particular substantially in a cross-sectional plane parallel to the surface), and in this way different strata or layers are formed in the fiber layer.
With the objects of the invention in view, there is also provided a particulate filter for use in an exhaust system of a mobile internal combustion engine. The particulate filter comprises a honeycomb body having at least one fiber layer and at least one at least partially structured sheet together forming channels. At least some of the channels have at least one microstructure. The at least one fiber layer has a layer thickness and at least one parameter varying in direction of the layer thickness.
The at least one parameter is selected from the group consisting of porosity and fiber diameter. In this context, a particulate filter having a configuration of the fiber layer which has been described above in accordance with the invention is very particularly preferred.
This particulate filter is preferably what is known as an “open filter system” as described in the introduction, in which context the contents of the disclosure of the above-mentioned prior art disclosed in German Utility Model DE 201 17 873 U1, corresponding to U.S. Patent Application Publication No. US 2004/0013580 A1; International Patent Application No. WO 02/00326, corresponding to U.S. Patent Application Publication No. US 2003/0097934 A1; International Patent Application No. WO 01/92692, corresponding to U.S. Patent Application Publication No. US 2003/0086837 A1; and International Patent Application No. WO 01/80978, corresponding to U.S. Patent Application Publication No. US 2003/0072694 A1, can be used for additional explanation over and above the following description. All currently known methods, in particular continuous and discontinuous methods, can be used to regenerate the particulate filter according to the invention, but continuous regeneration using the “CRT” method is preferred.
The configuration of the particulate filter with a honeycomb body is fundamentally known. In this case, a multiplicity of channels disposed substantially parallel to one another are formed, connecting an inlet side of the honeycomb body to an outlet side of the honeycomb body. The exhaust gas which is to be purified flows in through the inlet end side and passes through the channels as partial exhaust-gas streams. The microstructures effect pressure differences in the interior of the honeycomb body, so that the partial exhaust-gas streams at least partially penetrate through the fiber layer and are purified in the process. Honeycomb bodies of this type are preferably constructed with a cell density of at least 100 cpsi, preferably in the range of from 150 cpsi to 400 cpsi (cpsi: cells per square inch; 1 cpsi corresponds to one channel per 6.4516 square centimeters). The channels are usually each delimited by a subregion of the structured sheet and a subregion of the fiber layer. The sheet is likewise made from a corrosion-resistant material which is able to withstand high temperatures, in particular a metallic material. It is constructed with a sheet thickness (foil thickness) of less than 100 μm (micrometers) and preferably has a recurring (macro-)structure, e.g. a corrugation. Both the sheet and the fiber layer may be at least partially provided with one or various coatings, if appropriate also including catalytically active material. In order to ensure a permanent joining of sheets and fiber layers, they are joined to one another, in particular by brazing or welding.
In accordance with another feature of the invention, the at least one microstructure is disposed in such a way in a channel that a gas stream flowing through it is diverted toward the at least one fiber layer. For this purpose, the microstructure may be constructed as a guide surface, elevation, projection, etc., in order to provide pressure differences and/or flow-facing edges and thereby to divert the gas stream, which usually flows in laminar form inside the channel, toward the fiber layer. The entrained particulates are also diverted, together with the gas stream, toward the fiber layer, where they ultimately accumulate as they pass through or come into contact with the fiber layer. The residence time of the particulates in the interior of the channel, the fiber layer or the particulate filter is then maintained until at least a large proportion of them are converted into gaseous constituents. For this purpose, it is possible to carry out thermal conversion as well as conversion or regeneration using nitrogen oxides.
In accordance with a further feature of the invention, the particulate filter is configured in such a way that the microstructure and fiber layer form a gap with a gap width of less than 1.5 mm. It is advantageous for the gap width to be approximately 1.0 mm or in a range between 0.5 mm and 0.8 mm. In principle, it should be noted that a plurality of microstructures may be provided in the interior of a channel, in which case the gap does not have to be of identical construction either within a channel or in adjacent channels. However, the provision of a gap ensures that an “open filter system” is produced. Consequently, at least part of the gas stream flowing through the channel is made to bypass the microstructure without completely penetrating through the fiber layer. The size and/or shape of the microstructure has a considerable influence on the flow diversion toward or through the fiber layer.
In the configuration of the fiber layer with parameters which vary in the direction of the layer thickness which is proposed herein, the result of this is that some of the exhaust gas or gas stream penetrates through the fiber layer and in this way enters an adjacent channel, while a further part of the exhaust gas or gas stream continues to flow along the channel, bypassing the microstructure. Configuring the fiber layer with an edge layer which represents a lower flow resistance to the gas stream than centrally disposed layers allows this “bypass” partial gas stream to at least partially penetrate through the edge layer and thus likewise enables some of the particulates entrained therein to be deposited on the fibers. This increases the efficiency of the particulate filter with regard to the removal of particulates, in particular carbon particulates, from a gas stream, in particular an exhaust gas from an internal combustion engine.
With the objects of the invention in view, there is also provided an exhaust system of an internal combustion engine. The exhaust system comprises the particulate filter according to the invention. The term internal combustion engine is to be understood in particular as meaning engines which produce an exhaust gas containing solid particulates. A mobile engine which burns diesel fuel is of particular importance in this context.
With the objects of the invention in view, there is additionally provided a vehicle, comprising a particulate filter of the type described above. Vehicles are mentioned as a preferred use in addition to other application areas (lawn mowers, chain saws, etc.) since statutory provisions require particularly efficient purification of the exhaust gases from vehicles. This applies in particular to passenger automobiles and trucks.
With the objects of the invention in view, there is concomitantly provided a method for removing particulates from a gas stream. The method comprises providing a gas-permeable filter layer having fibers, a layer thickness and subregions with a parameter of differing magnitudes in direction of the layer thickness. The parameter relates at least to a porosity or a fiber diameter of the fibers. The gas stream is divided into partial gas streams each passing through different subregions of the filter layer.
In other words, this means that although the partial gas streams may equally well flow through one subregion or a few subregions of the filter layer together, they are ultimately divided, with one of the partial gas streams flowing through other and/or further subregions of the filter layer. This is intended in particular to express the fact that separation into the respective partial gas streams takes place not in the direction of the surface of the filter layer, but rather in the direction of its layer thickness. This means in particular that a partial gas stream completely flows through the gas-permeable filter layer, whereas another part of the gas stream only penetrates into the gas-permeable filter layer but emerges again on the same side or surface without completely flowing through the filter layer. The partial gas streams differ in this context, for example, with regard to their direction of flow, their flow velocity, their temperature, the extent to which they are laden with particulates, etc.
In accordance with another mode of the invention, as has already been stated above, it is particularly advantageous for a partial gas stream to be passed only through at least one edge layer of the filter layer, whereas a further partial gas stream flows through all of the subregions of the filter layer. In this context, it should also be noted that the term filter layer is to be understood as meaning both a fiber layer of the type according to the invention as well as a filter layer composed of other materials or substances which likewise have magnitudes of the above-mentioned parameters which vary in the direction of the layer thickness, with an extreme of these magnitudes being at a distance from the surfaces of the filter layer.
In accordance with a further mode of the invention, the partial gas stream which flows through only the edge layer is guided along a filter distance through the edge layer. This filter distance at least corresponds to the layer thickness of the filter layer. This means that the partial gas stream which does not completely flow through the filter layer (bypass) is in contact with the filter material over at least the same distance of flow path. As has already been stated, the efficiency of the layers or subregions of the filter layer may differ, but by ensuring the filtering distance described herein it is ensured that at least a proportionate filter action is achieved for this exhaust gas which is only passed through the filter material in the edge layers. It is preferable for the filter distance to be lengthened by the factor by which the adjacent strata or layers differ in terms of their efficiency or another parameter. The filter distance can be effected by the targeted provision of pressure differences or forced flow profiles, for example by the specific configuration of microstructures in a flow channel which is delimited by a gas-permeable filter layer of this type.
In accordance with a concomitant mode of the invention, a quantitative determination of the respective partial gas streams is effected by the filter layer itself. In other words, this means that the configuration of the filter layer itself has measures responsible for dividing the overall gas stream into partial gas streams. These measures may be realized by different configurations of the parameters of the fiber layer, i.e. they may also be inherent. For example, the configuration of the filter layer with different flow resistances or porosities in the direction of the layer thickness constitutes one possible way of effecting a quantitative determination or division of this type.
The method described herein can be realized particularly successfully with one of the proposed fiber layers according to the invention and/or a proposed configuration of the particulate filter according to the invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims, noting that the features recited individually in the claims can be combined with one another in any technologically expedient way and represent further advantageous configurations of the invention.
Although the invention is illustrated and described herein as embodied in a method for removing particulates from exhaust gases, and a corresponding fiber layer, particulate filter, exhaust system and vehicle, it is nevertheless not intended to be limited to the details shown, since 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.
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 SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagrammatic, perspective view of a filter layer which is suitable for the method according to the invention;
FIG. 1A is an enlarged, perspective view of a portion IA of FIG. 1 ;
FIG. 2 is an enlarged, fragmentary view of a fiber layer according to the invention;
FIGS. 3 and 3A are views similar to FIGS. 1 and 1A , of a further configuration of the fiber layer according to the invention;
FIGS. 4A and 4B are respective fragmentary, longitudinal-sectional and cross-sectional views of a channel of an embodiment of the particulate filter, in which FIG. 4B is taken along a line IVB-IVB of FIG. 4A , in the direction of the arrows;
FIG. 5 is a perspective view of a vehicle having an exhaust system; and
FIG. 6 is a cross-sectional view of a structure of a particulate filter.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawings in detail and first, particularly, to FIGS. 1 and 1A thereof, there is seen a diagrammatic and perspective view of a filter layer 23 , which is usually provided in a predetermined layer length 29 and layer width 30 . The filter layer 23 , as well as a fiber layer 1 shown in FIG. 2 , is delimited by two surfaces 6 which ultimately define a layer thickness 5 of the filter layer 23 . The gas-permeable filter layer 23 has a plurality of subregions 10 , namely respective first, second and third subregions 10 . 1 , 10 . 2 and 10 . 3 , in the direction of this layer thickness 5 , which differ on the basis of parameters that describe the filter layer 23 . The parameters which are characteristic of the filter layer 23 include, for example, a porosity 7 or a fiber diameter 8 of fibers 4 , if the filter layer 23 is constructed as a fiber layer 1 .
As can be seen from FIG. 1A , a gas stream 22 which impinges on the filter layer 23 will partially penetrate into inner regions of the filter layer 23 . After the entire gas stream 22 has penetrated through the first subregion 10 . 1 , it reaches the second subregion 10 . 2 . This second subregion 10 . 2 , which is disposed in a central region, has a porosity and/or fiber diameter which is impenetrable to part of the gas stream 22 . Accordingly, a first partial gas stream 24 . 1 is deflected at a transition to the second subregion 10 . 2 and flows back through the first subregion 10 . 1 before leaving the filter layer 23 . However, a second partial gas stream 24 . 2 which, for example, has a higher flow velocity or a lower level of particulates, etc., penetrates through the second subregion 10 . 2 . Then, the second partial gas stream 24 . 2 passes into the adjacent third subregion 10 . 3 , flows through the latter and emerges again on the opposite surface 6 . Both the first partial gas stream 24 . 1 and the second partial gas stream 24 . 2 were in contact with at least the first subregion 10 . 1 of the filter layer 23 . However, whereas the first partial gas stream 24 . 1 only flowed through a subregion 10 . 1 , the second partial gas stream 24 . 2 passed through all of the subregions 10 . 1 , 10 . 2 , 10 . 3 . In this case, the quantitative determination of the partial gas streams 24 was effected by the filter layer 23 itself, since it presents different flow resistances in its subregions 10 , leading to such a division of the gas stream 22 .
FIG. 2 diagrammatically depicts a portion of a fiber layer 1 . Fibers 4 with a first fiber diameter 8 are provided in the vicinity of the surfaces 6 which delimit the fiber layer 1 . Fibers 4 are also provided in a central region but have a different fiber diameter 8 . The differently shaped fibers 4 are permanently technically joined to one another and form a random assembly, with a porosity 7 being realized at the same time. In addition to this fragmentary view of a fiber layer 1 , the left-hand and right-hand sides of the figure diagrammatically depict profiles of magnitudes of the parameters of the porosity 7 and fiber diameter 8 over the layer thickness 5 .
The left-hand side of FIG. 2 illustrates the profile of the porosity 7 . An extreme 9 where the porosity 7 is lowest is located in the central region, i.e. at a distance from the surfaces 6 . The profile of the porosity 7 is substantially symmetrical with respect to a middle stratum or layer of the fiber layer 1 and configured with continuous transitions.
Similarly, the right-hand side of FIG. 2 illustrates the profile of the fiber diameter 8 over the layer thickness 5 . Due to the fact that fibers 4 with a small fiber diameter 8 are provided in the central region and fibers 4 with a thicker fiber diameter 8 are provided in the edge layers, there is a sudden change in the fiber diameters 8 , as is illustrated on the right-hand side. An extreme 9 is once again formed in the central region.
FIG. 3 once again diagrammatically depicts a fiber layer 1 with a particularly pronounced detail. FIG. 3A shows the fiber layer 1 with a coating 31 on both surfaces of the fiber layer 1 . The coating may, of course, also extend into inner regions or even over all free surfaces of the fibers 4 . The fiber layer 1 is configured in this case as an ordered combination of fibers 4 , in which the fibers 4 are constructed with a fiber diameter 8 which varies over their fiber length 11 . For this purpose, the fibers 4 have a central portion 12 , in which the fiber diameter 8 reaches an extreme 9 , as can also be seen diagrammatically on the right-hand side from the illustrated profile. In the example shown therein, the fiber diameters 8 are selected to be different in the vicinity of each surface 6 , so that in this case the profile of the fiber diameters 8 is not symmetrical over the fiber length 11 or layer thickness 5 . The identical, ordered orientation or alignment of the fibers 4 once again causes the formation of edge layers 25 which provide a configuration of the fiber layer 1 with parameters which vary in the direction of the layer thickness 5 . With the configuration of the fibers 4 illustrated herein it is also possible to provide further fibers 4 (for example of a different material or with a constant fiber diameter) in a subregion of the fiber layer 1 , in which the further fibers are integrated in the fiber combination.
FIGS. 4A and 4B are diagrammatic illustrations, in the form of fragmentary sectional views, of the structure of a particulate filter 13 according to the invention, which is suitable for use in an exhaust system of a mobile internal combustion engine. The particulate filter 13 includes a fiber layer 1 with at least one parameter, selected from the group consisting of porosity and fiber diameter, which varies in the direction of a layer thickness 5 and at least one at least partially structured sheet 14 , which together form a plurality of channels 15 . In the embodiment illustrated, the sheet 14 has microstructures 17 . A channel 15 of this type is illustrated in detail in the form of a longitudinal section in FIG. 4A . FIG. 4B diagrammatically indicates a cross section through the channel 15 , which is taken along a cross-sectional plane indicated in FIG. 4A , in the direction of viewing.
The mode of action is explained in more detail below. A gas stream 22 carrying particulates 21 , in particular an exhaust gas stream, flows through the channel 15 , where it impinges on a microstructure 17 which projects into the channel 15 . The result of this is that the gas stream 22 is diverted toward the fiber layer 1 . The fiber layer 1 has edge layers 25 and a central layer in the interior. Whereas the entire gas stream 22 penetrates through the first edge layer 25 , a middle layer, due to its parameters (such as for example porosity and/or fiber diameter), forms a flow resistance to a partial gas stream 24 which is such that the partial gas stream does not penetrate through this layer. Rather, this deflected partial gas stream 24 flows along a filter distance 26 through the edge region 25 before ultimately emerging back into the channel 15 . Another part of the gas stream 22 penetrates through this middle layer and also the edge layer 25 which adjoins it and emerges again on the opposite surface. As the gas stream 22 flows through the fiber layer 1 , the entrained particulates 21 collect on the fibers 4 of the fiber layer 1 , so that ultimately the gas stream 22 is purified.
The microstructures 17 are provided for the purpose of flow diversion and/or for producing pressure differences in adjacent channels 15 . These microstructures 17 include projections which are worked into the material or structure of the sheet 14 . It is possible to use pure deformation steps, but it is also possible for microstructures 17 of this type to be produced by stamping or other cutting processes, in which case openings 32 are generally introduced into the sheet 14 . This also provides flow communication between adjacent channels 15 , so that the exhaust gas which is to be purified can be mixed again and again. The microstructures 17 , which are formed in this case as guiding surfaces, form a gap 18 together with the fiber layer 1 , which gap has a predetermined gap width 19 . The configuration of the microstructure 17 and the configuration of the fiber layer 1 , as well as the characteristics of the flow of the gas stream 22 , now effect quantitative division into various partial gas streams 24 .
FIG. 5 shows a diagrammatic and perspective view of a vehicle 20 including an internal combustion engine 3 with an associated exhaust system 2 . The exhaust gas which is generated in the internal combustion engine 3 flows through the exhaust system in a preferred direction of flow 33 and, after it has been purified, is released to the environment. The exhaust system 2 includes an exhaust pipe 28 in which a plurality of different exhaust-gas treatment devices are provided in series. In the present case, the exhaust gas flows through the following components in succession: oxidation catalytic converter 27 , particulate filter 13 and catalytic converter 27 . In principle, however, the particulate filter 13 can be integrated in any combination of known exhaust-gas treatment devices. Connecting an oxidation catalytic converter 27 and a particulate filter 13 in series as shown herein in particular allows continuous regeneration of the particulate filter in accordance with the “CRT” principle described in the introduction hereto.
FIG. 6 diagrammatically depicts an end view of a particulate filter 13 which includes a housing 34 and a honeycomb body 16 located therein. The honeycomb body 16 is formed with a plurality of stacks 35 of fiber layers 1 and sheets 14 which have been wound together. The alternately stacked fiber layers 1 and structured sheets 14 form channels 15 through which an exhaust gas can flow. Non-illustrated microstructures 17 , which cause the gas streams 22 to flow through the fiber layer 1 , are provided in the interior of the channels.
The invention described herein allows particularly efficient removal of particulates from exhaust gases of mobile internal combustion engines.
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A method for removing particulates from a gas stream includes providing a gas-permeable filter layer having subregions with a parameter of differing magnitudes in the direction of the layer thickness. This parameter relates at least to the porosity, the fiber diameter of fibers or the fiber type content of the filter layer. The gas stream is divided into partial gas streams which are each passed through different subregions of the filter layer. Fiber layers, particulate filters, exhaust systems and vehicles based on this method are also provided.
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BACKGROUND OF THE INVENTION
[0001] A bar is a place for drinking and it is also a place where drink and snack food can be obtained. In public spaces a bar is a counter at which drinks are mixed by a bartender and this is mainly in hotels, taverns and pubs. Public bars typically store a variety of liquors and other nonalcoholic drink ingredients, and are organized to facilitate the bartenders' efficiency.
[0002] It has been suggested that the method of serving from a counter was invented as a means of more quickly serving the sudden rush of customers caused by passenger trains arriving at the refreshment rooms at railway station while the trains changed locomotives.
[0003] In an effort to privately possess and enjoy some of the benefits of a public bar many private bars copy the model of public bars. Advantages enjoyed by copying a public bar model into a private bar include availability of a dedicated space for relaxation and entertainment where drinks and snack food can be obtained and consumed. It also includes a set of furniture for the storage and display of drinks and snack food. Other facilities such as TV, sound system and bar accessories to enhance the self-sufficiency status of a bar are also included.
[0004] However there are some disadvantages inherent in the transfer of a space exclusively designed for public use into private use.
[0005] For example, unsuitability of the counter where there is an absence of a bartender and the user embarks on self service. This disadvantage stems from the physical obstruction by the counter and this obstruction hinders the free flow in the space and therefore makes self service clumsy. Bar accessories are not organized by reason of proximity and comfort as these accessories are usually stored behind the counter. Self service will be relatively less comfortable in the circumstance because of retrieval and storage chore.
[0006] Large private bars are generally custom made to suit particular spaces and therefore usually less able to fit other spaces. This creates a problem of adaptability.
[0007] There is also a problem of flexibility to the size of the bar. These bars are usually fixed in the number parts making up the bar set. It is therefore difficult to either readily remove or add more parts to meet a demand that may arise. For example it is difficult to increase or reduce the capacity of the shelves to display more or less bottles and glasses.
[0008] These private bars are usually not able to be used in different ways other than to obtain and consume drink and snack food. This lack of versatility is disadvantageous especially where space comes at a premium as it will be more efficient to have a bar which has more than one use.
[0009] Another problem is that wide range of diverse object and features belonging to different fields of entertainment are not usually incorporated into a bar to provide options. Lack of diversity in leisure items available for enjoyment in a private bar may lead to infrequent use of the bar.
[0010] Private bars are not easily personalized as they do not provide for the display of personal things and where the bar is already personalized it becomes very difficult to easily change the object of personalization.
[0011] Large bars usually draw attention especially in terms of bar objects, component and functions. A more discreet bar may be appropriate where an attention generated by a large bar is unwanted.
OBJECTS OF THE INVENTION
[0012] It is the main object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar.
[0013] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar but can also be used as a set for the display of artworks.
[0014] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar, yet the number of the multipurpose units can be reduced or increased.
[0015] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar, yet is adaptable through flexible configuration of the bar set.
[0016] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar that has the capability to permit the display of TV, artwork and an aquarium from one single multipurpose unit
[0017] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar and has the capability to permit the ease of storage and retrieval of all accessories.
[0018] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar that has the capability to permit the use of multipurpose unit as a, music speaker.
[0019] It is another object of the present invention to provide a set of compact, multipurpose units that can be used in a private bar that has a discreet nature in terms of the concealed and concealable components, objects and functions.
BRIEF SUMMARY OF THE INVENTION
[0020] These, and other, objects are achieved by a multipurpose bar set that can be used in a private bar to provide relaxation and entertainment in homes, hotels, offices or the like. The bar set is a collection of independent multipurpose units that are also compact. The advantage is the enhancement in flexibility in layout and configurations to suit spaces. The fact that the multipurpose units in the bar set can be reduced or increased as desired further enhances its flexibility to suit space. It is easy to add or remove multipurpose units than to change the whole bar set, for instance the requirement for a new private bar because of the desire for more bottle and glass display space can be solved by addition of bar cabinet units to increase capacities for bottles and glass display. Conversely bar cabinet unit with shelves can be used as a standalone bar as it includes a refrigerator, music system, a speaker, shelves for storage and display, pull out panel, and a door panel that can be used to display an artwork. The bar set can therefore be used for small as well as for a large private bar.
[0021] The bar cabinet unit comes with the option to be used as a bar cabinet or an art platform while the TV cabinet unit comes with the option to be used as TV stand, three dimensional artwork platform or an aquarium stand. The automatic lift means helps the movable door panels of the bar cabinet and the art panel of the TV cabinet unit to be lifted in and out of view. The bar set is thus a convertible bar and has the capability to permit the change of use from bar to an art place.
[0022] The bar set includes a single source for listening to music and viewing TV, three dimensional artwork and an aquarium. This TV cabinet unit is a multipurpose unit that gives the power to choose among three diverse field of entertainment. It is also advantageous to watch the three items of entertainment from one source.
[0023] The bar cabinet unit and TV cabinet unit all come with the option to be used as music speakers. Music speaker casings are concealed in these units while speaker grill means exterior of the music speaker casing is mounted on the units' surface. The music speakers are located in the music speaker casing.
[0024] Bar table unit which replaces the bar counter includes the table surface built-in edible display for easy self service. The cover of the edible display container provides an unhindered use of the entire table surface when it is in place and a transparent cover keeps the edibles visible while the container is covered. Bar table unit also includes a compact pedestal on which all accessories are stored and displayed for ease of storing and retrieval and for smooth and easy self service. These accessories include remote controls, wine opener, serviette dispenser, edible plates and a trash bin. The trash bin covers the champagne bucket which in turn contains the ice bucket. Co-operation of the trash slot near the table top and the bin at the base of the table unit makes it easy to bin the trash from the table top. The bar table unit also functions as a display platform through the presence of top and base artifact display containers.
[0025] Proximity of all bar accessories and the central location of the display controls at the bar table unit makes it easier to coordinate and utilize all facilities and amenities.
[0026] Ability to display artifacts or ornaments in the display containers beneath the table top and on the table base enhances personalization of the bar set. This is an advantage as private bars are usually not designed to allow personalization. The art panels also offer additional opportunity for the personalization of the bar set.
[0027] The plurality of independent automatic lift means and the plurality of individual concealable display create choice and options. It also gives the power to selectively display and expose leisure items of the bar and this helps to influence the use of the bar set
[0028] A concealed music system also creates option to shut down all display and still have active use of space even when nothing is displayed. Plurality of concealable objects in the bar set and the independence in concealing these objects enhances the manipulation and discreetness of the bar set especially in terms of the integrated objects and functions.
[0029] The bar set can be used privately in public places such as hotels, offices, and the like.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0030] FIG. 1 is a front elevational view for a bar set with the doors closed in the bar cabinet units, bar table unit and TV cabinet unit;
[0031] FIG. 2 is a front elevational view thereof with the display doors of the cabinet units and bar table unit open. Service panel also pulled out;
[0032] FIG. 3 is an isometric view thereof with all the doors and drawers of the cabinet units open. Doors of the bar table unit open;
[0033] FIG. 4 is a left side elevational view for a bar cabinet unit;
[0034] FIG. 5 is a right side elevational view thereof;
[0035] FIG. 6 is a rear elevational view thereof;
[0036] FIG. 7 is an isometric view from one side thereof with the front panel, right side panel, drawers, shelves and back of shelves removed;
[0037] FIG. 8 is a sectional view from one side thereof;
[0038] FIG. 9 is a front elevational view for a bar set showing artworks mounted to the exterior side of the door panels;
[0039] FIG. 10 is a front elevational view for a bar cabinet unit with the doors of the bar cabinet unit closed;
[0040] FIG. 11 is a front elevational view thereof with the display door of bar cabinet unit open
[0041] FIG. 12 is a left side elevational view thereof;
[0042] FIG. 13 is a right side elevational view thereof;
[0043] FIG. 14 is a rear elevational view thereof;
[0044] FIG. 15 is an isometric view from one side thereof with the front panel and right side panel removed;
[0045] FIG. 16 is a sectional view from one side thereof;
[0046] FIG. 17 is a top plan view for a bar table unit with the edible container covered with its lid;
[0047] FIG. 18 is top plan view thereof with the edible container open;
[0048] FIG. 19 is an isometric view from one side thereof with the pedestal door open, edible container covered with its lid;
[0049] FIG. 20 is an isometric view from one side thereof with the pedestal door open, edible container open and trash bin removed;
[0050] FIG. 21 is a rear elevational view thereof; and
[0051] FIG. 22 is a right side elevational view thereof.
[0052] FIG. 23 is a front elevational view for a TV cabinet unit;
[0053] FIG. 24 is a rear elevational view thereof;
[0054] FIG. 25 is left side elevational view thereof;
[0055] FIG. 26 is a right side elevational view thereof;
[0056] FIG. 27 is an exploded isometric view from one side thereof.
[0057] FIG. 28 is an isometric view from one side thereof with the drawer open.
DETAILED DESCRIPTION OF THE INVENTION
[0058] Shown in FIG. 1-3 is a bar set 80 that includes chairs J surrounding a bar table unit 10 . The bar set further includes a bar cabinet unit 50 and there are two of these bar cabinet unit in the bar set 80 . The bar set also includes a bar cabinet unit 90 and this bar cabinet unit are also two in the bar set 80 . Also included in the bar set is a bar table unit 10 and a TV cabinet unit 130 . The bar set can be formed of various materials. However the preferred materials include materials such as acrylic stone, glass, wood, metal, fiberglass-type materials, other plastic-type materials and the like.
[0059] Chair J is known and will not be discussed further.
[0060] Shown in FIGS.1-9 is a bar cabinet unit 50 that includes a top 61 , a bottom 70 , a first side 56 , a second side 57 , a front 51 and a rear 63 .
[0061] The front 51 includes two doors 54 and 64 and door panel 64 is also used as a panel for the display of artwork as will be discussed later. There are two other covers to the front of the bar cabinet 51 and these covers are the speaker grill means K 1 and ventilation grill means L 1 . The doors and the grills provide access to various compartments inside the cabinet as will be discussed below. As shown in FIG. 6 and FIG. 7 side 56 and Side 57 include anchor openings 59 and 60 for accessing screw nail holes N 3 and N 4 . Side 57 includes another ventilation grill L 2 , and a pull out panel opening 66 as indicated in FIG. 3 and FIG. 5 . Pull out panel opening 66 is the opening for a pull out panel means 55 . Grill means and the pull out panel means are well known and will not be discussed here. Metal bars M 1 and M 2 ( FIG. 7 ) are attached on both side of the rear 63 and screw nail holes N 3 and N 4 are for connecting the two metal bars to a support. Screw nail holes N 1 and N 2 ( FIG. 6 and FIG. 7 ) are for securing the bar set to a horizontal support above the bar set. The horizontal support enables the bar set to be located anywhere in the space other than beside a vertical support such as wall support.
[0062] The bar cabinet unit 50 include an electric lift means. This means is located inside the electric lift housing X 1 in compartment C 7 ( FIG. 7 ) and the electric housing X 1 is mounted on support 72 . Door panel 64 is suspended with a rope R 1 from the lift means that moves the door panel in a linear vertical direction. H 1 and H 2 guide the door on its path. The partition 73 creates a channel that links the two air ventilation grills L 1 and L 2 .
[0063] As best shown in FIG. 1 , FIG. 2 and FIG. 8 the suspended door panel 64 covers the shelve compartments C 1 , C 2 and C 3 when it is lowered down but reveals the compartments when it is lifted up into the space above the shelves compartment. The door also functions as an art panel when a two dimensional artwork is mounted to the exterior surface of the movable door panel as shown in FIG. 9 . In this instance the bar cabinet 50 then functions as an art platform. Bar cabinet unit 50 comes with the option to be used for a bar cabinet or for an art platform
[0064] The compartments C 1 , C 2 and C 3 as shown in FIG. 2 , FIG. 3 and FIG. 8 are used to display bottles however they could also be used to display other items including glasses and edibles. Compartments C 1 , C 2 and C 3 are back lighted by electric light means and this means is mounted on 73 . Back lighting means is well known and will not be discussed here.
[0065] The speaker grill means K 1 covers the drawer D 1 of compartment C 4 as shown in FIG. 3 and the drawer D 1 is mounted on the cabinet by rollers in tracks to move into and out of the cabinet. This compartment C 4 contains the music speaker casing SK 1 which has speaker grill means K 1 as its exterior skin. The music speaker is located in the speaker casing SK 1 . This music speaker casing and the speaker grill means conceal the music speaker while sound from the music speaker passes through the speaker grill means. Music control panel is also located in compartment C 4 and is powered from the main power cord. The presence of two bar cabinet unit 50 enables the location of right and left of speaker separately in each of the bar cabinet unit in the bar set 80 .
[0066] As best shown in FIG. 3 , FIG. 7 and FIG. 8 the bar set includes a refrigeration means which is accessed through door 54 . This means is located in compartment C 5 and is powered from the main power cord. Ventilation means include grill means L 1 , L 2 and compartment C 6 . Refrigeration and ventilation means are well known and will not be discussed here.
[0067] Shown in FIGS. 1-3 and FIGS. 9-16 is a bar cabinet unit 90 that includes a top 97 , a bottom 101 , a first side 94 , a second side 95 , a front 91 and a rear 98 .
[0068] The front 91 includes two doors 102 and 93 as indicated in FIG.1 , FIG. 3 and FIG. 10 . The doors provide access to various compartments inside the cabinet as will be discussed below. Door 102 provides access to a display compartment and the door is also used as panel for the display of artwork as will be discussed later.
[0069] Side 94 has an anchor opening 106 while second side 95 also includes an anchor opening 108 as shown in FIG. 3 FIG. 12 , FIG. 13 and FIG. 15 . Anchor opening 106 and 108 are for accessing the screw nail holes N 7 and N 8 as indicated in FIG. 14 and FIG. 15 . Metal bars M 3 and M 4 ( FIG. 15 ) are attached on either side of the rear 98 and screw nail holes N 7 and N 8 are for connecting the two metal bars to a support. Screw nail holes N 5 and N 6 ( FIG. 14 and FIG. 15 ) are for securing the bar set to a horizontal support above the bar set. The horizontal support enables the bar set to be located anywhere in the space other than beside the vertical support such as wall support.
[0070] Bar cabinet unit 90 include an electric lift means. This means is located inside the electric lift housing X 2 in compartment J 5 while the electric lift housing X 2 is mounted on lift support 105 ( FIG. 15 and FIG. 16 ). The door panel 102 is suspended with a rope R 2 from the lift means that moves the panel door in a linear vertical direction. H 3 guides the door on its path.
[0071] As best shown in FIG. 1 , FIG. 3 and FIG. 16 the door 102 covers the glass display compartment J 1 when it is lowered down but reveals the compartments when it is lifted up into the space above the glass display compartment. The door also functions as an art panel when a two dimensional artwork is mounted to the exterior surface of the door panel as shown in FIG. 9 . In this instance the bar cabinet then functions as an art platform. Bar cabinet unit 90 comes with the option to be used for a bar cabinet or for an art platform.
[0072] As best shown in FIG. 3 and FIG. 15 compartment J 1 includes pairs of protruded hangers Y on which the glasses are displayed and this compartment is back lighted by electric light means. This electric light means is mounted on rear 98 . The electric lighting means is well known and will not be discussed here.
[0073] Compartment J 2 , J 3 and J 4 as best shown in FIG. 3 , FIG. 15 and FIG. 16 are used for glass storage and the three compartment are accessed through door 93 as indicated in FIG. 1 , FIG. 2 , FIG. 10 , FIG. 11 and FIG. 15
[0074] Shown in FIGS. 1-3 and FIGS. 17-22 is a bar table unit 10 that includes a table top 35 , a collection of artifact containers on a platform 11 , a cabinet 12 which functions as the table pedestal and a table base 45 .
[0075] As best shown in FIG. 17 , FIG. 18 , FIG. 19 , and FIG. 20 the table top comprises of a panel 35 and the container cover 4 which is the part cut out from the middle of panel 35 . Panel 35 and container cover 4 together form a continuous flat table surface and the container cover 4 can be moved manually with the handle 2 from a closed position best shown in FIG. 17 and FIG. 19 to a open position shown in FIG. 18 and FIG. 20 . Cover 4 provides access to container 6 . The preferred material for the table top is transparent material however the container cover 4 may also be of opaque nature to conceal the contents of the container 6 .
[0076] The bar cabinet 12 includes a first side 37 , a second side 38 , a front 39 and a rear 40 as shown in FIG. 1 , FIG. 19 , FIG. 20 FIG. 21 and FIG. 22
[0077] The front 39 includes two doors 25 and 26 best shown in FIG. 1 . The doors provide access to various compartments inside the cabinet as will be discussed below. The cabinet 12 has a container 6 ( FIG. 18 and FIG. 20 ) for the display of edibles at the apex of the cabinet. This edible container continues right to the outside of the bar table unit through the artifact container platform 11 and table top 35 as indicated in FIG. 18 and FIG. 20 .
[0078] As best shown in FIG. 19 and FIG. 20 the cabinet compartments are designed for storage and display of the bar accessories. Remote controls are stored and displayed in compartments E 1 and E 2 . Wine openers are stored and displayed in compartment E 3 and E 4 . The serviette dispenser is stored and displayed in compartment E 5 while the plates are stored and displayed in the same compartment E 5 . Compartment E 6 and E 7 holds the trash bin 21 . Ice bucket is kept inside a Champagne bucket and both are stored in compartment E 6 . The trash slot T at the rear 40 co-operates with a trash bin 21 through compartment E 7 .
[0079] The bar table unit as best shown in FIG. 19 and FIG. 20 also include a collection of artifact containers A 1 , A 2 , A 3 and A 4 . These artifact containers are seen through the transparent table top 35 and are held in place by a platform 11 . Also included in the bar table unit is the table base 45 with artifact containers A 5 and A 6
[0080] Shown in FIG. 1-3 and FIGS. 23-28 is a TV cabinet unit 130 that includes a top 131 , a bottom 133 , a first side 135 , a second side 137 , a front 140 , and a rear 142 .
[0081] The first side 135 has a speaker grill means K 2 and this speaker grill means is the outer skin of a speaker casing SK 3 as shown in FIG. 28 . The rear 142 includes a translucent panel P ( FIG. 24 and FIG. 27 ) which allows natural light to reach the aquarium when it is concealed in compartment O 3 . Front 140 also include a pull out drawer D 2 ( FIG. 28 ) that contains the music speaker casing SK 2 . Located in this compartment is a music control panel powered from the main power cord. As shown in FIG. 27 the top 131 is comprised of three covers F 1 , F 2 and F 3 through which compartments O 1 , O 2 and O 3 inside the cabinet unit are accessed. The music system means is well known and will not be discussed here.
[0082] The music system drawer D 2 shown in FIG. 28 is mounted on the cabinet by rollers in tracks to move into and out of the cabinet.
[0083] The TV cabinet unit includes three electric lift means. These means are located in compartments O 1 , O 2 and O 3 ( FIG. 27 ) and are powered from the main power cord. The electric lift means is well known and thus will not be discussed in detail.
[0084] TV, three dimensional artwork and aquarium which are mounted on the electric lift means are located in compartments O 1 , O 2 and O 3 respectively ( FIG. 27 ). Independence of the three electric lift means provides for the independent display of the TV, artwork and aquarium. This means enables three diverse field of entertainment to originate from the same source—the TV cabinet unit. Only one of the displayed objects can be viewed at a time. This independence also, allows the TV cabinet unit to also function variously as a TV stand, three dimensional artwork platform and an aquarium stand.
[0085] Art platforms of the duplicated bar cabinet 50 and bar cabinet 90 as well as the three dimensional art platform of TV cabinet unit 130 give rise to a plurality of art platforms. Plurality of art platforms in a bar set makes it suitable for the display and view of artwork.
[0086] It is understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangements of parts described and shown.
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A bar set includes a collection of independent multipurpose units that can be reduced or increased in number. The set is also capable of flexible configurations. Every multipurpose unit in the bar set can be converted into an art platform and the plurality of these art platforms provides options of use. The display of aquarium, artwork and TV originates from a TV cabinet unit and this unit is also used as a music speaker. The bar cabinet unit includes compartments for electric lift means, movable panel, display shelves, pull out panel, music speaker and a fridge. The table unit includes a built-in container for table surface display of edibles with a container cover that also functions as a table surface. This unit also includes compartments for the display of remote controls, wine openers, plates and serviette dispenser and compartments for the storage of trash bins, champagne bucket and ice bucket.
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FIELD OF THE INVENTION
[0001] The present invention relates to a disk drive having a solenoid with multiple coils. More particularly, the present invention relates to such a disk drive were the multi-coil solenoid actuates multiple functions.
BACKGROUND OF THE INVENTION
[0002] A disk drive for receiving a removable disk is known. Examples of a disk drive include a conventional 3.5 inch ‘floppy’ disk drive, a ZIP disk drive as developed and marketed by IOMEGA Corporation of Roy, Utah, and the like. Such a disk drive is typically coupled to a processor or the like, and facilitates an exchange of information between the processor and the disk. The disk and the disk drive may be magnetically or optically based, for example.
[0003] The aforementioned disk may be housed within a disk cartridge, and can rotate freely within the cartridge. The disk may be mounted on a coaxial hub or may define a coaxial aperture, and the hub or aperture of the disk is externally accessible by way of an access aperture defined in one of the planar panels of the cartridge. Typically, the disk drive includes a frame or chassis and a disk motor which is mounted thereto, wherein during operation of the drive, the motor engages the hub or aperture of the disk through the cartridge access aperture and applies a rotating force to the disk by way of such hub or aperture.
[0004] The disk may be inserted into, retained within, and ejected from the disk drive by way of any of a variety of mechanisms. In at least some arrangements, the ejection aspect of the mechanism includes a lever or the like, and is actuated by way of a plunger of a solenoid contacting and appropriately moving the lever or the like. Ejection of a disk or disk cartridge is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail.
[0005] As retained within the disk drive, the disk is brought into contact with one or more read/write heads for reading data from and/or writing data to the disk. The heads are moved relative to the disk by a head assembly which includes the heads. Typically, the head assembly moves the heads to a retracted position and locks the heads in such retracted position when the heads are not expected to be active. Accordingly, the non-active heads are protected from damage and the like. In at least some arrangements, and similarly, to release the locked heads, the head assembly includes a lever or the like that is actuated by way of a plunger of a solenoid contacting and appropriately moving the lever or the like. Releasing a locked head assembly is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail.
[0006] Also, prior to ejecting the disk, the head assembly typically retracts or moves the heads away from the disk to avoid damage to the heads and the disk during such ejection. In at least some arrangements, the retraction aspect of the head assembly is embodied as a lever or the like, and is actuated by way of a plunger of a solenoid contacting and appropriately moving the lever or the like. Retraction of a head assembly is generally known or should be apparent to the relevant public and therefore need not be discussed herein in any detail. Typically, the retraction lever or the like of the head assembly and the head release lever or the like of the head assembly are separate (although they could be one and the same), ejection occurs by moving the lever a relatively large distance, and head lock/release occurs by moving the lever a relatively small distance.
[0007] Typically, the solenoid and plunger that actuates the ejection lever or the like is also the solenoid and plunger that actuates the retraction lever and head release lever, and such solenoid and plunger actuates ejection after actuating head lock/release. Actuating head lock/release may be accomplished with a relatively short stroke of the plunger by the solenoid, and actuating ejection may be accomplished with a relatively long stroke of the plunger by the solenoid. A solenoid and a disk drive having such a solenoid is set forth in more detail in U.S. Pat. No. 5,650,891, hereby incorporated by reference in its entirety.
[0008] Preferably, a disk drive mounted to a computer by way of a host port of the computer is powered through the host port and therefore does not require an external power supply. However, a solenoid such as the retraction/ejection/head release solenoid discussed above typically requires a relatively high operating current that is either a strain on the host port of a computer or that is not available from the host port of a computer.
[0009] Preferably, the solenoid as mounted to the disk drive is relatively short in height so that the overall disk drive can have a relatively small height (i.e., in a direction generally normal to the general planar extent of the disk drive). However, a solenoid such as the retraction/ejection/head release solenoid discussed above typically is relatively tall in height in order to generate the kind of magnetic flux necessary to actuate the plunger, especially for a relatively long plunger stroke.
[0010] Accordingly, a need exists for a disk drive having a solenoid with relatively low operating current and a relatively low height.
SUMMARY OF THE INVENTION
[0011] The present invention satisfies the aforementioned need by providing a storage drive for receiving thereinto, retaining, and ejecting therefrom a removable storage media cartridge having storage media. The storage drive has an actuator including a carriage assembly with a head mounted thereto. The actuator moves the head as mounted to the carriage assembly with respect to the storage media of the retained media cartridge. The storage drive also has a head locking lever for locking the carriage assembly in a retracted position and unlocking same, and a multi-coil solenoid for actuating the head locking lever.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing summary as well as the following detailed description of the present invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. As should be understood, however, the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0013] [0013]FIG. 1 is a perspective view of a typical data storage device, or disk drive;
[0014] [0014]FIG. 2 is a perspective view of a disk cartridge for use with the disk drive of FIG. 1;
[0015] [0015]FIG. 3 is a bottom view of the disk cartridge of FIG. 2;
[0016] [0016]FIG. 4 is a top view of the data storage device of FIG. 3 with a top cover of the device housing removed;
[0017] FIGS. 5 - 7 are top views of the data storage device of FIG. 4 illustrating the insertion of a disk cartridge into the device;
[0018] [0018]FIG. 8 illustrates further details of a portion of the data storage device of FIG. 3;
[0019] FIGS. 9 - 12 illustrate further details of the operation of a first movable member and a second movable member in accordance with the present invention;
[0020] [0020]FIG. 13 is a perspective view of a portion of the data storage device of FIGS. 1 - 12 , and in particular shows the single-coil solenoid thereof;
[0021] [0021]FIG. 14 is a top plan view of the single-coil solenoid of FIG. 13;
[0022] [0022]FIG. 15 is a schematic top plan view of the single-coil solenoid of FIG. 13;
[0023] [0023]FIG. 16 is a perspective view of a portion of a data storage device such as that of FIGS. 1 - 12 , and in particular shows a multi-coil solenoid thereof in accordance with one embodiment of the present invention;
[0024] [0024]FIG. 17 is a perspective view of the multi-coil solenoid of FIG. 16; and
[0025] [0025]FIG. 18 is a schematic top plan view of the multi-coil solenoid of FIG. 16.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] Certain terminology may be used in the following description for convenience only and is not considered to be limiting. For example, the words “left”, “right”, “upper”, and “lower” designate directions in the drawings to which 20 reference is made. Likewise, the words“inwardly” and“outwardly” are directions toward and away from, respectively, the geometric center of the referenced object. The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
[0027] Referring now to FIG. 1, there is shown a typical disk drive 40 . As was discussed above, the disk drive 40 is for receiving a removable disk (not shown) such as a conventional 3.5 inch ‘floppy’ disk or a“ZIP” disk as developed and marketed by IOMEGA Corporation of Roy, Utah, and the like. As seen, the disk drive 40 comprises an outer housing 42 having top and bottom covers 44 , 46 and a front panel 48 . A disk cartridge 10 (FIGS. 2 and 3) can be inserted into the disk drive 40 through a horizontal opening 51 in the front panel 48 of the disk drive 40 . An eject button is also provided on the front panel for automatically ejecting a retained disk cartridge from the disk drive 40 . The disk drive 40 shown in FIG. 1 is a stand-alone unit, although the disk drive 40 of the present invention as disclosed below is particularly suited as an internal disk drive of a computer (not shown).
[0028] [0028]FIGS. 2 and 3 show an exemplary disk cartridge 10 adapted for use in the disk drive 40 of FIG. 1. As shown, the disk cartridge 10 comprises an outer casing 12 having upper and lower shells 22 , 24 that mate to form the casing. A disk-shaped recording medium (not shown) is affixed to a hub 16 that is rotatably mounted in the casing 12 . An opening 21 on the bottom shell 24 of the casing 12 provides access to the disk hub 16 . A head access opening 30 in the front peripheral edge 20 of the disk cartridge 10 provides access to the recording surfaces of the disk (not shown) by the recording heads of the disk drive. A shutter 18 (not shown in FIG. 2) is provided on the front peripheral edge 20 of the disk cartridge 10 to cover the head access opening 30 when the cartridge is not in use. When the cartridge is inserted into the disk drive, the shutter 18 moves to the side exposing the head access opening 30 and thereby providing the heads of the drive with access to the recording surface of the disk (not shown). In the present embodiment, the casing houses a flexible or floppy magnetic disk, however, in other embodiments, the disk may comprise a rigid magnetic disk, a magneto-optical disk or an optical storage medium.
[0029] The opposite front corners of the disk cartridge 10 have a non-square shape defined by angled surfaces 20 c , 20 d that angle away from the front peripheral edge 20 of the cartridge at a predetermined angle. Additionally, a pair of projections 20 a , 20 b are formed on the front peripheral edge 20 of the cartridge. Each projection 20 a , 20 b is formed adjacent a respective one of the angled surfaces 20 c , 20 d at the point where the respective surface 20 c , 20 d begins to angle away from the plane of the front peripheral edge 20 of the cartridge 10 .
[0030] [0030]FIG. 4 is a top view of the disk drive 40 of FIG. 1 with the top cover 44 removed. The disk drive 40 comprises an internal platform 50 that slides along opposing side rails 52 , 54 between a forward position (FIG. 4) and a rearward position (FIG. 7). A pair of springs 56 , 58 bias the platform 50 toward its forward position.
[0031] An actuator 60 , which in the preferred embodiment comprises a linear actuator, is mounted to the rear of the platform 50 . The linear actuator 60 comprises a carriage assembly 62 having two lightweight flexible arms 64 , 66 . The recording heads 18 , 19 of the disk drive are mounted at the ends of the respective arms 64 , 66 . A coil 68 , which is part of a voice coil motor, is mounted at the opposite end of the carriage 62 . The coil 68 interacts with magnets (not shown) to move the carriage linearly so that the heads 18 and 19 can move radially over respective recording surfaces of a disk cartridge inserted into the disk drive.
[0032] A raised wall 53 is formed on the platform. The raised wall 53 extends across the width of the platform 50 , perpendicularly to the direction of motion of the carriage 62 . The raised wall 53 defines an eject member that engages the front peripheral edge 20 of the disk cartridge 10 upon insertion of the disk cartridge into the disk drive. The opposite side edges 55 a , 55 b of the eject member 53 are angled in the same manner as the opposite front corners 20 c , 20 d of the disk cartridge 10 . Thus, the shape of the eject member 53 mirrors the contour of the forward end face of the cartridge. As further shown, the front surface 57 of the eject member 53 has a pair of projections 53 a , 53 b positioned near the angled surfaces 55 a , 55 b.
[0033] The disk drive 40 further comprises a spindle motor 82 capable of rotating the recording medium of a disk cartridge at a predetermined operating speed. In the present embodiment, the spindle motor 82 is coupled to the platform 50 . When a disk cartridge is inserted into the disk drive, the hub 16 of the disk cartridge engages the spindle motor 82 of the disk drive 40 when the platform reaches its rearward position.
[0034] As embodied in the disk drive 40 illustrated herein, the disk drive 40 comprises a first movable member movably mounted in the disk drive for performing a respective function. In the embodiment described herein, the first movable member comprises an eject latch lever 70 movably mounted within the disk drive 40 . As described hereinafter, the eject latch lever 70 functions to releasably latch the platform 50 in its rearward position. In the present embodiment, the eject latch lever 70 is pivotally mounted on the platform 50 about a rotation shaft 70 b . A first spring (not shown) is coupled to the eject latch lever 70 (i.e., first movable member) at the rotation shaft 70 b in order to bias the lever 70 in a first direction (e.g., the X+direction). The eject latch lever 70 has a cutout 70 a adapted to releasably engage a latch projection 78 as the platform 50 moves backward into its rearward position. The biasing force of the first spring 90 urges the eject latch lever 70 into this latched position. In one embodiment, the latch projection 78 is formed as part of the top cover 44 (not shown) of the disk drive 40 .
[0035] The disk drive 40 also comprises a second movable member movably mounted within the disk drive 40 . In the embodiment described herein, the second movable member comprises a head locking lever 72 that is pivotally mounted on the platform 50 about a rotation shaft 72 b . As described hereinafter, the head locking lever 72 functions to lock and unlock the carriage 62 of the linear actuator 60 . A second spring (not shown) is coupled to the head locking lever 72 (i.e., second movable member) at its rotation shaft 72 b to bias the head locking lever 72 in the same direction as the eject latch lever 70 (i.e., the X+direction). An end 72 a of the head locking lever, which extends at a right angle to the main shaft of the lever 72 , is adapted to releasably engage an end 62 a of the actuator carriage 62 when the carriage 62 is in a fully retracted position, thereby locking the carriage in place and preventing inadvertent movement of the recording heads 18 , 19 .
[0036] A single electro-mechanical device comprising a solenoid 74 is mounted on the platform 50 and has a plunger 76 . When the solenoid 74 is energized by an electrical current, the plunger 76 moves in the X−direction from a normally extended position toward a retracted position. As the plunger 76 of the solenoid 74 moves toward its retracted position, an enlarged operating end 76 a of the plunger 76 engages the first and second movable members (e.g., eject latch and head locking levers 70 , 72 ) in order to pull the members in the X−direction against the respective biasing forces of the first and second springs 90 , 92 .
[0037] FIGS. 5 - 7 illustrate the insertion of a disk cartridge 10 into the disk drive 40 . For purposes of illustration only, some components of the disk drive 40 are not shown. Referring to FIG. 5, a disk cartridge 10 is inserted into the disk drive 40 through the opening 51 in the front panel 48 of the disk drive 40 . Initially, the platform 50 is in its forward position, as shown. As the disk cartridge 10 is pushed farther into the disk drive 40 , the pair of projections 20 a , 20 b on the forward end 20 of the cartridge 10 engage the corresponding pair of projections 53 a , 53 b on the front surface of the eject member 53 of the platform 50 . Thereafter, the disk cartridge 10 and platform 50 , including the eject member 53 , move together rearwardly against the biasing force of the springs 56 , 58 (FIG. 4).
[0038] The platform 50 rides in slots (not shown) along the opposing side rails 52 , 54 . The slots (not shown) in the opposing side rails 52 , 54 are contoured such that, as the platform 50 and disk cartridge 10 move rearwardly, the elevation of the platform 50 changes. Specifically, the platform 50 rises in order to bring the spindle motor 82 of the disk drive 40 into engagement with the hub 16 of the disk cartridge 10 . Engagement of the hub 16 and spindle motor 82 is completed when the platform 50 reaches its final rearward position (FIG. 7).
[0039] Referring to FIG. 6, as the platform 50 approaches its rearward position, the portion of the eject latch lever 70 just rearward of the cutout 70 a contacts an angled surface 78 a of the latch projection 78 . As the disk cartridge 10 pushes the platform 50 farther to the rear of the disk drive, the eject latch lever 70 rides along the angled surface 78 a pushing the eject latch lever 70 to the side (i.e., X−direction) against its normal spring bias. As shown in FIG. 7, when the platform reaches its full rearward position, the eject latch lever 70 springs back in the X+direction such that the cutout 70 a engages the latch projection 78 . This latches the platform 50 , and hence the eject member 53 , in its rearward position and maintains the disk cartridge 10 in the disk drive 40 . In this manner, the eject latch lever is said to be self-latching.
[0040] The eject member 53 may alternately be formed separately from the platform 50 and the platform 50 may be stationary. In such case, the eject member 53 alone will move from the forward position to the rearward position, and the eject latch lever 70 will be adapted to latch the eject member 53 in its rearward position. Also alternately, the platform 50 may be omitted.
[0041] [0041]FIG. 8 is a rear end view of the disk drive 40 illustrating the latched position of the eject lever 70 . As shown, the eject lever 70 has an elongate, downwardly extending projection 80 that extends downwardly from the lever 70 toward a circuit board 86 mounted on the bottom cover 46 of the disk drive housing. A switch 84 having a plunger 82 is mounted on the circuit board 86 . When the platform 50 reaches the rearward position and the cutout 70 a engages the latch projection 78 , the projection 80 extending from the eject lever 70 moves against the plunger 82 thereby activating the switch 84 . A controller (not shown) in the disk drive can sense the activation of the switch 84 and be alerted that the platform 50 has moved into the latched, rearward position. The controller can then initiate rotation of the spindle motor and can signal the solenoid 74 to move the head locking lever 72 and release the linear actuator.
[0042] Referring now to FIGS. 9 - 12 , the structure and operation of the solenoid 74 and the first and second movable members (i.e., levers 70 , 72 ) is described in greater detail. The single solenoid 74 is adapted to move the first and second members independently in order to selectively perform their respective functions. In particular, the solenoid is adapted to move the eject latch lever 70 (i.e., first member) and head locking lever 72 (i.e., second member) in order to selectively unlatch the platform 50 and/or unlock the carriage of the head actuator 53 . It is understood that the eject latch and head locking levers 70 , 72 shown represent merely one implementation. Alternately, the first and second movable members may comprise other movable components adapted to perform other disk drive functions. The following discussion of the operation of the eject latch and head locking levers 70 , 72 is intended merely to illustrate one exemplary implementation.
[0043] Each of the movable members (i.e., eject latch and head locking levers 70 , 72 ) has a small projection 70 c , 72 c positioned in the path of movement of the enlarged end 76 a of the solenoid shaft 76 . As the plunger 76 of the solenoid moves in the X−direction from its normally extended position (FIG. 9) to its fully retracted position (FIG. 11), the enlarged end 76 a of the plunger 76 engages with the respective projections 70 c , 72 c on the levers 70 , 72 , moving the levers 70 , 72 against the respective biasing forces of the first and second springs 90 , 92 .
[0044] As best shown in FIGS. 9 and 12, the respective projections 70 c , 72 c are positioned relative to the enlarged end 76 a of the plunger 76 such that the end 76 a of the plunger will contact the projection 72 c on the head locking lever 72 (i.e., first movable member) first and will move the head locking lever 72 a predetermined distance to an intermediate position (FIG. 10) of the plunger 76 before engaging the projection 70 c on the eject lever 70 . As such, the head locking lever 72 can be moved independently of the eject lever 70 .
[0045] The biasing force of the first spring 90 is greater than the biasing force of the second spring 92 . As such, the solenoid 74 can be energized with an electrical signal having a first current that is sufficient to move the plunger 76 of the solenoid 74 against the biasing force of the second spring 92 but is insufficient to move the plunger 76 against the biasing force of the first spring 92 . As shown in FIG. 10, when it is desired to unlock the carriage 62 of the head actuator 60 , an electrical signal having this first current can be applied to the solenoid 74 causing the plunger 76 of the solenoid 74 to move in the X−direction pulling the head locking lever 72 out of engagement with the end 62 a of the actuator carriage 62 . However, because the first current is insufficient to overcome the biasing force of the first spring 90 , the plunger 76 will stop moving when the enlarged end 76 a of the plunger 76 reaches its intermediate position and contacts the projection 70 c on the eject latch lever 70 . Thus, in this case, the head locking lever 72 moves to a disengaged position, while the eject lever 70 remains in its latched position. Once the actuator carriage 62 has moved forward and begun its normal operation, the first current can be removed from the solenoid 74 allowing the plunger 76 of the solenoid 74 to move back to its extended position (FIG. 9). At the same time, the second spring 92 will urge the head locking lever 72 back to the position shown in FIG. 9.
[0046] Like the eject latch lever 70 , the head locking lever 72 is self-latching or self-engaging. That is, when the head locking lever 72 is in the position shown in FIG. 9 and the rear end 62 a of the carriage 62 moves back toward the rear of the disk drive, the rear end 62 a contacts an inclined surface 72 d at the end 72 a of the lever 72 . As the carriage 62 moves farther to the rear, the end 62 a of the carriage will ride along the inclined surface 72 d of the head locking lever 72 causing the head locking lever 72 to move to the side against the bias of spring 92 . Once the carriage 62 reaches its full rearward position, the head locking lever 72 will spring back to its engaged position, and the carriage 62 will once again be locked in place, as illustrated in FIG. 9. More specifically, as shown in FIG. 9, the end 72 a of the head locking lever 72 locks the carriage 62 in place (i.e., engages the carriage 62 ) by blocking the rear end surface 62 b of the carriage 62 . It is desirable to lock the carriage in place whenever the disk drive 40 is not in use, or a disk cartridge has been removed from the disk drive 40 .
[0047] Referring now to FIG. 11, when it is desired to eject a disk cartridge from the disk drive, the eject button 52 on the front panel 48 of the disk drive 40 is pushed. A processor (not shown) in the disk drive detects the activation of the eject button and applies an electrical signal to the solenoid 74 having a second, stronger current than the first current that is sufficient to overcome the combined biasing force of both the springs 90 , 92 . In this case, the plunger 76 of the solenoid 74 moves from its extended position to its fully retracted position. As the plunger 76 moves to its fully retracted position, the enlarged operating end 76 a of the plunger engages the projections 70 c , 72 c on both levers 70 , 72 pulling both levers in the X−direction. This causes the cutout 70 a on the eject latch lever 70 to disengage from the latch projection 78 , thereby releasing the platform 50 (i.e., eject member 53 ). Once released, the platform 50 moves back to its forward position under the force of springs 56 , 58 . As the platform 50 moves back to the forward position, the disk cartridge is backed out of the opening 51 and can then be removed by a user. Immediately after unlatching the platform 50 , the second current is removed from the solenoid 74 so that the eject latch lever 70 and head locking lever 72 spring back to the positions shown in FIG. 5.
[0048] The magnitudes of the first and second currents required to overcome the biasing forces of the first and second springs are highly dependent on the characteristics of the particular solenoid employed. Significantly, though, the maximum current required by the solenoid 74 of the typical disk drive 40 is believed to be relatively high as compared to the maximum current available to the disk drive 10 from a host port of a typical computer. Thus, the disk drive 40 in an internal configuration (not shown) may require an external power supply.
[0049] Additionally, the solenoid 74 as mounted to the disk drive is relatively tall in height so that the overall disk drive 40 is relatively tall (i.e., in a direction generally normal to the general planar extent of the disk drive). Thus, the disk drive 40 in an internal configuration (not shown) may require excessive height space within a typical computer housing.
[0050] Referring now to FIGS. 13 - 15 , the solenoid 74 of the disk drive 40 of FIGS. 1 - 12 is shown in more detail. In particular, and as seen, the solenoid 74 is an open frame single-coil solenoid and has the aforementioned single coil E 1 wrapped on a bobbin E 2 , where the bobbin E 2 with coil E 1 is mounted to a frame E 3 . Such frame E 3 includes a generally U-shaped first piece E 4 having a rear portion E 5 and side portions E 6 , and a second piece E 7 comprising a front portion. As may be appreciated, the distal ends of the side portions E 6 are coupled to the ends of the second piece E 7 such that the frame E 3 is generally rectangular. As may also be appreciated, the bobbin E 2 with coil E 1 is mounted to the frame E 3 such that the axis of the coil E 1 is generally interposed between and extends generally parallel with the side portions E 6 of the first piece E 4 of the frame E 3 .
[0051] In operation, the coil E 1 is energized to develop a flux path E 8 that extends down the axis of the coil E 1 toward the second piece E 7 of the frame E 3 , then through the second piece E 7 toward each end thereof, then up each side portion E 6 toward the rear portion E 5 , then through the rear portion E 5 from each side portion E 6 and toward the central area of such rear portion E 5 , and then back down the axis of the coil E 1 . With such flux path E 8 , then, a plunger E 9 mounted to the second piece E 7 of the frame is drawn up the axis of the coil El and within the coil E 1 , bobbin E 2 , and frame E 3 . Note that such flux path E 8 includes a split where the flux diverges in the second piece E 7 .
[0052] In one embodiment of the present invention, to reduce the maximum current required by the solenoid of the typical disk drive 40 , and/or to reduce the height of the solenoid of the typical disk drive 40 , the single-coil solenoid 74 of FIGS. 1 - 15 is replaced by a multi-coil solenoid 74 m , as in FIGS. 16 - 18 . In particular, and as seen, the multi-coil solenoid 74 m has a pair of coils E 10 , E 11 wrapped on respective bobbins E 12 , E 13 , where each bobbin E 12 , E 13 with respective coils E 10 , E 11 is mounted to a frame E 14 in a side-by-side manner.
[0053] Here, the frame E 14 includes a front plate E 15 and a back plate E 16 , but does not include any side portions as with the solenoid 74 of FIGS. 1 - 1 5 . As may be appreciated, the front plate E 15 and the back plate E 16 do not physically contact one another. As may also be appreciated, the bobbins E 12 , E 13 with coils E 10 , E 11 are mounted to the frame E 14 such that the axes of the coils E 10 , E 11 are generally parallel to one another and are generally normal to the planar extents of each of the front plate E 15 and the back plate E 16 .
[0054] In operation, the coils E 10 , E 11 are energized to develop a flux path E 17 that extends down the axis of the coil E 10 toward the front plate E 15 , across the front plate E 15 toward the axis of the coil E 11 , up the axis of the coil E 11 toward the back plate E 16 , across the back plate E 16 toward the axis of the coil E 10 , and then back down the axis of the coil E 10 . With such flux path E 17 , then, a plunger E 18 mounted to the front plate E 15 of the frame E 14 is drawn up the axis of the coil E 10 and within the coil E 10 and bobbin E 12 . Note that such flux path E 17 is a single loop and therefore includes no split such as in the case of the flux path E 8 of the solenoid 74 of FIGS. 1 - 15 .
[0055] Note that in operating the coils E 10 , E 11 , actuation of the head lock lever 72 only and not the eject lever 70 may be achieved by applying a relatively lesser current to both coils E 10 , E 11 , and actuation of both the head lock lever 72 and the eject lever 70 may be achieved by applying a relatively greater current to both coils E 10 , E 11 . Alternatively, actuation of the head lock lever 72 only and not the eject lever 70 may be achieved by applying a current to one of the coils E 10 , E 11 , and actuation of both the head lock lever 72 and the eject lever 70 may be achieved by applying a current to both coils E 10 , E 11 . The amounts of current applied vary based on the particulars of the solenoid 74 m , and at any rate in any particular situation are known or should be apparent to the relevant public and therefore need not be described herein in any detail.
[0056] Importantly, to produce the same effect on the respective plungers E 9 , E 18 , the multiple coils E 10 , E 11 of the solenoid 74 m of the present invention as shown in FIGS. 16 - 18 operate at a maximum current that is significantly less than the maximum current of the single coil E 1 of the solenoid 74 of FIGS. 1 - 15 . That is, the multiple coils E 10 , E 11 and the overall design of the solenoid 74 m of the present invention as shown in FIGS. 16 - 18 are more efficient than the single coil E 1 of the solenoid 74 of FIGS. 1 - 15 . In fact, it has been shown empirically that the maximum current employed by the multiple coils E 10 , E 11 of the solenoid 74 m of the present invention as shown in FIGS. 16 - 18 is about one-third that of the maximum current employed by the single coil E 1 of the solenoid 74 of FIGS. 1 - 1 5 . Accordingly, a disk drive 40 having the solenoid 74 m of the present invention is more amenable to being supplied with power solely through the host port of a typical computer, and is less susceptible to the need for an external power source.
[0057] Also importantly, the solenoid 74 m of the present invention having the multiple coils E 10 , E 11 can be constructed to have a smaller height (i.e., in a direction generally normal to the general planar extent of the disk drive 40 ) as compared to the solenoid 74 having the single coil E 1 , and/or can be constructed to require less current as compared to the solenoid 74 . In particular, the coils E 10 , E 11 may have less windings than the coil E 1 , in which case the coils E 10 , E 11 are shorter, may have more windings than the coil E 1 , in which case the coils E 10 , E 11 use less current, or a combination thereof. Thus, a disk drive 40 having the solenoid 74 m of the present invention may be constructed to have a smaller height as compared with a disk drive 40 having the solenoid 74 , and/or may be constructed to use less current.
[0058] In the foregoing description, it can be seen that the present invention comprises a new and useful solenoid 74 m and disk drive 40 having such solenoid 74 m , where the solenoid 74 m has a relatively low operating current and a relatively low height. It should be appreciated that changes could be made to the embodiments described above without departing from the inventive concepts thereof. It should be understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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A storage drive receives thereinto, retains, and ejects therefrom a removable storage media cartridge having storage media. The storage drive has an actuator including a carriage assembly with a head mounted thereto. The actuator moves the head as mounted to the carriage assembly with respect to the storage media of the retained media cartridge. The storage drive also has a head locking lever for locking the carriage assembly in a retracted position and unlocking same, and a multi-coil solenoid for actuating the head locking lever.
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This application is a continuation division of application Ser. No. 08/576,974, filed Dec. 22, 1995, now abandoned.
Pseudomonas aeruginosa is recognized as a leading cause of life-threatening infection among compromised patient populations in hospitals. Cancer patients, and patients with burn wounds, cystic fibrosis, acute leukemia, organ transplants, and intravenous-drug addiction are particularly susceptible to acquiring a serious P. aeruginosa infection. The most serious infections include pneumonia, septicemia, malignant-external otitis, and meningitis. The mortality rate for such infections can exceed 50%, and is usually the highest for any bacterial pathogen (Cryz, S. J., Jr. In Pseudomnonas aeruginosa as an Opporunistic Pathogoen , Mario Campa etal., Eds. Plenum Press, New York, 1993, pp. 383-395. All documents cited herein infra and supra are hereby incorporated by reference thereto).
Therapy for the management of severe P. aeruginosa infections has been a problem for many years due to the debilitated condition of the patient and the high frequency of multiple antibiotic resistance of clinical isolates of this bacteria. Immunotherapy has been explored as an alternative. In this area, attention has focused on the virulence factors of P. aeruginosa . As with other bacterial pathogens, virulence of P. aeruginosa is multifactorial and is the product of many interacting factors involving both the bacterium and the human host.
P. aeruginosa is an opportunistic pathogen, therefore, a key component of this bacterium's pathogenicity is the ability of the microorganisms to adhere to epithelial cells of mucosal surfaces (E. H. Blackey, 1981 , J. Infect. Dis . 143: 325-345). The somatic pili of P. aeruginosa , protein filaments clustered around the flagellum and extending from the cell surface, have been implicated in adherence to host tissue (Ramphal et al., 1984 , Infect. Immun . 44: 38-40; Woods et al., 1980 , Infect. Immun . 29: 1146-1151). Pili are composed of monomeric subunits, pilin, which have a molecular weight of 15-18000 daltons (Frost and Paranchych, 1977 , J. Bacteriol . 131: 259-269; Sastry et al. ,1983 , FEBS Lett 151: 253-256; Sastry et al. ,1985 , J. Bacteriol . 164:571-577) and are arranged in a helical fashion within the pilus fiber (Watts et al. ,1983 , Biochemistry 22: 3640-3646). The pilins of P. aeruginosa are similar in structure and function to those produced by many Gram-negative bacteria such as species of the genera Dichelobacter(Elleman, T. C. 1988 Microbiol. Rev . 52:233-247), Eikenella (Rao and Progulske-Fox, 1993 J. Gen. Microbiol . 139: 651-660), Kingella (Weir and Marrs, 1992 , Infect. Immun . 60: 3437-3441), Moraxella (Marrs et al. 1985 , J. Bacteriol . 163: 132-139), Neisseria (Meyer et al., 1984 , Proc. Natl. Acad. Sci. USA 81: 6110-6114), and Vibrio (Faast etal., 1989, Gene 85: 227-231).
In P. aeruginosa , pilin is encoded by a single chromosomal copy (Pasloske et al., 1985 , FEBS Lett . 183: 408-412; Sastry et al., 1985 , J. Bacteriol . 164: 571-577), the pilA gene. The nucleotide sequence of several P. aeruginosa pilA genes is known and comparisons of deduced pilin primary structure and flanking DNA sequence have shown characteristic variation which allows differentiation of P. aeruginosa pilins into at least two groups, group I (such as pili strain 1244) and group II pilins (PA 103, T2A, PAO, PAK pilins) (Castric and Deal, 1994 , Infect. Immun . 62: 371-376). This pilus grouping is further supported by nucleotide sequence homology of the regions flanking the pilA gene. A surprising feature of this work was the discovery that group I pilin determinants were relatively common (58/95 and include different strains of different immunotypes as determined by polyclonal antibody reaction) among clinical isolates. These results indicate that group I pili represent a major clinical serogroup from which potential components of an anti-pilus vaccine with broad specificity may be obtained.
The use of P. aeruginosa pili as a vaccine presents many advantages. Unlike previous lipopolysaccharide-based Pseudomonas vaccines, pili produce minimal side effects and are well known to be immunogenic in humans, possibly due to antigen organization (Bachman, et al., 1993 , Science 262: 1448-1451) brought about by subunit arrangement in the fiber. Much is known of the biochemistry and molecular biology of the pili and the technology is available for the identification and characterization of pilus epitopes. Pili can be prepared easily in homogeneous form and methods described in this application allow large scale production of pili which are compatible with modern forms of vaccine delivery such as microencapsulation. The P. aeruginosa pili can be engineered to act as “carriers” for other protein epitopes, thereby conferring the advantages of pili to other antigens; DNA sequences coding for known protein epitopes (outer membrane proteins for example) could be used to replace known surface pilin epitopes by PCR methodologies. The advantages of peptide technology can be applied to pilus vaccines. Cocktails of peptide epitopes can be constructed to deal with antigenic variation seen in serotype populations.
SUMMARY OF THE INVENTION
The present invention relates to a pilus-based vaccine and is based on recent work showing that pili from group I strains of P. aeruginosa , a clinically common group, are glycosylated and that pili glycosylation may be involved in specific or nonspecific adhesion to the host cell independent of pilin protein-mediated attachment (Castric, P. ,1995 , Microbiology 141: 1247-1254). Glycosylated pili are shown to produce high bronchial titers when delivered by the intranasal route. Mice vaccinated with pure P. aeruginosa strain 1244 pili in this manner are protected against respiratory challenge with P. aeruginosa strain 1244.
More specifically, the present invention relates to a new gene sequence, pilO, the product of which glycosylates the pili of P. aeruginosa strains by adding the specific O-antigen subunits of the lipopolysaccharide (LPS) carried by that strain onto the pili resulting in antigenic glycosylated pili useful as a vaccine against infection with that strain.
Nucleotide sequencing of a region downstream from the pilin structural gene (pilA) of P. aeruginosa strain 1244 (a group I strain), revealed an open reading frame (ORF) potentially able to code for another protein. This ORF, called pilO, was flanked by a tRNA thr gene, which was followed by a transcriptional termination sequence. The tRNA thr gene and the termination sequence were nearly identical to sequences found immediately adjacent to the pilA gene of several P. aeruginosa strains. A 2200 base mRNA strand, which contained both the pilO and pilA transcripts, was prodcuced from this region, while 650 base transcript containing only pilA was present in a 100-fold excess over the longer transcript. Hyperexpression of the pilA gene in a pilO − strain resulted in normal pilus-specific phage sensitivity and twitching motility, two other functions of pili. The pilin produced by this strain however had a lower apparent Miv and a more neutral pI compared to that produced by a strain containing a functional pilO gene. This pilin failed to react with a sugar-specific reagent which recognized pilin produced by the strain containing a functional pilO gene (Castric, P.,1995 , Microbiology 141: 1247-1254).
Experiments have shown that pilO is specific for strain 1244 pilin. For example, strain 1244 will produce strain PA 103 pili (a group II pilin) from a plasmid carrying the cloned gene, but will not glycosylate the PA 103 pilin protein. However, pilO is not specific for the O-antigen attached to the strain 1244 pilin. pilO will glycosylate strain 1244 pili with the LPS O-antigen repeating units of other P. aeruginosa strains. For example, strain PAK (another group II strain), carrying a plasmid retaining both the pilO gene and strain 1244 pilin gene, will produce strain 1244 pili carrying the chemically and serologically distinctive strain PAK O-antigen. In fact, the potential for O-antigen range of glycosylation is extremely wide and can extend to virtually any Gram-negative bacterium, P. aeruginosa and other species.
The recent discovery of pilin glycosylation allows the design of vaccines specific for different strains of P. aeruginosa , or of Gram-negative bacteria, by the addition to the pilin core of the specific glycan produced in the bacteria for which a vaccine is desired and using the resulting pili as a vaccine. Other vaccines presently being studied are composed of the LPS associated with the O-antigen. The use of an LPS based vaccine has several serious drawbacks as compared to the use of glycosylated pili as a vaccine. Glycosylated pili contain the immunogenic portion (O-antigen) but not the toxic part (lipid A) of the LPS molecule resulting in a safer, better tolerated vaccine. The range of protection of a cocktail of glycosylated pili will be broader than a cocktail of LPS due to the common epitopes of the pilus protein. Protection will be both pilus based and O-antigen based. LPS purification is time consuming, expensive and difficult. Glycosylated pili can be produced in large amounts by a new method described in this application involving the use of broth cultures instead of the commonly used agar cultures. Purification of glycosylated pili is quickly accomplished, inexpensive, and requires only common laboratory procedures.
The design of a pilus vaccine and understanding the immunological relationship among native pili is dependent on the ability to determine which parts of the pilus surface make up the B-cell epitopes. The positions of the protein B-cell epitopes of the native strain 1244 pili were determined using the Geysen tethered peptide pin assay as described in Castric and Deal, 1994, supra. Four epitope regions were revealed representing the portions of the pilin primary structure which occupy the surface of the pilus fiber. These sequences would be important in peptide vaccine design. Two of these sequences, region (SEQ ID NO: 3) and region 4 (SEQ ID NO: 4) may also represent glycosylation recognition sequences according to recent results from peptide mapping of PilA.
Therefore, it is an object of the present invention to provide a pilO DNA fragment encoding 1386 nucleotides useful as a glycosylation sequence for 1244 pilin protein in the production of a diagnostic agent and a vaccine.
It is another object of the present invention to provide a pilO DNA fragment useful as a glycosylation sequence for pilin of other gram negative bacteria. The pilO protein is capable of glycosylating any protein which contains the pilin glycosylation recognition sequence. The sequence can be incorporated in several ways, for example, using PCR methods, the pilin glycosylation recognition sequence can be inserted into a gene of a known surface protein; this engineered gene can be incorporated into the chromosome of the host by gene replacement, and pilO hyperexpressed from a broad host range plasmid such as pPAC46 which grows and functions in nearly all Gram-negative bacteria.
It is another object of the present invention to provide an amino acid sequence for pilO protein encoding 461 amino acids.
It is another object of the invention to provide a recombinant vector comprising a vector and the above described DNA fragment.
It is another object of the invention to provide a recombinant vector comprising a vector and the above described DNA fragment functionally positioned next to a pilin gene, preferably the pilin gene of strain 1244.
It is a further object of the present invention to provide a host cell transformed with any of the above-described recombinant DNA constructs.
It is another object of the present invention to provide a method for producing pilO protein which comprises culturing a host cell under conditions such that a recombinant vector comprising a vector and the pilO DNA fragment is expressed and pilO protein is thereby produced, and isolating pilO protein for use as a glycosylation agent.
It is yet a further object of the invention to provide a method for producing glycosylated pilin or a pilin-glycan conjugate which comprises culturing a host cell under conditions such that the above-described DNA fragment is expressed and glycosylated pilin is produced, and isolating glycosylated pilin for use as a vaccine and diagnostic agent.
It is still another object of the invention to provide a purified pilO protein useful as a glycosylating agent.
It is a further object of the present invention to provide an antibody to the above-described glycosylated pilin for use as a therapeutic agent and a diagnostic agent.
It is yet another object of the invention to provide a P. aeruginosa vaccine comprising a pilin-glycan conjugate effective for the production of antigenic and immunogenic response resulting in the protection of a mammal against P. aeruginosa infection.
It is a further object of the invention to provide a multivalent Gram-negative vaccine comprising glycosylated pilins from a variety of strains or species of Gram-negative bacteria effective for the production of antigenic and immunogenic response resulting in the protection of a mammal infection with Gram-negative bacilli.
It is yet another object of the present invention to provide a method for the diagnosis of P. aeruginosa infection comprising the steps of:
(i) contacting a sample from an individual suspected of having the infection with antibodies which recognize glycosylated pilin or an attached glycan of P. aeruginosa ; and (ii) detecting the presence or absence of a complex formed between P. aeruginosa and antibodies specific therefor.
It is yet another object of the present invention to provide a method for the diagnosis of Gram-negative bacterial infection comprising the steps of:
(i) contacting a sample from an individual suspected of having the disease with antibodies which recognize glycosylated pilin or an attached glycan of Gram-negative bacteria; and (ii) detecting the presence or absence of a complex formed between P. aeruginosa and antibodies specific therefor.
It is yet another object of the present invention to provide a method for the diagnosis of P. aeruginosa from a sample using the polymerase chain reaction, said method comprising:
(I) extracting DNA from the sample; (ii) contacting said DNA with
(a) at least four nucleotide triphosphates, (b) a primer that hybridizes to pilO DNA, and (c) an enzyme with polynucleotide synthetic activity,
under conditions suitable for the,hybridization and extension of said first primer by said enzyme, whereby a first DNA product is synthesized with said DNA as a template therefor, such that a duplex molecule is formed; (iii) denaturing said duplex to release said first DNA product from said DNA; (iv) contacting said first DNA product with a reaction mixture comprising:
(a) at least four nucleotide triphosphates, (b) a second primer that hybridizes to said first DNA, and (c) an enzyme with polynucleotide synthetic activity,
under conditions suitable for the hybridization and extension of said second primer by said enzyme, whereby a second DNA product is synthesized with said first DNA as a template therefor, such that a duplex molecule is formed; (v) denaturing said second DNA product from said first DNA product; (vi) repeating steps iii-vi for a sufficient number of times to achieve linear production of said first and second DNA products; (vii) fractionating said first and second DNA products generated from said pilO DNA; and (viii) detecting said fractionated products for the presence or absence of pilO in a sample.
It is yet another object of the present invention to provide a method for the detection of P. aeroginosa in a sample which comprises assaying for the presence or absence of pilO RNA or DNA in a sample by hybridization assays.
It is a further object of the present invention to provide a diagnostic kit comprising a glycosylated pilin antibody and ancillary reagents suitable for use in detecting the presence P. aeruginosa in mammalian tissue or serum.
It is another object of the present invention to provide a diagnostic kit comprising antibodies against glycosylated pilins of Gram-negative bacteria and ancillary reagents suitable for use in detecting the presence of Gram-negative bacteria in mammalian tissue of serum.
It is a further object of the present invention to provide a diagnostic kit comprising primers specific for the amplification of pilO sequences and ancillary reagents suitable for use in detecting the presence P. aeruginosa in mammalian tissue or serum.
It is yet an object of the present invention to provide a therapeutic method for the treatment or amelioration of symptoms of P. aeruginosa and other species of Gram-negative bacilli, said method comprising providing to an individual in need of such treatment an effective amount of sera from individuals immunized with one or more pilin-glycan conjugate(s) in a pharmaceutically acceptable excipient.
It is further another object of the present invention to provide a therapeutic method for the treatment or amelioration of symptoms of Gram-negative infection, said method comprising providing to an individual in need of such treatment an effective amount of antibodies against the pilin-glycan conjugate or attached glycan of the Gram-negative bacteria thereby inhibiting the adhesion and colonization of the bacteria in the host in a pharmaceutically acceptable excipient.
It is another object of the present invention to provide a therapeutic method for the treatment or amelioration of symptoms of Gram-negative infection, said method comprising providing to an individual in need of such treatment an effective amount of glycosylated pili from a variety of strains or species of Gram-negative bacteria in order to inhibit adhesion of bacteria to a host cell.
It is yet another object of the present invention to provide a method for large scale production of pilin, either glycosylated or unglycosylated, for use as a vaccine and a diagnostic agent.
It is still another object of the present invention to provide antigenic epitopes of pilA, the pilin core protein, which are useful in peptide vaccine design.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims, and accompanying drawings where:
FIG. 1 shows sequence homology of the region downstream from the pilO gene (SEQ ID NO:5), with the region downstream of the pilA gene of P. Aeruginosa strain PA 103 (SEQ ID NO:6) (Johnson et al., 1986 , J. Biol. Chem. 261: 15703-15708). Colons indicate base homology. Regions containing significant dyad symmetry are indicated by opposing arrows. The tRNA gene region is highlighted.
FIG. 2 shows a comparison of the pilin gene regions of P. aeruginosa strain 1244 and strain PA 103. Potential transcriptional stops are indicated by the letter “t”. Restriction endonuclease sites are H, HindIII; N, NheI; P, PstI; S, SphI.
FIG. 3A & B are Northern blot analysis of mRNA extracted from P. aeruginosa strain 1244. 3 A. Probes were prepared from restriction fragments of cloned DNA indicated in the FIG. 2 map as follows: Lane 1, Probe 1 (the SphI-NheI fragment); Lane 2, Probe 2 (the NheI-PstI fragment); Lane 3, Probe 3 (the PstI-HindIII fragment). Arrows indicate positions of E. coli strain HB 101 ribosomal RNA. 3 B. Densitometric scan of lane 1 of panel A of this figure. Scanning was from bottom to top of the autoradiogram shown. Electrophoresis point of origin is marked by the arrow.
FIG. 4A & B show immunodetection of electrophoretically separated P. aeruginosa pilin. 4 A. SDS-PAGE of pilin at 5° C. Lane 1, 3 μg pilin produced by P. aeruginosa strain 1244N3(pPAC46), Lane 2, 3 μg pilin produced by P. aeruginosa strain 1244N3(pPAC24). Molecular weights are given as times 10 −3 . 4 B. Isoelectric focusing of pilin at 15° C. Lane 1, 3 μg pilin produced by P. aeruginosa strain 1244N3(pPAC24), Lane 2, 3 μg pilin produced by P. aeruginosa strain 1244N3(pPAC46). The pH gradient was determined by focusing pI standards on an identical gel in the absence of octyl glucoside.
FIG. 5 shows the detection of P. aeruginosa pilin carbohydrate by immunoblot. Lane 1, 10 μg pilin produced by P. aeruginosa strain 1244N3(pPAC46), Lane 2, 10 μg pilin produced by P. aeruginosa strain 1244N3(pPAC24). Molecular weights are given as times 10 −3 . Arrows indicate positions of these pilins on an identical blot using monoclonal antibody 6-45 for detection.
DETAILED DESCRIPTION
In one embodiment, the present invention relates to a DNA or cDNA segment which encodes pilO, a glycosylation sequence of pilA pilin core protein. The sequence of the gene, specified in SEQ ID NO: 1, was obtained by sequencing a region downstream from the P. aeruginosa 1244 pilA gene. The sequenced gene fragment comprising 1386 nucleotides of open reading frame with a 60.1% G+C content consistent with the general range given for P. aeruginosa chromosomal DNA.
DNA or polynucleotide sequences to which the invention also relates include sequences of at least about 6 nucleotides, preferably at least about 8 nucleotides, more preferably at least about 10-12 nucleotides, most preferably at least about 15-20 nucleotides corresponding, i e., homologous to or complementary to, a region of the pilO nucleotide sequence. Preferably, the sequence of the region from which the polynucleotide is derived is homologous to or complementary to a sequence which is unique to the pilO gene. Whether or not a sequence is unique to the pilO gene can be determined by techniques known to those of skill in the arL For example, the sequence can be compared to sequences in databarnks, e.g., Genebank. Regions from which typical DNA sequences may be derived include but are not limited to, for example, regions encoding specific epitopes, as well as non-transcribed and/or non-traslated regions.
The derived polynucleotide is not necessarily physically derived from the nucleotide sequence shown in SEQ ID NO:1, but may be generated in any manner, including for example, chemical synthesis or DNA replication or reverse transcription or transcription, which are based on the information provided by the sequence of bases in the region(s) from which the polynucleotide is derived. In addition, combinations of regions corresponding to that of the designated sequence may be modified in ways known in the art to be consistent with an intended use. The sequences of the present invention can be used in diagnostic assays such as hybridization assays and polymerase chain reaction assays and for the discovery of other pilO sequences.
In another embodiment, the present invention relates to a recombinant DNA molecule that includes a vector and a DNA sequence as described above. The vector can take the form of a plasmid such as any broad host range expression vector for example pMMB66EH and others known in the art.
In a further embodiment, the present invention relates to host cells stably transformed or transfected with the above-described recombinant DNA constructs. The host cell can be any Gram-negative bacteria for which glycosylated pilin is desired. The vector containing the pilO gene is expressed in the bacteria and the product of the pilO gene is able to add subunits of the specific O-antigen of the host bacteria to the core pilin producing glycosylated pilins which can be isolated for use as a vaccine and in diagnostic assays. For example, the plasmid pPAC46, described below in Materials and Methods, containing both the pilA and pilO wherein the pilA gene of strain 1244 was placed downstream from the sac promoter (in such a way as to inactivate the pilA promoter) of the broad host range expression vector pMMB66EH (Furste, et al., 1986, Gene 48: 119-131) results in high levels of glycosylated pilus production by hyper-expression of the pilA gene. Promoters other than the tac promoter include λ P L promoter, T7 promoter, and MalE promoter. Please see e.g., Maniatis, Fitsch and Sambrook, Molecular Cloning; A Laboratory Manual (1982) or DNA Cloning , Volumes I and II (D. N. Glover ed. 1985) for general cloning methods. The DNA sequence can be present in the vector operably linked to a highly purified IgG molecule, an adjuvant, a carrier, or an agent for aid in purification of glycosylated pilin. The transformed or transfected host cells can be used as a source of DNA sequences described above. When the recombinant molecule takes the form of an expression system, the transformed or transfected cells can be used as a source of the protein described below.
In another embodiment, the present invention relates to a pilO protein having an amino acid sequence corresponding to SEQ ID NO: 2 and encompassing 461 amino acids or any allelic variation thereof.
A polypeptide or amino acid sequence derived from the amino acid sequence in SEQ ID NO:2, refers to a polypeptide having an amino acid sequence identical to that of a polypeptide encoded in the sequence, or a portion thereof wherein the portion consists of at least 2-5 amino acids, and more preferably at least 8-10 amino acids, and even more preferably at least 11-15 amino acids, or which is immunologically identifiable with a polypeptide encoded in the sequence.
A recombinant or derived polypeptide is not necessarily translated from a designated nucleic acid sequence, or the sequence in SEQ ID NO:1; it may be generated in any manner, including for example, chemical synthesis, or expression of a recombinant expression system. In addition the polypeptide can be fused to other proteins or polypeptides for example, MalE protein for transport into the periplasm or for secretion from the cell.
In a further embodiment, the present invention relates to a method of producing glycosylated pilin which includes culturing the above-described host cells, under conditions such that the DNA fragment is expressed and a glycan specific for such host cells is added to the core pilin protein producing glycosylated pilin. The glycosylated pili can then be isolated using methodology well known in the art or by the new large scale production method described below. The glycosylated pili can be used as a vaccine for immunity against infection with the host bacteria or as a diagnostic tool for detection of host bacterial infection. The transformed host cells can be used to analyze the effectiveness of drugs and agents which inhibit adhesion of host bacteria to cells, such as host proteins or chemically derived agents or other proteins which may interact with the bacteria to down-regulate or alter the expression of piO or affect the ability of pili to adhere to cells. A method for testing the effectiveness of a drug or agent capable of inhibiting the adhesion of the Gram-negative bacteria being studies can be for example the adhesion assay of Deal and Krivan, Met. Enzymol . 236: 346-353.
In another embodiment, the present invention relates to antibodies specific for the above-described glycosylated pili. For instance, an antibody can be raised against the complete glycosylated pili or against a portion thereof. Persons with ordinary skill in the art using standard methodology can raise monoclonal and polyclonal antibodies to the pili (or polypeptide) of the present invention, or the specific O-glycan attached to the pilin, or a unique portion of the pilin. Material and methods for producing antibodies are well known in the art (see for example Goding, in, Monoclonal Antibodies: Principles and Practice , Chapter 4, 1986). In addition, the protein or polypeptide can be fused to other proteins or polypeptides which increase its antigenicity, thereby producing higher titers of neutralizing antibody when used as a vaccine. Examples of such proteins or polypeptides include any adjuvants or carriers safe for human use, such as aluminum hydroxide.
In a further embodiment, the present invention relates to a method of detecting the presence of Gram-negative bacterial infection or antibodies against Gram-negative bacteria in a sample. Using standard methodology well known in the art, a diagnostic assay can be constructed by coating on a surface (i.e. a solid support) for example, a microtitration plate or a membrane (e.g. nitrocellulose membrane), all or a unique portion of the glycosylated pili described above, for example the O-antigen, and contacting it with the serum of a person suspected of having a Gram-negative bacterial infection. The presence of a resulting complex formed between glycosylated pili and antibodies specific therefor in the serum can be detected by any of the known methods common in the art, such as fluorescent antibody spectroscopy or colorimetry. This method of detection can be used, for example, for the diagnosis and typing of Gram-negative bacterial infections.
The adhesion properties of the Gram-negative bacteria are critical to its virulence and central to the development of pathology. Consequently, the ability of an individual to reduce bacterial adhesion would determine the patient's ability to prevent infection or disease. This may take the form of antibodies which inhibit the adhesion of pili to cells; this can be measured in an assay for the detection of glycosylated pili as described below. Such assays can be used to screen individuals after receiving a Gram-negative vaccine to measure the production of protective antibodies. Another mechanism to reduce adhesion of pili to cells is by down-regulating or altering the adhesion receptors present on the cells. Glycosylated pili can be used to measure the availability of cell receptors by contacting labeled glycosylated pili to target tissue either ex vivo or in vivo and measuring the degree to which labeled pili bind to target tissue. Pili can be labeled by any detectable label known in the art such as a radionuclide, for example. In addition, pili, glycosylated or unglycosylated can be used as receptor analogs to block the adhesion receptors present on host cells, thereby reducing or inhibiting the adhesion of bacteria to host cells. These pili can be administered in a mouthwash for example.
In yet another embodiment, the present invention relates to a method of detecting the presence of Gram-negative bacteria pili in a sample. Using standard methodology well known in the art, a diagnostic assay can be constructed by coating on a surface (i.e. a solid support) for example, a microtitration plate or a membrane (e.g. nitrocellulose membrane), antibodies specific for Gram-negative pili suspected, and contacting it with serum or tissue sample of a person suspected of having Gram-negative bacterial infection. The presence of a resulting complex formed between pili in the serum and antibodies specific therefor can be detected by any of the known methods common in the art, such as fluorescent antibody spectroscopy or colorimetry. This method of detection can be used, for example, for the diagnosis of Gram-negative bacterial infection or for typing the specific Gram-negative bacteria causing such an infection.
In another embodiment, the present invention relates to a diagnostic kit which contains glycosylated pili from a specific strain or species Gram-negative bacteria or several different strains and species of Gram-negative bacteria and ancillary reagents that are well known in the art and that are suitable for use in detecting the presence of antibodies to Gram-negative bacteria in serum or a tissue sample. Tissue samples contemplated can be monkey and human, or other mammals.
In yet a further embodiment, the present invention relates to DNA or nucleotide sequences for use in detecting the presence or absence of P. aeruginosa using the polymerase chain reaction (PCR). The DNA sequence of the present invention can be used to design primers which specifically bind to the pilO DNA for the purpose of detecting the presence, absence, or quantitating the amnount of P. earuginosa . The primers can be any length ranging from 7-40 nucleotides, preferably 10-15 nucleotides, most preferably 18-25 nucleotides. Reagents and controls necessary for PCR reactions are well known in the art. The amplified products can then be analyzed for the presence or absence of pilO sequences, for example by gel fractionation, with or without hyridization, by radiochemistry, and immunochemical techniques. This method can also be used for typing a Gram-negative bacterial infection.
In yet another embodiment, the present invention relates to a diagnostic kit which contains PCR primers specific for pilO, and ancillary reagents that are well known in the art and that are suitable for use in detecting the presence or absence of P. aeruginosa in a sample using PCR. Samples contemplated can be human or other mammals.
In another embodiment, the present invention can be used to diagnose P. aeruginosa infection by using the DNA sequences for detecting the presence or absence of pilO in genomic DNA using hybridization assays such as Southern or northern hybridizations and other hybridization assays well known to a person with ordinary skill in the art.
In another embodiment, the present invention relates to a vaccine for protection against Gram-negative bacterial infections. The vaccine comprises glycosylated pili, or a portion thereof, from a specific strain or species of Gram-negative bacteria or preferably, a pool of glycosylated pili from different strain or species of Gram-negative bacteria to be used as a multivalent vaccine. The vaccine can be prepared by inducing expression of a recombinant expression vector comprising pilA and pilO in a Gram-negative host(s) and purifying the glycosylated pili described above. The purified solution is prepared for administration to mammals by methods known in the art, which can include filtering to sterilize the solution, diluting the solution, adding an adjuvant and stabilizing the solution. The vaccine can be lyophilized to produce a vaccine against Gram-negative bacteria in a dried form for ease in transportation and storage. Further, the vaccine may be prepared in the form of a mixed vaccine which contains the glycosylated pili described above and at least one other antigen as long as the added antigen does not interfere with the effectiveness of the vaccine and the side effects and adverse reactions are not increased additively or synergistically.
The vaccine may be stored in a sealed vial, ampule or the like. The present vaccine can generally be administered in the form of a liquid or suspension. In the case where the vaccine is in a dried form, the vaccine is dissolved or suspended in sterilized distilled water before administration. Generally, the vaccine may be administered orally, subcutaneously, intradermally or intramuscularly but preferably intranasally in a dose effective for the production of neutralizing antibody and protection from infection or disease.
In another embodiment, the present invention relates to a method of reducing Gram-negative bacterial infection symptoms in a patient by administering to said patient an effective amount of anti-pili or anti-glycosylated pili antibodies, or pili (glycosylated or unglycosylated) as described above, or other agents capable of blocking pili function. Since glycosylated pili are involved in adhesion of bacteria to host cells, inhibiting or reversing the adhesion of bacteria may reduce or eliminate the development of Gram-negative bacterial infections. When providing a patient with anti-pili or anti-glycosylated pill antibodies, or agents capable of inhibiting pili function or expression for example receptor analogs such as pili themselves to a recipient patient, the dosage of administered agent will vary depending upon such factors as the patient's age, weight, height, sex, general medical condition, previous medical history, etc. In general, it is desirable to provide the recipient with a dosage of the above compounds which is in the range of from about 1 pg/kg to 10 mg/kg (body weight of patient), although a lower or higher dosage may be administered.
In another embodiment, the present invention provides a method for large scale production of pili. Pure, undenatured pili in milligram quantities are required for vaccine use. Current methods of pili purification present difficulties. Cells grown on solid media adhere tenaciously, producing large quantities of slime. The vigorous treatment required to dislodge the cells damages the pilus fibers and releases cellular materials (LPS is a common contaminate; flagella, which copurify with the pili are usually present). Growth in broth cultures, especially using high levels of agitation, suppresses production of pili, probably because they are broken off during this vigorous agitation.
The present method overcomes the suppression of pili production in broth cultures by using RpoN − strains for pili production. Any Gram-negative bacterial strain can be made RpoN − according the published protocols (Ishimoto and Lory, 1989 , Proc. Natl. Acad. Sci. USA 86: 1954-1957). This new method routinely yields milligram quantities of pure native pili per liter of culture by overcoming the suppression of pili production in broth and comprises the steps of:
(1) transforming an RpoN − Gram-negative bacteria with a vector containing the pilin structural gene with or without pilO; (ii) growing the transformed bacteria in broth culture with vigorous agitation; and (iii) purifying pili from the supematant fluid of said broth cultures.
In yet another embodiment, the present invention provides immunogenic epitopes from the pilA structural pilin gene representing possible glycosylation recognition sequences. These epitopes were mapped by standard peptide mapping techniques. These epitopes include the amino acid sequences designated SEQ ID NO:3 and SEQ ID NO:4. These peptides can be generated in any manner, including for example, chemical synthesis, or expression of a recombinant expression system. In addition the polypeptide can be fused to other proteins or polypeptides which increase its antigenicity, such as adjuvants for example, thereby producing higher titers of anti-pilin antibodies for protection against P. aeruginosa infection. In addition, these peptides may be used with or without glycosylation as a vaccine or for the production of antibodies which can then be used to generate passive immunity against P. aeruginosa infection.
In addition, the strain 1244 peptide sequence conferring glycosylation can be incorporated into other P. aeruginosa cell surface proteins of potential vaccine value using standard recombinant DNA methodologies. Examples of such cell surface proteins include flagella and outer membrane proteins such as F and P. This recognition sequence could be likewise incorporated into surface proteins of vaccine potential from other bacteria such as Bordetella pelussis, Francisella species, Neisseria meningiditis, Neisseria gonorrhoeae, Vibrio cholerae, Brucella species, certain strains of Escherichia coli , and Yersinia species. Expression of pilO from a plasmid in such an organism would result in the addition of the organisms specific O-antigen to this protein.
Described below are examples of the present invention which are provided only for illustrative purposes, and not to limit the scope of the present invention. In light of the present disclosure, numerous embodiments within the scope of the claims will be apparent to those of ordinary skill in the art.
The following MATERIALS AND METHODS were used in the examples that follow.
Bacterial strains and culture conditions. P. aeruginosa 1244, a clinical isolate which has been used in pilus-mediated adhesion studies (Ramphal et al., 1984 , Infect. Immun . 44: 38-40), was provided by A. T. McManus, U.S. Army Institute of Surgical Research, San Antonio, Tex. P. aeruginosa strain 1244N3, a mutant which is unable to make pili or produce pilin (Ramphal et. al., 1991 , Infect. Immun . 59: 1307-1311) due to an inactivated rpoN gene, was furnished by S. Lory, University of Washington. Cultures were grown on LB medium (Sambrook etal., 1989 , Molecular Cloning: a Laboratorv Manual , vol. 1, 2nd edn. Cold Spring Harbor, N.Y.: Cold Spring Harbor Laboratory) at 37° C. Antibiotic concentrations in selective media used for P. aeruginosa were as follows: carbenicillin (Cb), 500 μg ml −1 ; tetracycline (Tc), 50 μg ml −1 . Antibiotics used with E. coli were: ampicillin (Ap), 75 μg ml −1 ; spectinomycin (Sp), 25 μg ml −1 ; tetracycline (Tc), 10 μg ml −1 .
Nucleotide sequencing. The Sanger dideoxy method (Sanger et al., 1977 , Proc. Natl. Acad. Sci. USA 74: 5463-5467) was used. The template was single-stranded M13 subclones of phage Lambda or plasmid clones (Castric et al., 1989 , Mol. & Gen. Genet . 216: 75-80) containing DNA downstream from the pilA gene. Synthetic primers, derived from known sequences, or universal primers were employed.
Plasmid constructs. The plasmid pPAC46, which contained both pilA and pilO, was constructed by ligating the SphI-HindIII plasmid fragment containing the pilA and adjacent DNA ( FIG. 2 ) of pPAC202 (Castric et al., 1989, supra) to plasmid pUC18 digested with these same enzymes. The EcoRI-HindIII fragment of this construct, pPAC 124, was ligated with the broad host range expression vector pMMB66EH (Ap r , lacI q ; Furste et al., 1986, supra) which had been digested with the same restriction enzymes. Plasmid pPAC24, which contained pilA, but not pilO, was constructed by ligating the pPAC124 EcoRI-NheI fragment containing thepilA gene with pUC19 digested with EcoRI and XbaI. The EcoRI-HindIII fragment of this construct, which contained only the pilA gene, was ligated with pMMB66EH digested with the same restriction enzymes. The pilA gene of both pPAC24 and pPAC46 was under control of the vector tac promoter. Since the SphI site used in plasmid construction is located within the pilA promoter neither pPAC24 nor pPAC46 were able to express the pilin structural gene using the P. aeruginosa promoter. Plasmid DNA was introduced into E. coli by transformation (Sambrook et al., 1989, supra), and was transferred to P. aeruginosa by triparental mating (Ruvkun & Ausubel, 1981, Nature 289: 65-88).
Northern blot analysis. RNA was extracted as described by Reddy (1989, In Current Protocols in Molecular Biology , vol. 1, 4.4.1.-4.4.7. Edited by F. M. Ausubel et al. New York: John Wiley) and separated by formaldehyde-agarose gel electrophoresis, stained with ethidium bromide, and transferred to nitrocellulose paper by capillary blot as described by Sambrook et al., (1989, supra). Probe DNA, isolated from pPAC24 or pPAC46, was labelled by nick translation using [α- 32 P] dCTP. Prehybridization, hybridization, and washing steps were as described by Sambrook et al., 1989. Detection of hybridization was by autoradiography. Densitometric scanning was carried out using an LKB Ultroscan laser densitometer.
Purification of pili. Production of pili by expression of the pilA genes of plasmids pPAC24 and pPAC46 in P. aeruginosa 1244N3 was carried out using LB agar- or LB broth-cultures grown in the presence of 5 mM isopropyl-thiogalactoside (IPTG). LB agar-grown cells were resuspended in LB broth. These cells (as well as broth-grown cells) were depiliated by four excursions through a 22-gauge needle. Cells were removed by centrifugation (7,500 g for 15 min). The pili remaining in the supernatant fluid were purified by a variation of the method of Silipigni-Fusco (1987 , Studies in the role of somatic pili as virulence and inmunityfactors in the pathogenicity of Pseudomonas aeruginosa . Ph.D. thesis, University of Pittsburgh, USA). In this procedure the supernatant fluid was made 0.1 M with respect to MgCl 2 , and stored on ice for 60 min. The resulting precipitate, which contained the pilus fibres, was removed by centrifugation at 12,000 g for 15 min.
Pilin analysis. N-terminal amino acid sequence analysis and amino acid analysis was performed on purified pilin from strain 1244N3(pPAC24). This protein was subjected to PAGE (15% T) which was followed by electroblotting to polyvinylidene difluoride paper. Preliminary staining showed that pilin was the major protein present and that it was well separated from the minor contaminants present. Pilin bands were excised and subjected to gas-phase sequencing and to amino acid analysis (University of Pittsburgh Peptide Facility).
Pilin immunoblot analysis. Pilins were separated by PAGE (12.5% T in the presence of either 0.1% SDS at 5° C. or 30.0 mM octyl glucoside at 15° C.) or subjected to isoelectric focusing (pH 3.0 to 9.5) in the presence of 30.0 mM octyl glucoside at 15° C. using the LKB-Pharmacia Phastsystem. Proteins were transferred to nitrocellulose paper by diffusion blotting; pilin adsorbed to the paper was detected using anti-pilin monoclonal antibody 6-45 (Saiman et al., 1989, Immun. 57: 2764-2770) as previously described (Castric et al., 1989, supra). The presence of pilin-bound sugar residues was detected by first derivatizing purified pili using the DIG Glycan Detection kit of Boehringer Mannheim Biochemica (Indianapolis). This protein was subjected to SDS-PAGE (12.5% T) using the BioRad MiniProtean II system in which temperature was neither controlled nor monitored. Pilin was electroblotted to nitrocellulose paper, probed with an alkaline phosphatase-labelled antibody specific for the hapten used in pilin derivatization, and developed as described by Boehringer Mannheim Biochemica (Indianapolis).
Electron microscopy. Cells to be analyzed by electron microscopy were grown on LB agar plates at 37° C. for approximately eighteen hours and suspended in phosphate buffered saline. The cells were coated on 200 mesh formvar-coated copper grids, subjected to staining with 1% uranyl acetate, and viewed in a Philips 201 electron microscope.
Pill functionality tests. The phage sensitivity test was performed by streaking a loop of pilus-specific phage PE69 on an LB agar plate. This was cross-streaked with diluted P. aeruginosa 1244 strains to be tested. Phage sensitivity was interpreted from the absence of growth at the cross-streak junction. Twitching (Henrichsen, 1983 , Annu. Rev. Microbiol . 37: 81-93) was determined by streaking strains of interest on a well dried LB agar plate where motility was scored as spreading growth at between 48 and 72 hours at 37° C.
EXAMPLE 1
Nucleotide Sequence Analysis
The nucleotide sequence downstream from the P. aeruginosa strain 1244 pilA gene contains a potential transcriptional termination structure situated between positions 626 to 708 (noted previously in Castric et al., 1989, supra). A ribosome-binding site (GGAG) is seen at position 717 followed closely by three start codons, the first of which is located immediately in frame with a stop codon (TGA). The second and third, GTG and ATG, are in frame with each other and begin an open reading frame (referred to hereafter as pilO) which extends 1383 base pairs, using the ATG codon, to position 2114. Codon usage of the 461 codons of the pilO gene is consistent with that of most other P. aeruginosa genes (West & Iglewski, 1988 , Nucleic Acids Res . 16: 9323-9335). However, significant differences are seen when it is compared,with the adjacent pilA gene or with the pilA genes of other P. aeruginosa strains (West & Iglewski, 1988, supra; Castric & Deal, 1994, supra). While the phe codons, TTT and TTC, have frequencies of 20/29 and 9/29, respectively, in the pilA gene, these codons occur at rates of 6/25 and 19/25, respectively, in the pilO gene. The arg codons, CGT and GCG, appear at rates of 26/31 and 2/31 in the piLA gene, but occur at rates of 7/31 and 11/31, respectively, in the pilO gene. In addition, the G+C % content of pilO (60.1%) is consistent with the general range given for P. aeruginosa chromosomal DNA (West & Iglewski, 1988), but quite different from the value of 52.2% determined for the strain 1244pilA gene. A search of the Genbank database revealed no sequences with significant homology to the pilO gene.
A tRNA thr gene, which contains an anticodon recognizing the rare codon ACG, can be seen just downstream of the pilO gene between positions 2166 and 2241, and is followed, between positions 2245 and 2282, by a potentially bidirectional transcriptional stop containing a 17 bp loop stem. A tRNA gene and transcriptional stop region have been noted previously (Hobbs et al., 1988, Gene 62: 219-227) as occurring immediately downstream from the P. aeruginosa strain PAK pilA gene, and may also be seen in the analogous region of the pilA genes of P. aeruginosa strains PAO and PA 103 (Johnson et al., 1986, supra). A homology comparison ( FIG. 1 ) shows that the tRNA-transcriptional stop region described in this paper is virtually identical with the pilA-proximal regions of strain PA 103 beginning at position 2421 and continuing 275 base pairs to the end of the sequence. It is interesting to note that the first S bases of this region (GAGTG) are also found, as a direct repeat, in the pilA-O intragenic region gene beginning at position 676, suggesting a possible site of genetic recombination. These results are summarized in FIG. 2 where the organization of these regions may be compared.
EXAMPLE 2
Transcription of PilO
Northern blots ( FIG. 3 ) of strain 1244 mRNA showed that probe 1, composed of pilA DNA, recognized 650 base (RNA 2) and 2200 base (RNA 1) species. The smaller transcript was present in approximately a 100-fold excess over the larger mRNA as determined by densitometric scanning. By analogy with work on other P. aeruginosa pilA genes (Johnson et al., 1986) the transcription startpoint may be presumed to begin between positions 150 and 160, suggesting that the larger transcript extends into the pilO region. The intermediate-sized RNA fragments might be formed by early termination, due to the loop structure referred to earlier, or might be degradation products of the larger species. Probe 2, which was composed of pilO DNA, hybridized only with the larger fragment and the intermediate pieces suggesting that the origin of the 2200 base mRNA is in the pilA region and that synthesis of this molecule extends downstream through the pilO gene. This was confirmed by the reaction of probe 3 which was composed of DNA from the latter part of the pilO gene and the tRNA-transcriptional stop region. This probe hybridized with the larger fragment but with neither thepilA transcript nor the intermediate fragments. This probe also hybridized with a very small RNA population, presumably tRNA produced by the pilO-associated gene as well as with cross-reacting species. Overall these results indicate that pilA, pilO and probably the adjacent tRNA gene are part of a single transcriptional unit which utilizes the pilA promoter.
EXAMPLE 3
Influence of PilO on Pilus Function
Since both pilA and pilO are part of the same transcriptional unit, the inactivation of the pilA promoter will also eliminate pilO expression. P. aeruginosa strain 1244N3 is a mutant which is unable to make pili or produce pilin (Ramphal et al., 1991 , Infect. Immun . 59: 1307-1311) due to an inactivated rpoN gene. This strain was used as the genetic background for expression of the pilA gene, carried on recombinant plasmids pPAC24 (containing only pilA) or pPAC46 (bearing both pilA and pilO), under control of a tac promoter. Electron microscopy showed that while strain 1244N3 produced no pili both derivatives 1244N3(pPAC24) and 1244N3(pPAC46), when grown in the presence of IPTG, produced pilus fibres which were indistinguishable from those of the wild-type (results not shown). Both strains 1244N3(pPAC24) and 1244N3(pPAC46), in the presence of IPTG, were sensitive to the pilus-specific bacteriophage PE69 and demonstrated twitching motility on dried agar plates, properties lacking in strain 1244N3. These results indicated that the absence of pilO did not appear to influence the ability of the pilus to extend and retract, qualities necessary for twitching and for phage sensitivity.
EXAMPLE 4
Influence of PilO on Pilin Structure
Although strain 1244N3 was unable to produce pilin, as determined by Western blot (results not shown), complementation of this strain with either plasmid pPAC24 or pPAC46, under inducing conditions, allowed production of this protein (FIG. 4 A). While the molecular weight of mature pilin of strain 1244 predicted from the nucleotide sequence of the pilA gene (Castric el al., 1989, supra) is 15,653, the apparent size of pilin produced by strain 1244N3(pPAC46), or by wild-type strain 1244 (results not shown) is approximately 16,900. Pilin produced by strain 1244N3(pPAC24), which lacks a functional pilO gene, had an apparent molecular weight of 15,600. Identical results were obtained when gradient SDS-PAGE was employed. A small fraction of the pilin produced by strain 1244N3(pPAC24) migrated with wild-type pilin when the BioRad MiniProtean II PAGE system (15% T) was employed (results not shown).
To explore the significance of this apparent molecular weight difference it was necessary to see if the N-terminus of pilin produced by strain 1244N3(pPAC24) was in any way altered. When this protein was subjected to N-terminal amino acid analysis, the sequence of mature pilin, X TLIELM (the first residue produced no reaction presumably because it was the masked amino acid N-methyl-phenylalanine), was obtained. Amino acid analysis of blotted pilin was also carried out to determine the integrity of the carboxy-terminal region. The pilin of P. aeruginosa 1244 contains 6 prolines (Castric et al., 1989), mainly in the carboxy-terminal region. The observed molecular weight difference of approximately 1,200, if caused by cleavage in this region, would require breaking the bond between residues 136 and 137 of mature pilin resulting in a change in apparent proline number from 6 to 3. Normalization (with alanine) of actual values obtained gave a proline/alanine (P/A) ratio of 0.36, with a P/A ratio of 0.20 predicted for a truncated form and a P/A ratio of 0.35 predicted for mature pilin. Normalization with leucine values gave a proline/leucine (P/L) of 0.68 (a P/L ratio of 0.33 is predicted for a truncated form and a P/L ratio of 0.67 for mature pilin). These results suggest that the pilin carboxy-terminal region must be substantially intact.
Purified pili from strains 1244N3(pPAC24) and 1244N3(pPAC46) were treated with periodic acid to oxidize any sugar residues present. These proteins were then treated with digoxygenin-succinyl-ε-amidocaproic acid hydrazide which will form a covalent bond with oxidized sugars. After SDS-PAGE these proteins were electroblotted to nitrocellulose paper and probed with an anti-digoxygenin antibody preparation. FIG. 4 shows that pilin from strain 1244N3(pPAC46) reacted with this antibody indicating the presence of sugar moieties, while pilin from strain 1244N3(pPAC24) gave no reaction.
Pili were dissociated into pilin monomers and dimers in the presence of 30.0 mM octyl glucoside (Watts et al., 1982a, Can. J. Biochem . 60: 867-872; Watts et al., 1982b, J. Bacteriol. 151: 1508-1513; Watts et al., 1983 , Biochemistry 22: 687-691), subjected to isoelectric focusing, then blotted to nitrocellulose paper, and probed with pilin-specific monoclonal antibodies. Pilin produced by strain 1244N3(pPAC46) or by wild-type strain 1244 (results not shown) had a pI of 4.75 (FIG. 4 B). Pilin from strain 1244N3(pPAC24), which lacked a functional pilO gene, had a pI of approximately 6.25. The pI of mature strain 1244 pilin is predicted from the pilA gene sequence (assuming that the amino-terminus is blocked and the two cysteines form a disulfide) to be 7.00. These results indicate that a significant alteration in pilin charge arrangement (neutralization of positive charges or introduction of negative ones) is brought about by the presence of the pilO gene. The difference in charge between these two pilin forms was confirmed by PAGE in the presence of 30.0 mM octyl glucoside at pH 8.8. Pilin from strain 1244 or strain 1244N3(pPAC46) had a greater net negative charge than pilin from strain 1244N3(pPAC24) (results not shown). Pilin from strains 1244 and 1244N3(pPAC46) also focused at pH 4.75 in the presence of 8.0 M urea and 2.5% (v/v) Triton X-100 (results not shown). Pilin preparations from strain 1244N3(pPAC46) or the wild-type strain contained trace amounts of the neutral pilin form (results not shown) possibly due to chemical or enzymatic action. The small: amounts of the acidic pilin form produced by strain 1244N3(pPAC24) (FIG. 4 B), as well as the higher molecular weight form described above, may be due to low levels of pilO gene expression by the host strain. These results altogether suggest that the P. aeruginosa strain 1244pilO gene is required for a posttranslational pilin modification, specifically a glycosylation.
EXAMPLE 5
Preparation of Glycosylated PA1244 Pili
One liter (in a 2.8 liter Fernbach flask) of a medium (LB broth containing Carbenicillin [200 μg/ml], Tetracyline [50 μg/ml], and isopropyl thiogalactoside [IPTG, 5 mM]) was inoculated with 25 ml of an overnight culture of Pseudononas aeruginosa 1244N3(pPAC46) grown with the same medium (minus the IPTG). This host strain is RpoN − . The inoculated medium was incubated at 37C with rotary agitation 250 rpm for 7 hours. The overnight starter culture was grown under the same conditions in a 125 ml Erlenmyer flask.
After incubation the cells were removed by centrifugation (4,200×g for 15 min). 30 g of Polyethylene glycol (PEG) 6000 and 20.3 g MgCl 2 were added to the supernatant fluid which was stored overnight at 4C. The light grey-tan precipitate (containing the pili) was removed by centrifugation (13,20×g for 30 min).
This material was suspended with 50 ml 10.0 mM Tris/HCl, pH 7.6 containing 20% sucrose and centrifuged (4,200×g for 15 min). The precipitate was discarded and the supernatant fluid was reprecipitated with PEG and MgCl 2 as described above, and stored overnight at 4C. The light grey-tan precipitate (containing the pili) was removed by centrifugation (13,20×g for 30 min) and suspended with 25 ml 10.0 mM Tris/HCl, pH 7.6 containing 20% sucrose.
Ammonium sulfate was added to 35% saturation. After 30 min at 4C this material was centrifuged (4,200×g for 15 min) and the precipitate discarded. Ammonium sulfate was added to the supernatant fluid to 65% saturation. After 60 min at 4C this material was centrifuged (4,200×g for 15 min) and the supernatant fluid was discarded. The pellet contained the pili were subjected to polyacrylamide gel electrophoresis (PAGE) which showed, with silver staining, only trace amounts of contaminating protein and only minor amounts of LPS on gels in which pilin was overloaded. This procedure routinely produced 10 to 20 mg of pilin protein (as determined by the BCA test) per liter of cells.
EXAMPLE 6
Animal Model
ICR mice (25-30 g) were immunized with P. aeruginosa strain 1244 pili at a concentration of 5 mg/mouse/dose diluted in physiologic saline. The following immunization schedules were used to determine antibody response: i.n./i.n., s.c./s.c., i.p./i.p., i.n./s.c., s.c./i.n., i.n./i.p., i.p./i.n.. The time interval between the doses was 7 days. For i.n. immunization, mice were anesthetized i.p. with ketamine HCl (80 mg/kg) and xylazine HCl (8 mg/kg) prior to the instillation of pili. Pili were delivered i.n. in a final volume of 25 μl using sterile aerosol resistant pipet tips for each mouse to prevent contamination. The final volume for i.p. and s.c. injection was 100 μl. Control mice received physiologic saline only
At days +3, +7, +10 and +14 after the second dose, mice were sacrificed by CO 2 inhalation to obtain serum samples via cardiac puncture as well as bronchoalveolar lavage (BAL) samples for antibody titers. For BAL samples, lungs were washed once with 1 ml of sterile physiologic saline via a 25 G hypodermic needle inserted into the trachea.
Antibody titers were determined by means of an ELISA using 96-well plates coated with P. aeruginosa 1244 pili at a concentration of 2 mg/ml (50 ml/well, 4° C., over night [O/N]). After blocking and washing, samples were serially diluted (2-fold) in duplicate in blocking buffer and incubated O/N at 4° C. Bound antibodies were detected using goat-anti-mouse-IgG/alkaline phosphatase labelled, goat-anti-mouse-IgM/alkaline phosphatase labelled, and goat-anti-mouse-IgA/alkaline phosphatase labelled (Incubation O/N, 4° C.); plates were developed with p-Nitrophenylphosphate in diethanolamine buffer and read in a Biotek® Ceres 900 C ELISA reader. ELISA titers are defined as log 10 of the dilution which gave a change of A 405 of 0.200 after 30 min.
For protection studies, P. aeruginosa 1244 was grown to mid-log phase in trypticase soy broth for 4 h at 37° C. After washing the bacteria with physiologic saline, the OD 650 was adjusted to 0.480 which corresponded to an estimated CFU count of 2×10 8 /ml. Mice were challenged i.n. using 2 different doses (LD 100 , LD 5 ) at day +7 after the second dose of pili. Anesthesia was done as described above, and bacteria were delivered in a final volume of 50 ml. Mortality and body weight were monitored daily for 14 days. Control mice received physiologic saline only. Time to recovery in sublethal challenge experiments was defined as number of days until the baseline body weight was regained or (if animals did not reach their baseline body weight) as number of days until stabilization of body weight (3 consecutive days with weight change 0.5 g).
TABLE 1
ANTIBODIES AGAINST PILI (Mice: ICR)
BAL
Serum
Route,
Sample day:
Ig class
3
7
10
14
3
7
10
14
IN/IN
IgG
2.76
2.80
2.15
1.83
4.13
5.59
4.09
5.12
IgM
1.85
0.50
0.50
0.50
3.91
2.97
2.93
2.80
IgA
1.90
2.74
2.00
0.50
2.50
2.40
2.09
0.50
IN/SC
IgG
0.50
1.85
1.77
1.70
3.64
5.61
5.78
5.61
IgM
0.50
0.50
0.50
0.50
3.44
3.95
3.64
2.85
IgA
0.50
0.50
0.50
0.50
1.15
1.40
1.27
0.50
TABLE 2
ANTIBODIES AGAINST LPS (Mice: ICR)
BAL
Serum
Route,
Sample day:
Ig class
3
7
10
14
3
7
10
14
IN/IN
IgG
0.50
0.50
0.50
0.50
2.05
1.90
1.77
2.37
IgM
0.50
0.50
0.50
0.50
2.68
2.43
1.96
1.97
IgA
0.50
0.96
0.50
0.50
0.50
0.50
0.50
0.50
IN/SC
IgG
0.50
0.50
0.50
0.50
2.22
2.43
2.13
2.09
IgM
0.50
0.50
0.50
0.50
2.79
2.90
2.83
2.69
IgA
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
TABLE 3
ANTIBODIES AGAINST PILI (Mice: C3H/HeJ)
Route
BAL
Serum
Ig class
IgG
IgM
IgA
IgG
IgM
IgA
IN/IN
0.50
0.50
0.50
3.26
3.11
0.50
IN/SC
0.50
0.50
0.50
3.33
3.35
0.50
TABLE 4
ANTIBOTIES AGAINST LPS (Mice: C3H/HeJ)
Route
BAL
Serum
Ig class
IgG
IgM
IgA
IgG
IgM
IgA
IN/IN
0.50
0.50
0.50
1.49
2.09
0.50
IN/SC
0.50
0.50
0.50
1.39
1.86
0.50
notes:
All data are medians (not means) from 3 mice. They represent the log 10 of 10-fold dilutions which gave a change of A 410 of 0.200/15 min. Background readings (everything except serum or BAL samples) were always below 0.020. Serum samples from normal ICR as well as C3H/HeJ mice gave no readings higher than the background.
Data from C3H/HeJ mice are from day +7 after the 2nd dose only.
Limit of detection: 0.499 1:3
TABLE 5
Survival @
Survival (L/D)
end of study
Treat-
Challenge with
day
alive/
%
Group #
ment
Strain
CFU given a
0
1
2
3
4
5-13
14
total
alive
10-6
i.n.-i.n.
P. aer.
6.1 × 10 6
5/0
5/0
5/0
3/2
3/0
3/0
3/0
3/5
60
1-17
″
12.4.4
2.25 × 10 6
5/0
4/1
4/0
4/0
4/0
4/0
4/0
4/5
80
1-20
″
″
6.75 × 10 6
5/0
5/0
4/1
4/0
3/1
3/0
3/0
3/5
60
total
″
″
5.03 × 10 6
15/0
14/1
13/1
11/2
10/1
10/0
10/0
10/15
66.70
10-6
i.n.-s.q.
″
6.1 × 10 6
5/0
4/1
1/3
1/0
1/0
1/0
1/0
1/5
20
1-17
″
″
2.25 × 10 6
5/0
5/0
4/1
4/0
4/0
4/0
4/0
4/5
80
1-20
″
″
6.75 × 10 6
5/0
4/1
1/3
1/0
1/0
1/0
1/0
1/5
20
total
″
″
5.03 × 10 6
15/0
13/2
6/7
6/0
6/0
6/0
6/0
6/15
40
10-6
controls
″
6.1 × 10 6
4/0
1/3
0/1
0/40
0
1-17
″
″
2.25 × 10 6
4/0
3/1
2/1
0/2
0/4
0
1-20
″
″
6.75 × 10 6
5/0
3/2
1/2
0/1
0/5
0
total
″
″
5.03 × 10 6
13/0
7/6
3/4
0/3
0/13
0
a CFU given in “total” represents the mean out of the CFU of the 3 experiments (SEM = 1.99 × 10 6 )
Every immunization schedule tested resulted in IgG and IgM antibody titers in serum as well as in BAL fluid. Only immunization twice via the i.n. route, however, yielded significant levels of IgA antibodies both locally and systemically. Based on these findings, we chose to compare wot different routes (i.n./i.n., i.n./s.q.) with the bacterial challenge given at day +7 after the boost dose. While all of the control mice died within 3 days, 66.7% of the mice immunized i.n./s.c. (P=0.03 1). In sublethal infections, time to recovery as measured by regaining body weight was shorter in the group immunized i.n./i.n. (7.1±0.8 days, mean ±SEM) than in the control group (9.6±0.8 days). Thus, we were able to demonstrate that pili from P. aeruginosa are highly immunogenic. Mucosal immunization via the intranasal route protects mice significantly from a lethal pulmonary challenge with the homologous strain and leads to faster recovery in sublethal lung infections.
EXAMPLE 7
Location of the Site of Pilin Glycosylation
Digestion of pure glycosylated strain 1244 pilin (apparent molecular weight as determined by SDS-PAGE was 16,800) with V8 protease produced a 9,000 molecular weight peptide which reacted with anti-LPS monoclonal 11.14 on Western blot. N-terminal analysis of this fragment showed that this peptide with this N-terminus would be predicted to have a molecular weight of 7,700. Altogether, these results show that the pilin glycosylation site is in the region bounded by residue 75 and the carboxy-terminus, encompassing peptide regions 3 (SEQ ID NO: 3) and 4 (SEQ ID NO:4), two regions found to contain linear B-cell epitopes (Castric and Deal, 1994, supra) and may be important in peptide vaccine design. Further, peptide sequencing indicated that residue 95 did not produce the expected threonine residue suggesting that epitope region 3 is the site of glycosylation.
Discussion
While glycosylation of prokaryotic proteins appears to be primarily restricted to the archaebacteria (Lechner & Wieland, 1989 , Annu. Rev. Biochem . 58: 173-194), reports have suggested the association of polysaccharide with pili (Armstrong et al., 1981 , J. Bacteriol . 145: 1167-1176; Robertson et al., 1977 , J. Gen. Microbiol . 102: 169-177). Virji etal. (1993 , Mol. Microbiol . 10: 1013-1028) presented strong evidence (carbohydrate detection of blotted pilin and chemical removal of sugars) that Neisseria meningitidis pilin is glycosylated. Results presented in this paper suggest that pilin from P. aeruginosa 1244 also is glycosylated. The composition of the pilin-associated material remains to be determined, however several candidates, including the acidic moieties of the lipopolysaccharide core, alginic acid subunits, as well as other acidic elements or phosphorylated compounds, must be considered. Limitations of SDS-PAGE prevent reliable molecular weight determinations of glycosylated proteins, a test which must await the use of a more accurate technique such as mass spectrometry. Linkage of glycosylated proteins is usually via the reducing end of an oligosaccharide sugar through an O- or N-linkage to the hydroxyl group of serine (or threonine) or the amide group of asparagine (Montreuil et al., 1986, In Carbohydrate Analysis, a Practical Approach , pp. 143-204. Edited by M. F. Chaplin & J. F. Kennedy. Oxford: IRL Press). The residues in the region of N-linked moieties have the characteristic consenus sequence N-X-S (or T). While this sequence may be found in the N. meningitidis pilin primary structure (Virji et al., 1993), it is absent in P. aeruginosa strain 1244 pilin, suggesting the presence of an N-linkage, a different sequence specificity, or the utilization of an alternative method of attachment. Clearly much work remains in the characterization of this pilinassociated material.
Previous work (Frost & Paranchych, 1977; Paranchych et al., 1979) has indicated that pili from P. aeruginosa strains PAO and PAK contained no sugar residues. Since the primary structure of pili from strain 1244 is distinctive when compared to those of strains PAO and PAK (Castric & Deal, 1994), pilus modification may represent a strain difference. P. aeruginosa strains producing pili antigenically related to those of strain 1244 are common among clinical isolates (Castric & Deal, 1994). Thus, pilin glycosylation by this bacterium could be useful in clinical identification. Likewise, demonstration of the presence of the pilO gene could be of diagnostic value.
Since the absence of glycosylation seems to have no effect on either the formation of pilus fibres or extension and retraction of these fibres (as measured by bacteriophage sensitivity and twitching motility), the function of this modification is unclear. Because all pilin monomers appear to be modified [this must include both the pilin membrane pool (Watts et al., 1982c, J. Bacteriol . 152: 687-691) as well as pilus fibres), these glycoproteins must contribute greatly to the overall cell surface negativity. Bacterial avoidance of phagocytosis through inhibition of attachment has been well documented (Densen & Mandell, 1980 , Rev. Infect. Dis . 2: 817-838). Diminished phagocytosis by neutrophils because of electrostatic repulsion has been demonstrated both by streptococcal M protein (Fischetti, 1989 , Clin. Microbiol. Rev . 2: 285-314) and the pili of Neisseria gonorrhoeae (Heckels et al., 1976 , J. Gen. Microbiol . 76: 359-364). Such a mechanism could also benefit P. aeruginosa when growing saprophytically where the avoidance of phagocytic amoebae could be an important survival mechanism.
Specific recognition by the pili allows attachment of the pathogen to host cells containing the proper receptors (Baker, 1993, In Pseudomonas aeruginosa, the Opportunist: Pathogenesis and Disease , pp. 7-24. Edited by R. B. Fick. Boca Raton: CRC Press; Heckels et al., 1976). The acidic modification might stabilize this attachment through the formation of salt bridges once specific binding had occurred. Alternately pilin glycosylation may be involved in specific or nonspecific adhesion to the host cell which is independent of pilin protein-mediated attachment. Adhesion studies utilizing PilO + and PilO − variants of P. aeruginosa strain 1244, as well as glycosylated and nonglycosylated pili, will be required to clarify these points.
The genetic evidence presented in this paper relates the presence of pilin glycosylation to a functioning pilO gene indicates that this process has a specific cellular role. This is strongly supported by the findings that the pilO gene is part of the pilA transcriptional unit. Although the pilA and pilO genes, along with a tRNA thr gene, are present in the form of an operon, two major transcription products are generated (an individual pilA message and apilA/pilO/tRNA thr transcript) which are present in a ratio of about one hundred to one. Such results would not be unexpected as pilin is a major cell protein, while PilO would likely be required in only catalytic or regulatory amounts. The difference in transcription levels could be the result of premature termination of message synthesis or relative instability of the transcript corresponding to the pilO region. The role of translation efficiency should also be considered a factor in differential gene expression since the beginning of the pilO message contains a short loop region which includes the start codon. Such a structure has been suggested to be able to significantly reduce translation (Gold, 1988 , Annu. Rev. Riochem . 57: 199-233), and may function to further control expression of a gene coding for a product required in small amounts when it shares a promoter with a gene coding for a product needed in large amounts.
The pilO gene product is predicted to code for a protein with a molecular weight of 50,862 using as start codon the ATG beginning at position 729 (FIG. 1 ). Hydropathy profile (Kyte & Doolittle, 1982 , J. Mol. Biol . 157: 105-132) of the primary structure indicates that PilO contains nine hydrophobic regions which are flanked by clusters of charged residues. Secondary structure prediction (Chou & Fassman, 1974 , Biochemistry 13: 211-221) suggests that large portions, of these hydrophobic regions are composed of β-structure which are of adequate length to span the 3.0 nm membrane lipid core. Positively charged residues flanking the hydrophobic segments could be expected to stabilize this structure through ionic interaction with membrane phospholipids, while charged and polar residues in these regions would promote a surface solvent interaction on both sides of a membrane. Although the location of PilO has not been demonstrated, the high degree of hydrophobicity within the predicted transmembrane regions suggests that it resides in the cytoplasmic membrane. This location would be ideal if PilO functions catalytically on the periplasm side of the cytoplasmic membrane to transfer carrier lipid-bound oligosaccharide subunits to emerging pilin monomers.
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The present invention relates to a broadly reactive vaccine against Gram-negative bacteria which is composed of a biological glycan-pilus conjugate. The conjugate core is a common pilus type to which is attached the glycan of choice in vivo. Pooling of these bioconjugates produces a multivalent vaccine. These pili give high bronchial titers when delivered by the intranasal route. Mice vaccinated with pure glycosylated P. aeruginosa strain 1244 pili in this manner are protected against respiratory challenge with P. aeruginosa strain 1244. The present invention further relates to a DNA and amino acid sequence of a new gene, pilO, which is capable of glycosylating pilin of Gram-negative bacteria and uses thereof.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to devices used to pull connectorized optical fiber cables through cable ducts, and more particularly, to such devices for use with what is known as loose buffer tube optical fiber cable.
2. Description of the Prior Art
The use of optical fibers is becoming prevalent in the telecommunications and data communications industries, and new building structures are being provided with cable ducts for the subsequent installation of optical fiber cables. Additionally, the telephone companies have found that the space in existing duct systems can be more effectively utilized by the use of optical fiber cable because of its small outer diameter, which is typically less than 0.90 inch.
A typical 4-inch duct has installed therein sub-ducts such as, for example, three 11/4-inch sub-ducts, or four 1-inch subducts, through which optical fiber cable is to be installed.
A typical optical fiber cable is represented in FIG. 1, where there is shown a loose buffer tube type cable 2. The cable is formed about a central strength member 4 which may be formed of either a single steel or a dielectric member or a plurality of twisted members. Disposed about the central strength member 4 is usually a plastic jacketing material 6. Buffer tubes 8 carrying optical fibers 10 are wrapped around the central strength member in a helical or reverse helical manner. On occasion, filler tubes, such as a tube 12 are used to take up space when the cable capacity does not require the use of all buffer tubes. A binder tape or thread 14 is helically wrapped around the buffer tubes for maintaining them in the proper orientation, and a first inner polyethylene jacket 16 is extruded about the binder tape. A ripcord 18 is provided to assist in removing the inner jacket 16. A strength and protective member in the form of a corrugated steel armor layer 20 may be provided for additional protection against possible rodent damage. The armor 20 is usually coated with a thin layer of plastic material. A second ripcord 22 is used to assist in removal of the armor 20. A final polyethylene outer jacket 24 is provided for additional cable protection.
The above structure is a typical loose buffer tube cable construction used in many optical fiber installations at the present time.
Due to the extremely small size of the optical fiber and the difficulty of making fiber splices in the field, it has become common to provide connectorized optical fiber cables wherein connectors are provided at the ends of each buffer tube 8 for connecting the fibers within the buffer tube to the fibers of another cable. Connectorized cables are produced by a number of manufacturers including Alcatel Cable Systems and AT&T.
Due to the fragile nature of optical fibers, pulling cables through pre-installed ducts is a difficult and tedious task, which task is exacerbated when the cable is connectorized and a plurality of connectors at the ends of buffer tubes must also be pulled through the ducts. Invariably, the cable connectors would be damaged during installation. Pulling eye assemblies were devised to facilitate the installation of cables through ducts. The pulling eyes provided a means for gripping the cable and, in particular, the strength components of the cable, so that stresses would not be exerted on the optical fibers while the cable was pulled through the duct system. With the advent of the connectorized optical fiber cables, the pulling eyes assumed an additional task of protecting the cable connectors during installation.
Most manufacturers of connectorized cable provide some form of pulling eye. In most pulling eyes, a braided metallic hose was used to attach a nose piece to a cable clamping device, with the pulling tension being exerted on the braided metal hose, as opposed to the cable components. The protected interior of the braided metal hose provided a secure chamber in which the cable connectors could be protected.
Due to the small size of the cable ducts, the cable diameter had to be maintained at a minimum, as did the diameter of the pulling eye assembly. Most existing pulling eyes have too large a diameter and therefore require larger duct sizes. In addition, the pulling eye had to be of such size that it could pass through bends having a predetermined minimum radius. A standard size requirement for pulling eyes is that a cable with an outer diameter of 0.750 inch must pass through a 1-inch sub-duct with a 24-inch bend radius.
Another requirement that must be met during the installation of a non-dielectric connectorized cable through existing ductwork is that electrical continuity must be maintained throughout the length of the optical fiber cable system, so that the cable can be grounded to drain any electrical charge that may build up on the cable, either as a result of static electricity or inadvertent contact with an electrical source. Thus, grounding of the steel armor layer is essential for safety purposes.
SUMMARY OF THE INVENTION
The present invention contemplates a pulling eye assembly to be used for pulling connectorized loose buffer tube cable through ducts. The pulling eye assembly is designed to protect the loose buffer tubes, the optical fibers and the connectors during installation and use. The pulling eye is designed to provide electrical continuity when the cables are installed using metallic components. The design is such that moisture is prevented from entering the optical fiber cable at junction points between cables.
The pulling eye uniquely uses a soft metal crimping sleeve having a serrated inner surface adapted to receive the cable diameter and at least a strip of cable armored material which is folded back, for providing electrical continuity with the crimping sleeve. A collet holder is provided with a conical central opening for receiving the cable strength member and longitudinal channels formed along an outer surface for receiving the buffer tubes. A pair of collets are driven into the conical opening of the collet holder through the use of a hollow set screw to forcibly engage the cable strength, member. A tubular housing is disposed over the collet holder to maintain the buffer tubes in their proper position, and to rigidly engage the crimping sleeve at one end and a braided metal hose at a second end, in which the connectors associated with the buffer tubes are protectively disposed during installation of the optical fiber cable.
The crimping sleeve is crimped onto the outer jacket of the cable and over a strip of steel armor for providing a waterproof connection and electrical continuity. 0-rings are provided on the crimping sleeve and on one end of the braided hose assembly to provide a watertight seal with the tubular housing.
A primary objective of the present invention is to provide a pulling eye assembly which may be used to pull connectorized loose buffer tube type optical fiber cables through cable ducts.
Another objective of the present invention is to provide a pulling eye assembly that protects the loose buffer tubes, optical fibers and connectors during installation and use.
Another objective of the present invention is to provide electrical continuity between optical fiber cables being connected together and any additional metal components used in the connection housing.
Another objective of the present invention is to provide a pulling eye assembly which protects the optical fibers and connectors from water ingress.
Another objective of the present invention is to allow the installation of a cable with an outer diameter of up to 0.75 inch into a 1-inch sub-duct with a 24-inch bend radius.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective cutaway view showing an optical fiber cable of the prior art.
FIG. 2 shows a connectorized optical fiber cable.
FIG. 3 shows an assembled pulling eye attached to an optical fiber cable.
FIG. 4 is an exploded view showing the components of the pulling eye assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 2, there is shown a connectorized cable 2 having attached thereto a cable clamping apparatus 26 of a pulling eye assembly of the present invention. The cable clamping apparatus 26 engages the central strength member 4 of cable 2 and also has a portion thereof crimped onto the outer cable jacket 24 of cable 2. Shown extending through the cable clamping apparatus are three buffer tubes 8, one of which is shown connected to a flexible spiral tubing 28, through which the optical fibers extend for connection to a connector 30. Connector 30 is any one of several available standard optical fiber connectors; however, the invention is shown using the LIGHTRAY connector sold by Alcatel Cable Systems, Inc. of Claremont, N.C. A strain relief mechanism 32 is disposed between the connector 30 and the flexible spiral tubing 28, and a removable dust cover 34 is disposed over the connector 30.
Prior to installation of the cable clamping apparatus onto the cable, a portion of the corrugated steel armor 20 is stripped and folded back, as shown at 36 in FIG. 2. This portion of the steel armor is in electrical contact with the cable clamping apparatus 26. It is to be understood that each of the buffer tubes 8 that is used is terminated with a connector 30; however, for the sake of clarity only one tube is shown with a connector. Preferably the buffer tubes are terminated at different lengths so that no two connectors 30 are at the same distance from the cable clamping apparatus 26, thereby facilitating the placement of the connectors within the pulling eye assembly.
Referring to FIG. 3, there is shown an assembled pulling eye comprising a cable clamping apparatus 26 and flexible hose assembly 37. Hose assembly 37 includes a nose piece 38, a braided metal hose 40 and a connector collar 42, all structurally connected together and connected as an assembly to the cable clamping apparatus 26. The braided metal hose 40 provides a hollow interior space into which the buffer tubes and connectors may be protectively disposed. The braided hose 40 includes corrugated internal components which provide both flexibility and a hermetic seal for the prevention of the ingress of moisture to the optical fibers and connectors. An outer layer of braided metal is provided to transfer a pulling force exerted on the nose piece 38 to the cable clamping apparatus 26 without exerting tension on the optical fibers contained within the hose 40.
Referring to FIG. 4, there is shown an exploded view of the pulling eye assembly of the present invention comprising the cable clamping apparatus 26 and the hose assembly 37. The cable clamping apparatus 26 includes a crimping sleeve 44 formed of a non-corrosive, malleable, electrically-conductive metal, such that it may be crimped over the jacket of cable 2. Crimping sleeve 44 has an opening therethrough, defined by an inner surface having a diameter slightly larger than the outer diameter of cable 2. Formed on the inner surface of the crimping sleeve are serrations 46, which could be in the form of threads and function to improve the grip to the outer jacket, and to pierce the thin plastic coating disposed over the corrugated steel armor 20, a strip of which is shown as 36 in FIGS. 2 and 3.
Crimping sleeve 44 includes a collar 48 having four depressions 50 formed in an outer surface thereof and disposed 90 degrees apart. A shoulder 52 is formed on the collar, and a O-ring 54 is positioned against said shoulder. Preferably the crimping sleeve is formed of brass, which provides the desired physical and electrical characteristics for the crimping sleeve.
During installation of the crimping sleeve onto cable 2, the various layers of the cable are stripped back appropriate distances, and a portion of the steel armor 20 is folded back over the cable outer jacket 24. The outer jacket adjacent the stripped end is coated with a silicone gel, and the crimping sleeve 44 is slipped over the cable components, to a position so that it encompasses the coated portion of the outer jacket 24. The crimping sleeve 44 is then crimped onto the cable jacket preferably using an octagon-shaped crimping tool, so that the metal is not excessively deformed and a good seal is formed between the crimping sleeve and the outer jacket 24. During crimping, the serrations 46 pierce the coating of the armor strip 36 to provide electrical contact between the crimping sleeve and the corrugated armor 20 and also penetrate the outer jacket for improved gripping.
The various layers of the cable 2 are stripped and the buffer tubes containing the optical fibers are cut so that each extends a different distance from the end of the jacket 24. The central strength member 4 is cut to protrude only slightly beyond an end of the jacket 24. The jacket 6 over the central strength member 4 is stripped back, and the central strength member is preferably roughened so that the pulling eye assembly makes a secure attachment thereto.
A collet holder 56 is adapted to receive a pair of collets 66 for gripping the central strength member 4 of cable 2. The collet holder 56 is formed of a non-corrosive material, such as stainless steel, and includes a central cylindrical portion 58 having a conical opening 60 extending therethrough. Opening 60 is partially conical and partially cylindrical. The conical portion is at an end adjacent the crimping sleeve and widens in the direction away from sleeve 44. The cylindrical portion is threaded and has a diameter approximately equal to the maximum diameter of the conical portion. Longitudinal channels 64 are symmetrically located around the exterior of the cylindrical portion 58.
The collet holder 56 could be machined from a single piece having a central opening, with an external surface having formed therein channels. In the alternative, the collet holder 56 could be molded from a hard synthetic material, such as plastic, with only the threads being machined. A hollow set screw 68 has an opening 70 formed therethrough, through which the central strength member 4 is disposed.
During assembly, the central strength member 4 extends into the center of the collet holder 56, with one of said collets 66 disposed on each side of the central strength member. The set screw 68 is slipped over the central strength member and is threaded into the threaded portion of the opening 60 to forcibly drive the collets 66 into the conical portion of opening 60 so as to exert a clamping force onto the central strength member 4.
The buffer tubes 8 are disposed in the channels 64 of collet holder 56 so that the buffer tubes are protected and guided through the cable clamping apparatus 26.
A stainless steel cylindrical sleeve 72 has eight threaded openings 74, four disposed at each end thereof, at positions, 90 degrees apart. The sleeve 72 is slipped over the collet holder 56 and is secured to the collar 48 of the crimping sleeve 44 through the use of four set screws, not shown, which are threaded into openings 74 so as to engage the depressions 50 formed in collar 48. 0-ring 54 engages both the crimping sleeve 44 and the sleeve 72 to provide a hermetic seal therebetween.
The hose assembly 37 includes, at an inner end thereof, an extension of the collar 42 which includes a shoulder 76 against which an 0-ring 78 is disposed. Four depressions 80 are formed in a surface of the collar and are located at positions displaced 90 degrees from each other.
During assembly, the buffer tubes 8 terminated by the connectors 30 are inserted into the hose assembly, which assembly is inserted into the far end of sleeve 72 and is attached thereto by the use of set screws, not shown, inserted into the threaded openings 74 for engaging the depressions 80. The set screws are threaded sufficiently far into the threaded openings 74 so that they do not extend significantly above the surface of the sleeve 72. The 0-ring 78 engages the surface of collar 42 and sleeve 72 to provide a hermetic seal therebetween.
After the complete assembly of the pulling eye onto a connectorized optical fiber cable, a flexible wire or rope is guided through the duct so as to extend the full length of the duct, after which, the wire is attached to the nose piece 38, so that the cable may be pulled through the duct. The tension on the pulling eye assembly is exerted through the braided metal hose 40, so that no strain is exerted on the optical fibers. The optical fibers are maintained within the buffer tubes, and the buffer tubes and connectors are protected within the hose assembly 40 to prevent damage during the installation procedure. Electrical continuity is provided from cable to cable to prevent injury from accumulated static electricity or the accidental contact of the cable to an electrical source. The assembly is water tight to prevent the ingress of water, which would deteriorate the optical fibers and the connectors. The components are of sufficiently small size that they may be slid without difficulty through a 1-inch sub-duct, even with a 24-inch bend radius.
After the cable is fully installed within the duct, the hose assembly 37 of the pulling eye is removed, while the cable clamping apparatus 26 remains attached to the cable to protect the fibers and to provide electrical continuity. If the cable is terminated in a junction box or housing, a lead wire can be connected from the housing to the sleeve 72 and attached by means of a screw inserted into one of the threaded holes 74. Alternatively, electrical continuity may be established by securing the pulling eye in the housing with a metallic clamp. The junction box or housing may then be connected to ground to provide a means for discharging any electricity.
Thus, the above-described pulling eye assembly provides a unique structure that satisfies all of the objectives heretofore set forth. The use of the collet holder significantly reduces the pulling eye diameter by allowing the loose buffer tubes to fit into the closely-spaced channels, thereby maintaining minimum diameter. The serrated interior surface of the crimping sleeve provides for both electrical continuity and a good hermetic seal.
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A pulling assembly for connectorized optical fiber cables is formed of a flexible metal braided hose portion for conveying a pulling force to said cable and for providing a chamber in which the cable connectors may be housed during a cable pulling operation. A cylindrical housing is attached to one end of said braided metal hose and includes a concentrically-arranged central strength member gripping apparatus and a buffer tube alignment structure disposed about the central strength member gripping apparatus. A crimping sleeve is attached to an opposite end of said cylindrical housing fixing said concentric arrangement within the cylindrical housing and being crimpably engageable with an outer surface of an optical fiber cable.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a United States National Phase application of International Application PCT/EP2008/001895 and claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2007 013 175.7 filed Mar. 20, 2007, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a process and an automatic commissioning unit for filling an order container by means of ejectors and a conveyor belt.
BACKGROUND OF THE INVENTION
[0003] An automatic commissioning unit with ejectors for commissioning products onto a conveyor belt, in which the products commissioned onto the conveyor belt are transported to an order container and are released into this order container, is known from EP 0 213 360 A1. A product storage means, which extends as a vertical shaft slightly inclined in relation to the vertical direction of the automatic commissioning unit, is arranged in front of and above each ejector. Products of the same class are stacked up in direct contact one on top of another in the vertical shaft. The horizontal ejector located at the deepest point of the product stack pushes out, when necessary, the lowermost product of the stack in the direction of the conveyor belt. If the lowermost product has been pushed out, the product stack is displaced downward by the height of one product under its own weight. Products can thus be ejected or commissioned in a separate manner. The drawback is, besides the limited height of the product stack or product storage capacity, especially that only stackable products can be stored and commissioned, mostly in a cuboid form. Bulky products cannot be handled. If bulky, i.e., nonstackable products shall be jointly commissioned, these products must be commissioned by a human operator manually from a storage container and either placed on the conveyor belt or introduced directly into the order container.
[0004] The object of the present invention is to create a process and an automatic commissioning unit of the type mentioned in the introduction for filling an order container, in which bulky, i.e., nonstackable products can also be commissioned reliably, rapidly and effectively.
SUMMARY OF THE INVENTION
[0005] The basic object of the present invention is accomplished by a process and commissioning unit according to the invention.
[0006] The essence of the present invention in a process and automatic commissioning unit mentioned in the introduction for filling an order container by means of ejectors and a conveyor belt is that products to be commissioned are stored in the ejectors themselves, which are designed as a circulating belt, as a horizontal product row when the circulating belt is stopped, and are released onto the conveyor belt or directly into the order container by actuating the circulating belt. The ejector is consequently designed according to the present invention itself as a (main) product storage means of the automatic commissioning unit—not as, e.g., an auxiliary storage means, for example, adjoining a flow shelf. The ejector according to the present invention does not have to extend exactly horizontally. It is obvious that it may also be inclined and hence arranged obliquely in relation to the horizontal. Identical products belonging to the same class are primarily stored in a single product storage means. When the circulating belt is actuated, a minimum filling level of products stored on the circulating belt is automatically measured and the circulating belt is automatically stopped for refilling products
[0007] In particular, the circulating belt can be moved backwards for refilling products by a predetermined amount automatically or by manual actuation. The minimum filling level of products being stored on the circulating belt can be displayed optically or/and acoustically.
[0008] Each product to be commissioned may preferably be introduced into and stored, separately, on a product storage place of the circulating belt, preferably in a product compartment, and the products being stored on the product storage places, especially in the product compartments, may be released separately.
[0009] When speaking of a circulating belt, this may also be a circulating link chain, a cleat belt or nap belt or the like within the framework of the present invention.
[0010] In particular, bulky, irregularly configured products—products for which handling cannot be automated with the ejectors known from the state of the art described in the introduction—can be stored and commissioned into an automatic commissioning unit by the present invention in such a manner that this can be handled by means of an automatic commissioning unit. The handling of products of nearly any desirable dimensions or shapes can be automated, such as teddy bears, peanut bags, coffee packs, gauze bandages and the like. Cuboid dimensions are not necessary. Stackability of the products is not a prerequisite.
[0011] One or more products are thrown onto the conveyor belt positioned at the head end of the circulating belt if necessary. The conveyor belt is preferably the central belt of the automatic commissioning unit itself. The ejector may be actuated with conventional central belt technology. Products are now thrown onto an area of the central belt that is assigned to an order at the correct point in time.
[0012] It is, furthermore, advantageous that the manual operation of filling the product storage means is uncoupled in time from the commissioning operation (“stock in the pipeline”). Refilling guided by filling level display at the end of the pipeline is possible. The present invention makes possible any desired design combination with existing automatic central belt units (modular design). Essentially horizontal product storage means are possible not only next to each other, arranged at a distance or without a distance from one another, but also in two or more levels one on top of another. Various pipeline widths and different distances between naps or transverse walls may be set up depending on the dimensions of the products.
[0013] The products stored in product compartments may be preferably released partly sliding onto the conveyor belt under their own weight. Conventional product columns with stackable products may also be stored in vertical shafts in the automatic commissioning unit and fed to the conveyor belt by means of lower, conventional pushing ejectors.
[0014] The ejector according to the present invention may be used for filling level management and/or automatic inventory control.
[0015] The product storage places, especially the product compartments, may also be defined as virtual deposition sites for products.
[0016] The present invention will be described in more detail below on the basis of exemplary embodiments with reference to the drawings attached. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the drawings:
[0018] FIG. 1 is a schematic perspective view of an automatic commissioning unit according to the present invention with a central conveyor belt and ejectors in the form of horizontal product storage means located in one plane;
[0019] FIG. 2 is a perspective view of a product storage means according to FIG. 1 ;
[0020] FIG. 3 is a schematic cross sectional view through a product storage means with omission of the longitudinal side walls;
[0021] FIG. 4 is a schematic side view of the automatic commissioning unit according to FIG. 1 with another plane of horizontal product storage means;
[0022] FIG. 5 is a schematic top view of an automatic commissioning unit according to the present invention together with adjacent overstock shelves;
[0023] FIG. 6 a is a product storage means according to FIG. 4 shown in one of four positions of a filling of products from the rear according to the right side of the drawing;
[0024] FIG. 6 b is a product storage means according to FIG. 4 shown in another one of four positions of a filling of products from the rear according to the right side of the drawing;
[0025] FIG. 6 c is a product storage means according to FIG. 4 shown in another one of four positions of a filling of products from the rear according to the right side of the drawing;
[0026] FIG. 6 d is a product storage means according to FIG. 4 shown in another one of four positions of a filling of products from the rear according to the right side of the drawing; and
[0027] FIG. 7 is a detail view taken from the right-hand part of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring to the drawings in particular, According to FIGS. 1 , 4 and 5 , an automatic commissioning unit 1 comprises ejectors in the form of horizontal product storage means for commissioning products 3 onto a conveyor belt 2 , wherein the products 3 commissioned onto the conveyor belt are transported to an order container 10 and are released into this order container. The order container contains the products of a single commissioned order.
[0029] The automatic commissioning unit 1 is a so-called automatic central belt unit and has such a lower, horizontal conveyor belt 2 in the form of a so-called central belt, which extends longitudinally centrally in relation to the A-frame 8 of the automatic commissioning unit.
[0030] Assigned to the automatic commissioning unit 1 are overstock containers or shelves 11 , 12 on one longitudinal side of the automatic commissioning unit 1 proper according to the top part of FIG. 5 , and overstock containers or shelves 13 on the other longitudinal side according to the bottom part of FIG. 4 , namely, in the reaching area of the hands of human operators, who fill the automatic commissioning unit with products on both sides. It can be seen that a minimum product filling level has been reached during a commissioning.
[0031] The longitudinal side of the automatic commissioning unit 1 located to the left of the A-frame 8 in FIG. 4 is filled with stackable products from the overstock shelf 13 as in the state of the art described in the introduction. The products are then located in a stack in vertical commissioning shafts, which are located in the left oblique plane of the A-frame 8 according to FIG. 4 .
[0032] The longitudinal side of the automatic commissioning unit 1 located to the right of the A-frame 8 in FIG. 4 is filled according to the present invention, by contrast, with bulky, i.e., nonstackable products 3 from the overstock shelves 11 and 12 , as will be described below.
[0033] The horizontal product storage means according to the present invention is a drivable circulating belt 4 , which can be actuated for the separate ejection of a product 3 onto the conveyor belt 2 , with product storage places, especially with product compartments 5 , which extend in a dense row along the circumference.
[0034] The product compartments 5 have vertical naps, bars or transverse walls 6 according to FIGS. 2 and 7 , which extend over the entire width of the circulating belt 4 , preferably at right angles to the circulating belt.
[0035] In another embodiment variant, the product storage places, especially the product compartments 5 , may be arranged in a dense row along the circulating length of the circulating belt 4 and defined as virtual deposition sites for products 3 .
[0036] The distance between adjacent naps, bars or transverse walls 6 is adjustable.
[0037] The circulating belt 4 according to FIG. 3 has a profile 4 ′ having a double T-shaped cross section, which is displaceably guided in a self-supporting aluminum profile 14 and is driven by a motor M on the head side of the circulating belt 4 according to FIG. 4 . Brackets 21 are arranged laterally from the profile 4 ′ for a sensor system as well as lateral guides (not shown) and covers. The aluminum profile 4 ′ transmits the weight of the products 3 to a module bracket or the A-frame 8 . The weight of the products 3 is supported at the rear longitudinal end E 2 of the circulating belt 4 on the floor via vertical supports 9 .
[0038] The sensor system of each circulating belt 4 comprises four sensors. A refill sensor 15 according to FIG. 2 , which is shown in an enlarged detail view in FIG. 7 , is located in the rear part of the circulating belt. An empty sensor 16 and an ejection sensor 17 according to FIGS. 2 and 6 a through 6 d are located in the front head part of the circulating belt 4 on the upper side of the circulating belt, and a positioning sensor 18 or nap sensor, which is needed for accurately positioning the circulating belt, are located on the underside.
[0039] The circulating belt 4 may be composed of chain links
[0040] Individual chain links may be designed as transverse walls, which can be installed at desired longitudinal distances to form an individual product compartment 5 .
[0041] The carrying run of the circulating belt 4 has stationary vertical longitudinal side walls 7 according to FIG. 2 .
[0042] The distance between the two longitudinal side walls 7 may optionally be made adjustable.
[0043] One longitudinal end E 1 of the circulating belt 4 is located above or in the area of the conveyor belt 2 , and each product storage place, especially each product compartment 5 , is provided for a single product 3 .
[0044] In the top view, the circulating belt 4 extends at right angles or obliquely to the conveyor belt 2 .
[0045] The product storage places, especially the product compartments 5 , of the carrying run of the circulating belt 4 can be equipped with products.
[0046] A plurality of horizontal circulating belts 4 are arranged preferably directly next to one another, as this can be seen especially in FIG. 1 .
[0047] According to FIG. 5 , an operating space B for laterally filling the product storage means by a human operator may be provided between circulating belts 4 arranged next to each other.
[0048] Even though only a single horizontal plane is shown in FIG. 1 at horizontal circulating belts in one embodiment variant, a plurality of horizontal circulating belts 4 are arranged one on top of another in another embodiment variant, as this is schematically shown in FIG. 4 .
[0049] Circulating belts 4 located higher are optionally placed obliquely and are located deeper on the side facing away from the conveyor belt 2 .
[0050] The aforementioned, essentially horizontal circulating belts 4 are shown in the arrangement according to the top left part of FIG. 5 . A human operator fills these circulating belts 4 , if necessary, from the rear longitudinal end E 2 of the circulating belts, from the longitudinal side L or from the operating space B. The human operator brings the nonstackable products 4 needed for filling from the overstock shelves 11 located within reach. The human operator confirms the performed filling by actuating a button.
[0051] Furthermore, circulating belts 4 , which are operated by a human operator, are provided in the nearly vertical plane of the A-frame 8 of the automatic commissioning unit 1 in the exemplary embodiment according to FIG. 5 on the upper longitudinal commissioning side, on the right side. The human operator fills these vertical circulating belts 4 when needed with nonstackable, rarely commissioned products (“slow turnover items”), which are kept ready in the overstock shelves 12 located within easy reach.
[0052] To fill an order container 10 in an automatic commissioning unit 1 by means of ejectors and conveyor belt 2 , products 3 to be commissioned are stored in the ejector itself, designed as a circulating belt 4 , as a horizontal product row R preferably when the circulating belt 4 is stopped and released onto the conveyor belt 2 or directly into the order container 10 by actuating the circulating belt.
[0053] Each product 3 to be commissioned is entered separately, on a product storage place each of the circulating belt 4 , preferably into a product compartment 5 of the circulating belt, and stored, and the products being stored on the product storage places, especially in the product compartments, are released separately.
[0054] The products 3 being stored in the product compartments 5 are released during commissioning onto the conveyor belt 2 according to FIG. 4 under their own weight, partly sliding.
[0055] A filling operation of a circulating belt 4 from the rear end E 2 will be described below on the basis of FIGS. 6 a through 6 d.
[0056] With the circulating belt 4 actuated, a minimum filling level F of products 3 being stored on the circulating belt is automatically measured and the circulating belt, which is moving counterclockwise during a commissioning operation according to FIG. 6 a , is automatically stopped. Stopping is brought about according to FIG. 6 a by the empty sensor 16 , which recognizes the empty space of the assigned product compartment in the absence of a product 3 and it not only stops the circulating belt but also sends an optical and/or acoustic message to the half-empty display 19 at the rear end of the circulating belt 4 . The human operator then recognizes from the half-empty display the fact that the minimum degree of filling is not reached and is directed to this circulating belt. A button 20 for requesting filling, with which the horizontal product row of the minimum filling level F is moved in the direction of the arrow according to FIG. 6 a into the rearmost position of the circulating belt according to FIG. 6 b , is arranged at the rear end of the circulating belt. The refilling sensor 15 recognizes there the presence of the product row and moves again to the left by one product compartment according to the direction of the arrow in FIG. 6 b . According to FIG. 6 c , the human operator now fills a product 3 into the rearmost product compartment, and the refill sensor 15 moves the circulating belt by one product compartment in the direction of the arrow in FIG. 6 c . The human operator now fills one product 3 after another, always into the rearmost product compartment, until the ejection sensor 17 at the head of the circulating belt recognizes the filled frontmost product compartment and stops the circulating belt. If the circulating belt or the product storage means is filled according to FIG. 6 d , the human operator is prompted by the display 19 to again confirm the performed filling with the button 20 . The ejector is inactive for the duration of filling. Since filling usually takes place outside the commissioning times, this is not a problem.
[0057] Consequently, the circulating belt 4 is moved backwards by a predetermined amount automatically or by manual actuation for refilling products 3 , and the minimum filling level F of products being stored on the circulating belt 4 is displayed optically and/or acoustically.
[0058] The ejector may be used to manage the filling level and/or to automatically control inventory.
[0059] In particular, the ejector manages the degree of filling by counting the ejections that have taken place since the last filling by means of the ejection sensor 17 and relating them to the overall pipeline length or product storage means length.
[0060] The control computer of the automatic commissioning unit can prompt the pipeline or product storage means for inventory for an automatic inventory control. The pipeline now moves its product row R backwards and again forwards only once and counts the free product compartments.
[0061] The needed feeding of products can also be detected. The refilled quantity is automatically detected by the guided filling of the pipelines at the rear end and a report on this quantity can be passed on to a higher-level inventory management system.
[0062] While specific embodiments of the invention have been described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A method and an automatic picking machine is provided for filling an order container by means of an ejector and conveyor belt. An ejector is provided configured as a revolving belt directly as a substantially horizontal product storage element. The stored products ( 3 ) to be picked are placed onto the conveyor belt ( 2 ) or directly into the order container ( 10 ) upon actuation of the revolving belt. The preferably bulky non-stackable products ( 3 ) are located preferably individually in product compartments ( 5 ) of the ejector and are ejected individually.
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FIELD OF THE INVENTION
This invention relates to the regulation of blood flow in human patients. More particularly, it relates to the therapeutic use of a known compound in the prevention and/or treatment of complications associated with unsatisfactory circulation, e.g. of the type that are observed in diabetics, although the treatment is also suitable for non-diabetics.
BACKGROUND OF THE INVENTION
The compound 4-guanidinobutyramide (hereinafter "4GAB"), having the formula HN═C(NH 2 )--NH--(CH 2 ) 3 --CONH 2 , is a naturally-occurring compound that is known for therapeutic purposes. GB-A-1195199 and GB-A-1195200 disclose 4GAB as a hypoglycaemic agent, the latter in combination with insulin, for the treatment of diabetes. In U.S. Pat. No. 3,639,628, 4GAB is shown to reduce abnormally high levels of blood urea in diabetics. It is also stated that "improvements of retinopathy and neuropathy have been observed"; it has now been shown that 4GAB has little or no effect on retinopathy, and indeed that it is not effective at the capillary level.
Aminoguanidine is a compound having a somewhat similar structure to 4GAB, which has been proposed for the prevention of diabetic complications. Aminoguanidine may suppress advanced glycosylation end-products, and has been reported to prevent the capillary lesions of retinopathy in diabetic rats.
SUMMARY OF THE INVENTION
According to the present invention, 4GAB or a physiologically-acceptable salt thereof, is used for the purposes of arteriolar dilatation. 4GAB is therefore useful in the regulation of blood flow, and in the prevention and/or management of complications that are observed, often in diabetics, in tissues such as the kidneys, nerves, skin and Islets of Langerhans. It may also have utility in treating male impotence (in diabetic cases, perhaps in cases of senile impotence, and more generally), by facilitating penile erection.
DESCRIPTION OF THE INVENTION
Without wishing to be bound by theory, it appears that 4GAB exerts its dilatatory effect through NO release through small vessels, arterioles. 4GAB is a compound in the metabolic sequence from the brain constituent GABA to arginine which itself is a precursor of NO. The metabolism of 4GAB to arginine is controlled by enzymes that may be glucose-related.
This mechanism explains the absence of effect on retinopathy and perhaps also the effects that have previously been associated with the administration of 4GAB. The mechanism and the results presented below show that 4GAB is of particular utility in treating or preventing renal complications, neuropathy and autonomic neuropathy (possibly by affecting neuronal nutrition) and providing improved circulation, e.g. in dementias or in counteracting the reduced circulation usually observed in old age.
In both diabetic and non-diabetic patients, 4GAB may act as an anti-neuropathic and, at least in some cases, as a protrophic agent. For example, it may reverse peripheral neuropathy and also incontinence associated with lack of suppression of urination. Infants lack control through a regular cycle of release, and a similar condition can develop in adult life and particularly in old age.
The possible mechanism and effects of 4GAB have been confirmed by the injection of radioactively-labelled 4GAB into mice. Radioautographs showed that almost all the injected 4GAB was immediately taken up in the walls of blood vessels. No specific localisation in any of the body organs concerned with glucose metabolism, e.g. the liver, kidneys and muscles, could be recognised.
4GAB can be produced simply and inexpensively. It is essentially non-toxic. It can be formulated with physiologically-acceptable carriers or excipients of any conventional type, depending on the mode of administration. Formulations, modes of administration and dosages are exemplified in GB-A-1195200 and U.S. Pat. No. 3,639,628, the contents of which are herein incorporated by reference.
The following Examples illustrate the utility of 4GAB.
EXAMPLE 1
A subject who was healthy but whose peripheral circulation was poor took tablets of 4GAB for a month. He reported a return of libido and penile erections, and that his feet were warmer to the touch.
EXAMPLE 2
Before treatment with 4GAB, a diabetic patient had a high fixed pulse rate. When he performed the Valsalva manoeuvre, it was obvious that he had lost the variations of pulse rate associated with slow deep breathing and forced breathing. This was presumably due to a specific diabetic autonomic neuropathic effect inhibiting the vagus nerve impulses to his cardiovascular system. An electrocardiogram of the patient showed the fast fixed pulse rate and, more importantly, a failure for any alteration of pulse rate as a result of deep breathing.
The patient was given 500 mg of 4GAB by mouth three times a day for two weeks. At the end of the treatment, his resting pulse had fallen from a fixed rate of 95 to just over 80 per minute and there were small variations in his pulse rate during deep breathing.
EXAMPLE 3
A group of 8 diabetics with fast resting pulses was tested. The pulses were monitored both at rest and during the Valsalva manoeuvre.
Administration of 4GAB was associated with a clear reduction in the resting pulse rate, which returned to earlier levels within 2-3 months of ceasing therapy. It was also observed that the patients were brought under control after 2-3 months by repeating the therapy. 7 of the 8 subjects showed an improvement in the sinus arrhythmia reflex, i.e. a return of pulse variation.
EXAMPLE 4
A patient whose diabetes had been treated over 30 years with insulin suffered from numbness in her feet. After 1-2 years of therapy with 4GAB, her requirement for insulin was reduced, and the patient reported sensations of feeling in her previously numb feet and also that sweating had returned in the skin of her lower legs. The administration of 4GAB did not prevent deterioration in her vision and the occurrence of retinal haemorrhages from her diabetic retinopathy. These observations are consistent with the theory that 4GAB affects the blood flow to the Islets of Langerhans.
EXAMPLE 5
A long-term diabetic patient was suffering from mild diabetic neuropathy, albumin urea and a succession of mild renal infections. Her treatment was augmented by the adminstration of 500 mg 4GAB per day, in tablet form. The 4GAB had a sparing effect on her insulin requirement. The clinical progress of her retinopathy was not affected, but the progress of her renal disease was, in contrast, remarkably slow. In the early stages of the augmented treatment, her glomerular filtration rate (GFR) was 28-30. 10 years later, her GFR was recorded as 40 (without any corresponding rise in blood urea levels).
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The subject invention pertains to methods of using 4-guanidinobutyramide, or a physiologically-acceptable salt thereof, in a mammal or human to improve blood circulation.
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BACKGROUND OF THE INVENTION
1. Field of the Prior Art
The present invention relates to ferroelectric liquid crystal compositions. More particularly, the present invention relates to ferroelectric liquid crystal compositions having a quick response property wherein the phase transition series assumes an isotropic liquid→a cholesteric phase→a chiral smectic C phase in the named order from the high temperature side without assuming a smectic phase, and to switching elements using the same.
2. Description of the Prior Art
Liquid crystal compounds are widely used as materials in display elements, and most of these liquid crystal elements are of the TN type display system, and the liquid crystal materials are in the nematic phase.
The TN type display system has advantages such as moderated eye fatigue and extremely small consumption of electric power because of being a non-emissive type, whereas it has disadvantages such as slow response and disappearance of display at certain visual angles.
In recent years, this system is being improved in such ways as to keep the characteristics of flat displays, and particularly, a faster response and the enlargement of the visual angle are demanded.
In order to meet these demands, improvements in liquid crystal materials have been attempted. However, as compared with other emissive type displays (e.g., electroluminescence displays and plasma displays, it is apparent that the TN type display has a much slower response time and has a smaller visual angle.
In order that characteristics of the liquid display element such as features of the non-emissive type and small consumption of electric power may be maintained and in order that a quick response corresponding to that of the emissive type displays may be assured, it is essential to develop a novel liquid display system in place of the TN type display system.
In one of such attempts, a display system in which the optical switching phenomenon of ferroelectric liquid crystals is utilized has been suggested by N.A. Clark and S. T. Lagewall (see Appl. Phys. Lett., 36, p 899, 1980).
The presence of the ferroelectric liquid crystals was announced for the first time in 1975 by R. B. Mayer et al. (see J. Phys., 36, p 69, 1975), and from the view of structure, these crystals belong to the chiral smectic C phase, the chiral smectic I phase, the chiral smectic F phase, the chiral smectic G phase, and the chiral smectic H phase (hereinafter referred to simply as "S C *", "S I *", "S F *", "S G ", and "S H *", respectively).
In the chiral smectic phase, molecules are in layers and inclined with respect to the surface of the layer, and the helical axis is vertical to this layer surface.
In the chiral smectic phase, spontaneous polarization takes place, and therefore, when a DC electric field is applied to these layers in parallel with the layers, the molecules turn around the helical axis in accordance with its polarity. The display element of ferroelectric liquid crystals utilizes this switching phenomenon.
Nowadays, of the chiral smectic phases, much attention is particularly paid to the S C * phase.
The display system in which switching phenomenon of the S C * phase is utilized can be further classified into two types: a birefringence type system using two polarizers and a guest/host type system using a dichroic dye.
Features of these display systems are:
(1) Response time is very short.
(2) Memory properties are present.
(3) Display performance is not affected by the visual angle.
Thus, the display systems have the possibility of achieving the high-density display and is considered to be effectively utilizable in display elements. However, also in these display systems, there are many problems to be solved.
The display systems that use the switching phenomenon of the S C * phase are accompanied by problems, for example, as follows:
(1) the layers deform into the shape of the letter L (the resulting shape is called the chevron structure), and therefore a zigzag defect is formed;
(2) the molecules adopt a splayed arrangement, and therefore complete memory properties cannot be obtained; and
(3) in order to secure memory properties, it is required to make the thickness of the cell 2 μm or less, but mass production of such a cell is difficult under the present fabrication technique. In particular, the problems under (1) and (2) must be solved for displays utilizing ferroelectric liquid materials as display elements in order to prevent deterioration of display quality.
However, recently, C. Bowry et al. have proposed a new idea to solve the above problems [see Euro Display 87, 33 (1987)].
They state that when a cell to which SiO had been deposited obliquely is used, and as the S C * material, use is made of a material whose phase transition series is the I SO →N*→S C * (wherein I SO stands for an isotropic liquid, and N* stands for a cholesteric phase), the above structure having the shape of the letter L can be obviated, so that the zigzag defect is hardly recognized. According to their idea, the use of a cell having an obliquely deposited thin film has brought about good memory properties.
Therefore, recently, the study of display elements using ferroelectric liquid crystal materials of this system has become very popular.
However, there are few practical ferroelectric liquid crystal materials having an I SO →N*→S C * type phase transition series. For example, since ferroelectric liquid crystal compositions for guest/host type display elements disclosed in Japanese Patent Laid-Open Publication No. 22889/1987 that was filed by the present applicants takes on an I SO →N*→S C * type phase transition series, it can be used in the system proposed by C. Bowry et al.
However, the response time of the ferroelectric liquid crystal compositions disclosed in Japanese Patent Laid-Open Publication No. 22889/1987 is very long (for example in the case of a ferroelectric liquid crystal composition disclosed in Example 4), and is not practical.
Consequently, further improvement in the responsiveness is eagerly demanded.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a ferroelectric liquid crystal composition having quick response properties that possesses an isotropic liquid → cholesteric phase→chiral smectic C phase type transition, and assumes an S C * phase over wide temperature ranges inclusive of room temperature.
A second object of the present invention is to provide an optical switching element excellent in response properties that uses said liquid crystal composition.
According to a first aspect of the present invention, there is provided a ferroelectric liquid crystal composition having quick response properties, characterized in that the ferroelectric liquid crystal composition contains at least each of:
a component A of one or more compounds selected from the group consisting of compounds of the formula (I): ##STR7## wherein R 1 and R 2 , which may be the same or different, represent each an alkyl group having 1 to 18 carbon atoms;
and compounds of the formula (II): ##STR8## wherein R 3 and R 4 , which may the same or different, represent each an alkyl group or an alkoxy group having 1 to 18 carbon atoms;
a component B of a compound of the formula (III): ##STR9## wherein R 5 represents an alkyl group or alkoxy group having 1 to 18 carbon atoms, and * indicates an asymmetric carbon atom;
a component C of a compound of the formula (IV): ##STR10## wherein R 6 represents an alkyl group or alkoxy group having 1 to 18 carbon atoms, X represents ##STR11## Y represents a hydrogen atom or a halogen atom, and * indicates an asymmetric carbon atom; and
a component D of a compound of the formula (V): ##STR12## wherein R 7 represents an alkyl group or alkoxy group having 1 to 18 carbon atoms, n is an integer of 0 to 10, Z represents a hydrogen taom or a halogen atom, and indicates an asymmetric carbon atom,
the proportion of said component A being 20 to 80 wt. %, that of the component B being 5 to 30 wt. %, that of the component C being 3 to 10 wt. %, and that of the component D being 3 to 20 wt. %, preferably the proportion of said component A being 50 to 75 wt. %, that of the component B being 10 to 30 wt. %, that of the component C being 3 to 7 wt. %, and that of the component D being 3 to 20 wt. %, based on the total amount of said four components A, B, C, and D, and the phase transition series assumes an isotropic liquid→a cholesteric phase a chiral smectic C phase in the named order from the high temperature side.
According to a second aspect of the present invention, there is provided a ferroelectric liquid crystal composition, comprising at least the components A, B, C and D defined above and a component E of a compound of the formula (VI): ##STR13## wherein R 8 represents an alkyl group or alkoxy group having 1 to 18 carbon atoms, R 9 represents an alkyl group having 2 to 18 carbon atoms or an alkoxy group having 1 to 18 carbon atoms, and * indicates an asymmetric carbon atom,
with the amount of the component E being 3 to 10 wt. %, based on the total amount of said components A, B, C, and D, and the phase transition series of said composition assumes an order of isotropic liquid→cholesteric phase→chiral smectic C phase, starting from the high temperature side.
In formulae (I) to (VI), the carbon atoms of alkyl groups or alkoxy groups are preferably 6 to 12 in R 1 and R 2 , 4 to 14 in R 3 and R 4 , 5 to 16 in R 5 , 5 to 12 in R , 6 to 12 in R 7 , 3 to 7 in R 8 , 4 to 6 in R 9 .
According to a third aspect of the present invention, there is provided an optical switching element that uses the ferroelectric liquid crystal composition described in the first or second aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The compounds represented by the general formulae (I) and (II) that constitute the component A used in the present invention are non-chiral compounds, but they assume a S C phase, etc., and since they possess very low viscosities, they are very useful in a smectic phase composition as a base. Although the inventors have disclosed their usefulness in Japanese Patent Laid-Open Publication No. 291679/1986, they are also very useful as a component of the ferroelectric liquid crystal composition which the present invention aims at.
For example, the phase transition temperatures of the compound of the general formula (I) wherein R 1 =C 6 H 13 -, and R 2 =C 8 H 17 - are C r -26° C.-S C -47° C.-S A -58° C. -N-65° C.-I SO wherein N represents a nematic phase, the compound assumes an S C phase in a relatively low temperature range while the phase transition temperatures of the compound of the formula (II) wherein R 3 =C 7 H 15 -, and R 4 =C 8 H 17 - are C r -58° C.-S C -134° C.-S A -144° C.-N-157° C.-I SO , and the compound assumes an S C phase in a relatively high temperature range. Therefore, if a compound represented by the general formula (I) is combined with a compound represented by the general formula (II), a base S C mixture having an S C phase over a wide temperature range from a low temperature range to a high temperature range can be obtained.
Of non-chiral compounds represented by the general formula (I) or (II) that serve as the component A of the present invention, typical compounds assuming an S C phase etc. are compounds listed in Tables 1 and 2 below.
TABLE 1______________________________________ ##STR14##R.sup.1 R.sup.2 R.sup.1 R.sup.2______________________________________C.sub.6 H.sub.13 C.sub.6 H.sub.13 C.sub.9 H.sub.19 C.sub.7 H.sub.15" C.sub.9 H.sub.19 " C.sub.8 H.sub.17" C.sub.10 H.sub.21 " C.sub.9 H.sub.19" C.sub.11 H.sub.23 " C.sub.10 H.sub.21C.sub.7 H.sub.15 C.sub.9 H.sub.19 C.sub.10 H.sub.21 C.sub.8 H.sub.17" C.sub.10 H.sub.21 C.sub.11 H.sub.23 C.sub.7 H.sub.15" C.sub.11 H.sub.23 " C.sub.8 H.sub.17C.sub.8 H.sub.17 C.sub.8 H.sub.17 C.sub.12 H.sub.25 C.sub.7 H.sub.15" C.sub.9 H.sub.19 " C.sub.8 H.sub.17" C.sub.10 H.sub.21" C.sub.11 H.sub.23______________________________________
TABLE 2______________________________________ ##STR15##R.sup.3 R.sup.4 R.sup.3 R.sup.4______________________________________C.sub.4 H.sub.9 O C.sub.4 H.sub.9 C.sub.6 H.sub.13 O C.sub.12 H.sub.25C.sub.5 H.sub.11 O C.sub.4 H.sub.9 C.sub.7 H.sub.15 O C.sub.4 H.sub.9" C.sub.5 H.sub.11 " C.sub.5 H.sub.11" C.sub.6 H.sub.13 " C.sub.6 H.sub.13" C.sub.7 H.sub.15 " C.sub.7 H.sub.15" C.sub.8 H.sub.17 " C.sub.8 H.sub.17" C.sub.9 H.sub.19 " C.sub.9 H.sub.19" C.sub.10 H.sub.21 " C.sub.10 H.sub.21" C.sub.12 H.sub.25 " C.sub.12 H.sub.25C.sub. 6 H.sub.13 O C.sub.4 H.sub.9 C.sub.8 H.sub.17 O C.sub.4 H.sub.9" C.sub.5 H.sub.11 " C.sub.5 H.sub.11" C.sub.6 H.sub.13 " C.sub.6 H.sub.13" C.sub.7 H.sub.15 " C.sub.7 H.sub.15" C.sub.8 H.sub.17 " C.sub.8 H.sub.17" C.sub.9 H.sub.19 " C.sub.9 H.sub.19" C.sub.10 H.sub.21 " C.sub.10 H.sub.21C.sub.8 H.sub.17 O C.sub.12 H.sub.25 C.sub.12 H.sub.25 O C.sub.5 H.sub.11C.sub.9 H.sub.19 O C.sub.4 H.sub.9 " C.sub.6 H.sub.13" C.sub.5 H.sub.11 " C.sub.7 H.sub.15" C.sub.6 H.sub.13 " C.sub.8 H.sub.17" C.sub.7 H.sub.15 " C.sub.9 H.sub.18" C.sub.8 H.sub.17 " C.sub.10 H.sub.21" C.sub.9 H.sub.19 " C.sub.12 H.sub.25" C.sub.10 H.sub.21 C.sub.14 H.sub.29 O C.sub.4 H.sub.9" C.sub.12 H.sub.25 " C.sub.5 H.sub.11C.sub.10 H.sub.21 O C.sub.4 H.sub.9 " C.sub.6 H.sub.13" C.sub.5 H.sub.11 " C.sub.7 H.sub.15" C.sub.6 H.sub.13 " C.sub.8 H.sub.17" C.sub.7 H.sub.15 " C.sub.9 H.sub.19" C.sub.8 H.sub.17 " C.sub.10 H.sub.21" C.sub.9 H.sub.19 " C.sub.12 H.sub.25" C.sub.10 H.sub.21" C.sub.12 H.sub.25C.sub.11 H.sub.23 O C.sub.4 H.sub.9C.sub.12 H.sub.25 O C.sub.4 H.sub.9C.sub.5 H.sub.11 C.sub.5 H.sub.11 C.sub.6 H.sub.13 C.sub.14 H.sub.29" C.sub.6 H.sub.13 C.sub.7 H.sub.15 C.sub.5 H.sub.11" C.sub.7 H.sub.15 " C.sub.6 H.sub.13" C.sub.8 H.sub.17 " C.sub.7 H.sub.15" C.sub.9 H.sub.19 " C.sub.8 H.sub.17" C.sub.10 H.sub.21 " C.sub.9 H.sub.19" C.sub.12 H.sub.25 " C.sub.10 H.sub.21" C.sub.14 H.sub.29 " C.sub.12 H.sub.25C.sub.6 H.sub.13 C.sub.5 H.sub.11 " C.sub.14 H.sub.29" C.sub.6 H.sub.13 C.sub.8 H.sub.17 C.sub.5 H.sub.11" C.sub.7 H.sub.15 " C.sub.6 H.sub.13" C.sub.8 H.sub.17 " C.sub.7 H.sub.15" C.sub.9 H.sub.19 " C.sub.8 H.sub.17" C.sub.10 H.sub.21 " C.sub.9 H.sub.19" C.sub.12 H.sub.25 " C.sub.10 H.sub.21C.sub.8 H.sub.17 C.sub.12 H.sub.25 C.sub.10 H.sub.21 C.sub.14 H.sub.29" C.sub.14 H.sub.29 C.sub.12 H.sub.25 C.sub.5 H.sub.11C.sub.9 H.sub.19 C.sub.5 H.sub.11 " C.sub.6 H.sub.13" C.sub.6 H.sub.13 " C.sub.7 H.sub.15" C.sub.7 H.sub.15 " C.sub.8 H.sub.17" C.sub.8 H.sub.17 " C.sub.9 H.sub.19" C.sub.9 H.sub.19 " C.sub.10 H.sub.21" C.sub.10 H.sub.21 " C.sub.12 H.sub.25" C.sub.12 H.sub.25 " C.sub.14 H.sub.29" C.sub.14 H.sub.29 C.sub.14 H.sub.29 C.sub.5 H.sub.11C.sub.10 H.sub.21 C.sub.5 H.sub.11 " C.sub.6 H.sub.13" C.sub.6 H.sub.13 " C.sub.7 H.sub.15" C.sub.7 H.sub.15 " C.sub.8 H.sub.17" C.sub.8 H.sub.17 " C.sub.9 H.sub.19" C.sub.9 H.sub.19 " C.sub.10 H.sub.21" C.sub.10 H.sub.21 " C.sub.12 H.sub.25" C.sub.12 H.sub.25 " C.sub.14 H.sub.29______________________________________
As non-chiral compounds represented by the general formula (I) or (II) used as a component of the present ferroelectric liquid crystal composition, ones having an S C phase are preferable although compounds not assuming an S C phase can be used if the compounds are intended to be components that are used in amounts in the ranges where the compounds will not make extremely narrow the S C * phase temperature range of the resulting ferroelectric liquid crystal composition, and that lower the viscosity or adjust the S C * phase temperature range.
The compounds represented by the general formula (III) that serve as the component B are chiral compounds disclosed in Japanese Patent Laid-Open Publication No. 219251/1984 filed by the present applicants, are not large in spontaneous polarization, do not assume an S A phase, have an S C * phase in a very high temperature range, and exhibit a cholesteric phase in a very wide temperature range (for example, C r -81° C.-S C *-131° C.-N*-175° C.-I SO in the case of R 5 =C 8 H 17 O-). Therefore, the compounds represented by the general formula (III) that serve as the component B play a very important role for the exhibition of the I SO →N*→S* type phase transition in the composition intended by the invention.
As compounds represented by the formula (III) which constitute component B in the present invention, the following compounds are typical compounds. ##STR16##
The compounds represented by the formula (IV) that serve as the component C are chiral compounds whose patent applications were filed by the present applicant and were laid open (for example see Japanese Patent Laid-Open Publication Nos. 43/1986, and 210056/1986), many of them exhibit an I SO →N*→SC* type phase transition like the compounds represented by the formula (III) that serve as the component B, and since they assume an N* phase and an S C * phase in a high temperature range, they play an important role for the exhibition of an ISO→N*→S C * type phase transition in the ferroelectric liquid crystal composition intended by the the present invention.
Further, as a rule, among the response time (τ), the spontaneous polarization value (P S ), and the viscosity (η) of a ferroelectric liquid crystal material, there is the following relationship: ##EQU1## wherein E represents the electric field intensity, and therefore such a compound that it has a low viscosity, and a large spontaneous polarization value is desired. Since the compounds represented by the formula (IV) and constituting the component C have high spontaneous polarization values (≃100 nC/cm 2 ), they play an important role for the exhibition of an I SO →N* →S C * type phase transition and a quick response time in the ferroelectric liquid crystal composition intended by the present invention.
For example, the phase transition temperatures of the compound represented by the formula (IV) wherein
R 6 =C 6 H 13 O-, ##STR17## and Y=-H are C r -71° C.-S C *-98° C.-N*-123° C.-I SO , and the spontaneous polarization value is 110 nC/cm 2 (T-T C =-30° C).
Further, the phase transition temperatures of the compound wherein R 6 =C 8 H 17 O-, ##STR18## and Y=-F are C r -52° C.-S C *-104° C.-N*-109° C.-I SO , and the spontaneous polarization value is 132 nC/cm 2 (T-T C =-30° C).
Even the compounds represented by the formula (IV) that have an S A phase can be used as a component that will be incorporated to cause a quick response property and will be exhibited so long as its amount is in the range where it will not adversely affect the phase transition series (I SO →N*→S C * type) of the ferroelectric liquid crystal composition intended by the present invention.
As the compounds represented by the formula (IV) that serve as the component C of the present invention, typically the following compounds can be mentioned: ##STR19##
The compounds represented by the formula (V) that serve as the component D are chiral compounds whose patent application was filed by the present applicant and was laid open (see Japanese Patent Laid-Open Publication No. 169765/1987) have low viscosities, the temperature range of the S C * phase extending to very low temperatures, and they play a role for lowering the lower limit of the S C phase in the ferroelectric liquid crystal composition intended by the present invention. For example, the phase transition temperatures of the compound represented by the general formula (V) wherein R 7 =C 8 H 17 -, Z =-F, and n =5 are C r -10° C.-S C *-33° C. -S A -43° C.-I SO , and the phase transition temperatures of the compound represented by the general formula (V) wherein R 7 =C 9 H 18 -, Z=-H, and n =4 are C r -10° C.-S C *-47° C.-S A -59° C.-I SO .
As the compounds represented by the formula (V) that serve as the component D, typically the following compounds can be exemplified: ##STR20##
Although the present invention can be attained by combining the above components A, B, C, and D, when the component E, given below, is further incorporated, a very practical ferroelectric liquid crystal composition that is improved in its response property can be provided.
The compounds represented by the general formula (VI) and that serves as the component E are chiral compounds whose patent application was filed (see Japanese Patent Laid-Open Publication No. 103,977/1987) exhibit an I SO →N*→S C * type phase transition like the compounds represented by the general formula (III) that are the component B, and the N* phase and the S C * phase have high temperature ranges. Further, since the spontaneous polarization thereof is very large (≃300 nCcm -2 ), in the ferroelectric composition intended by the invention, they exhibit an I SO →N*→S C * type phase transition and at the same time play an important role for exhibiting quick response property (for example in the case of R 8 =C 6 H 13 O-, and R 9 =-OC 4 H 9 , the phase transition temperatures are C r -88° C.-S C *-104° C.-N*-113° C.-I SO , and the spontaneous polarization value is 378 nC.cm -2 (T-T C =-10° C.)).
It is preferable to use, as the compounds represented by the formula (VI), compounds having the S C * phase, which compounds represented by the formula (VI) are compatible with the compounds represented by the formula (I) or (II) that serve as the component A, and even if they don't have the S C * phase, when they are mixed with the component A, the S C * phase and the N* phase are exhibited over a wider temperature range.
Consequently, even compounds that do not exhibit the S C * phase can be used in the ferroelectric liquid crystal composition intended by the present invention. Typical compounds of the compounds represented by the formula (VI) that serve as the component E are the following ##STR21##
In order to provide liquid crystal compositions having intended properties with the best use of the properties of the components A, B, C, D, and E being made, the proportions of the components A, B, C, D, and E have been studied in various ways, and as stated before, it has been found the proportions are suitably such that the component A is used in an amount of 20 to 80 wt. %, the component B is used in an amount of 5 to 30 wt. %, the component C is used in an amount of 3 to 10 wt. %, the component D is used in an amount of 3 to 20 wt. %, and the amount of the component E is 3 to 10 wt. %, based on the total of the amounts of the components A, B, C, and D, leading to the completion of the present invention.
When the amounts of the components A, B, C, D, and E used are less than the lower limits, the effect of the blending of the components A, B, C, D, and E is not enough.
As for the component A, although it is very low in viscosity, and is useful as the base S m mixture, if the amount of the component A exceeds 80 wt. % of the composition, the amounts of the chiral compounds become lowered relatively, the spontaneous polarization decreases,and the response time is adversely affected.
As for the component B, although it exhibits the cholesteric phase over a very wide range, if the amount thereof exceeds 30 wt. % of the composition, the viscosity of the composition becomes high, and the response time is adversely affected.
As for the component C, many of the compounds serving as the component C exhibit the I SO →N*→S C * phase transition, some of them have the S A phase, and since the component C increases the viscosity of the composition, and adversely affects the response time, the upper limit of the proportion of the component C is 10 wt. %.
As for the component D, although the component C is low in viscosity and the temperature range of the S C phase of the component D extends to a lower temperature, since the component D has an S A phase, the proportion of the component D is up to 20 wt. %.
As for the component E, although the component E exhibits the N* phase and the S C * phase in high temperature ranges, and the spontaneous polarization is very large, if the amount of the component E exceeds 10 wt. %, based on the total amount of the components A, B, C, and D, the viscosity of the composition becomes high, and the response time is adversely affected, so that the upper limit of the amount of the component E is 10 wt. %.
When the present liquid crystal composition is used as a basic composition, a ferroelectric liquid crystal material free from any zigzag defect, exhibiting good orientation characteristics, and having quick response can be obtained, and when the liquid crystal material is used, a liquid crystal element fairly good in contrast, good in memory properties, and high in response speed can be provided.
As unique applications of the present ferroelectric liquid crystal composition, can be mentioned, for example, high-speed liquid crystal shutters, and high-definition liquid crystal displays.
EXAMPLES
Now the present invention will be described in more detail with reference to the following examples, but the present invention is not limited by the examples.
Various measurements in the present invention were carried out by the methods shown below.
The value of spontaneous polarization (P S ) was measured by theSawyer-Tower method, and the tilt angle (θ) was determined by first applying an electric field sufficiently higher than the critical field to the cell which had been subjected to homogeneous alignment, extinguishing the helical structure, reversing the polarity, and measuring the mobile angle (corresponding to 2θ) of the extinction position under crossed nicols.
The response time was determined by putting each composition in the cell having an electrode interval of 2 μm which had been subjected to an alignment treatment, and measuring the change in intensity of transmitted light at the time when rectangular waves having V pp of 20 V and 1 KHz were applied.
The S C * pitch was determined by directly measuring each interval between striped lines (dechiralization lines) corresponding to the helical pitch under a polarizing microscope by the use of a cell having a thickness of about 200 μm which had been subjected to homogeneous treatment.
The N* pitch was indirectly determined by measuring the interval (l) between the line defects (disclination lines) under a polarizing microscope by the use of a wedge type cell, based on the theoretical relationship: P (pitch) =2l tan θ wherein θ represents the tilt angle of the wedge type cell.
Although, in some of the examples, the composition contained, in addition to the compounds represented by the formulae (I) to (VI), other compounds for extending the pitch of the N* phase or the S C * phase, the incorporation of these compounds brings about no problem because they would not impair the properties of the ferroelectric liquid crystal composition intended by the present invention.
EXAMPLE 1
Compounds represented by the formula (I) to (V) were used to prepare a ferroelectric liquid crystal composition having the following formulation: ##STR22##
The above ferroelectric liquid crystal composition shown the following phase transition temperatures: ##STR23##
At 25 ° C., the P S was 5 nC.cm - 2, the tilt angle was 35° , and the response time was 660 μsec. The pitch of the N* phase was 18 μm at 73 ° C., and the pitch of the S C * phase was 6 μm at 25 ° C.
The orientation characteristics were very good, and when the composition was poured in a cell that had been subjected to SiO oblique deposition, and had a cell thickness of 2 μm, and transparent electrodes, uniform orientation free from any defect were obtained, and a liquid crystal element having very good contrast (not less than 1 : 20) was obtained.
As apparent from the above, it was found that by combining compounds represented by the formulae (I) to (V) according to the invention, a ferroelectric liquid crystal composition exhibiting the S C * phase over a wide temperature range including room temperature, and an I SO →N* →S C type phase transition series, and having quick response property can be obtained.
EXAMPLE 2
Compounds represented by the formulae (I) to (VI) were used to prepare a ferroelectric liquid crystal composition having the following formulation: ##STR24##
The above ferroelectric liquid crystal composition showed the following phase transition temperatures: ##STR25##
The P S was 17 nC.cm -2 at 25 ° C., the tilt angle was 32° , and the response time was 190 μsec. Further, the helical pitch of the N* phase was 32 μm at 71 ° C., and the pitch of the S C * phase was 10 μm at 25° C.
The orientation characteristics were very good, and when the composition was poured in a cell that had a cell thickness of 2 μm, and transparent electrodes like the cell used in Example 1, uniform orientation free from any defect were obtained, and a liquid crystal element with very good contrast (not less than 1 : 20) was obtained.
As apparent from the above, it was found that by adding a compound represented by the formula (VI) that had served as the component E to a combination of compounds represented by the formulae (I) to (V) that had served as the components A, B, C, and D according to the invention, a ferroelectric liquid crystal composition exhibiting an I SO →N*→S C * type phase transition series, and improved further in response time thereby having high speed response could have been obtained.
EXAMPLE 3 TO 9
In the same way as in Example 1 or 2, ferroelectric liquid crystal compositions having the formulations as shown in Table 3 (wherein (S) indicates the absolute position or configuration was prepared and assessed. The properties of the liquid crystal compositions obtained in Examples 3 to 9 are shown in Table 4.
TABLE 3 Example No. (wt. %) Structural formula 3 4 5 6 7 8 9 Component A:formula (I) ##STR26## 6 6.5 5 6 5 5 5 ##STR27## 21 22.75 17.5 21 17.5 17.5 17.5 ##STR28## 12 13 10 12 10 10 10 Component A:formula (II) ##STR29## 12 13 20 12 20 15 15 ##STR30## 9 9.75 7.5 9 7.5 12.5 12.5 Component B:formula (III) ##STR31## 10 10 15 10 15 15 10 ##STR32## 15 10 5 10 5 10 5 Component C:formula (IV) ##STR33## 5 5 5 5 ##STR34## 5 5 5 Component D:formula (V) ##STR35## 5 10 10 5 ##STR36## 5 5 5 5 5 Component E:formula (VI) ##STR37## 5 Additional component ##STR38## 10 10 10
TABLE 4______________________________________ Example No. 3 4 5 6 7 8 9______________________________________Phasetransitiontemperature (°C.)C.sub.r → S.sub.C * -10 -12 -9 -12 -13 -12 -10S.sub.C * → N* 64 63 67 72 74 70 72N* → I.sub.SO 92 92 94 95 104 105 100Spontaneous 2 2 3 3 3 3 17polarizationvalue** (nC · cm.sup.-2)Tilt 31 30 31 31 32 30 32angle** (°)Response time** 800 750 760 750 770 800 190(μsec)Helical pitch** 4 4 4 3 6 6 11(μm)______________________________________ **value at 25° C.
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The present invention provides a ferroelectric liquid crystal composition wherein the phase transition series of the composition assumes an order of isotropic liquid→cholesteric phase→chiral smectic C phase starting from the high temperature and to a switching element good in contrast, and memory properties using the same. The composition comprises a composition that contains a component A of a compound having the formula: ##STR1## and/or a compound having the formula: ##STR2## wherin R 1 and R 2 represent each an alkyl group having 1 to 18 carbon atoms;
a component B of a compound of the formula: ##STR3## a component C of a compound of the formula: ##STR4## and a component D of a compound of the formula: ##STR5## wherein R 3 , R 4 , R 5 , R 7 , and R 8 represent each an alkyl group or alkoxy group having 1 to 18 carbon atoms, x represents ##STR6## Y and Z represent each a hydrogen atom, or a halogen atom, n is an integer of 0 to 10, and * indicates an asymmetric carbon atom; and
with the proportion of said component A being 20 to 80 wt. %, that of the component B being 5 to 30 wt. %, that of said component C being 3 to 10 wt. %, and that of said component D being 3 to 20 wt. %, based on the total amount of said four components A, B, C and D.
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I. FIELD OF THE INVENTION
[0001] The present invention relates to sprayer systems, such as are commonly used to discharge chemicals to eradicate weeds, insects, etc. The invention more particularly refers to a sprayer system that is mounted onto the platform of a vehicle for easy maneuverability, and even more particularly to a tank for a sprayer system that is adapted to be received by the platform of the vehicle such that it can be easily moved between the wheel wells of the vehicle.
II. DESCRIPTION OF THE RELATED ART
[0002] The present invention contemplates a new and improved tank for a sprayer system which is simple in design, effective in use, and overcomes the foregoing difficulties and others while providing better and more advantageous overall results.
[0003] Sprayer systems for discharging chemical substances, such as pesticides, are well known in the art. Typically, the systems include a pump, an engine, a tank, and a hose. The system may also include a reel for holding the hose.
[0004] It is also well known in the art to mount these sprayer systems to the platform of a vehicle, such as a truck, to facilitate in the discharge of the chemical substances. The tank is commonly attached to a frame, which, in turn, is attached to the platform of the truck. The frame secures the tank to the truck and prevents unwanted movement of the tank. The pump, engine, hose and/or reel are then either attached to the frame or otherwise positioned on the truck.
[0005] Unfortunately, the presently used tanks are inefficiently designed and, thus, the amount of useable space on the truck platform is significantly reduced. In addition, the fit of the assembled sprayers within the platform is compromised and the accessibility of the controls for the sprayer system is restricted.
[0006] The present invention attempts to overcome these deficiencies in the prior art by providing for a tank that is compact and can be easily maneuvered within the platform of the truck. This is accomplished by providing a tank having a bottom portion that is adapted to be received by a truck platform between the wheel wells so that the tank can be easily moved past the wheel wells. This enables the tank to be placed in numerous positions on the truck platform. In addition, the tank preferably has a first top panel that is adapted to receive the pump, engine, hose and/or reel. Since the foregoing are mounted onto the tank, the useable space on the platform is increased. Further, the first top panel is preferably positioned near the edge of the platform so that the sprayer system controls are easily accessible and convenient for a user.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, a new and improved tank for a sprayer system is provided which is designed to increase the usable space on the platform of a vehicle.
[0008] The tank has a top and a bottom portion. The bottom portion of the tank is adapted to be received by the platform between the wheel wells. This enables the tank to be easily moved from a first position, which is toward the front of the vehicle and behind the wheel wells, to a second position, which is toward the back of the vehicle and in front of the wheel wells. The tank can be moved past the wheel wells by sliding it across the platform of the vehicle. Since the tank does not have to be lifted above the wheel wells to be moved, the possibility of back strain or other medical problems that are associated with the lifting heavy objects is reduced, if not completely eliminated.
[0009] Preferably, the bottom portion of the tank has a length L 1 which is less than the length L 2 between the wheel wells of the vehicle. Similarly, the top portion of the tank preferably has a length L 3 which is less than or equal to the length L 4 of the vehicle platform. This prevents the tank from extending outside of the perimeter of the platform. As such, the vehicle can be more easily maneuvered and the hazards associated with an object extending beyond the perimeter of a vehicle are eliminated.
[0010] Preferably, the tank includes a first top panel. The first top panel is substantially horizontal and has a first surface that is adapted to receive an associated pump and/or engine. The first top panel may also include a second surface that is adapted to receive a reel. The first top panel is preferably positioned at one end of the tank, near the edge of the platform. This enables a user to easily access the controls of the sprayer system. Further, the controls can be positioned such that they can be easily accessed by a user standing outside of the vehicle on a curb.
[0011] Preferably, the tank is mounted onto a frame, which, in turn, is attached to the vehicle. The frame secures the tank to the vehicle and prevents unwanted movement of the tank. The engine, pump, hose and/or reel can be mounted to either the tank or the frame. If the foregoing are mounted to the frame, they are preferably located in positions that are substantially equivalent to their positions on the tank, as described above.
[0012] It is an objective of this invention to provide a tank that is easily and efficiently manufactured and marketed.
[0013] It is a further objective of this invention to provide a tank that is of durable and reliable construction.
[0014] It is still a further objective of this invention to provide a tank that has all of the advantages of the prior tanks and none of the disadvantages.
[0015] Still other benefits and advantages of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention may take physical form in certain parts and arrangement of parts. A preferred embodiment of these parts will be described in detail in the specification and illustrated in the accompanying drawings, which form a part of this disclosure and wherein:
[0017] [0017]FIG. 1 is a perspective view of the tank;
[0018] [0018]FIG. 2 is a side view of the tank;
[0019] [0019]FIG. 3 is a back view of the tank;
[0020] [0020]FIG. 4 is a bottom view of the tank;
[0021] [0021]FIG. 5 is a perspective view of the frame;
[0022] [0022]FIG. 6 is a perspective of view of the tank, illustrating the frame attached to tank;
[0023] [0023]FIG. 7 is a perspective view of the tank, illustrating the engine, pump, and reel mounted onto the first top panel of the tank;
[0024] [0024]FIG. 8 is a side view of a truck;
[0025] [0025]FIG. 9 is a rear view of a truck; and,
[0026] [0026]FIG. 10 is a rear view of a truck showing the tank positioned on the platform of the truck.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to the drawings, which are for purposes of illustrating a preferred embodiment of the invention only, and not for purposes of limiting the invention FIGS. 1 - 4 show a preferred embodiment of a tank 10 , FIG. 5 shows a preferred embodiment of a frame 138 , FIG. 6 shows the tank 10 , positioned within the frame 138 , FIG. 7 shows a pump 134 , engine 135 and reel 136 mounted onto the frame 138 , FIGS. 8 and 9 show an associated truck 78 , and FIG. 10 shows the tank 10 , placed on the platform 76 , of the associated truck 78 .
[0028] With reference to FIGS. 1 - 4 and 7 , a preferred embodiment of the tank 10 is illustrated. The tank 10 is comprised of a bottom portion 12 and a top portion 14 , which define a cavity for holding chemicals, such as pesticides, that are to be discharged by a sprayer system 16 . In this embodiment, the bottom portion 12 has a generally rectangular or square shape. The bottom portion 12 includes a bottom panel 18 , a right or first side panel 20 , a left or second side panel 22 , a front panel 24 , a back panel 26 , a right or first rim panel 28 and a left or second rim panel 30 . The front and back panels 24 , 26 have an equivalent length L 1 , shown in FIG. 2. The length L 1 is less than length L 2 , shown in FIGS. 9 and 10, between the wheel wells 72 , 74 of the vehicle 78 , to enable the tank 10 to easily move past the wheel wells 72 , 74 . The first and second side panels 20 , 22 are positioned substantially opposite each other on substantially vertically-oriented planes with their lower ends 32 , 34 attached to the corresponding ends 36 , 38 of the bottom panel 18 and their upper ends 40 , 42 extending substantially upward. The front panel 24 is positioned between the first and second side panels 20 , 22 on a substantially vertically-oriented plane with its lower end 44 attached to the corresponding end 46 of the bottom panel 18 and its upper end 48 extending substantially upward. Sides 50 , 52 of the front panel 24 are attached to corresponding sides 54 , 56 of the first and second side panels 20 , 22 . The back panel 26 is positioned substantially opposite the front panel 24 between the first and second side panels 20 , 22 on a substantially vertically oriented plane. A lower end 58 of the back panel 26 is attached to a corresponding end 60 of the bottom panel 18 and its upper end of the back panel 59 extends substantially upward. Sides 62 , 64 of the back panel 26 are attached to corresponding sides 55 , 57 of the first and second side panels 20 , 22 . A first rim panel 28 is positioned on a substantially horizontally oriented plane with its corresponding end 68 attached to the upper end 40 of the first side panel 20 . A second rim panel 30 is also positioned on a substantially horizontally oriented plane with its corresponding end 70 attached to the upper end 42 of the second side panel 20 .
[0029] In the preferred embodiment, the first and second side panels 20 , 22 are curved and the remaining panels 18 , 24 , 26 , 28 , 30 of the bottom portion 12 are substantially planar. The curve is substantially equivalent to the curve of a standard wheel well 72 , 74 . The curve of the first and second side panels 20 , 22 facilitates movement of the tank 10 past the wheel wells 72 , 74 . However, the panels 18 , 20 , 22 , 24 , 26 , 28 , 30 can have any shape chosen using sound engineering judgment.
[0030] With continuing reference to FIGS. 1 - 4 , the top portion 14 of the tank 10 is comprised of a right or first top panel 80 , a left or a second top panel 82 , a right or a first side panel 84 , a left or a second side panel 86 , a front panel 88 , a back panel 90 and a middle panel 94 . The front and back panels 88 , 90 have an equivalent length L 3 , shown in FIG. 2. Lower end 92 of the front panel 88 of the top portion 14 is attached to the upper end 48 of the front panel 24 of the bottom portion 12 and is positioned on a substantially vertically oriented plane. Lower end 96 of the back panel 90 of the top portion 14 is attached to an upper end 59 of the back panel 26 of the bottom portion 12 and is positioned on a substantially vertically oriented plane. Lower end 98 of the first side panel 84 is attached to outer end 100 of the first rim panel 28 and is positioned in a substantially vertically oriented plane. Sides 101 , 103 of the first side panel 84 are attached to corresponding sides 102 , 106 of the front and back panels 88 , 90 . Lower end 110 of the second side panel 86 is attached to the outer end of the second rim panel 30 and is positioned in a substantially vertically oriented plane. Sides 105 , 107 of the second side panel 86 are attached to corresponding sides 104 , 108 of the front and back panels 88 , 90 . The first top panel 80 is positioned in a substantially horizontally oriented plane and is attached to upper ends 114 , 116 , 118 of the front panel 88 , the back panel 90 , and the first side panel 84 . The first top panel 80 preferably extends across approximately one-third of the length L 3 . The middle panel 94 is positioned substantially opposite the first side panel 84 in a substantially vertically oriented panel with its lower end 98 attached to end 120 of the first top panel 80 . The second top panel 82 is positioned in a substantially horizontally oriented plane and is attached to the upper ends 114 , 116 , 122 , 124 of the front 88 , back 90 , second side 86 and middle panels 94 . The second top panel 82 extends approximately two-thirds of the length L 3 . The second top panel 82 preferably includes an inlet 128 for receiving a hose 126 of the sprayer system 16 .
[0031] In the preferred embodiment of this invention the pump 134 , engine 135 , and reel 136 are attached to the frame 138 , shown in FIG. 5. However, the foregoing may also be attached to the tank 10 . In such instance, the first top panel 80 will include first and second surfaces 130 , 132 . The first surface of the top panel 130 is adapted to receive the engine and/or pump 134 of the sprayer system 116 . The second surface 132 is adapted to receive an optional reel 136 , which holds the hose 126 . The placement of the engine 135 , pump 134 and/or reel 136 on the first top panel 130 of the tank 10 increases the usable space of the platform 76 . In addition, this placement allows the controls for the foregoing parts of the sprayer system 116 to be positioned such that they can be easily accessed by a user.
[0032] In the preferred embodiment, the second top panel 82 is curved and the remaining panels 80 , 84 , 86 , 88 , 90 of the top portion 14 are substantially planar. The curved shape increases the volume of the tank 10 and, thus, enables the tank 10 to store more chemicals. However, the panels 80 , 82 , 84 , 86 , 88 , 90 can have any shape chosen using sound engineering judgment.
[0033] In the preferred embodiment, the length L 3 is less than length L 4 of the vehicle platform 76 , shown in FIGS. 9 and 10. This enables the tank 10 to be easily maneuvered and prevents the tank 10 from extending outside of the platform 76 and creating a hazard. However, this is only a preferred embodiment of the invention and should not be construed to limit the invention in any manner. As such, the upper portion 14 of the tank 10 can have any length L 3 chosen using sound engineering judgment.
[0034] The tank 10 can be comprised of any material chosen using sound engineering judgment, such as metal or polymeric materials.
[0035] The tank 10 has been described with reference to its preferred embodiment. However, this is only a preferred embodiment and should not be construed to limit the invention in any manner. The tank 10 can have any shape chosen using sound engineering judgment, so long as the length L 1 is less than the length L 2 . In addition, the tank 10 can be a single unitary piece, or it can be comprised of individual components. If the tank is comprised of individual components, the components can have any form chosen using sound engineering judgment and are not limited to the components described herein, which are only a preferred embodiment of the invention.
[0036] With reference to FIG. 5, the frame 138 for use in connecting the tank 10 to the platform 76 , shown in FIGS. 8 - 10 , is illustrated. The frame 138 is comprised of a bottom frame portion 140 , a top frame portion 142 , and support bars 144 , 146 , 148 , 150 for attaching the bottom frame portion 140 to the top frame portion 142 . The bottom frame portion 140 has a substantially planar rectangular or square shape and is adapted to receive the bottom portion 12 of the tank 10 . The bottom frame portion 140 is comprised of a right or first side bar 152 , a left or second side bar 154 , a front bar 156 , a back bar 158 , and first and second support bars 160 , 162 . The front and back bars 156 , 158 are positioned substantially opposite each other. Ends 172 , 174 of the first side bar 152 are attached to the corresponding ends 164 , 168 of the front and back bars 156 , 158 . Similarly, ends 173 , of the second side bar 154 are attached to a corresponding end 174 of the first and second side bars 154 , 156 . First and second support bars 160 , 162 are positioned between the front and back bars 156 , 158 and attached to the first and second sidebars 152 , 154 . Preferably, the distance between the front and back bars 156 , 158 and the first and second support bars 160 , 162 are substantially equal.
[0037] With continuing reference to FIG. 5, the top frame portion 142 is illustrated. The top frame portion 142 has a substantially rectangular shape and is comprised of a right or first side bar 180 , a left or second side bar 182 , a front bar 184 , and a back bar 186 . The front and back bars 184 , 186 are positioned substantially opposite each other. The ends of first side bar 196 , 198 are attached to corresponding ends 188 , 192 of the front and back bars 184 , 186 . Similarly, ends 100 , 102 of second side bar 182 are attached to corresponding ends 190 , 194 of the front and back bars 184 , 186 . The front and back bars 184 , 186 each have a first, second, and third member 204 , 206 , 208 . The first member 104 is positioned in a substantially horizontally oriented plane and end 210 of the first member 104 is attached to the left or first end 212 of the second member 206 . The second member 206 is preferably angled downward and the right or second end 214 of the second member 206 is attached to end 216 of the third member 208 .
[0038] Preferably, the top frame 142 includes first, second, and third top bars 218 , 220 , 222 , shown best in FIGS. 6 and 7. The first top bar 218 has a first member 224 , which is positioned in a substantially vertically-oriented plane and is attached to and extends substantially upward from the first side bar 184 , a second member 226 , which is positioned in a substantially horizontally-oriented plane and is attached to the first member 224 and extends across the frame 138 toward the back bar 186 , and a third member 228 , which is positioned in a substantially vertically-oriented plane and is attached to and extends downward from the second member 226 and is attached to the back bar 186 . The first top bar 218 is positioned such that it is located near the middle panel 94 of the tank 10 . The second and third top bars 220 , 222 are positioned in a substantially horizontally-oriented plane and are removeably attached to the second side bar 182 and the first top bar 218 via brackets 219 . The second and third top bars 220 , 222 are removeably attached to the frame 138 to enable the tank 10 to be easily placed within the frame 138 , as shown best in FIG. 6.
[0039] The top frame 142 may also include first and second support members 232 , 234 . The support members 232 , 234 are preferably triangular in shape. The first support member 232 is attached to the first support bar 144 and the third portion of the front bar 208 . The second support member 234 is attached to the second support bar 146 and the third portion of the back bar 208 .
[0040] Preferably, the top portion 142 of the frame 138 includes first and second platform bars 236 , 238 that are adapted to receive the pump 134 , engine 135 , and reel 136 . The first platform bar 236 is positioned substantially opposite the first side bar 180 and is attached to the third portion 216 of the front and back bars 184 , 186 . The distance between the first platform bar 236 and the first side bar 180 is sufficient to enable the reel 136 to be attached thereto, as shown best in FIG. 7. A second platform bar 238 is positioned between the front and back bars 184 , 186 and is oriented substantially parallel thereto. The second platform bar 238 defines a first area 244 for receiving the pump and/or engine 134 and a second area 246 for receiving the reel 136 , shown best in FIG. 6. A plate 248 may be attached to the first side bar 180 and the first platform bar 236 to aid in the reception of the engine and/or pump 134 .
[0041] Preferably, the first and second areas 244 , 246 of the frame 138 correspond to the first and second surfaces 130 , 132 of the tank 10 . However, the engine 134 , pump 134 , and reel 136 can be attached to the frame 138 at any location and in any manner chosen using sound engineering judgment.
[0042] The frame 138 can be comprised of any material chosen using sound engineering judgment, such as metal or polymeric materials
[0043] The frame 138 has been described with reference to its preferred embodiment. However, this is only a preferred embodiment and should not be construed to limit the invention in any manner. The frame can have any shape chosen using sound engineering, so long as it is capable of receiving the tank 10 . In addition, the frame 138 can be a single unitary piece or it can be comprised of individual components. If the frame 138 is comprised of individual components, the components can have any form chosen using sound engineering judgment and are not limited to the components described herein, which are only a preferred embodiment of the invention.
[0044] In the preferred embodiment, the tank 10 is attached to the platform 76 of the vehicle 78 via the frame 138 . However, the tank 10 can be attached to the vehicle 78 by any means chosen using sound engineering judgment. Similarly, the tank 10 can be placed on the platform 76 without the aid of a securing means, such as the frame 138 .
[0045] The connections between the tank 10 , engine 134 , pump 134 , hose 126 , and optionally, the reel 136 are well known in the art and, thus, will not be described in detail herein.
[0046] The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of the specification. It is intended by applicant to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
[0047] Having thus described the invention, it is now claimed:
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The present invention provides a tank having a bottom portion that is adapted to be received by a truck platform between the wheel wells so that the tank can be easily moved past the wheel wells. In addition, the tank preferably has a first top panel that is adapted to receive the pump, engine, hose and/or reel. Since the foregoing are mounted onto the tank, the useable space on the platform is increased. Further, the first top panel is preferably positioned near the edge of the platform so that the sprayer system controls are accessible and convenient for a user.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of and Applicant claims priority under 35 U.S.C. §§120 and 121 of parent U.S. patent application Ser. No. 12/084,813, filed Oct. 10, 2008 , now U.S. Pat. No. 8,056,586, which application is a national stage application under 35 U.S.C. §371 of PCT/DE2006/001926 filed on Nov. 3, 2006, which claims priority under 35 U.S.C. §119 of German Application No. 10 2005 053 521.6 filed on Nov. 8, 2005 and German Application No. 10 2006 010 582.6 filed Mar. 6, 2006, the disclosures of each of which are hereby incorporated by reference. The international application under PCT article 21(2) was not published in English.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a woven fabric comprising weft wires. In particular, the invention relates to an all-metal woven fabric comprising weft wires.
2. The Prior Art
Woven fabric, in particular metal woven fabric, is being used for increasingly varied tasks. A usage very much in demand recently is as a facade cladding for buildings. Frequently, separate objects are placed on the woven fabric. In the case of facade cladding, these can, for example, be support rods with LEDs or other light sources which are either aligned so that they illuminate the woven fabric or direct light away from the woven fabric. In other cases of application, water pipes are fastened to the woven fabric, for example, in order to achieve a decorative effect with water trickling down in pearls on the woven fabric. In addition, decorative elements, loudspeakers and a multiplicity of other objects can be fastened to the woven fabric.
The fastening of objects on the woven fabric is not always easy and frequently requires a large amount of work time which makes a woven fabric provided with objects very expensive to install. In most cases, an attempt is made to place an object to be fastened to the woven fabric either directly on to the woven fabric and then fix it with fastening wires. If the object is not intended to abut directly against the nonwoven fabric, it has hitherto been regarded as unavoidable to first fix a holder on the woven fabric which projects outwards. The actual object can then be fastened to its projecting end. All the previously known methods are therefore relatively expensive.
SUMMARY OF THE INVENTION
It is the object of the invention to provide an improvement compared with the prior art.
This object is achieved by a woven fabric comprising warp threads or wires and comprising weft wires, wherein the woven fabric has an offset weft wire. The wire in the woven fabric is particularly well suited for fastening objects of any kind as a result of the strength inherent in a wire. The weft wire can therefore advantageously be selected for this task both in a woven fabric having no metal components apart from the wire and also in an all-metal woven fabric. Whereas conventional weft wires run at least substantially one-dimensionally, the invention makes it possible to achieve a considerably easier connection of objects to the weft wire. By specifically shaping the offset region of the weft wire, in particular wire regions can be created which are particularly well suited for clipping on an object or at least are more easily accessible and reachable for manual fastening.
The threads or wires can be made of any materials. However, metal or plastic is preferred. Monofilament or multifilament wires are suitable depending on the intended use.
The offset in the weft wire can in particular be U-shaped. A U-shaped offset is mechanically particularly easy to produce and forms a bracket which projects from the non-offset part of the weft wire. This is particularly suitable for fastening objects thereon.
The aforesaid is achieved to a particular extent if the offset comprises at least two, in particular four, right angles. Thus, the first deflection in the course of the weft wire can in particular take place by a right angle so that the weft wire is guided out from the woven fabric perpendicular to its remaining direction of progress, is there bent with two further right angles to form a U-shape and then dips back into the woven fabric at a right angle.
Regardless of its precise shape, however, it is advantageous if the offset projects from the woven fabric. In this way, it is more easily accessible both for manual and for mechanical connections.
The extent by which the offset projects from the woven fabric depends on numerous circumstances. Firstly, it is important how stable the weft wire is and what load it is intended to bear in the operating state. The designated function can also predefine suitable dimensions. This is the case, for example, when supports for light sources which floodlight the woven fabric are to be arranged at the tips of the protruding offsets in the woven fabric. In order to be able to illuminate a large area of the woven fabric for given light-emission scattering angles of the light sources, a very large distance can be required from the plane of the woven fabric. Thus, in many cases it can be advantageous if the offset guides the weft wire further out from the woven fabric than the distance between two warp threads, in particular possibly by more than twice the distance between two warp threads.
From the production technology point of view, it is advantageous if the offset lies in the course of the weft wire, that is between two warp threads and not at the edge of the woven fabric. If the offset lies in the woven fabric, both the leg of the weft wire guiding this out from the woven fabric and also that leg guiding said weft wire back into the woven fabric can rest statically on the respectively next warp threads. On the other hand, the offset would tend to twist easily under loading if it were arranged at the edge of the woven fabric.
The woven fabric is particularly stable if the offset lies between two immediately adjacent warp threads.
In order that a woven fabric of the proposed type can be stored and transported before its final usage location in a space-saving and easy-to-handle manner, it is proposed that the offset weft wire should be turned about an axis defined by its portion located in the woven fabric and can thus be laid completely flat onto the woven fabric. In this way, it is possible to roll up the woven fabric like a conventional woven fabric. During the rolling-up, the offset can be laid flat and rolled up into the roll without resulting in an excessively large increase in the volume of the woven fabric roll.
It is understood that the woven fabric can already be advantageously used with an offset. In particular, however, it can also have a multiply offset weft wire and/or a plurality of offset weft wires. In this case, the offsets can be uniformly spaced apart along the weft wire, likewise the plurality of offset weft wires. In these ways, the bearing capacity for objects is perceptibly increased in a simple manner.
In order to be able to fix two offsets at an angle to one another and/or to the woven fabric after installing the woven fabric, it is proposed that a tension thread is provided. The tension thread can in particular run along all the offsets of the woven fabric which are lined up linearly with respect to one another so that if necessary, a plurality of tension threads are provided. Ideally, each offset has a fastening with a tension thread. After installing the woven fabric, the individual offset weft wires then only need to be turned or bent into their desired position; when the tension thread is then fastened to all the offsets and the tension thread is fixed in particular outside the woven fabric or at the edge of the woven fabric as far as possible under tensile stress, the offsets are protected from any undesired turning about then non-offset sections located in the woven fabric. In addition, such a fastening by means of a tension thread increases the bearing capacity.
It is understood that the object forming the basis of the invention is also achieved by a method for producing a woven fabric comprising warp threads or wires and comprising weft wires, wherein in the loom the warp thread is fanned by a fan dimension to allow the weft wire to pass through when the weft wire is provided with an offset and is then guided further in its original axis, wherein the offset has a smaller dimension than the fan dimension. It can be seen immediately that such a method of producing the woven fabric leads to a woven fabric of the type described previously. In this case, it is mechanically easily possible to execute the offset within the fanned warp threads so that the actual weaving process is completely uninfluenced by the offset in the weft wire. In this case, the offset can easily guide the weft wire almost as far from its axis as the warp thread is fanned in the loom. For example, if the fan dimension in the loom is 20 cm, it is easily possible to fix the offset of the weft wire at 19 cm.
If a previously described woven fabric is used as the base structure for bearing an object separate from the woven fabric, it is proposed that the object is borne on the offset. It has already been explained that the offset is particularly easily accessible for fastening the objects and as a result of the possible distance from the plane of the woven fabric for particular functions, brings with it further advantages, for example, when the object comprises an electronically drivable light source which is to be used, for example, to illuminate the woven fabric.
In accordance with the explanations already given previously, the object is also achieved by a method for installing a building cladding with media-reproducibly interlinked light sources, wherein a woven fabric of the type described previously is first suspended on the building and then supports for the light sources are fastened to the offsets, in particular are clipped to these. In this case, an all-metal woven fabric is particularly suitable as a building cladding. This can also be used particularly advantageously in relation to its light reflections as soon as interlinked light sources, in particular interlinked LEDs are provided, which reproduce photos or films via a triggering electronic system. If the light source supports are merely clipped on the offsets, i.e., fastened to these by means of a latching mechanism, the light source supports can be exchanged subsequently particularly easily if these should be defective.
In addition, in accordance with the explanations already given previously, the object is also achieved by a method for rolling a woven fabric of the preceding type, wherein the offset lies flat to the woven fabric during rolling up. A woven fabric rolled up in such a manner can then be transported in a particularly space-saving manner to its subsequent location of use, for example, to a building where it is to form the cladding. After unrolling, the offsets can then be pivoted again into the desired position relative to the plane of the woven fabric.
Offset wires on conveyor belts or in filter fabrics are mentioned as further applications.
The invention is explained in detail hereinafter by means of an exemplary embodiment with reference to the drawings. In this context, the same or functionally the same components can have identical reference numerals. In the figures
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a plan view of an all-metal woven fabric with two offset weft wires,
FIG. 2 shows a side view of the woven fabric from FIG. 1 according to the characterisation II-II there,
FIG. 3 shows a detail of the plan view from FIG. 1 with an offset in the weft wire,
FIG. 4 shows a side view of the detail in FIG. 3 according to the characterisation IV-IV there,
FIG. 5 shows a schematic view from above of the detail from FIG. 3 according to the characterisation V-V there and
FIG. 6 shows a side view from FIG. 4 with the offset weft wire in a folded-out and in a laid-flat position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The metal woven fabric 1 in FIGS. 1 to 6 substantially spatially consists of metal warp threads (denoted as an example with 2 , 3 ) and conventional weft wires (denoted as an example with 4 , 5 ).
However, the metal woven fabric 1 differs from a conventional woven fabric in that at those positions at which weft wires 4 , 5 would still be found at a regular spacing in a conventional woven fabric, two offset weft wires 6 , 7 are present in the woven fabric here. Like the conventional weft wires 4 , 5 , the offset weft wires 6 , 7 are integrated in the woven fabric 1 and are thus held by the warp threads 2 , 3 .
In the course of each offset weft wire 6 , 7 , however, the weft wire is offset by 90° at a first position 8 (only shown as an example on the weft wire 6 ) and leads from there out from a woven fabric plane 9 . The weft wire 6 is slightly curved in its course 10 but proceeds continuously approximately at right angles to the woven fabric plane 9 from said plane.
At a distinct distance from the woven fabric plane 9 the offset weft wire 6 is bent again substantially at right angles at a second position 11 and now continues substantially parallel to its original course 12 and to the woven fabric plane 9 . However, before it has bridged a field width 13 between the neighbouring warp threads 2 , 3 , it is again bent by 90° at a third position 14 and leads back alongside the course 10 parallel thereto in a course 15 (covering the leading-out course 10 ) back to the woven fabric plane 9 . There the weft wire 6 is again offset by 90° at a fourth position 16 and now continues its original course 12 in the remaining woven fabric.
At the second right angle 11 and at the third right angle 14 , the weft wire 6 is not simply bent as at the right angles 8 and 16 but is bent slightly in such a manner that a visible U-contoured groove 17 is obtained in the transverse viewing direction according to FIGS. 2 , 4 and 6 . At least one partially translucent tube 18 is pressed into each groove 17 . The tubes 18 are fitted with light emitters, preferably with light-emitting diodes. These can be switched on and off individually via a central control. Cable to the LEDs or to other electronic components or other light emitters can be accommodated inconspicuously in the tubes 18 and thus, for example, guided to the edge of the woven fabric 1 .
In this way, the metal woven fabric 1 can be specifically illuminated statically and dynamically with the aid of the LEDs in the tubes 18 . Light-emitting diodes or other light emitters are preferably provided in the colours red, green and blue (preferably in the ratio 2:2:1) so that the woven fabric 1 can be illuminated in a large number of colours. If the ratio of the observer distance to the fineness of the grid of lamps or the support tubes 18 and support offsets 10 , 17 , 15 required for this purpose is sufficiently large, a static or moving picture can thus be produced for the observer.
It can be seen that the offset weft wires 6 , 7 can be easily pivoted almost up to a right angle about their regions 12 running in the woven fabric plane 9 , i.e. as far as a position in which the brackets 21 , 22 lie almost flat on the remaining woven fabric. Such a position is illustrated in FIG. 6 . The U-shaped bracket head 17 carries the tube 18 with the LEDs in a folded-out position of the bracket 21 and can easily be pivoted jointly with said bracket along a pivot path 20 into a transport position completely flat on the woven fabric plane 9 ( 17 ′, 18 ′). In this position the entire woven fabric 1 can be rolled up like a conventional woven fabric and despite the protruding brackets 21 , 22 of the offset weft wires 6 , 7 , only a slight increase in the volume of a woven fabric roll is obtained.
In order to fix the supporting brackets 21 , 22 in their pivoted-out position for operation, two tension cables 23 , 24 , 25 , 26 are fastened to the woven fabric 1 , each leading to the bracket 17 and being likewise fixed there. The tension cables 23 , 24 or 25 , 26 form a triangle in side view in relation to the woven fabric plane (cf. FIGS. 2 , 4 ) so that any deflection of a supporting bracket 21 , 22 or clamping bracket 17 immediately sets one of the tension cables 23 or 24 and/or 25 or 26 respectively under tension and thereby held in the folded-out position. A guide groove is provided on the bracket 17 for fixing the tension cables 23 , 24 , 25 , 26 , preferably at the centre of the bracket as shown in FIG. 5 .
In the folded-out position, in a suitable configuration the respective light sources in the support tubes 18 project a large light cone (limits characterised by the reference numerals 27 ) towards the woven fabric 1 . At the same time, the tubes can easily be turned about their longitudinal axis (shown by the turning arrow 28 ) so that the light cone 27 of the light emitters can be individually adapted to any support tube 18 . At the same time, the clamping brackets 17 can be designed so that they securely fix the tubes 18 in their alignment for operation by the mere engaging or clamping force.
In detail the warp threads 2 , 3 are each formed as wire cables grouped in threes.
It should be noted that the woven fabric view in FIGS. 1 and 2 can only represent a section from a larger woven fabric. The invention is particularly meaningful for those woven fabrics in which each illuminant tube 18 is held by at least two offsets 21 or 22 along a weft wire 6 or 7 . However, the invention is not restricted to such applications.
The precise fastening of the tubes or other objects separate from the woven fabric at the tip of the U-shaped supporting brackets 21 , 22 can be effected in manifold ways, for example, in addition to the clamping or engagement shown, also by means of small metal wires, plastic clips or other means.
What is important for the invention is that a continuously producible woven fabric has support structures protruding from the woven fabric plane, i.e. the offset brackets.
It should also be noted that the tension cables not only fulfil their function when they directly connect respectively one supporting bracket to the remaining woven fabric but also when tension cables are attached between supporting brackets, in which case only one, preferably two, brackets need be fixed in their pivot angle. A tension cable can again be used for this purpose which, at these positions, leads from the tension bracket to the remaining woven fabric or to the edge of the woven fabric. The tension wire cables can in particular be fixed at the edge of the woven fabric on supporting rods there under tension.
In use, the woven fabric according to the invention can be produced and appropriately used in various orders of magnitude, starting from a small decorative woven fabric mat, for example, in window size as far as claddings for entire building facades which can even extend over entire high-rise buildings, wherein, as has already been indicated previously, tubes can be used as objects to be supported, which are specifically supplied with current via multimedia control electronics so that light sources integrated therein emit coloured light either towards the woven fabric and/or away from the woven fabric. This first variant is particularly suitable for immersing the woven fabric in colour effects which can also change over time. The second variant is particularly suitable for presenting a static and/or dynamic picture to a far-removed observer when the resolution of the light sources is suitably dense. For example, advertising films or art films can be observed in this way on a building facade.
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A woven fabric includes warp threads or wires and includes weft wires, wherein, the woven fabric includes an offset weft wire. The offset is particularly suitable for fastening objects separate from the woven fabric. A method uses the woven fabric as a facade hanging by using the woven fabric as a base structure for bearing an object separate from the woven fabric. The object is borne on the offset separate from the woven fabric.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of U.S. application Ser. No. 13/199,670 filed Sep. 7, 2011. The patent application identified above is incorporated here by reference in its entirety to provide continuity of disclosure.
FIELD OF THE INVENTION
[0002] The present invention relates to damping mechanisms slowing the closure of cabinet door hinges. In particular, the invention relates to a detachable, adjustable, and reusable attachment for connection to pre-existing hinge assemblies that provides a damped door closure.
BACKGROUND OF THE INVENTION
[0003] In the field of cabinetry and mill work a pervasive problem is uncontrolled closure of doors. Uncontrolled closure often results in slamming of cabinetry doors creating unwanted noise and premature wearing of cabinet hinges and cabinet faces. The art has responded generally to this problem by providing damping mechanisms.
[0004] Damping mechanisms are generally comprised of a spring loaded piston contained in a fluid filled cylinder for engagement with the back side of the cabinet door. In the prior art, the damping mechanism is often very close to the pivot axis of the hinge. Such placement increases the force perpendicular to the piston rod on closure of the cabinet door thereby wearing the piston rod and the seals which contain the damping fluid. Failure of the seals or the piston rod thus shortens the life cycle of the entire hinge because of the failure of the damping piston.
[0005] Premature failure is also caused by the inability of prior art hinges to adjust to the weight of the cabinet door on which they are employed.
[0006] U.S. Pat. No. 4,190,925 to Koivusalo discloses a damped hinge. A first hinge plate is attached to the door and a second to the door frame. The first hinge plate is provided with a pair of guide sleeves in which a force-transmitting rod is guided for movement in a direction parallel to the hinge axis. A helical cam attached to the second hinge plate and the piston rod follows a slot when the door swings and moves the piston rod. The piston rod is housed vertically thus adding bulk to the hinge assembly. Since the hinge is integral to the damper, failure of the damper requires replacement of the hinge. Further, the angle of contact of the hinge with the damper is extreme, leading to premature wear and failure.
[0007] U.S. Pat. No. 5,383,253 to Lin discloses a hydraulic buffer hinge The device couples a cushion spring connected to two swinging plates with a hydraulic buffer to slow the return stroke of a swinging door. The cushion spring is aligned parallel to the pivot axis of the hinge while the piston of the hydraulic buffer is aligned perpendicularly to the pivot axis of the hinge. The damping force of the self-contained hydraulic buffer is not adjustable. Upon failure, the entire hinge assembly requires replacement.
[0008] U.S. Pat. No. 6,928,699 to Sawa discloses an automatic closing door hinge mechanism. A first wing plate includes a cylinder and a piston while a second wing plate includes an operation rod engaged with the piston. A cam is formed on the piston. An engaging part provided on the operation rod is movable in the cam. A sphere on the outer surface of the piston moves in a lengthwise groove in the cylinder to allow the piston to slide within the cylinder. Impact of the door closing is pneumatically damped within the cylinder. The apparatus is bulky and requires replacement upon failure of the piston.
[0009] Referring to FIGS. 1A and 1B , the prior art also includes “piggy back” type damper arrangement 5000 having body 5001 designed to attach to hinge arm 6001 of recessed hinge arrangement 6000 . The placement of damper arrangement 5000 in the prior art is on top of hinge arm 6001 and adjacent to hinge plate 6003 . The placement allows for contact of absorber 5003 with hinge plate 6003 of hinge cup 6002 for approximately 20 degrees of travel of hinge 6000 between impact position 3000 and closed position 3001 . Because of the 20 degree hinge travel, the throw of absorber 5003 is extremely short and relatively ineffective at slowing the closure of a typical cabinet door. The addition of damper arrangement 5000 more than doubles the total height of hinge arm 6001 located in the cabinet thereby interfering with storage space and cabinet use.
[0010] Further, when the damper mechanism fails, the entire hinge assembly must often be replaced. Removing the entire cabinet door and replacing the hinge instead of repairing it increases the cost of replacement.
[0011] Thus, there is a need for a damper hinge device that is compact and removable.
[0012] There is also a need for a damper hinge device that extends the life cycle of the mechanism and the surrounding cabinetry.
[0013] There is also a need for a damper hinge device which is capable of contact point adjustment to provide for various applications.
[0014] It is also desirable to effectuate a damped hinge mechanism which extends the operational contact angle thereby allowing for extended contact and more effective door closure.
[0015] It is also desirable to effectuate a damper hinge mechanism with a low profile to reduce interference with operation and conserve space.
SUMMARY
[0016] In a preferred embodiment, the damper hinge mechanism comprises a body having a connector portion and a housing portion, a spring damper assembly slidingly and removably engaged with the interior of the housing portion.
[0017] The spring damper assembly comprises a cylinder slidingly engaged with a piston and a piston rod. The cylinder is filled with a damping fluid such as mineral oil surrounding the piston rod and a spring biasing the piston. The cylinder includes a flexible tip for engagement with the hinge part mounted on the cabinet door. In various embodiments, the flexible tip is a dense energy absorbing foam rubber, rubber, or plastic.
[0018] In one embodiment, the connector portion includes a fastening hook and a plurality of support abutments for removable engagement with a standard hinge body. In this embodiment, the housing portion is angled with respect to the connector portion to engage the hinge part mounted on a swinging door at an angle which reduces stress on the piston and cylinder.
[0019] In another embodiment, the connector portion includes a securing hook, an adjustment hole to allow a user to adjust the hinge, and a cam locking mechanism. In this embodiment, the housing portion has a gap along the axis of the housing portion to reduce weight and material costs. This embodiment further comprises an adjustment knob for adjusting the contact point and the compressive strength of the spring damper assembly with a hinge part mounted on a swinging door. The piston rod is removably supported by the adjustment knob. The adjustment knob is threaded into the housing portion, providing axial adjustment for the spring damper assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The disclosed embodiments will be described with reference to the accompanying drawings. Like pieces in different drawings carry the same number.
[0021] FIG. 1A is a side view of a damper of the prior part.
[0022] FIG. 1B is a side view of a damper of the prior art.
[0023] FIG. 2 is an exploded isometric view of a preferred embodiment.
[0024] FIG. 3A is a top view of a preferred embodiment attached to a hinge.
[0025] FIG. 3B is a free body diagram of the forces acting on a damper of the prior art.
[0026] FIG. 3C is a free body diagram of the forces acting on a spring damper assembly of a preferred embodiment.
[0027] FIG. 4A is a top view of a preferred embodiment attached to a pre-mounted hinge at an open position.
[0028] FIG. 4B is a top view of a preferred embodiment attached to a pre-mounted hinge at an impact position.
[0029] FIG. 4C is a top view of a preferred embodiment attached to a pre-mounted hinge at a closed position.
[0030] FIG. 5 is an exploded isometric view of a preferred embodiment.
[0031] FIG. 6A is a detail elevation view of a connector portion of a preferred embodiment.
[0032] FIG. 6B is an assembled partial section view a connector portion of a preferred embodiment, taken along line I-I of FIG. 6A .
[0033] FIG. 6C is a partial section view a connector portion of a preferred embodiment, taken along line II-II of FIG. 6A .
[0034] FIG. 6D is detail view of a connector portion in a retracted position of a preferred embodiment.
[0035] FIG. 6E is detail view of a connector portion in a partial extended position of a preferred embodiment.
[0036] FIG. 6F is detail view of a connector portion in an extended position of a preferred embodiment.
[0037] FIG. 6G is a detail view of a connector portion in a partial retracted position of a preferred embodiment.
[0038] FIG. 7A is a top view of a preferred embodiment attached to a pre-mounted hinge at an open position.
[0039] FIG. 7B is a top view of a preferred embodiment attached to a pre-mounted hinge at an impact position.
[0040] FIG. 7C is a top view of a preferred embodiment attached to a pre-mounted hinge at a closed position.
DETAILED DESCRIPTION
[0041] Referring to FIG. 2 , attachment 10 comprises body 100 , receiver 500 , and spring damper assembly 400 . Body 100 has connector portion 200 and housing portion 300 . Connector portion 200 has base 201 , attached to housing portion 300 , side 202 , side 203 , end 204 , and end 205 . Connector portion 200 extends generally radially from housing portion 300 . Side 202 , end 205 , and side 203 form a generally rectangular channel at end 205 . Side 202 , end 204 , and side 203 form a generally rectangular channel at end 204 . Fastening hook 207 and support 217 are attached to base 201 . Housing portion 300 is off-set with respect to connector portion 200 .
[0042] Base 201 has support abutments 209 , 210 , 215 , and 211 , all of which are angled to facilitate the off-set position of housing portion 300 and are adjacent to side 202 attached to base 201 . Support abutment 215 is adjacent to side 202 and fastener hook 207 . Base 201 further has support abutments 212 , 213 , 216 , and 214 , all of which are angled to facilitate the off-set position of housing portion 300 and are adjacent to base 201 and side 202 . Support abutment 216 is adjacent to side 203 and fastener hook 207 . Support abutment 209 is positioned adjacent to side 202 , generally opposite from support abutment 212 adjacent to side 203 . Support abutment 210 is positioned adjacent to side 202 , generally opposite support abutment 213 adjacent to side 203 . Support abutment 211 is positioned adjacent to side 202 , generally opposite support abutment 214 adjacent to side 203 .
[0043] Housing portion 300 has spring damper end 302 , inside surface 303 , and outside surface 304 .
[0044] In a preferred embodiment, body 100 is made of a durable plastic, but can be made of other rigid materials such as cast aluminum, metal, metal alloy, or zinc die cast.
[0045] Receiver 500 has flange 501 , barrel 502 , inside surface 507 , and outside surface 506 . Flange 501 has hole 503 and slots 505 , 508 , and 509 at proximal end 504 to slidingly receive spring damper assembly 400 . Receiver 500 is inserted into hole 306 and outside surface 506 is frictionally engaged with inside surface 303 of housing portion 300 .
[0046] In a preferred embodiment, receiver 500 is made of a durable plastic, but can be made of other materials such as a durable metal or metal alloy.
[0047] Spring damper assembly 400 is slidingly engaged with inside surface 507 of receiver 500 and removably supported by receiver end 510 . Spring damper assembly 400 comprises cylinder 420 having proximal end 401 , distal end 402 , and outside surface 403 . Flexible tip 404 has a generally convex shape and is removably attached to distal end 402 by frictional engagement with mounting post 413 and distal end 402 . Guide flanges 405 , 406 , and 407 are attached to outside surface 403 at proximal end 401 and slidingly engage with slots 505 , 508 , and 509 in flange 501 of receiver 500 . Piston rod 408 is slidingly engaged with proximal end 401 and is connected to a piston. The piston is slidingly engaged with an inside surface of cylinder 420 . The inside surface of cylinder 420 forms a fluid chamber, which contains a damper fluid. Piston rod 408 is concentrically aligned with a piston guide in proximal end 401 . The piston guide forms a seal with piston rod 408 to prevent the damper fluid from escaping cylinder 420 . The piston has at least one fluid channel through which the damper fluid can pass. A spring is positioned between the piston and distal end 402 and urges against the piston and distal end 402 .
[0048] In a preferred embodiment, cylinder 420 is formed of extruded plastic or other suitable materials for lightweight durability and affordability. Piston rod 408 is made of aluminum, but can be made of other metals or metal alloys with similar lightweight and strength properties. The piston is made of aluminum or can be made of other durable, lightweight materials known in the art. Flexible tip 404 may be made of plastic, rubber, or a dense energy absorbing foam rubber. The damper fluid is a mineral oil, but other fluids known in the art may be suitably employed. The damper fluid fills approximately 80% of the volume of the inside of cylinder 420 less the volumes of piston rod 408 , the piston, and the spring. Other suitable fluid capacities known in the art may be employed as well. The spring is made of a durable metal with a spring constant in a range of approximately 10 lbs./inch to 20 lbs./inch.
[0049] Referring to FIG. 3A , attachment 10 is attached to hinge 600 with fastener hook 207 hooked onto the side of a hole in hinge 600 . Hinge 600 has door portion 650 , hinge cup 651 , and hinge plate 652 . Housing portion 300 and spring damper assembly 400 are positioned at an off-set angle with respect to connector portion 200 . Support abutments 212 , 213 , 216 , and 214 and fastening hook 207 are angled to facilitate the off-set position of housing portion 300 and spring damper assembly 400 by extending generally perpendicularly from the off-set position of housing portion 300 and spring damper assembly 400 . Connector portion 200 is positioned along axis 950 and housing portion 300 and spring damper assembly 400 are positioned along axis 951 . Axis 950 and axis 951 are separated by off-set angle ω.
[0050] In a preferred embodiment, off-set angle ω is in a range of about 1° to about 20°.
EXAMPLE 1
[0051] Referring to FIG. 3B , when hinge plate 652 impacts prior art damper 5003 , the forces exerted on prior art damper 5003 are defined as follows:
(1) F 1x =F 1 cos β; where F 1 is the force of the door exerted by hinge plate 652 and β is the angle between F 1 and the x-axis. (2) F 1x d 1 =m 1 ; where m 1 is the moment exerted on the piston inside prior art damper 5003 to counteract F 1x and d 1 is the distance the center of the piston is located from the x-axis at impact, and (3) F 1x d 1 =F 2 d 2 +F 3 d 3 ; where d 2 and d 3 are the distances the edges of the piston are from the center of the piston and F 2 and F 3 are the forces exerted on the piston. F 1y is negligible because prior art damper 5003 moves along the y-axis to absorb F 1y .
[0055] Referring to FIG. 3C , when hinge plate 652 impacts spring damper assembly 400 of the preferred embodiment, the forces exerted on spring damper assembly 400 and the results are as follows:
[0000] F′ 1x =F 1 cos β′;
[0000]
F
1
=
F
1
x
′
cos
β
′
[0000] and from
[0000]
F
1
=
F
1
x
cos
β
,
then
;
F
1
x
cos
β
=
F
1
x
′
cos
β
′
;
[0000] where β′=β+ω, ω is the off-set angle of the preferred embodiment, with β=45°, ω=10°;
[0000]
cos
(
β
+
ω
)
cos
β
=
.573
.707
≈
19
%
[0000] reduction from F 1x to F′ 1x ; therefore a 9.5% reduction from F 2 and F 3 to F′ 2 and F′ 3 , respectively; thereby reducing m 1 to m′ 1 .
[0056] The example shows that the force resisted by the cylinder F′ 1x is reduced, thereby reducing wear on the cylinder and increasing the useful life of the damping mechanism.
[0057] Referring to FIGS. 4A , 4 B, and 4 C in use, attachment 10 is attached to hinge 600 , which is fastened to cabinet 00 . Attachment 10 is clipped onto hinge 600 with fastener hook 207 . To detach attachment 10 , attachment 10 is pulled from hinge 600 . Hinge 600 has door portion 650 , which is attached to door 750 . Door portion 650 and door 750 begin at open position 806 and travel through angle a with a closing speed sufficient to propel door portion 650 and door 750 to closed position 808 to ensure door 750 will close and not remain open after contact with spring damper assembly 400 . Angle a is approximately 120°. Spring damper assembly 400 is in ready position 809 .
[0058] At impact position 807 , door portion 650 applies force 903 on spring damper assembly 400 . The flexibility of flexible tip 404 and the contents of cylinder 420 of spring damper assembly 400 urge to absorb force 903 . As door 750 and door portion 650 continue to swing closed through angle λ, piston rod 408 remains stationary relative to housing portion 300 and receiver 500 . Angle λ is approximately 30°. Spring damper assembly 400 slides through housing portion 300 against the bias of the spring and the piston attached to piston rod 408 , moving through the inside of cylinder 420 to closed position 808 . The damper fluid moves through the fluid channels in the piston to dampen force 903 .
[0059] Referring to FIG. 5 in another embodiment, attachment 1000 comprises body 1100 , spring damper assembly 400 , and adjustment knob 1500 . Body 1100 has connector portion 1200 and housing portion 1300 . Connector portion 1200 has base 1201 , attached to housing portion 1300 . Connector portion 1200 extends generally radially from housing portion 1300 . Base 1201 is attached to sides 1202 and 1203 . Base 1201 has ends 1204 and 1205 . Side 1202 , base 1201 , and side 1203 form a generally rectangular channel. End 1204 includes securing hook 1206 . Base 1201 has adjustment hole 1207 and cam locking mechanism 1208 . Cam locking mechanism 1208 further includes hole 1209 to receive fastener 1210 . Fastener 1210 has cam pin 1227 . Fastener 1210 is situated through hole 1209 . Cam pin 1227 is inserted through hole 1225 of cam lock 1211 and hole 1230 of cam cap 1220 and secured to cam cap 1220 , as will be further described below. Adjustment hole 1207 has sufficient dimensions to allow a user to adjust a pre-mounted hinge to which attachment 1000 is attached.
[0060] Housing portion 1300 has receiver end 1301 , spring damper end 1302 , outside surface 1303 , and inside surface 1304 . Receiver end 1301 has hole 1308 . Hole 1308 has internal threads 1309 , which are adapted to receive adjustment knob 1500 . Spring damper end 1302 has hole 1306 . Hole 1306 has slot 1305 to slidingly receive guide flange 405 on spring damper assembly 400 . Gap 1307 is positioned axially along housing portion 1300 to conserve weight and material costs.
[0061] In a preferred embodiment, body 1100 is made of a zinc die cast, but can be made of a suitable plastic, a suitable metal, or a suitable metal alloy. Fastener 1210 can be a multitude of fasteners known in the art. Cam lock 1211 and cam cap 1220 are made of a durable metal, but can be made of a durable plastic or metal alloy.
[0062] Adjustment knob 1500 has receiving hole 1505 to removably support piston rod 408 of spring damper assembly 400 . Adjustment knob 1500 further has a set of external threads that match internal threads 1309 in hole 1308 of housing portion 1300 .
[0063] In a preferred embodiment, adjustment knob 1500 is made of a durable plastic, but can be made of a durable metal or metal alloy.
[0064] Spring damper assembly 400 is slidingly engaged with inside surface 1304 of housing portion 1300 and removably supported by receiving hole 1505 of adjustment knob 1500 . Spring damper assembly 400 comprises cylinder 420 having proximal end 401 , distal end 402 , and outside surface 403 . Flexible tip 404 has a generally convex shape and is removably attached to distal end 402 by frictional engagement with mounting post 413 and distal end 402 . Guide flange 405 is attached to outside surface 403 at proximal end 401 and is slidingly engaged with slot 1305 of housing portion 1300 . Piston rod 408 is slidingly engaged with proximal end 401 and is connected to a piston. The piston is slidingly engaged with the inside surface of cylinder 420 . The inside surface of cylinder 420 forms a fluid chamber, which contains a damper fluid. Piston rod 408 is concentrically aligned with a piston guide in proximal end 401 . The piston guide forms a seal with piston rod 408 to prevent the damper fluid from escaping cylinder 420 . The piston has at least one fluid channel through which the damper fluid can pass. A spring is positioned between the piston and distal end 402 and urges against the piston and distal end 402 .
[0065] In a preferred embodiment, cylinder 420 is formed of extruded plastic or other suitable materials for lightweight durability and affordability. Piston rod 408 is made of aluminum, but can be made of other metals or metal alloys with similar lightweight and strength properties. The piston is made of aluminum or can be made of other durable, lightweight materials known in the art. Flexible tip 404 may be made of plastic, rubber, or a dense energy absorbing foam rubber. The damper fluid is a mineral oil, but other fluids known in the art may be suitably employed. The damper fluid fills approximately 80% of the volume of the inside of cylinder 420 less the volumes of piston rod 408 , the piston, and the spring. Other suitable fluid capacities known in the art may be employed as well. The spring is made of a durable metal with a spring constant in a range of approximately 10 lbs./inch to 20 lbs./inch.
[0066] Adjustment knob 1500 is threadingly engaged with receiver end 1301 . Spring damper assembly 400 slides into hole 1306 at spring damper end 1302 . Guide flange 405 slides into slot 1305 to allow piston rod 408 to be removably supported in receiving hole 1505 .
[0067] The damping functionality is adjusted by turning adjustment knob 1500 in direction 1900 or in direction 1901 . Advancing adjustment knob 1500 further axially into housing portion 1300 in direction 1902 at receiver end 1301 results in increasing the compressive strength of spring damper assembly 400 because spring damper assembly 400 extends further axially away from housing portion 1300 at spring damper end 1302 and catches the swinging door earlier in its swing path.
[0068] Retreating adjustment knob 1500 out of housing portion 1300 in direction 1903 at receiver end 1301 results in decreasing the compressive strength of spring damper assembly 400 because the swinging door will meet spring damper assembly 400 further along in its swing path.
[0069] Referring to FIG. 6A , cam locking mechanism 1208 includes riser 1213 , which is attached to base 1201 . Channel 1214 is connected onto riser 1213 and is generally “TU”-shaped to slidingly receive cam lock 1211 . Cam lock 1211 is seated into inside surface 1215 of channel 1214 . In a preferred embodiment, cam lock 1211 has a 5% to 10% tolerance of dimensions to enable cam lock 1211 to slidingly engage with channel 1214 .
[0070] Fastener 1210 has shaft 1228 and cam pin 1227 . Cam pin 1227 is attached to the end of shaft 1228 in an off-center position on flat surface 1229 . Shaft 1228 is situated through hole 1209 and adjacent to cam lock 1211 . Cam pin 1227 is situated through hole 1225 of cam lock 1211 to attach to cam cap 1220 by insertion into hole 1230 and welded into place by a welding means known in the art. Bottom surface 1212 of cam cap 1220 is then slidingly secured onto surface 1226 of cam lock 1211 . Cam pin 1227 freely rotates within hole 1225 .
[0071] In another embodiment, cam cap 1220 is eliminated and the end of cam pin 1227 is stamped to deform the end of cam pin 1227 to a diameter larger than the diameter of hole 1225 to secure cam pin 1227 to cam lock 1211 . Cam pin 1227 freely rotates within hole 1225 .
[0072] Referring to FIGS. 5 and 6A , soft close hinge attachment 1000 is mounted onto a pre-mounted hinge by securing hook 1206 and cam locking mechanism 1208 . Cam locking mechanism 1208 secures soft close hinge attachment 1000 to a pre-mounted hinge by turning fastener 1210 in direction 2000 or 2001 . The rotation of fastener 1210 and the off-center position of cam pin 1227 advances cam lock 1211 in direction 2002 extending partially over adjustment hole 1207 ; thereby coupling soft close hinge attachment 1000 to a pre-mounted hinge, as will be further described below.
[0073] To detach attachment 1000 from a pre-mounted hinge, fastener 1210 is rotated in direction 2000 or 2001 , thereby retreating cam lock 1211 in direction 2003 to re-seat cam lock 1211 on riser 1213 , as will be further described below. Attachment 1000 is then pulled from the pre-mounted hinge.
[0074] Referring to FIGS. 6B and 6C , shaft 1228 of fastener 1210 resides in recess 1250 and hole 1209 . Cam pin 1227 is loosely positioned in hole 1225 of cam lock 1211 . Cam pin 1227 is fixed in hole 1230 of cam cap 1220 by welding, press fit or a suitable epoxy adhesive. Cam lock 1211 is slidingly positioned between flat surface 1229 of shaft 1228 and bottom surface 1212 of cam cap 1220 . Cam pin 1227 is free to rotate within hole 1225 . Cam lock 1211 is constrained to slide in channel 1214 by riser 1213 . In an alternate embodiment, cam cap 1220 is formed by physically deforming cam pin 1227 during assembly.
[0075] Recess 1250 and hole 1209 have an oblong shape to enable fastener 1210 to move laterally within hole 1209 and recess 1250 to compensate for the offset position of cam pin 1227 , as will be described below.
[0076] The movement of cam lock 1211 and fastener 1210 will be described with reference to FIGS. 6D-6G . For clarity, cam cap 1220 is not shown.
[0077] Referring to FIG. 6D , cam lock 1211 is in a retracted position and seated in channel 1214 . Shaft 1228 of fastener 1210 has central axis 1251 . To advance cam lock 1211 from the retracted position towards adjustment hole 1207 , shaft 1228 may be rotated in a clockwise direction or a counterclockwise direction about central axis 1251 .
[0078] Referring to FIG. 6E , by way of example, cam lock 1211 is in a partially extended position. Shaft 1228 is rotated in hole 1209 about central axis 1251 in a counterclockwise direction approximately 90° from the retracted position in FIG. 6D to the partially extended position as shown. The rotation of shaft 1228 causes cam pin 1227 to rotate in hole 1225 of cam lock 1211 and shaft 1228 to translate in hole 1209 to urge cam lock 1211 towards adjustment hole 1207 along axis 1252 .
[0079] Referring to FIG. 6F , cam lock 1211 is in an extended position, partially covering adjustment hole 1207 . Shaft 1228 is rotated in hole 1209 about central axis 1251 approximately 90° in a counterclockwise direction from the partially extended position in FIG. 6E to the extended position as shown. The rotation of shaft 1228 causes cam pin 1227 to rotate in hole 1225 of cam lock 1211 and shaft 1228 to translate in hole 1209 to urge cam lock 1211 towards adjustment hole 1207 .
[0080] In the extended position, cam lock 1211 engages a pre-mounted hinge to secure attachment 1000 to the hinge.
[0081] To retreat cam lock 1211 from the extended position away from adjustment hole 1207 , shaft 1228 may be rotated in a clockwise direction or a counterclockwise direction about central axis 1251 .
[0082] Referring to FIG. 6G by way of example, cam lock 1211 is in a partially retracted position. Shaft 1228 is rotated in hole 1209 about central axis 1251 from the extended position in FIG. 6F in a counterclockwise direction approximately 90° to the partially retracted position as shown. The rotation of shaft 1228 causes cam pin 1227 to rotate in hole 1225 of cam lock 1211 and shaft 1228 to translate in hole 1209 to retreat cam lock 1211 away from adjustment hole 1207 along axis 1252 .
[0083] To complete the retraction of cam lock 1211 , shaft 1228 is rotated in hole 1209 about central axis 1251 in a counterclockwise direction approximately 90° from the partially retracted position in FIG. 6G to the retracted position in FIG. 6D . The rotation of shaft 1228 causes cam pin 1227 to rotate in hole 1225 of cam lock 1211 and shaft 1228 to translate in hole 1209 to retreat cam lock 1211 away from adjustment hole 1207 along axis 1252 and reseat cam lock 1211 in channel 1214 . In the retracted position, attachment 1000 may be detached from the pre-mounted hinge.
[0084] It will be appreciated by those skilled in the art that shaft 1228 may be rotated in a clockwise direction to extend and retract cam lock 1211 , thereby reversing the order of positions described in FIGS. 6D , 6 E, 6 F, and 6 G.
[0085] Referring to FIGS. 7A , 7 B, and 7 C, in use, attachment 1000 is attached to hinge 1600 with securing hook 1206 and cam locking mechanism 1208 , which is fastened to cabinet 1700 . Hinge 1600 has door portion 1650 , which is attached to door 1750 . Door portion 1650 and door 1750 begin at open position 1806 and travel through angle θ with a closing speed sufficient to propel door portion 1650 and door 1750 to closed position 1808 to ensure door 1750 will close and not remain open after contact with spring damper assembly 400 . Angle θ is approximately 120°. Spring damper assembly 400 is in ready position 1809 .
[0086] At impact position 1807 , door portion 1650 applies force 1903 on spring damper assembly 400 . The flexibility of flexible tip 404 and the contents of cylinder 420 of spring damper assembly 400 urge to absorb force 1904 . As door 1750 and door portion 1650 continue to swing closed through angle γ, piston rod 408 remains stationary relative to housing portion 1300 and adjustment knob 1500 . Angle γ is approximately 30°. Spring damper assembly 400 slides through housing portion 1300 against the bias of the spring and the piston attached to piston rod 408 , moving through the fluid chamber to closed position 1808 . The damper fluid moves through the at least one fluid channel to dampen force 1904 .
[0087] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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A detachable and adjustable damper hinge attachment for connection to pre-installed hinge hardware to dampen the closing motion of a swinging cabinet door. The attachment comprises a housing and a spring damper assembly slidingly and removably engaged with the housing. The housing includes an attachment means for detachable engagement with a hinge body. The spring damper assembly extends from the housing and contacts a portion of the hinge to which the door is mounted. One embodiment positions the spring damper assembly to more perpendicularly meet the door portion of the hinge. Another embodiment includes an adjustment knob for adapting the contact point of the spring damper assembly.
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TECHNICAL FIELD
[0001] The present invention relates to an electrospinning apparatus, and more particularly by controlling solution temperature from nozzle equipped on nozzle block tubular bodies, controlling electrospin solution viscosity, nanofiber with various components and thickness could be manufactured, nozzle block front-end is arranged in divergent shape, there aren't density difference and voltage difference, nanofiber with uniform quality could be produced, only using metering pump, or by alternatively using metering pump and overflow prevent system, solution usage amount is decreased, and simultaneously mass-producing nanofiber in low cost.
BACKGROUND ART
[0002] Generally, Electrospinning is technology producing micro diameter fiber by spinning fiber material solution in charging state, recently nanometer fiber (below, ‘nanofiber’) could be manufactured, and research regarding this is actively in progress. Nanofiber produced by electrospinning means fiber having average diameter of 5 to 1000 nm, like this if fiber diameter decreases, new features appear. For example, increase in ratio of surface to volume, enhance in surface functionality, enhance in mechanical property including tension.
[0003] Here, Nanofiber is applied in many application field because it has high ration of surface to volume, and excellent flexibility regarding surface functional group.
[0004] Nanofiber is applied in many fields because of such excellent features. For example, a web comprising such nanofiber is separation membrane-type material with porosity, and applied in various field such as a variety of filter kinds, wound dressings, and artificial supporters.
[0005] Also, nanofiber has excellent filtering effect in filter usage, and nanofiber manufactured from polymer with electrical conductivity is coated on glass, perceives amount of sun light, and can make window color change.
[0006] Moreover, in the case nanofiber with conductivity is used as lithium ion battery electrolyte, electrolyte leak could be prevented, battery size and weight are largely decreased, in the case of making nanofiber with artificial protein similar to biological tissue, it is used as bandage absorbed directly in body or artificial skin.
[0007] Manufacture method of nanofiber includes drawing, template synthesis, phase separation, self assembly, and electrospinning.
[0008] Especially, among the manufacture methods, electrospinning method is widely applied as a method of consecutively mass-producing nanofiber from various polymers.
[0009] Such electrospinning method is between two electrode having opposite polarity, one pole of electrode in spinning nozzle portion, another pole in collector, charged spinning material is discharged in air through spinning nozzle portion, subsequently draw electric charged filament in air, or through another filament, manufactures micro fiber. In other words, charged and discharged filament is through severe galloping because of electric effect such as mutual resistance in electrical-field formed between nozzle and collector, and extremely thinned.
[0010] An electrospinning apparatus which manufactures nanofiber by electrospinning comprising a storage tank storing spinning solution, a distribution pipe transferring spinning solution quantitatively, a metering pump for supplying spinning solution in required amount, a nozzle block in which a plurality of nozzles to discharge spinning solution is arranged, a collector collecting spin fiber and located oppositely to the nozzle block, and a voltage generating device for providing voltage.
[0011] Type of polymer and solvent used when producing nanofiber with such electrospinning apparatus, solvent type, polymer solution concentration, and spinning room temperature and humidity are known to affect diameter and spinning property of produced nanofiber.
[0012] Temperature and humidity regarding electrospinning area, region occurring electrospinning (below, indicated as ‘spinning region’), temperature by changing spinning solution viscosity, modifies spinning solution surface tension, eventually affects spin nanofiber diameter.
[0013] In other words, in the case spinning region temperature is relatively high and solution viscosity is low, nanofiber with relatively thin fiber diameter is manufactured, and in the case temperature is relatively low and solution viscosity is high, nanofiber with relatively thick fiber diameter is manufactured.
[0014] Therefore, in order to manufacture nanofiber with constant fiber diameter distribution, spinning room temperature and humidity should be controlled to maintain constantly according to given condition, for this, there are drawbacks such as equipment expense and energy expense cost a lot.
[0015] Meanwhile, in order to overcome strength limit of electrospin nanofiber using one type of polymer solution, enhanced nanofiber is manufactured by laminating and mixing polymer solution having different component.
[0016] In the case of manufacturing such multiple layer nanofiber, there is strong point such as enhanced nanofiber is manufactured, but relatively nanofiber thickness becomes thicker, when polymer solution electrospin and integrated to a collector, as one polymer solution is used, there is problem that two or more electrospinning apparatus are needed, and there are problems such as installation expense and energy expense cost a lot, manufacture line becomes longer, and processing time is increased.
[0017] Meanwhile, when manufacturing nanofiber through the electrospinning apparatus, factors deciding nanofiber characteristics are matter feature such as density, dielectric feature, and surface tension, and control factor such as distance between a nozzle and a collector, voltage between a nozzle and a collector, charge density in electrical field, electrostatic pressure in nozzle, and spinning material injection speed.
[0018] Moreover, when producing extra fine denier fiber using the electrospinning apparatus, factors determining extra fine denier fiber feature are tip form of nozzle and nozzle pack, electric field interference according to distance among nozzle tip, electric field charge density, and electrostatic pressure in nozzle.
[0019] When manufacturing a product by electrospinning through the electrospinning apparatus, regarding a nozzle among important factors determining a product feature, by manufacturing nanofiber using one or few nozzle, production speed is very low so it is difficult to commercialize.
[0020] Therefore, in order to commercialize electrospinning, it is needed to figure out problems regarding nozzle form and problems regarding spinning nozzle through research on interference among nozzle.
[0021] Meanwhile, nanofiber manufacture device (refer to Japanese Patent No. 4402695) which recycles collected polymer solution overflowed from a plurality of nozzle's outlet as nanofiber material is known, as illustrated in FIG. 1 , the nanofiber manufacture device ( 900 ) comprises; a plurality of nozzle ( 912 ) discharging polymer solution upward from an outlet; a nozzle block ( 400 ) having polymer solution supply path ( 914 ) which supplies polymer solution to the plurality of nozzle ( 912 ); a voltage generating device ( 930 ) which applies voltage between the nozzle block ( 400 ) and a collector ( 700 ); a spinning solution main tank ( 100 ) which stores polymer solution that is material of the nanofiber; a metering pump ( 950 ) which supplies polymer solution stored in the spinning solution main tank ( 100 ) to polymer solution supply path ( 914 ) of the nozzle block ( 400 ); and a retrieval pump ( 120 ) which retrieves overflowed polymer solution from outlet of the plurality of nozzle ( 912 ) and returning overflowed polymer solution to the spinning solution main tank ( 100 ).
[0022] Though according to the nanofiber manufacture device as stated above, phenomenon of polymer solution lump which isn't spun from nozzle attached to a collector plate (below, indicated as “Droplet phenomenon”) could be slightly resolved, we are in the state of requiring technology to cut down amount of polymer solution used by preventing droplet phenomenon.
DISCLOSURE
Technical Problem
[0023] The present invention is contrived to solve the problems, the purpose is to provide an electrospinning apparatus capable of producing nanofiber having various ingredients and thicknesses by controlling the temperature of at least one solution discharged from nozzles mounted on the pipe of a nozzle block and thus controlling the viscosity of the solution which is electrospun; producing nanofiber having uniform quality without applying a density difference and a voltage difference by disposing the front end portions of the nozzles in a flare shape; and mass-producing nanofiber at a low cost as well as reducing the amount of the solution used by removing an overflow prevention system and using a metering pump alone or by using the metering pump and the overflow prevention system alternatively or in a hybrid manner.
Technical Solution
[0024] In order to achieve the objects stated above, the present invention is an electrospinning apparatus manufacturing nanofiber by electrospinning method, comprising: a nozzle block in which a plurality of nozzles discharging polymer solution is arranged, a collector installed and placed separately from the nozzle block and integrating nanofiber, a voltage generating device applying high voltage between the collector and the nozzle, an elongated sheet conveyed between the collector and the nozzle, wherein the nozzle block comprises a plurality of tubular bodies which connected to a plurality of nozzles, and a heat line or a pipe connected to temperature adjusting device inside each tubular body to control temperature of polymer solution.
[0025] Here, each tubular body is equipped on the nozzle block detachable, the heat line provided in each of tubular body is formed in coil form or linear form, and the pipe in each of tubular body is formed in U form.
[0026] Moreover, electrospinning method of manufacturing nanofiber by discharging polymer solution from a plurality of nozzles connected to tubular body is one among bottom-up type, top-down type, or parallel type.
[0027] Meanwhile, An electrospinning apparatus, manufacturing nanofiber by electrospinning method, comprising a nozzle block in which a plurality of nozzles discharging two or more polymer solution is arranged, a collector installed and placed separately from the nozzle block and integrating nanofiber, a voltage generating device applying high voltage between the collector and the nozzle, an elongated sheet conveyed between the collector and the nozzle, wherein the nozzle block comprises a plurality of tubular bodies, and a heat line or a pipe connected to temperature adjusting device inside each tubular body to control temperature of polymer solution, further comprising two or more polymer solution storage tanks for storing polymer solution with different component separately, and polymer solution flowing pipe for flowing polymer solution in each polymer solution storage tank.
[0028] Here, the polymer solution is one or more among polylactic acid (PLA), polypropylene (PP), polyvinyl acetate (PVAc), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene napthalate (PEN), polyamide (PA), polyurethane (PU), polyvinyl alcohol (PVA), polyetherimide (PEI), polycaprolactone (PCL), poly lactic-co-glycolic acid (PLGA), silk, cellulose, and chitosan.
[0029] In this case, each tubular body is equipped on the nozzle block detachable, the heat line provided in each of tubular body is formed in coil form or linear form, and the pipe in each of tubular body is formed in U form.
[0030] Also, electrospinning method of manufacturing nanofiber by discharging polymer solution from a plurality of nozzles connected to tubular body is one among bottom-up type, top-down type, or parallel type.
[0031] Meanwhile, an electrospinning apparatus manufacturing nanofiber by electrospinning method, comprising:
[0000] a nozzle block, in which a plurality of nozzles discharging polymer solution is arranged, comprising a nozzle plate arranged multi-pipe-type nozzle in sheath/core form, two or more spinning solution storage plate located bottom of the nozzle plate, and a plurality of nozzles, which discharge polymer solution, connected to nozzle for overflow removal;
a collector installed and placed separately from the nozzle block and integrating nanofiber;
a voltage generating device applying high voltage between the collector and the nozzle;
an elongated sheet conveyed between the collector and the nozzle, wherein front end portion of the nozzle connected to the nozzle block is in a flare shape.
[0032] Here, the front end portion of the nozzle is in flare shape and makes 5 degrees to 30 degrees with a cylinder axis of the nozzle, the number of nozzle switch flare-shaped front end portion is 10% to 30% of the total nozzles provided in the nozzle block.
[0033] Moreover, the electrospinning method is one among bottom-up electrospinning method which a nozzle block is located a collector bottom, top-down electrospinning method which a nozzle block is located a collector top, and parallel electrospinning method which a nozzle block and a collector is located parallel or in similar angle.
[0034] Meanwhile, electrospinning apparatus manufacturing nanofiber by electrospinning method, comprising: a nozzle block in which a plurality of nozzles discharging polymer solution is arranged, a collector installed and placed separately from the nozzle block and integrating nanofiber, a voltage generating device applying high voltage between the collector and the nozzle, a spinning solution main tank storing polymer solution, and a middle tank storing polymer solution supplied from the spinning solution main tank, further comprising a metering pump for measuring discharging amount from the nozzle.
[0035] Also, an electrospinning apparatus manufacturing nanofiber by electrospinning, comprising: a nozzle block in which a plurality of nozzles discharging polymer solution is arranged, a collector installed and placed separately from the nozzle block and integrates nanofiber, a voltage generating device applying high voltage between the collector and the nozzle, a spinning solution main tank storing polymer solution, a recycling tank recycling and storing polymer solution, and a middle tank storing polymer solution supplied from the spinning solution main tank, further comprising an overflow prevention system for preventing polymer solution from overflow, and a metering pump for measuring discharging amount from the nozzle, wherein the overflow prevention system and the metering pump are used alternatively or in hybrid type.
[0036] Here, the overflow prevention system comprises a concentration correction device to correct polymer solution concentration.
Advantageous Effects
[0037] The present invention having the composition stated above, by controlling one or more polymer solution viscosity by equipped a temperature adjusting device in each tubular body of a nozzle block, electrospinning nanofiber with various thickness and various components is discharged, thereby nanofiber with various thickness and various components could be manufactured, manufacturing process is simplified and simultaneously manufacture cost is down, nanofiber having uniform quality could be manufactured. Also by adjusting polymer solution amount, amount of polymer solution attached to a nozzle, which is not integrated to a collector, is minimized and simultaneously polymer solution consumption is minimized, and mass-producing nanofiber is possible in low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 illustrates a schematic diagram of nanofiber manufacture device according to the prior art,
[0039] FIG. 2 shows a drawing of an electrospinning apparatus according to the present invention,
[0040] FIG. 3 is a top plan view illustrating a polymer solution supply device of the electrospinning apparatus according to the present invention,
[0041] FIG. 4 is a front section illustrating a schematic diagram of one exemplary embodiment of tubular body of the electrospinning apparatus according to the present invention,
[0042] FIG. 5 is a side section depicting A-A′ line,
[0043] FIG. 6 is a front section showing a schematic diagram of another exemplary embodiment of tubular body of the electrospinning apparatus an according to the present invention,
[0044] FIG. 7 is a side section depicting B-B′ line,
[0045] FIG. 8 is a front section view showing a schematic diagram of other exemplary embodiment of tubular body of the electrospinning apparatus an according to the present invention,
[0046] FIG. 9 is a side section illustrating C-C′ line,
[0047] FIG. 10 is a top plan view illustrating another embodiment of polymer solution supply device of the electrospinning apparatus according to the present invention,
[0048] FIG. 11 is a schematic diagram showing a nozzle block installed double pipe nozzle of the electrospinning apparatus according to the present invention,
[0049] FIG. 12 depicts a schematic diagram of front-end of nozzle of the electrospinning apparatus according to the present invention,
[0050] FIG. 13 is a schematic diagram of metering pump provided in the electrospinning apparatus according to the present invention,
[0051] FIG. 14 depicts a schematic diagram of overflow system and provided metering pump of the electrospinning apparatus according the present invention.
DESCRIPTION OF REFERENCE NUMBERS OF DRAWINGS
[0000]
1 : electrospinning apparatus,
10 : case,
11 : electro spinning room,
20 : collector,
30 : auxiliary belt device,
31 : auxiliary belt,
32 , 33 , 34 : auxiliary belt roller,
40 : polymer solution supply device,
41 : nozzle block,
42 : nozzle,
43 : tubular body,
44 , 44 a , 44 b : spinning solution main tank,
45 : polymer solution flow pipe,
50 : voltage generating device,
60 : temperature adjusting control device,
61 : temperature adjusting control device connector,
62 a , 62 b : heat line,
63 : pipe,
100 : spinning solution main tank,
110 : nozzle block left-right reciprocating device,
111 : agitator motor,
112 : dielectric rod,
113 : agitator,
120 : retrieval pump,
152 : insulator,
201 , 271 : agitating device,
222 , 224 , 226 : valve,
230 : middle tank,
232 : partition,
234 : bubble removal filter,
236 the first storage,
238 : the second storage,
239 : the first sensor,
253 : metering pump,
256 : storage tank,
270 : recycling tank,
300 : spinning solution drop device,
400 : nozzle block,
404 : nozzle for air supply,
405 : nozzle plate,
407 : the first spinning solution storage plate,
408 : the second spinning solution storage plate,
410 : temporal storage pipe for overflowed liquid,
411 : air storage pipe,
412 : overflow outlet,
413 : air inlet,
414 : nozzle support plate for air supply,
415 : nozzle for overflow removal,
416 : nozzle support plate for overflow removal,
420 : front-end of nozzle,
500 : multi-pipe-type nozzle,
501 : the first pipe in multi-pipe-type nozzle,
502 : the second pipe in multi-pipe-type nozzle,
700 : collector,
900 : electrospinning apparatus,
912 : nozzle,
914 : supply path,
930 : voltage generating device,
950 : metering pump,
a: convey direction,
W: elongated sheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0113] Below, specifically explains a desirable embodiment of the present invention reference to an attached drawing. Also, the present embodiment doesn't limit the present invention extent of a right, but merely suggests an example, various modifications in the extent of not leaving the technological main point is possible.
[0114] FIG. 2 shows a drawing of an electrospinning apparatus according to the present invention, FIG. 3 is a top plan view illustrating a polymer solution supply device of the electrospinning apparatus according to the present invention, FIG. 4 is a front section illustrating a schematic diagram of one exemplary embodiment of tubular body of the electrospinning apparatus according to the present invention, FIG. 5 is a side section depicting A-A′ line, FIG. 6 is a front section showing a schematic diagram of another exemplary embodiment of tubular body of the electrospinning apparatus an according to the present invention, FIG. 7 is a side section depicting B-B′ line, FIG. 8 is a front section view showing a schematic diagram of other exemplary embodiment of tubular body of the electrospinning apparatus an according to the present invention, FIG. 9 is a side section illustrating C-C′ line, FIG. 10 is a top plan view illustrating another embodiment of polymer solution supply device of the electrospinning apparatus according to the present invention, FIG. 11 is a schematic diagram showing a nozzle block installed double pipe nozzle of the electrospinning apparatus according to the present invention, FIG. 12 depicts a schematic diagram of front-end of nozzle of the elctrospinning apparatus according to the present invention, FIG. 13 is a schematic diagram of metering pump provided in the electrospinning apparatus according to the present invention, FIG. 14 depicts a schematic diagram of overflow system and provided metering pump of the electrospinning apparatus according the present invention.
[0115] As illustrated in the drawing, the electrospinning apparatus ( 1 ) for producing nanofiber is for electrospinning on carried elongated sheet (W) following a desired direction (a) by a convey device, comprises a main control device for controlling every each operating part, VOC handling device (not shown) for removing volatility component, which is occurred when stacking nanofiber on the elongated sheet (W), by burning, and an inert gas supply device which supplies inert gas in electro spinning room ( 11 ) in the case error is detected in the electrospinning apparatus.
[0116] In the embodiment, only the electrospinning apparatus ( 1 ) is illustrated, and the convey device, the main control device, the VOC handling device and the inert gas supply device are not illustrated.
[0117] The electrospinning apparatus ( 1 ) according to the present invention is to be installed in a room adjusted temperature 20 to 40° C. and humidity 20 to 60%, the electrospinning apparatus ( 1 ) comprises a case ( 10 ) with conductivity, an auxiliary belt device ( 30 ) assisting convey of the elongated sheet (W), a collector ( 20 ) located in the case ( 10 ) and upper side of the elongated sheet (W) to apply high voltage, a nozzle block ( 41 ) in which a plurality of nozzle ( 42 ) discharging polymer solution is arranged and installed directed to the collector ( 20 ), a voltage generating device ( 50 ) applying high voltage between the collector ( 20 ) and the nozzle ( 42 ), and an electrospinning room ( 11 ) having a space covering the nozzle block ( 41 ) and the collector ( 20 ).
[0118] Moreover, a polymer solution supply device ( 40 ) for supplying polymer solution in the nozzle ( 42 ) is provided.
[0119] In this case, the auxiliary belt device ( 30 ) is installed an auxiliary belt ( 31 ) covering the collector ( 20 ), the elongated sheet (W) is contacted to the outer side of the auxiliary belt ( 31 ) and conveyed by according to driving of an auxiliary belt roller ( 32 , 33 ) which rotates the auxiliary belt ( 31 ), the elongated sheet (W) contacted to the auxiliary belt ( 31 ) outer side effectively conveys without driven by the collector ( 20 ) high voltage applied in both sides.
[0120] Here, the elongated sheet (W) could be made by non-woven fabric, fabric, knitting comprising various materials, or etc., and the thickness could be set from 5 to 500 μm.
[0121] Meanwhile, the voltage generating device ( 50 ) applies desired voltage between the collector ( 20 ) and each of the nozzle ( 42 ), one part accesses to the collector, and the other part accesses to each tubular body ( 43 ).
[0122] Polymer solution flow of the nozzle block ( 41 ) according to the embodiment of the present invention supplies from polymer solution storage tank ( 44 ) stored polymer solution through polymer solution flow pipe ( 45 ) to each of the tubular body ( 43 ).
[0123] Also, polymer solution supplied to each of the tubular body ( 43 ) is discharged through a plurality of nozzles ( 42 ), and integrated on the elongated sheet (W) in nanofiber form.
[0124] In this case, in each of the tubular body ( 43 ) a plurality of nozzle ( 42 ) along the tubular body ( 43 ) length direction, is equipped in predetermined space, material of the nozzle ( 42 ) and the tubular body ( 43 ) comprising electric conductor member, and equipped in the tubular body ( 43 ) in the state of electrically accessed.
[0125] Here, in order to control the temperature of polymer solution supplied to each of the tubular body ( 43 ) according to each tubular body ( 43 ), heat line ( 62 a ) is provided in each of the tubular body ( 43 ), the heat line ( 62 a ) is connected to a temperature adjusting control device ( 60 ) through a temperature adjusting control device connection ( 61 ).
[0126] In other words, as illustrated in FIGS. 3 and 4 , in each of the tubular body ( 43 ) the heat line ( 62 a ) in coil form is provided, the heat line ( 62 a ) is connected to the temperature adjusting control device ( 60 ) through the temperature adjusting control device connection ( 61 ), and the temperature of polymer solution supplied in the tubular body ( 43 ) is adjusted and controlled.
[0127] A heat line ( 62 a ) in the tubular body ( 43 ) is provided in single heat line and formed in coil form, but it is possible to provide two or more heating line ( 62 a ) formed in coil form.
[0128] Meanwhile, though in one embodiment of the present invention, the heat line ( 62 a ) in coil form in the tubular body ( 43 ) is provided, as illustrated in FIGS. 6 and 7 , in the tubular body ( 43 ) a heat line ( 62 b ) in linear form is provided, the heat liner ( 62 b ) is connected to the temperature adjusting control device ( 60 ) through the temperature adjusting control device connection ( 61 ), and the temperature of polymer solution supplied in the tubular body ( 43 ) is adjusted and controlled.
[0129] Also, as illustrated in FIGS. 8 and 9 , in the tubular body ( 43 ) pipe ( 63 c ) in U form is provided, the pipe ( 63 c ) connected to the temperature adjusting control device ( 60 ) through the temperature adjusting control device connection ( 61 ), and the temperature of polymer solution supplied in the tubular body ( 43 ) is adjusted and controlled.
[0130] As stated above, according to the aim of the present invention, in order to control temperature of the polymer solution in each tubular body ( 43 ), the heat line ( 62 a , 62 b ) or the pipe ( 63 ) is provided in the tubular body ( 43 ), polymer solution viscosity could be controlled by adjusting temperature of polymer solution supplied in the tubular body ( 43 ) using the temperature adjusting control device ( 60 ).
[0131] Meanwhile, though in one embodiment of the present invention, one polymer solution storage tank ( 44 ) supplying the polymer solution is provided to electrospin one polymer solution, as illustrated in FIG. 10 , it is also preferable that two or more polymer solution storage tank ( 44 a , 44 b ) are provided, in each of the polymer solution storage tank ( 44 a , 44 b ) two or more different polymer solution is each supplied, and electrospinning each of the polymer solution.
[0132] In this case, in each of the tubular body ( 43 ) of the electrospinning apparatus ( 1 ) with two or more polymer solution storage tank ( 44 a , 44 b ), the heat line ( 62 a ) in coil form, the heat line ( 62 b ) in linear form, or the pipe ( 62 c ) in U form is provided, the heat line ( 62 a , 62 b ) or the pipe ( 62 c ) is connected to the temperature adjusting control device ( 60 ) through the temperature adjusting control device connection ( 61 ).
[0133] The heat line ( 62 a , 62 b ) or the pipe ( 62 c ) is provided in the tubular body ( 43 ), the heat line ( 62 a , 62 b ) or the pipe ( 62 c ) connected to the temperature adjusting control device ( 60 ) through the temperature adjusting control device connection ( 61 ), and the temperature of polymer solution supplied in the tubular body ( 43 ) is adjusted and controlled.
[0134] As stated above, according to the aim of the present invention, in order to control temperature of two or more different polymer solution in each tubular body ( 43 ), the heat line ( 62 a , 62 b ) or the pipe ( 63 ) is provided in the tubular body ( 43 ), polymer solution viscosity could be controlled by adjusting temperature of polymer solution supplied in the tubular body ( 43 ) using the temperature adjusting control device ( 60 ).
[0135] Meanwhile, explaining the electrospinning apparatus according to the related art, reference to FIG. 1 , the nozzle ( 912 ) is provided to discharge polymer solution in upward direction from an outlet, polymer solution is supplied from the nozzle block ( 400 ) to the nozzle ( 912 ) through the polymer solution supply path ( 914 ), metering pump ( 950 ) which supply polymer solution stored in the spinning solution main tank ( 100 ) to polymer solution supply path ( 914 ) of the nozzle block ( 400 ), and the retrieval pump ( 12 ) which retrieves overflowed polymer solution from outlet of the nozzle ( 912 ) and return polymer solution to the spinning solution main tank ( 100 ). The nozzle ( 912 ) exit provided in the nozzle block ( 400 ) comprises upward nozzle forming in upper direction, the collector ( 700 ) is located in the nozzle block ( 400 ) upper side, and spinning solution comprising polymer solution electrospins in upward direction.
[0136] Here, the nozzle ( 912 ) installed in the nozzle block ( 400 ) of the electrospinning apparatus ( 900 ), as illustrated in FIG. 11 , comprising a multi-pipe-type nozzle ( 500 ), the multi-pipe-type nozzle ( 500 ) is formed in two or more pipes for simultaneously electrospinning two or more different polymer spinning solution, the first pipe ( 501 ) located in inner side and the second pipe ( 502 ) located outer side of the first pipe are combined in sheath/core form.
[0137] For this, in the nozzle block ( 400 ), a nozzle plate ( 405 ) in which a multi-pipe-type nozzle ( 500 ), that pipes are combined in sheath/core form, is arranged, the first spinning solution storage pipe ( 407 ) and the second spinning solution storage pipe ( 408 ) located in the bottom of the nozzle plate ( 405 ) and which are formed in two or more for providing spinning solution to the multi-pipe-type nozzle ( 500 ), an nozzle for overflow removal ( 415 ) forming in form of covering the multi-pipe-type nozzle ( 500 ), connected to the nozzle for overflow removal ( 415 ), a temporal storage pipe for overflow liquid ( 410 ) is located uppermost side of the nozzle plate ( 405 ), an nozzle support plate for overflow removal ( 416 ) located uppermost side of the temporal storage pipe for overflow liquid ( 410 ) and supports the nozzle for overflow removal ( 415 ), an nozzle for air supply ( 404 ) covering the multi-pipe-type nozzle ( 500 ) and the nozzle for overflow removal ( 415 ), an air storage pipe ( 411 ) supplying air to the nozzle for air supply ( 404 ), and a nozzle support plate for air supply ( 414 ) which supports the nozzle for air supply ( 404 ) and located in the uppermost-end of the nozzle block ( 400 ), and air inlet ( 413 ) which is located in the lowermost-end of the nozzle support plate for air supply ( 414 ) and supplies and stores air to nozzle for overflow removal ( 415 ), and an overflow outlet ( 412 ) which discharges overflow liquid stored in the temporal storage pipe for overflow liquid ( 410 ).
[0138] By the nozzle for overflow removal ( 415 ) provided in the electrospinning apparatus ( 900 ) in order, around the multi-pipe-type nozzle ( 500 ), spinning solution which didn't spin is removed, and by the nozzle for air supply ( 404 ), to enlarge integrated distribution of nanofiber, air is supplied.
[0139] Here, the temporal storage pipe for overflow liquid ( 410 ) is produced as insulator, and after temporally storing remained spinning solution flowed in through the nozzle for overflow removal ( 415 ), conveys it to a spinning solution supply pipe (not drawn).
[0140] Also, by the air storage pipe ( 411 ) located upper side of the temporal storage pipe for overflow liquid ( 410 ), air is supplied to the nozzle for air supply ( 404 ) covering the multi-pipe-type nozzle ( 500 ) and the nozzle for overflow removal ( 415 ).
[0141] Meanwhile, the nozzle support plate for air supply ( 414 ) provided in the uppermost side of the nozzle block ( 400 ) arranged the nozzle for air supply ( 404 ) is formed in nonconductive material, the nozzle support plate for air supply ( 414 ) is located in the nozzle block ( 400 ), electric power affecting between the collector ( 700 ) and the multi-pipe-type nozzle ( 500 ) is focused only on the multi-pipe-type nozzle ( 500 ), so electrospinning is smoothly in progress only in the multi-pipe-type nozzle ( 500 ) part.
[0142] In this case, the distance from the upper tip of the multi-pipe-type nozzle ( 500 ) to the upper tip of the nozzle for air supply ( 404 ) is 1-20 mm, and favorably 2-15 mm. In other words, the nozzle for air supply ( 404 ) height is 1-20 mm and favorably 2-15 mm higher than the multi-pipe-type nozzle ( 500 ). In the case of distance between upper tip of the multi-pipe-type nozzle ( 500 ) and upper tip of the nozzle for air supply ( 404 ) is less than 1 mm, in other words, when the multi-pipe-type nozzle ( 500 ) and the nozzle for air supply ( 404 ) are located in almost same level, the multi-pipe-type nozzle ( 500 ) part doesn't effectively form jet stream, the area of nanofiber attached to the collector ( 700 ) becomes smaller, in the case of distance between upper tip of the multi-pipe-type nozzle ( 500 ) and upper tip of the nozzle for air supply ( 404 ) is more than 20 mm, not only nanofiber formation of the electrospinning apparatus debases as electric force weaken by high voltage flowing between the collector ( 900 ) and the multi-pipe-type nozzle ( 500 ), but also jet stream length and formed pattern become unstable. Specifically, it disturbs stability in jet stream formed part from taylor cone, smooth nanofiber spinning becomes difficult.
[0143] Meanwhile, when producing nanofiber non-woven fabric, air jetting speed jetted from the nozzle for air supply ( 404 ) is 0.05 m-50 m/s, and more preferably 1-30 m/s. In other words, in the case air jetting speed jetted from the nozzle for air supply ( 404 ) is less than 0.05 m/s, spread of nanofiber collected on the collector ( 700 ) is low and collecting area isn't largely enhanced, in the case air jetting speed jetted from the nozzle for air supply ( 404 ) is more than 50 m/s, air jetting speed is too fast that area of nanofiber focused on the collector ( 700 ) decreases, more seriously not as nanofiber but in thick form attached to the collector ( 700 ), so nanofiber formation and nanofiber fabric-woven formation remarkably fall.
[0144] Here, an electric conductor plate (not shown), in which pins the pins are arranged the same as the multi-pipe-type nozzle ( 500 ) arrangement, is installed in the nozzle plate ( 405 ) direct rear-end, the electric conductor plate is connected to the voltage generating device ( 930 ) as illustrated in FIG. 1 .
[0145] Moreover, a heating device (not shown) with indirect heating method is installed in direct rear-end of the spinning solution supply pipe (not shown).
[0146] The electric conductor plate (not shown) carries out a role of applying high voltage to the multi-pipe-type nozzle ( 500 ), the spinning solution supply pipe stores spinning solution flowing from the spinning solution drop device to the nozzle block ( 400 ), and carries out a role of supplying to the multi-pipe-type nozzle ( 500 ). In this case, the spinning solution supply pipe is preferably manufactured in minimized space to minimize spinning solution storage amount.
[0147] In this case, from the rear-end of gas flowing pipe (not shown), gas is flowed, the part of where gas first flows in is connected to a filter (not shown). The spinning solution drop device ( 300 ) rear-end formed spinning solution outlet (not drawn) inducing dropped spinning solution to the nozzle block ( 400 ). The spinning solution drop device ( 300 ) middle part is formed in hollow state for spinning solution drop in a spinning solution delivery table (not drawn) lowermost part.
[0148] Spinning solution flowed in the spinning solution drop device ( 300 ) slide down following the spinning solution delivery table, and in the lowermost part, spinning solution drop, and spinning solution flow is blocked one or more times.
[0149] Here, specifically looking into principle of spinning solution drop, when gas flows in the sealed spinning solution drop device ( 300 ) upper side following filter and gas intake pipe, the pressure of the spinning solution delivery table naturally becomes irregular by swirl gas, pressure difference occurs in this case, so spinning solution drops.
[0150] For flowed gas in the present invention, air or inert gas such as nitrogen could be used.
[0151] The nozzle block ( 400 ) of the present invention, in order to even electrospin nanofiber distribution, by the nozzle block left-right reciprocating device ( 110 ), in progress direction and orthogonal direction of electrospin nanofiber, does left-right reciprocating movement.
[0152] Meanwhile, in the case of producing filament, electrospinning in the state of not doing left-right reciprocating the nozzle block ( 400 ) being fixed, after producing nanofiber web with a certain width, bridging and elongating it and filament is produced.
[0153] Also, inside the nozzle block ( 400 ), more particularly inside the spinning solution supply plate (not shown), to prevent spinning solution gelation in the nozzle, an agitator ( 113 ) agitating spinning solution stored in the nozzle block ( 400 ).
[0154] The agitator ( 113 ) is connected to an agitator motor ( 111 ) by a nonconductive dielectric rod ( 112 ).
[0155] In the case of installing the agitator ( 113 ) in the nozzle block ( 400 ), when electrospinning solution including inorganic metal, or electrospinning spinning solution dissolved using mixed solvent for a long time, spinning solution gelation in the nozzle block ( 400 ) could be effectively prevented.
[0156] Also, uppermost side of the nozzle block ( 400 ) is connected to a retrieval pump ( 120 ) conveying in force excessively supplied spinning solution in the nozzle block ( 400 ) to a spinning solution main tank ( 100 ).
[0157] The retrieval pump ( 120 ) carries in force excessively supplied spinning solution in the nozzle block to the spinning solution main tank ( 100 ) by influx air.
[0158] Moreover, the heating device (not shown) in direct heating method or indirect heating method is installed in the collector ( 700 ) of the present invention, and the collector ( 700 ) is fixed or successively rotates.
[0159] Meanwhile, front-end of nozzle ( 420 ) of the multi-pipe-type nozzle ( 500 ) provided in the nozzle block ( 400 ) of the electrospinning apparatus ( 900 ) is preferably in cylinder shape and in flare shape 5 to 30 angle with a cylinder axis.
[0160] Also the flare-shaped front-end of nozzle ( 42 ) of the multi-pipe-type nozzle ( 500 ) has a form narrowing from upper side to lower side, simply it is flare shape but wedge shape is possible. Front-end ( 420 ) of the multi-pipe-type nozzle ( 500 ) forming in flare shape is preferably accounting 10 to 30% of the nozzle block ( 400 ), but it is not limited to this.
[0161] Here, inner side of the nozzle front-end ( 420 ) is provided air inlet (not shown).
[0162] Meanwhile, according to the electrospinning apparatus ( 1 ) of the present invention, the nozzle front-end ( 420 ) of some part of the nozzle block ( 400 ) is in flare shape, without arrangement density difference and voltage difference, mass-producing nanofiber with uniform quality, and web comprising such nanofiber is separation material having porosity, applied in various fields such as various filter kinds, wound dressings, artificial supporters.
[0163] Below, through the embodiment, more specifically explains for a person who has an average knowledge in the technical field of the present invention could easily repeatedly carry out. However, scope of a right of the present invention is not limited to the embodiment, including equivalent technical idea modification.
Embodiment 1
[0164] According to a nanofiber manufacture device which features 20% of front-end of nozzle of nozzle block in flare shape, distance between electrode and nozzle is 40 cm, applied voltage is 20 kV, spinning solution flow is 0.1 mL/h, temperature is 22° C., humidity is 20% and produces nanofiber nonwoven by electrospinning.
[0165] In this case, as there is no interference among nozzles, nanofiber non-fabric collected in predetermined discharging amount on a collector could be produced.
[0166] Meanwhile, the electrospinning apparatus ( 1 ) of the present invention, as illustrated in FIGS. 13 and 14 , provided a metering pump, or provided a metering pump and overflow system, controlling polymer solution amount, not integrated to the collector, minimize amount attached to the nozzle, simultaneously minimize polymer solution consumption.
[0167] In other words, as illustrated in FIG. 13 , the collector ( 20 ) of the electrospinning apparatus ( 1 ) comprising an electric conductor, through an insulator ( 152 ), attached to a case ( 10 ), and located upper than a nozzle block ( 41 ).
[0168] In this case, the electrospinning apparatus ( 1 ) overflows polymer solution from an outlet (not shown) of a plurality of upward nozzle ( 42 ), discharging polymer solution from the outlet of a plurality of upward nozzle, and electrospinning nanofiber.
[0169] Also, in the embodiment, a voltage generating device ( 50 ) of the electrospinning apparatus ( 1 ) applies high voltage between a plurality of upward nozzle ( 42 ) and the collector ( 20 ).
[0170] Plus terminal of the voltage generating device ( 50 ) accesses to the collector ( 20 ), minus terminal of voltage generating device ( 50 ) accesses to the nozzle block through the case ( 10 ), an auxiliary belt device ( 30 ) has an auxiliary belt ( 31 ) synchronizes in the elongated sheet (W) carrying speed, and an auxiliary belt roller ( 34 ) assisting rotation of the auxiliary belt ( 31 ).
[0171] Here, the five auxiliary belt roller ( 34 ) s are provided, among the auxiliary belt roller ( 34 ), one or two or more auxiliary belt roller ( 34 ) is driving roller, the other auxiliary belt roller ( 34 ) is driven roller. Since the auxiliary belt ( 31 ) is arranged between the collector ( 20 ) and the elongated sheet (W), the elongated sheet (W) doesn't be drawn by the collector ( 20 ) applied high voltage and smoothly conveys.
[0172] Meanwhile, a spinning solution main tank ( 100 ) stores polymer solution which is nanofiber material, in the spinning solution main tank ( 100 ) and a recycling tank ( 270 ) having an agitator ( 201 , 271 ) for preventing polymer solution separation and coagulation, a valve ( 22 ) controls carrying polymer solution from the spinning solution main tank ( 100 ), the valve ( 226 ) controls polymer solution carry from the recycling tank ( 270 ).
[0173] Here, a middle tank ( 230 ) stores polymer solution supplied from the spinning solution main tank ( 100 ) or the recycling tank ( 270 ), the middle tank ( 230 ) has a partition ( 232 ), a bubble removal filter ( 234 ), and the first sensor ( 239 ), the partition ( 232 ) covers supplied part supplying polymer solution.
[0174] Meanwhile, the middle tank ( 230 ) comprises the first storage ( 236 ) which stores polymer solution before removing bubble by a bubble removal filter ( 234 ), and the second storage ( 238 ) which stores polymer solution after removing bubble by the bubble removal filter ( 234 ).
[0175] Also, a supply device ( 240 ) including one pipe, and supplies polymer solution stored in the second storage ( 238 ) of the middle tank ( 230 ) to polymer solution supply path.
[0176] Here, a metering pump ( 253 ) provided in the elctrospinning apparatus ( 1 ) is located in a supply device ( 240 ) which is between the middle tank ( 230 ) and the nozzle block ( 41 ), by minutely adjusting polymer solution which is attached to the nozzle ( 42 ) not integrated to the collector ( 20 ), and minimizes polymer solution consumption.
[0177] Meanwhile, in the electrospinning apparatus ( 1 ) the metering pump ( 253 ) and overflow system are provided, by adjusting polymer solution amount, minimizes the amount of polymer solution attached to the nozzle ( 42 ) and not integrated to the collector ( 20 ), and simultaneously minimizes polymer solution consumption. In other words, as illustrated in FIG. 14 , the valve ( 224 ) of the elctrospinning apparatus ( 1 ) controls polymer solution flowing from the spinning solution main tank ( 100 ) and the recycling tank ( 270 ) to the middle tank ( 230 ), control by the valve ( 224 ) is conducted according to solution level measured by the first sensor ( 239 ).
[0178] Also, the middle tank ( 23 ) stores polymer solution supplied from the spinning solution main tank ( 100 ) or the recycling tank ( 270 ), the middle tank ( 230 ) is arranged rear-end of the middle tank ( 230 ) is located upper than front-end of the upward nozzle ( 42 ).
[0179] In addition, a pump ( 254 ) generates electric power to carry polymer solution to the recycling tank ( 270 ) which is located upper than the nozzle block ( 41 ) nearby.
[0180] Polymer solution of the embodiment of the elctrospinning apparatus ( 1 ), as illustrated in FIG. 13 , adjusted by the metering pump ( 253 ), in the case of droplet phenomenon doesn't occur, an overflow prevention system isn't operated, and in the case of droplet phenomenon occurs, the overflow system operates in hybrid type.
[0181] Here, polymer solution, not electrospinned in the collector ( 20 ) and attached to the nozzle ( 42 ), is stored in a storage tank ( 256 ) and filled in the recycling tank ( 270 ), in the recycling tank ( 270 ) solution density correction device is additionally provided, and polymer solution is directly supplied to the middle tank ( 230 ) and reused.
[0182] Meanwhile, a metering pump ( 253 ) is used alternatively or in hybrid type with the overflow prevention system discharging polymer solution from the nozzle ( 42 ) outlet, and added device for correction of solution concentration.
[0183] In this case, as device correcting the polymer solution concentration, a viscosity sensor installed in the recycling tank ( 270 ) and measuring viscosity of stored solution and device providing solvent to the recycling tank ( 270 ) by contrasting value and predetermined value.
[0184] While the present invention is described with reference to particular embodiments thereof, it will be understood by those skilled in the art that variations or amendment may be made therein without departing from the sprit and scope of the invention. The scope of the present invention is not limited by those variations or amendments, but by the following claims.
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The present invention relates to an electrospinning apparatus, and the purpose of the present invention is to provide an electrospinning apparatus capable of producing nanofiber having various ingredients and thicknesses by controlling the temperature of at least one solution discharged from nozzles mounted on the tubular bodies of a nozzle block and thus controlling the viscosity of the solution which is electrospun; producing nanofiber having uniform quality without applying a density difference and a voltage difference by disposing the front end portions of the nozzles in a flare shape; and mass-producing nanofiber at a low cost as well as reducing the amount of the solution used by removing an overflow prevention system and using a metering pump alone or by using the metering pump and the overflow prevention system alternatively or in a hybrid manner.
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This is a division of application Ser. No. 09/286,092 filed on Apr. 2, 1999 now U.S. Pat. No. 6,597,822.
This invention was made with U.S. Government support under grant NAS 1-20579 awarded by the National Aeronautics and Space Administration. The U.S. Government has certain rights in this invention.
FIELD OF THE INVENTION
The current invention applies to the field of fiber-optic sensors, wherein a dimensional change in a fiber having a Bragg grating is detected using a measurement system comprising broad=band sources, optical power splitters, a high-sensitivity wavelength discriminator, optical detectors, and a controller.
BACKGROUND OF THE INVENTION
There are several modern methods for fabricating optical waveguides for the low-loss containment and delivery of optical waves. One such waveguide is optical fiber which slightly higher index of refraction than the surrounding cladding. Typical values for the core diameter are of order 10 μm for single-mode fiber operating at communications wavelengths of 1300-15500 nm, and 50 μm or 62.5 μm for highly multi-mode fiber. Whether single-mode or multi-mode, the cladding diameter ha s most commonly an overall diameter of 125 μm, and a plastic jacket diameter is typically 250 μm for standard telecommunications fiber. The glass core is generally doped with germanium to achieve a slightly higher index of refraction than the surrounding cladding by a factor of roughly 1.003. The jacket is generally plastic and is used to protect the core and cladding elements. It also presents an optically discontinuous interface to the cladding thereby preventing coupling modes in the cladding to other adjacent fibers, and usually plays no significant part in the optical behavior of the individual fiber other than the usually rapid attenuation of cladding modes in comparison with bound core modes.
As described in the book by Snyder and Love entitled “Optical Waveguide Theory” published by Chapman and Hall (London, 1983), under the assumptions of longitudinal invariance and small index differences for which the scalar wave equation is applicable, the modal field magnitudes may be written
Ψ( r, φ, z )=ψ( r , φ) exp{ i (β z−ωt )}
where
β is the propagation constant ω is the angular frequency t is time z is the axial distance r, φ is the polar trans-axial position along the fiber.
Single-mode fibers support just one order of bound mode known as the fundamental-mode which we denote as ψ 01 , and which is often referred to in the literature as LP 01 . The transverse field dependence for the fundamental-mode in the vicinity of the core may be approximated by a gaussian function as
ψ 01 ( r , φ)=exp{−( r/r 01 ) 2 }
where r 01 is the fundamental-mode spot size.
Optical fiber couplers, also known as power splitters, are well known in the art, and generally comprise two fibers as described above having their jackets removed and bonded together with claddings reduced so as to place the fiber cores in close axial proximity such that energy from the core of one fiber couples into the core of the adjacent fiber. One such coupler is a fused coupler, fabricated by placing two fibers in close proximity, and heating and drawing them. The finished fused coupler has the two cores in close proximity, enabling the coupling of wave energy from one fiber to the other. A further subclass of fused coupler involves a substantially longer coupling length, and is known as a wavelength discriminator. The characteristics of a wavelength discriminator include wavelength-selective coupling from an input port to a first output port, as well as a second output port. As the wavelength is changed over the operating range of the wavelength discriminator, more energy is coupled into the first output port, and less is coupled into the second output port. The operation of a wavelength discriminator is described in “All-fibre grating strain-sensor demodulation technique using a wavelength division coupler” by Davis and Kersey in Electronics Letters, Jan. 6, 1994, Vol. 30 No. 1.
Fiber optic filters are well known in the art, and may be constructed using a combination of optical fiber and gratings. Using fiber of the previously described type, there are several techniques for creating fiber optic gratings. The earliest type of fiber grating-based filters involved gratings external to the fiber core, which were placed in the vicinity of the cladding as described in the publication “A single mode fiber evanescent grating reflector” by Sorin and Shaw in the Journal of Lightwave Technology LT-3:1041-1045 (1985), and in the U.S. patents by Sorin U.S. Pat. No. 4,986,624, Schmadel U.S. Pat. No. 4,268,116, and Ishikawa U.S. Pat. No. 4,622,663, All of these disclose periodic gratings which operate in the evanescent cladding area proximal to the core of the fiber, yet maintain a separation from the core. A second class of filters involve internal gratings fabricated within the optical fiber itself. One technique involves the creation of an in-fiber grating through the introduction of modulations of core refractive index, wherein these modulations are placed along periodic spatial intervals for the duration of the filter. In-core fiber gratings were discovered by Hill et al and published as “Photosensitivity in optical fiber waveguides: Application to reflected filter fabrication” in Applied Physics Letters 32:647-649 (1978). These gratings were written internally by interfering two counter propagating electromagnetic waves within the fiber core, one of which was produced from reflection of the first from the fiber end face. However, in-core gratings remained a curiosity until the work of Meltz et al in the late 1980s, who showed how to write them externally by the split-interferometer method involving side-illumination of the fiber core by two interfering beams produced by a laser as described in the publication “Formation of Bragg gratings in optical fibers by a transverse holographic method” in Optics Letters 14:823-825 (1989). U.S. patents Digiovanni U.S. Pat. No. 5,237,576 and Glenn U.S. Pat. No. 5,048,913, also disclose Bragg gratings. a class of grating for which the grating structure comprises a periodic modulation of the index of refraction over the extent of the grating. Short-period gratings reflect the filtered wavelength into a counter-propagating mode, and, for silica based optical fibers, have refractive index modulations with periodicity on the order of a third of the wavelength being filtered. Long-period gratings have this modulation period much longer than the filtered wavelength, and convert the energy of one mode into another mode propagating in the same direction, i.e., a co-propagating mode, as described in the publication “Efficient mode conversion in telecommunication fibre using externally written gratings” by Hill et al in Electronics Letters 26:1270-1272 (1990). The grating comprises a periodic variation in the index of refraction in the principal axis of the core of the fiber, such variation comprising a modulation on the order of 0.1% of the refractive index of the core, and having a period associated with either short or long-period gratings, as will be described later.
The use of fiber-optics in temperature measurement is disclosed in U.S. Pat. No. 5,015,943 by Mako et al. A laser source is beam split into two fibers, one of which is a sensing fiber exposed to an elevated temperature, and one of which is a reference fiber in an ambient environment. The optical energy from the two fibers is summed together, and an interference pattern results. As the temperature changes, the physical length of the sensing fiber optic cable changes, which causes the interference pattern to modulate. Each modulation cycle represents one wavelength change in length. Counting these interference patterns over time enables the measurement of temperature change.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for the measurement of sensor grating pitch, wherein the change in grating pitch can originate from a strain applied to the sensor grating, or it may originate from a temperature change wherein the sensor grating expands or contracts due to the coefficient of thermal expansion of the optical fiber enclosing the sensor grating. A pair of fibers, each having a sensor grating, is illuminated by a pair of broadband sources coupled through a pair of optical power splitters, and this sensor grating reflects wave energy over a narrow optical bandwidth. Reflected wave energy from the narrow-band sensor grating is passed through a wavelength discriminator, comprising a long-drawn optical coupler. A normalized power ratio comprises the difference in first and second detector power levels divided by the sum of the first and second power level. This intensity ratio is compared to the wavelength discriminator characteristic stored in a controller to look up the wavelength from a normalized power ratio value, and hence the pitch of the sensor grating. As the characteristic of the wavelength discriminator is essentially temperature invariant, this very accurately yields the sensor grating pitch. Comparing this reflected wavelength to the known wavelength of the grating indicates a change in wavelength brought about by either a temperature change or by the presence of a strain. In the case where a second sensor is also monitored, one sensor may be used as a reference to monitor the temperature of the second sensor, which is used to measure applied strain. In this manner, the temperature effect of the strain gauge may be cancelled by using the measured result of the reference sensor. Commutating the two sources in separate non-overlapping intervals enables the independent measurement of temperature, or strain, or any combination of the two.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a prior art grating.
FIGS. 1 b, c, d show the spectral behavior of the prior art grating of FIG. 1 a.
FIG. 1 e is a prior art coupler/wavelength discriminator
FIG. 1 f is a section view of the fused area of FIG. 1 e.
FIG. 2 is a block diagram of the fiber optic sensor system.
FIG. 3 is a block diagram of the controller of FIG. 2 .
FIG. 4 is a wavelength discriminator.
FIG. 5 is a graph of the response of a wavelength discriminator including reflected grating power applied to this wavelength discriminator.
FIG. 6 is a graph of the output function of the wavelength discriminator normalized power ratio (P1−P2)/(P1+P2).
FIG. 7 is the dynamic state of various internal nodes of the fiber optic sensor system during operation.
FIG. 8 is a three-wavelength, temperature/strain sensor.
FIG. 9 shows the wavelength detection properties of FIG. 8 .
FIG. 10 is a multi-wavelength strain/temperature measurement system.
FIG. 11 is an alternate wavelength detector for FIG. 10 .
FIG. 12 is a multi-wavelength strain/temperature measurement system using tunable gratings.
FIG. 13 shows the voltage waveforms for FIG. 12 .
FIG. 14 shows a temperature/strain measurement system having an alternate wavelength discriminator comprising a broadband grating and a splitter.
FIG. 15 shows the block diagram of the measurement controller of FIG. 14 .
FIG. 16 shows the input to the first and second detectors versus wavelength for the measurement system of FIG. 14 .
FIG. 17 shows a temperature/strain measurement system using a wavelength discriminator comprising a coarse wavelength discriminator and a fine wavelength discriminator.
FIG. 18 shows the characteristic transfer function for the fine wavelength discriminator and the coarse wavelength discriminator of FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 a shows a prior art internal grating filter, comprising an optical fiber having a core 1 , a cladding 2 , and a grating 3 fabricated within the extent of the core 1 . The grating 3 comprises a modulation of the index of refraction of core 1 having a regular pitch 4 , where the grating 3 is used to create short-period grating behavior. For reflection of waves through the grating at wavelength λ b , the short-period grating function is as follows:
Λ b =λ b /2n
where
Λ b =pitch of the desired Bragg grating. λ b =conversion wavelength: For short period gratings. λ b is the wavelength for which incident fundamental mode wave energy is converted to counter-propagating (traveling in the opposite direction) wave energy. n=effective index of refraction of the fiber, which is dependent on the mode of the propagated wave.
Examining now the transfer curves for a short-period grating 3 , FIG. 1 b shows the input source spectrum 7 applied to port 5 , and FIG. 1 c shows the reflected spectrum 8 and grating peak 9 reflected back to port 5 . FIG. 1 d shows the remaining optical energy continuing to port 6 . Filter notch 11 represents wave energy reflected by the short period Bragg grating back to the input port 5 , and is represented as spectrum 8 having peak 9 corresponding to the Bragg wavelength. The use of reflected wave energy at peak 9 is generally not available without the use of an optical coupler or some other device sensitive to the propagating direction of this wave.
FIG. 1 e shows a prior art optical coupler. First fiber having a core 12 and cladding 13 is placed in proximity with a second fiber having a core 15 and a cladding 14 . Together, these fibers are heated and drawn to fuse the two fibers into one having a coupling length 16 . FIG. 1 f shows a section view of this fused middle section. Coupling length 16 and separation 17 determine the coupling characteristics of the coupler. If the coupling length 16 is short, a broadband coupler having a coupling coefficient related to separation 17 is formed. This is the typical construction for power splitter configurations. If the length 16 is many wavelengths long, a narrowband coupler is formed, also known as a wavelength discriminator. The characteristics of a wavelength discriminator are similar to those of a coupler, with an additional wavelength dependence, as shown in FIG. 5 , which is described later.
FIG. 2 shows the present fiber-optic sensor. Measurement system 20 is coupled to fibers 45 and 51 . Each of fibers 45 and 51 has a Bragg grating 46 and 52 respectively. Measurement system 20 further comprises a controller 22 having a first source enable output 24 coupled to first source 36 , which may be any source of optical energy having a spectrum which includes the wavelength of the grating 46 on fiber 45 . A broadband light-emitting diode (LED) would provide an inexpensive broadband source. Similarly, second source enable output 26 is coupled to second source 40 , which has the same requirement of including in its output spectrum the wavelengths of the grating 52 of fiber 51 . Broadband sources 36 and 40 respectively couple energy through standard power splitters 42 and 44 , which provide optical energy to gratings 46 and 52 respectively. The gratings 46 and 52 may be internal Bragg gratings or external short period gratings. The short-period grating has the property of reflecting optical energy at the grating wavelength back to couplers 42 and 44 , where it is split into optical energy provided to cables 41 and 43 to wavelength discriminator 38 , the operation of which will be discussed later in FIG. 4 . Output wave energy, from wavelength discriminator 38 is separated into a first output on fiber 31 travelling to first detector 30 , which provides a voltage 28 proportional to the input optical level delivered on fiber 31 . Similarly, optical wave energy from the second output 33 of wavelength discriminator 38 is delivered to the second detector 34 , which produces a voltage 32 to controller 22 proportional to the input optical level delivered on fiber 33 .
FIG. 3 describes in detail the controller 22 of FIG. 2 . Controller 22 further comprises a microprocessor 78 which produces first source enable output 24 and second source enable output 26 . In addition, first detector input 28 and second detector input 32 are processed by buffer amplifiers 62 and 64 respectively, which isolate the detector element from the following electronics, and produce respectively outputs 82 and 84 . These are processed by a difference amplifier 66 to produce a difference output at 86 , which is converted from an analog signal to a digital signal by A/D converter 74 , delivering a digital representation 90 of this signal to microprocessor 78 . Amplifier 68 produces a detector sum output 88 , which is similarly converted to a digital signal 92 by A/D converter 76 , which is also input to microprocessor 78 . A keypad 72 for input and a display 70 are also coupled to the microprocessor 78 , as is an auxiliary interface 80 . Microprocessor 78 may be chosen from several available units, including the PIC16 C71 from Micro-Chip. Inc. of Chandler, Ariz, which has the A/D converters 74 and 76 incorporated internally. As is clear to one skilled in the art, many microprocessor choices are available for 78 , including devices with internal or external ROM, RAM, A/D converters, and the like, of which many candidates from the Micro-Chip PIC-16 family would be suitable. While a particular microprocessor is shown for illustrative purposes, it is clear to one skilled in the art that other units could be substituted for these devices without changing the operation of the sensor. The principal requirements of microprocessor 78 are the ability to control the first and second sources, and to process the values provided by the first and second detectors in a manner which determines the wavelength of the sensor grating.
FIG. 4 shows the wavelength discriminator 38 . The wavelength discriminator has a first splitter input port 41 , a second splitter input port 43 , a first detector output port 31 , and a second detector output port 33 . FIG. 5 shows the normalized output of wavelength discriminator 38 for the case where a swept-wavelength input is applied to first splitter input 41 , and no input is provided to second splitter input 43 . Curve 100 shows the output level of first detector output 31 , while curve 104 shows the output level of second detector output 33 . As can be seen from the graph, as the wavelength is varied from 1300 nm to 1316 nm, the first detector and second detector outputs vary in a complimentary manner, such that the sum of the first detector output and second detector output is nearly constant. The wavelength discriminator is a symmetric device, so if no optical signal were applied to first input 41 and a swept wavelength optical signal were applied to second input 43 , curve 100 would show the level of second output port 33 , while curve 104 would show the level of first output port 31 .
FIG. 6 shows a plot for normalized power ratio derived from first output curve 100 and second output curve 104 . If these two complimentary curves 100 and 104 are plotted as (P1−P2)/(P1+P2), then the plot of FIG. 6 results, and we may now determine wavelength over monotonic regions such as from 1304 nm to 1312 nm by simply looking up the wavelength given the (P1−P2)/(P1+P2) normalized power ratio. Curve 114 represents the response to first source 36 , and curve 112 represents the response to second source 40 . The advantage of performing this lookup in this ratiometric manner of FIG. 6 as opposed to the absolute output level on the curve 100 of FIG. 5 is that variations in source power are normalized out of the result. Specifically, changes in the output power of sources 36 and 40 would modulate the values shown in plots 100 and 104 of FIG. 5 . but not the normalized power ratio shown in the plot of FIG. 6 .
Further examining the operation of the measurement system of FIG. 2 , the first measurement is performed with only first source 36 enabled. Optical energy travels through first coupler 42 to fiber 45 , and to grating 46 . Optical energy at the wavelength λ 1 of grating 46 is reflected through fiber 45 back to first coupler 42 , through fiber 41 , where it is presented to wavelength discriminator 38 . No input is present on fiber 43 because second source 40 is not enabled. Optical energy from grating 46 is reflected, for example, at λ 1 =1309 nm. as shown in curve 102 of FIG. 5 , and 0.4 volts is generated at 28 by first detector 30 . The second output 33 of wavelength discriminator 38 is applied to the second detector 34 , producing 0.6 volts at 32 as shown in curve 103 of FIG. 5 . By now finding the normalized power ratio of (0.4−0.6)/(0.4+0.6)=−20, it can be seen that this corresponds to 1309 nm wavelength on curve 114 at point 109 in FIG. 6 .
An entirely separate measurement can be made by disabling first source 36 and enabling second source 40 . In this case, optical energy would leave second splitter 44 through fiber 51 to grating 52 . Optical energy at wavelength λ 2 52 would be returned to second splitter 44 through fiber-optic cable 51 , leave second splitter 44 through fiber-optic cable 43 , entering wavelength discriminator 38 . Analogous to the earlier described processing, first source 36 would be disabled, hence no optical energy would be present in fiber 41 . In the case of wave energy input to fiber 43 instead of fiber 41 , the output characteristic of FIG. 5 would be reversed such that curve 100 would be the output energy on fiber 33 , and curve 104 would represent the output energy of fiber 31 . If the grating 52 were reflecting at λ 2 =1306 nm. then second detector 34 would produce 0.75 volts as shown in curve 108 of FIG. 5 . First detector 30 would produce 0.25 volts as shown in curve 106 of FIG. 5 . The normalized power ratio of FIG. 6 would be (0.25−0.75)/(0.25+0.75)=−0.5, corresponding to 1306 nm on curve 112 of FIG. 6 at point 107 .
FIG. 7 shows the sensor measurement system operating in the earlier-described case where the wavelength of first sensor 46 is λ 1 =1309 nm and the wavelength of second sensor 52 is λ 2 =1306 nm. First, the detector offsets are determined by turning both first source 36 and second source 34 off. This produces the detector offset values OS 1 and OS 2 , which will be necessary to subtract from the power difference and power sum before calculation of the normalized power ratio (P1−P2)/(P1+P2). Thereafter, first source 36 and second source 40 are alternately enabled as shown in FIG. 7 . First detector 30 and second detector 34 produce the P1 and P2 values shown, and the difference sum, and the normalized power ratio value of difference/sum are computed as shown, wherein the power difference (P1−P2) and the sum (P1+P2) represent power quantities after removal of offsets OS 1 and OS 2 , which thereafter form the normalized power ratio (P1−P2)/(P1+P2). If the plot of FIG. 6 normalized power ratio were kept in the memory of the microprocessor, either as a series of interpolated points, or as a power series wherein only the coefficients f0, f1, f2, f3 . . . fn of a polynomial are stored, and the power
λ ( P1 , P2 ) = f 0 + f 1 [ P1 - P2 P1 + P2 ] + f 2 [ P1 - P2 P1 + P2 ] 2 + f 3 [ P1 - P2 P1 + P2 ] 3 + … + f n [ P1 - P2 P1 + P2 ] n
series is of the form
where
λ(P1, P2)=wavelength as a function of detector power ratio (P1−P2)/(P1+P2).
It would be possible to convert the given normalized power ratio(P1−P2)/(P1+P2) back to a wavelength λ 1 =1309 nm for the first sensor, and λ 2 =1306 nm for the second sensor. This determination could be done using either a look-up table derived from the normalized power ratio, or by storing the coefficients of a power series based on the normalized power ratio, and thereafter calculating for wavelength based on this power series.
If the sensors were operating either as temperature sensors or strain sensors, the applied strain or temperature could be computed from the following relationship:
Δλ=α1 ΔT +α2 ΔS
where
Δλ=change in sensor wavelength α1=coefficient of thermal change for sensor ΔT=change in sensor temperature α2=coefficient of strain change for sensor ΔS=change in sensor strain
In this equation, the change in sensor wavelength is expressed as the sum of a temperature related change and a strain related change. The coefficients al and al would be stored in the controller along with initial condition values to solve for total strain and total temperature. In this manner, any combinations of strain and temperature could be determined given a change in sensor wavelength and the wavelength discriminator characteristic curve, and first and second detector, inputs.
FIG. 8 shows a strain/temperature measurement system having a 3-way wavelength discriminator 162 . This system is analogous to the system described in FIG. 2 , however, for an n-way wavelength discriminator, the output port associated with the excited port has the response shown in plot 186 , while the remaining ports have the characteristic shown in plot 188 . For example, in the case of FIG. 8 , first source 134 sends broadband excitation through first splitter 136 , and wave energy at the example grating wavelength λ 1 =1300 nm is reflected through splitter 136 to wavelength discriminator port 167 . For this case, the output at port 168 has the characteristic shown in plot 186 , while the second output 174 and third output 180 have the responses shown by curve 188 . For λ 1 =1300 nm, the response of the first detector is shown as point 192 , while the second the third detectors have the response shown by point 194 . As before, a normalized plot of the response of curves 186 and 188 is shown in plot 190 . For the case of an n-way wavelength discriminator, the output curve 190 would be
P ( normalized ) = [ Pdet ( a ) - { Pdet ( b ) + Pdet ( c ) … + Pdet ( n ) } Pdet ( a ) + { Pdet ( b ) + Pdet ( c ) … + Pdet ( n ) } ]
where
Pdet(a)=output power from excited channel Pdet(b) through Pdet(n)=output power from non-excited channel.
A lookup table constructed from the values of curve 190 would produce the value for λ 1 =1300 nm as shown at point 196 . Similarly, when second source 144 excites grating 150 , wave energy at the exemplar wavelength λ 2 =1305 nm would return through splitter 146 , fiber 173 , and now fiber 174 would contain the response shown in plot 186 . Fibers 168 and 180 would contain wave energy shown in plot 188 . corresponding to point 200 . The normalized power ratio for λ 2 =1305 nm is represented by point 204 of the plot 190 . The case where third source 154 excites grating 160 is shown in third detector response 186 , and first and second detector responses 188 . For the case where third grating wavelength is 1310 nm, the responses of the third detector. first and second detectors, and normalized power ratio are shown in points 206 , 208 , and 210 . It is clear to one skilled in the art that this system is extendable to n ports of measurement, where each port has a source, a splitter, and each splitter port is connected to an input port of an n-way wavelength discriminator. Each output port of the n-way wavelength discriminator is coupled to a detector, and the response of each detector is measured, and the normalized power ratio is formed from the ratio of the difference between the response of an excited port and the responses of all of the non-excited ports, divided by the sum of all of the responses of excited and non-excited ports.
FIG. 10 shows a strain/temperature sensor system 211 attached to a fiber 220 comprising a plurality of gratings 224 , 226 , and 230 . These sensors operate as earlier described, but are sequentially applied to various parts of a fiber 220 . Each sensor 224 , 226 , and 230 reflects wave energy at respective unique wavelengths λ 1 , λ 2 , and λ n . Since gratings 224 and 226 have no effect on out-of-band waves at λ n , splitter 218 delivers to fiber 268 the superposition of reflected unique wavelengths λ 1 through λ n . Wavelength separator 236 has broadband outputs which respond only to the range of reflected wavelengths for that given output. For example, output 235 is responsive only to the range of λ 1 , and output 243 is only responsive to the range of λ 2 , and output 249 is only responsive to the range of λ n . This requires that the sensor wavelengths and wavelength separator characteristics be chosen such that isolated response of a given wavelength separator to a given sensor grating wavelength occur. In this manner, output 235 represents exclusively the range of wavelengths of sensor 224 , output 243 represents exclusively the range of wavelengths of sensor 226 , and output 249 represents exclusively the range of wavelengths of sensor 230 . The conversion of the outputs of separator 236 into a detected wavelength occurs as was earlier described in FIGS. 4 , 5 , and 6 . In this manner, multiple sensors can share a single fiber, as long as each produces a unique wavelength.
An alternate wavelength measurement apparatus 318 is shown in FIG. 11 , which performs the same function as 270 of FIG. 10 . While the wavelength measurement apparatus 270 uses a wavelength separator 236 followed by narrowband wavelength discriminators 234 , 242 , and 248 , the wavelength measurement apparatus 318 of FIG. 11 utilizes a broadband wavelength discriminator 316 followed by wavelength separators 312 and 314 . These produce complimentary outputs 296 and 304 for λ 1 , complimentary outputs 298 and 306 for λ 2 , and complimentary outputs 300 and 308 for λ n . Detectors 232 , 240 , 246 , 238 , 244 , and 250 operate in a manner identical to those of FIG. 10 .
FIG. 12 shows a measurement system 340 connected to fiber 350 , which has a series of sensors 352 , 354 , and 358 , which operate the same as those described earlier in FIG. 10. A single broadband source excites fiber 350 through splitter 348 . Splitter 348 returns aggregate reflected waves from sensors 352 , 354 , and 358 on fiber 356 . A series of tunable filters 362 , 364 , and 368 is coupled to detector 360 . Each of these filters is tuned over a narrow range through the application of a control voltage 372 , 374 , and 378 . In operation, filters 364 and 368 have a voltage applied which reflects wave energy out of the range reflected by the sensors 354 and 358 , enabling the passage of waves reflected by sensor 352 to pass through and on to tunable filter 362 . Tunable filter 362 is swept over its tuning range, and produces a minimum output at detector 360 at the point where the grating 352 matches the tuned filter 362 . Controller 380 has the characteristic of tunable filter 362 stored in memory such that the voltage 372 producing a minimum detected output 370 enables the extraction of corresponding wavelength for λ 1 . Next, tunable filters 362 and 368 are tuned out of the band of grating 352 and 358 , and tunable filter 364 is swept over its range until a detector minimum is found. As earlier, this minimum voltage corresponds to the wavelength λ 2 . This process continues for as many sensor gratings and tunable filters that are present in the system. In practice, there are many ways of fabricating tunable gratings, including the application of a material with an index of refraction which varies with an applied voltage, the application of a tensile force to a fiber having a grating, or the application of a magnetic field to a grating in close proximity to a material having an index of refraction which changes with an applied magnetic field. It should be clear to one skilled in the art that there are many different ways of practicing such tunable filters, wherein an applied control voltage changes the wavelength of reflection of the tunable filter.
FIG. 13 shows the waveforms for the system of FIG. 12 . Tunable filter control voltage points 390 , 392 , and 394 correspond to the detector minima 396 , 398 , and 400 shown, and therefore enable the recovery of sensor wavelengths λ 1 λ 2 , and λ n .
While the foregoing description is drawn to specific implementations, it is clear to one skilled in the art that other embodiments are available. For example, the earlier described functions SUM and DIFF, which relate to the normalized power ratio, could be implemented using operational amplifiers computing these measurements as analog values, or they could be implemented digitally, operating on digitized detector values. These converters could be either integral to the microprocessor, or external, and the sum and difference values could either be computed through direct reading of the values of the detectors, or through reading sum and difference voltages of alternate circuitry. While the multiple sensor system of FIGS. 10 and 12 are drawn to a 3 sensor system, it is clear to one skilled in the art that these could be drawn to arbitrary numbers of channels operating as strain sensors, temperature sensors, or both. There are also many ways of extracting sensor wavelength from the systems described. For clarity, time division processing has been shown, wherein at a particular time, only a single channel of the system is active, and only one particular wavelength value is recovered. In addition to the explicitly described method of time division processing, there are many modulation schemes wherein each of the sensor values is modulated in frequency or amplitude, and later demodulated to recover the desired value. In this manner, all of the channels of the system could operate simultaneously, rather than sequentially. The use of specific examples for illustration and understanding of the operation of the system does not imply an exclusive manner in which these systems could be implemented.
FIG. 14 shows a strain/temperature measurement system 20 similar to that of FIG. 2 , but with a different wavelength discriminator. In the alternate embodiment of FIG. 14 , the elements having the same numbering as those of FIG. 2 perform the same function as earlier described, but the wavelength discriminator now comprises third splitter 400 which has as inputs the previously described fibers 41 and 43 , and has a normalizing output 406 which is wavelength-invariant compared to wavelength determining output 405 . The wavelength-determining output 405 is formed from broad-bandwidth grating 404 , which has an output amplitude varying with wavelength over the tuning range of the sensor gratings, as will be described later. First detector 408 and second detector 410 accept optical inputs 405 and 406 , respectively, and produce electrical outputs 412 and 414 which are proportional to the respective optical inputs 405 and 406 .
FIG. 15 shows the controller 401 of FIG. 14 , which is similar to the controller of FIG. 3 , and has similarly-functioning elements numbered the same as those of FIG. 3 , as was described earlier. First detector output 412 drives buffer 416 and produces output 420 , which is digitized by analog-digital converter 424 and is presented as a digital input 428 to microprocessor 78 . Second detector output 414 drives buffer 418 to produce signal 422 which is converted to a digital input 430 by analog-digital converter 426 and delivered to microprocessor 78 .
FIG. 16 shows the characteristic response of the wavelength discriminator having a normalizing input 406 , represented by response curve 464 , and wavelength-determining input 405 , represented by response curve 450 . As the reflected wave from grating 46 or grating 52 passes through third splitter 400 , equal amounts of energy are presented into grating 404 , and to normalizing input 406 , As the wavelength applied to third splitter 400 is varied, normalizing output 406 follows the response of curve 464 , while the wavelength-determining input 405 follows the response of curve 450 , in accordance with the characteristic response of broadly tuned grating 404 , whose characteristics are chosen to include a monotonic region from first discrimination wavelength 452 to final discrimination wavelength 454 . In the case where grating 46 is reflecting a wavelength of 1306 nm, curve 460 represents the spectral energy of reflected energy from grating 46 , which is applied to curve 460 to produce an output of approximately 1.0 units. This same reflected response 456 applied to grating 404 having the response of curve 450 and produces an output of approximately 0.25 units. As can be seen from FIG. 16 , as long as the range of input wavelength is between first discrimination wavelength 452 and final discrimination wavelength 454 , it is possible to recover the wavelength from curve 450 . By using the ratio of response 450 to response 464 , the effect of intensity variations in first source 36 and second source 40 is removed, as was discussed for the system of FIG. 2 . By keeping a copy of the characteristic curve of this normalized function of curve 450 divided by curve 464 in the microprocessor 78 , it is possible to resolve any input wavelength in the range first discrimination wavelength 452 to final discrimination wavelength 454 when given the first detector output 412 and second detector output 414 . As described earlier, this determination can be made by storing the response of curves 450 and 452 in a look-up table, or by specifying the curve as the coefficients of a polynomial, or in many other ways, all of which form representations of the characteristic curves of 450 or the ratio of curve 450 divided by curve 452 .
FIG. 17 shows another embodiment 503 of a temperature/strain sensor comprising the old elements of FIG. 2 with a new wavelength discriminator circuit. This new wavelength discriminator comprises third splitter 470 , fourth splitter 488 , a coarse wavelength discriminator 474 , and a fine wavelength discriminator 492 , coarse wavelength first and second detectors 478 and 484 , and fine wavelength discriminator first and second detectors 504 and 498 . The operation of the coarse wavelength discriminator comprising coarse wavelength discriminator 474 , first detector 478 , and second detector 484 is similar to that described in FIGS. 4 , 5 , and 6 , and has a usable wavelength range matched to that of the sensor grating operating range. However, in addition to the coarse wavelength discriminator, a fine wavelength discriminator comprising fine wavelength discriminator 492 , and first detector 504 and second detector 498 are used. Third splitter 470 and fourth splitter 488 produce the signals for simultaneous delivery to the coarse and fine wavelength discriminators, as all 4 detectors are used simultaneously, although as described earlier, the first source 36 and second source 40 , operate during different intervals, or have orthogonal modulation functions which enable the discrimination of the two detector outputs through the use of a modulation function applied to the sources and a demodulation function applied to the detectors.
FIG. 18 shows the details of the fine and coarse wavelength discriminators. Curves 516 and 510 represent the optical response of the wavelength discriminator, as measured at fibers 476 and 482 , as well as the detected electrical responses of 480 and 486 to changes in wavelength of sensor 46 or 52 , all of which function as earlier described in the system of FIG. 2 . For the case of sensor 46 reflecting optical energy at 1302 nm. fiber 472 carries optical wave energy which is provided to coarse wavelength discriminator 474 . First output optical fiber 476 carries the energy of curve 512 , while second output optical fiber 482 carries the energy of curve 514 . Fine wavelength discriminator 492 has many more cycles in the same monotonic range of coarse wavelength discriminator 474 , as is seen by the periodicity of curves 510 and 516 of the coarse wavelength discriminator, compared to curves 522 and 524 of the fine wavelength discriminator. The monotonic curve of 510 and 516 is necessary over the tuning range of the reflecting gratings 46 and 52 to ensure single-wavelength resolution. The multiple cycles of discriminator 522 and 524 enable the more precise measurement of wavelength when used in combination with the coarse wavelength discriminator 474 . Fine wavelength discriminator is fed by fiber 491 , and has a first output 502 which carries the energy of curve 522 and a second output 496 which carries the energy of curve 524 when excited by the signal of fiber 491 . When the input signal is provided by fiber 493 , the characteristic of the first and second outputs reverse, as was described earlier in FIGS. 4 , 5 , and 6 . In this manner, sensor 46 reflecting a 1302 nm wavelength produces a first coarse detector response of 512 , a second coarse detector response of 514 , a first fine detector response of 526 , and a second fine detector response of 528 . Sensor 52 reflecting a wavelength of 1311 nm produces a first coarse detector response of 518 , a second coarse detector response of 520 , a first fine detector response of 532 , and a second fine detector response of 530 . As is clear to one skilled in the art, any combination of curve storage methods for maintaining the characteristic curves of 510 , 516 , 522 , and 524 or the difference divided by the sum of curves 510 to 516 , or curves 522 and 524 could be stored using the previously described look-up tables, polynomial coefficients, or interpolated points for use by the microprocessor 78 of the controller 501 of FIG. 17 .
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A fiber optic sensor comprises two independent fibers having Bragg gratings which are coupled to commutating broadband optical sources through splitters and wavelength discriminators. The ratio of detected optical energy in each of two detectors examining the wave intensity returned to a wavelength discriminator coupled with the characteristic of the wavelength discriminator determines the wavelength returned by the grating. In another embodiment, tunable filters are utilized to detect minimum returned wave energy to extract a sensor wavelength Reference to the original grating wavelength indicates the application of either temperature or strain to the grating. In another embodiment, a plurality of Bragg grating sensor elements is coupled to sources and controllers wherein a dimensional change in a fiber having a Bragg grating is detected using a measurement system comprising broad-band sources, optical power splitters, a high-sensitivity wavelength discriminator, optical detectors, and a controller.
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BACKGROUND OF THE INVENTION
1. This invention relates to a comminuting device and, in particular, to a device for shaving or planning wood, or reducing scrap wood to useful products.
2. Brief Statement of the Prior Art
Various devices have been used for comminuting wood, such as wood scraps, e.g., cut-offs, culls, etc., which are produced by furniture manufacture, building construction, etc. The wood scraps are a desirable source of bedding for animals when they are formed into shavings. Other uses include packing material, potpourri, and soil amendments. The wood scraps can also be used as fuels in commercial furnaces for power generation if comminuted into a usable form.
Various devices have been devised for shredding or shaving wood scraps. Generally, all of these devices suffer from high energy requirements and are subjected to considerable vibration and pounding, resulting in loud noise levels and hazardous operations. Additionally, the prior shaving devices are: difficult to maintain and service, and are not well adapted to handle wood scraps of widely varied shapes and sizes. The comminuting devices currently in use frequently jam, interrupting the operation, and requiring the operator to free the jammed wood scrap. The comminuted products obtained with these devices are solid sticks or pieces of wood, and are not suitable for high value products such as animal bedding or potpourri.
OBJECTIVES OF THE INVENTION
It is an objective of this invention to provide a comminuting device which can be reliably used for reducing wood scraps into useful shapes and sizes.
It is a further objective of this invention to produce a wood shaving device that will produce wood shavings of consistent quality, size and thickness.
It is also an objective of this invention to provide a wood shaving device which is capable of long periods of operation without jams.
It is a further object of this invention to provide an adjustable mounting for cutter blades in a wood shaving device.
Other and related objectives will be apparent from the following description of the invention.
BRIEF STATEMENT OF THE INVENTION
This invention comprises a wood shaving device which utilizes a rotating cutting member, which supports a plurality of cutting blades which move past a radially positioned doctor bar. The cutting blades are arranged in a spaced-apart array on the shaving device, lying along non-radial paths so that the predominant action is a successive impact of individual cutting blades, rather than a simultaneous impact of two or more blades against the wood scrap. The cutting blades are preferably supported on a rotating cutting wheel which has a plurality of through apertures, with one each of the cutting blades removably mounted immediately adjacent each through aperture. The cutting blades are rotated past the doctor bar which restricts movement of the wood, resulting in a shaving action on the wood. The wood shavings pass through the through apertures of the cutting wheel and are removed. The wood shaving device includes a hopper with tapered sidewalls and a hydraulic ram that travels along an inclined chute to press the wood scraps into the cutting station. At least one, and preferably two, hydraulically actuated kicker plates are provided to dislodge any wood jams during the operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the FIGURES, of which;
FIG. 1 is an elevational partial sectional side view of the shaving device along line 1-1' of FIG. 2;
FIG. 2 is an elevational sectional view of the front of the shaving device of the invention along line 2-2' of FIG. 1;
FIG. 3 is an elevational sectional view of the rear of the shaving device of the invention along line 3-3' of FIG. 1;
FIG. 4 is an elevational sectional view of the side of the wood shaving device of the invention along line 4-4' of FIG. 2;
FIG. 5 is a an enlarged sectional view of the main shaft of the wood shaving device of the invention;
FIG. 6 is a plan view of the preferred cutting wheel used in the wood shaving device of the invention;
FIG. 7 is an enlarged view of the area within line 7-7' of FIG. 6;
FIG. 8 is an enlarged view of a portion of a cutting wheel of an alternative embodiment;
FIG. 9 is an enlarged view of a cutter on the cutting side of the cutting wheel used in the invention;
FIG. 10 is a sectional view along lines 10-10' of FIG. 9; and
FIG. 11 is a view of the cutter on the discharge side of the cutting wheel used in the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to FIGS. 1-4, the wood shaving device 10 of the invention utilizes a rotating member 12 which can be a drum or wheel. Preferably a wheel 12 is employed. The cutting wheel 12 is mounted on a shaft 14 supported on the mainframe 17 of the device, within a comminuting housing 16, which is formed of sheet metal side and top panels, also supported by the mainframe. The electrical drive motor 60 is mounted on the bottom frame 47 of the housing 16 and is connected to the shaft 14 by a drive pulley 64, belts 66 and driven pulley 68 which is secured to the drive shaft 14. The wheel 12 supports cutting knifes which are not shown in FIGS. 1-4, but which are shown in FIGS. 5-9.
The housing 16 is generally rectangular in cross section and has a hopper 18 in its upper section. The hopper 18 is formed with an inclined side wall 20 (see FIG. 1), and an inclined side wall 22 which extends over the support shaft 14 for the cutting wheel 12. At the base of the hopper 18 and immediately adjacent the cutting face,26 of the wheel 12 (see FIG. 1) a doctor bar 28 is adjustably mounted in the assembly. This doctor bar 28 forms a stationary anvil that prevents passage of the wood scraps so that they are shaved by the cutters on the cutting wheel.
As shown in FIGS. 1 and 2, the front wall 20 of the hopper is opposite the cutting wheel is intersected by an inclined feed ramp 30 which extends to the doctor bar 28. A hydraulic cylinder 32 is permanently mounted on the feed ramp 30, mostly outside of the hopper 18. The end of the piston rod 36 of the hydraulic cylinder extends into attachment to a feed ram 38 which has a vertical ram plate 40 and a rearwardly extending ram housing 41, which in its retracted position shown in FIG. 1 surrounds the hydraulic cylinder 32. The piston rod 36 of the hydraulic cylinder 32 advances the ram 38 towards the surface of the wheel, stopping short of contacting the wheel at full extension, thereby serving to forcefully direct the wood scraps down the feed ramp 30 and against the rotating cutter wheel 12, orienting the wood scraps vertically so that the cutting action is along the grain of the wood.
The cutting wheel 12 is shown in FIG. 6, which is a view from the back side of the wheel 12. The wheel 12 has a plurality of cutter blades 42. Each of the cutter blades 42 is immediately adjacent a through aperture 44. As shown in greater detail in FIGS. 7-11, each through aperture 44 is a slot which is coextensive with, and slightly wider than the width of the cutter blade 42.
The outboard row of cutting blades 42 is located on the cutting wheel 12 to project slightly beyond the outer periphery of the wheel, as apparent from the illustration of FIG. 7. As there illustrated, the through aperture slot 44 is open to the peripheral sidewall of the wheel and the cutting blade projects a slight distance, typically from about 0.005 to about 0.025 inch beyond the circumference of the wheel 12. It has been found that this substantially reduces the tendency of wood scraps to jam in the wood shaving device.
Referring now to FIGS. 1, 3 and 4, wood shavings which are formed by the cutter blades 42 pass through the apertures 44 of the wheel, exiting the hopper and discharging into a removal section 46 that is enclosed by a shroud 48 which extends about the cutting wheel 12. The cutting wheel has a plurality of fan blades 50 on its backside, disposed at equal angular spacings about the outer periphery of the wheel, e.g., ten fan blades can be spaced at 36 degree angular increments. The shroud 48 opens into a duct 52 with an angularly offset neck 54. A secondary comminuting device, such as a shredder wheel 56 is rotationally mounted in the duct 52 and has a plurality of blades 58 to reduce the size of the shavings, if desired. The shredder wheel 56 is driven by its own electrical motor, not shown. If desired, a plurality of stationary blades 51 can be interspaced between the blades 58 to improve the shredding action, and sizing screens 53 can be placed at the opening to the discharge chute: 54 to control the maximum particle size. Any oversized particles are deflected by the screen 53 back into the shroud 48 to be reprocessed by the shredder wheel 56.
The wood shavings are discharged from the neck 54 into suitable storage facilities, e.g., a hopper, bags or other containers, or transferred to a material handling device such as a conveyor, auger, etc.
Referring now to FIG. 4, a plurality of kicker plates are used to prevent jamming of the irregularly sized wood scraps in the hopper. A large kicker plate 70 is pivotally mounted on inclined front wall 20 of hopper 18. This kicker plate 70 has a tab 71 which is apertured to receive a fastener coupling to the end of a piston rod 72 of a hydraulic cylinder 74. The opposite end 76 of the hydraulic cylinder 74 is pivotally supported by a bracket 78 on the undersurface of the front wall 20 of the hopper 18, thereby providing an articulated connection which, upon extension of the piston rod 72, forces the kicker plate 70 into the hopper 18 to the extended position shown by the broken lines.
Preferably, a second and smaller kicker panel 80 is pivotally supported on the upper portion of sidewall 22 of the hopper 18. The upper portion of the wheel 12 is cut away in the view of FIG. 4, to provide a clear view of panel 80. The kicker panel 80 also has a tab 82 which is pivotally attached to the piston rod 84 of a second hydraulic cylinder 86 that is pivotally supported on the outside of the rear wall 88 of the hopper. The actuation of the hydraulic cylinder 86 will project the kicker panel 80 into the hopper, dislodging any wood scraps in its path.
The cutting wheel 12 is rotationally mounted on the comminuter mainframe 17 on a drive shaft 14 that extends across the housing. As shown in FIG. 5, the drive shaft 14 for the cutting wheel is mounted on bearings 92 and 98 carried by support brackets that are fixedly mounted on a pair of brackets 94 on opposite sides of the comminuter housing. The drive shaft 14 is received within a thrust sleeve 93 and is distally supported by a bearings 92 and 98 that bear against the thrust sleeve 97. The thrust sleeve 97 is axially restrained by the taper lock bushing 100 in the hub of the driven pulley 104. The drive shaft 14 is fixedly secured to the hub 102 of the cutter wheel 12. The negative thrust is transmitted through the drive shaft 14 to the taper lock bushing 100 and back through thrust sleeve 97, the inner race of bearing 92 and through sleeve 97 into the double tapered roller bearing 98. Sleeve 99 is used to axially retain the hub position relative to bearing 98. In this fashion axial thrusts on the cutter wheel are absorbed by the tapered thrust bearings.
At its opposite end, the shaft 14 supports the drive pulley 68. The drive pulley 68 is linked with an endless belt 66 to the output drive pulley 64 of the drive motor 60 which is mounted on plate 47 which is supported on the mainframe 17 of the device.
The cutter blades 42 are mounted on the cutting wheel 12 in the array which is illustrated in FIG. 6. As there illustrated, each cutter of the cutting wheel has a cutter blade 42 (see FIG. 4) which is positioned to span across a slot 44 that constitutes a through aperture in the cutting wheel 12. Each blade 42 as described hereinafter, is removably and adjustable fixed in the cutting wheel 12 with its cutting edge 112 extending across the through aperture slot 44. As apparent from FIG. 6, the cutting blades are arrayed in an alignment which does not lie on any common radial of the wheel. In this manner, each of the cutting blades 42 will successively impact the wood scraps, thus providing a continuous sequence of closely time-spaced impacts, rather than a single massive impact which would be experienced if the cutting blades 42 were aligned on radials of the cutting wheel. Preferably, each array of cutting blades is aligned on a helical path 114 which is illustrated in FIG. 6.
Each of the blades 42 is removably and adjustable supported in the assembly. FIGS. 9-11 illustrate the blade mounting assembly. As shown in FIG. 9, the wheel 12 has through apertures in the form of elongated slots 44. Each slot 44 is contiguous with a recess 116 in the cutting face of the wheel. Preferably the recess 116 is a generally rectangular pocket orthogonal to the elongated through slot 44. The recess 116 is separated from the slot, at its lower portion, by a wall 118 having an inclined upper edge 120. The wall 118 serves as a support for the knife 42 which is a rectangular blade having a cutting edge 112. The blade 42 rests on the inclined upper edge 120 of the intermediate wall 118 and is fixedly secured in place by a knife clamp block 122 that seats in the recess 116. The clamp block 122 has a central threaded aperture 124 which aligns with a through aperture 126 in the bottom wall 128 of the recess 116 and a lock screw 130 is extended through the aperture 126 and into engagement in the threaded aperture 124 of the clamp block 122 thereby permitting the clamp block to be compressed against the blade 42, securing the blade in its desired position. The clamp block 122 has an inclined face 132 which rests against the surface of the cutting blade 42, compressing the cutting blade and fixedly securing it. At its opposite end 117, the side wall of the clamp block 122 is chamfered slightly, e.g., up to about 5 degrees (2 degrees shown) to allow for full compressive force to be applied to the blade 42. A height adjustment screw 134 is provided in a threaded aperture 136 in the bottom wall of the recess 116 and the advance or retraction of screw 134 raises and lowers the cutting blade 42 in the assembly. The height of the blade above the surface of the cutting wheel can be fixedly adjusted from 0.0 to about 0.25 inch, and commonly is set at about 0.005 to 0.025 inch, thereby producing wood shavings which are well suited as pet and horse bedding.
Although the blades are shown with their cutting edges lying on radials of the cutting wheel, it is apparent that they can be skewed, or tilted from this alignment. Tilting of the blades in planing and shaving devices has the effect of changing the attack angle of the blades and decreases the cutting force required. The same benefit can be achieved by tilting the blades of the wood shaving device of this invention by an angle up to 45 degrees, if desired. An example of a tilted blade is shown in FIG. 8, in which the cutting edge 112 of the blade 42 is tilted an angle A from the radial 140. The pocket 116 is machined in wheel 12 at the same angle A. The angle A is illustrated as 30 degrees, however in can be at any angle from 5 to 45 degrees, if desired.
The blades 42 can be serviced from the back side of the cutting wheel 12 by loosening of the lock screw 130 in the clamp block 122 and advancing or retracting of the height adjustment screw 134.
The operation of the wood shaving device is preferably automated by timing and other control circuits. The woods scamps are discharged into hopper 18 by a belt or chain conveyor which receives the wood scraps from a supply hopper. The conveyor is operated by a timer circuit and moves a pre-set distance or travel and then stops. The hydraulic cylinder simultaneously advances the feed ram forward, forcing wood scraps in the hopper against the cutting face of the wheel 12.
The electrical power to the drive motor 60 is monitored and when the power reaches a pre-set value, the ram and conveyor are stopped. After the power reduces to an acceptable level, the hydraulic supply to the feed ram cylinder is restored and the ram continues forward unless stopped again. In the event of a jam at the cutter wheel, the feed ram goes through three successive attempts to reactivate, and then the control circuit sounds an audible alarm and shuts down the device.
The kicker plates 70 and 80 are activated periodically during operation, insuring that larger wood scraps do not jam in the hopper.
Once the ram reaches full travel, the hydraulic supply to the ram cylinder is reversed, retracting the ram. The hydraulic supply automatically reverses when the ram is withdrawn to return the ram to its forward travel.
In a typical embodiment a wood shaving device with a 37 inch diameter wheel with 130 cutters disposed in the spaced-apart array shown in FIG. 6 is driven with a 75 horsepower electrical motor at about 600 revolutions per minute. The knife blades are adjusted to provide an elevation of 0.02 inch above the surface of cutting wheel. The wood shaving device is used to produce wood shavings from a mix of soft redwood, pine and red oak wood scraps having maximum width and thickness of 12 by 12 inches. The length is unlimited, and only depends on the wood scrap feeding conveyor used to introduce the wood into the device. The wood shaving device readily handles about 5 cubic yards of wood scraps per hour, and produces wood shavings having a volume approximately 2.5 to 3 times the volume of the wood fed to the device.
The invention thus provides a wood shaving device having a rotatable cutting member which supports removable and adjustable knives that arranged in an array on the cutting surface of the cutting member which does not lie along a common linear path on the cutting surface, thereby avoiding the simultaneous impacting of more than a single cutting blade against a workpiece. The wood shaving device is provided with an automatic feed ram and with remotely actuated kicker plates that dislodge any jams of the wood scraps pieces, ensuring continuous and uninterrupted operation.
The invention has been described with reference to the illustrated and presently preferred embodiment. It is not intended that the invention be unduly limited by this disclosure of the presently preferred embodiment. Instead, it is intended that the invention be defined, by the means, and their obvious equivalents, set forth in the following claims:
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There is disclosed a wood shaving device which utilizes a rotating cutting member that supports a plurality of cutting blades which move past a stationary doctor bar. The cutting blades are arranged in a spaced-apart array on the shaving device, lying along non-radial paths so that the predominant action is a successive impact of individual cutting blades, rather than a simultaneous impact of two or more blades against the wood scrap. The cutting blades are preferably supported on a rotating cutting wheel which has a plurality of through apertures, with one each of the cutting blades removably mounted immediately adjacent each through aperture. The cutting blades are rotated past the doctor bar which restricts movement of the wood, resulting in a shaving action on the wood. The wood shavings pass through the through apertures of the cutting wheel and are removed. The wood shaving device includes a hopper with tapered sidewalls and a hydraulic ram that travels along an inclined chute to press the wood scraps into the cutting station. At least one, and preferably two, hydraulically actuated kicker plates are provided to dislodge any wood jams during the operation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to consolidating updates of database changes and, more specifically, to reducing the number of unmergeable records in a change accumulation data set.
2. Relevant Technology
Reliable management of databases is of paramount importance for modern day society which depends heavily on such databases for storage of critical information. Typically, users require that the database be constantly operational and accessible. Modern day database systems are substantially robust in that they infrequently experience a failure. Nevertheless, when a failure does occur the database recovery must be efficient and accurate to minimize loss to the users. Thus, database recovery is an operation which must be performed expeditiously in order to minimize down time for users. A database experiencing an extensive period of downtime may create an economic disaster.
A database contains database data sets and is managed by a complex database management system. One example of a database management system is the Information Management System (IMS) available from IBM Corp., Armonk, N.Y. The IMS is used extensively to serve a substantial number of databases in operation today. The IMS allows access to one or more databases in order for users to interact with the data maintained on the database. The majority of user access to a database involves transactional operations.
As users update database data sets in the database, the database management system records the updates in a log data set. The log data set is an amount of data, such as a file, which reflects a series of updates to the database. Log data sets are typically recorded in sequential records which have defined start and end points.
Users may make backup copies or a series of backup copies of the database periodically to assist in the recovery of a database. The backup copies may be recorded on tape archives by tape management systems. The backup copy is used as a base to restore the database to its state prior to a database failure. In recovery, subsequent updates to the database are applied from records on the log data sets. Recovery further requires storage of attributes of the database and the backup. Database management systems often include a repository which comprises several attributes of the database and the backup copy. Database management systems use some form of a repository relating to the database and the backup copy to assist in recovery.
Database management systems include a recovery utility to respond to a database failure. Upon database failure, the recovery utility creates a new database and writes the backup copy to the new database. The recovery utility further applies all updates to the database from when the backup copy was last created. Information used to restore the new database from the last state of the backup copy may be taken from the log data sets and recovery control information.
To assist in database recovery a utility, referenced herein as a change accumulation utility, accumulates updates and places them in a change accumulation data set (CADS). The CADS is an accumulation of changes in the log records that apply to the new database and are used as input during database recovery. The CADS may reflect updates for more than one database. A typical database record is updated a portion at a time and there may be overlapping updates which requires a sequential order of recovery. The change accumulation utility receives all the overlapping updates and incorporates the changes and merges overlapping updates.
In order to create the CADS, the change accumulation utility reads log data sets. Typically, users organize their multiple databases into change accumulation groups so that the change accumulation utility operates as efficiently as possible. A user can run the change accumulation process against one change accumulation group and use an optional secondary output—the set of log records that were not written to the change accumulation data set—as input to the change accumulation utility for the next change accumulation group to be processed. This can be done for each change accumulation group in which the current change accumulation run uses the secondary output of the previous change accumulation run. This serial process is managed directly by the user. Users usually run accumulation periodically so that when a database data set in a change accumulation group requires recovery, the time required to run a final change accumulation job and subsequent database recovery job is minimized. This sequential recovery process is quite complex.
The recovery utility reads the entire CADS into memory and applies that portion of the CADS that is relevant to the database data set being restored. Each record has an identification that's sequential and the database data sets are restored in a sequential order. The recovery utility addresses each record to see if there is a change in data for that record. If so, the CADS is accessed and the relevant record merged into the new database.
During routine operation, the database management system periodically creates updates in the database and in the log data set. Over time, several updates are created but are not permanently stored in the database until they are physically written on the database. In general, database activity is based on being able to “commit” updates to a database. A commit point is a point in time where updates become permanent parts of the database. The span of time between commit points is referred to as a “commit scope” or “unit of recovery” (UOR). If something goes wrong, such as a write error to the database, and the updates can not be made, all the updates produced since the last commit point are “aborted.” It is as if the updates never happened.
One method for implementing database updates and commit point processing is for the database manager to maintain the database changes in storage and not apply the changes to the databases until the commit point is reached. A copy of the database data that is changed is written to the log as the update is created. When the commit point is reached, and all operations are as expected, the updates are written to the databases. If an error occurs, the storage containing the database updates is freed.
A common update to the database is termed a transaction which is a unitary logical piece of work that may include performing a variety of activities. At its simplest level a transaction may involve decreasing one account balance and increasing another. The activities performed in the transaction may extend beyond a first commit point and will not be permanent until a subsequent commit point.
The change accumulation utility creates the CADS by taking log data sets that have been committed up to a certain commit point by combining them together. The committed log data sets are readily applied to the new database during recovery because they are permanent. Updates that occur after the last recorded commit point are not readily applied to the new database because there is no guarantee that the updates will be committed at a later commit point. Failure of a commit point results in an abort of the update and any related transactions. If the updates need to be aborted, the log record is retrieved and the copies of the unchanged database data are applied, in effect backing out the changes. Thus, updates that occur after the commit point are not necessarily committed to the database.
Each CADS comprises a detail record which is a record of committed updates from one or more logs. Each detail record is a series of contiguous bytes which can be overlaid into the backup copy of one database physical record. Applying all of the detail records in the CADS is equivalent to rerunning all of the transactions against the data base which were entered since a backup copy was made up to a “merge-end point.” The merge-end point is a point in the log separating mergeable updates from updates which may not be merged into detail record because all change records are not available for these updates. In shared sessions, merge end points are established at the location of sharing session boundaries such as at the end of a completed sharing session.
Updates which cannot be merged are written to records which are termed “spill records.” Spill records can only occur in a sharing session when multiple database management systems are sharing a database. The majority of database management systems run in a shared session to maximize use of a database. Spill records contain update data stored in the CADS in their entirety as individual identities and are not as compact as merged detail records. When the relevant log records become available, the spill records may be read in a subsequent change accumulation process and may be merged with other updates. Because updates contained in spill records are not merged, they increase the size of a CADS which in turn increases the amount of time needed to read and process a CADS. Reducing the number of spill records reduces the size of the CADS and improves the processing time of database recovery and subsequent change accumulation processes.
Thus, it would be an advancement in the art to provide a system and method to reduce the number of spill records in a CADS. It would be a further advancement in the art to reduce the number of spill records in a CADS by establishing a merge end point at a later position in commonly shared logs. It would be yet another advancement in the art to reduce the number of spill records by incorporating known features in database systems. Such an invention is disclosed and claimed herein.
SUMMARY OF THE INVENTION
The invention establishes a merge end point in the logs of a plurality of database management systems which share a common database. The merge end point is established at a later point to thereby reduce the number of unmergeable records. The system of the present invention comprises a log archive module which determines the location of each log volume end-start point in the logs. A log volume end-start point is the approximate position wherein the medium storing the log records is filled and is switched. Thus, the current medium, such as a tape, ends and a new medium starts at the end-start point. The log archive module assigns a time value to each log volume end-start point to indicate their positions.
The invention further comprises a database recovery control module which receives the positions of the log volume end-start points. The database recovery control module determines the most recent log volume end-start point for each log. The database recovery control module next determines which of the most recent log volume end-start points has the minimum time value. This log volume end-start point is the latest identifiable point wherein all log records for all logs may be merged. This log volume end-start point is selected as the merge end point. Thus, the merge end point need not be selected at the end of a completed sharing session. A change accumulation utility is able to incorporate the merge end point in a CADS to separate updates between those that are merged in the detail and those that are stored in the spill records.
These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other more detailed and specific objects and features of the present invention are more fully disclosed in the following specification, with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a computer system suitable for implementing one embodiment of the invention;
FIG. 2 is a block diagram of components illustrating communications and interconnections between components for a database system;
FIG. 3 is an illustration of log time lines used for reference with the present invention;
FIG. 4 is a block diagram illustrating one embodiment of a system for reducing unmergeable records in accordance with one embodiment of the invention; and
FIG. 5 is a flow diagram illustrating one embodiment of a method for reducing unmergeable records.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the invention is now described with reference to the Figures, where like reference numbers indicate identical or functionally similar elements. The components of the present invention, as generally described and illustrated in the Figures, may be implemented in a wide variety of configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.
Various components of the invention are described herein as “modules.” In one embodiment, the modules may be implemented as software, hardware, firmware, or any combination thereof.
For example, as used herein, a module may include any type of computer instruction or computer executable code located within a memory device and/or transmitted as electronic signals over a system bus or network. An identified module may, for instance, comprise one or more physical or logical blocks of computer instructions, which may be organized as an object, procedure, function, or the like.
Nevertheless, the identified modules need not be located together, but may comprise disparate instructions stored in different locations, which together implement the described functionality of the module. Indeed, a module may comprise a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
FIG. 1 is a schematic block diagram illustrating a computer system 10 in which a plurality of modules may be hosted on one or more computer workstations 12 in a network 14 . The network 14 may comprise a wide area network (WAN) or local area network (LAN) and may also comprise an interconnected system of networks, one particular example of which is the Internet.
A typical computer workstation 12 may include a logic device 16 and may be embodied as a central processing unit (CPU), microprocessor, a general purpose programmable device, application specific hardware, a state machine, or other processing machine. The logic device may be operably connected to one or more memory devices 18 . The memory devices 18 are depicted as including a non-volatile storage device 20 , such as a hard disk drive, CD-ROM drive, tape drive, or any other suitable storage device. The memory devices 18 may further include a read-only memory (ROM) 22 , and a random access volatile memory (RAM) 24 . The RAM 24 may be used to store instructions by the logic device 16 during execution. The memory devices 18 may further include a virtual memory 26 which, in one embodiment, is a portion of the non-volatile storage 20 which is used to extend the RAM 24 .
Preferably, the computer workstation 12 operates under the control of an operating system (OS) 28, such as OS/2, WINDOWS NT, WINDOWS 98, UNIX, or the like. In one embodiment, the operating system 28 may be loaded from the storage 20 into the RAM 24 at the time the workstation 12 is booted.
The computer workstation 12 may also include one or more input devices 30 , such as a mouse or keyboard, for receiving inputs from a user. Similarly, one or more output devices 32 , such as a monitor or printer, may be provided within, or be accessible from, the workstation 12 .
A network interface 34 , such as an Ethernet card, may be provided for coupling the workstation 12 to other devices via the network 14 . Where the network 14 is remote from the computer workstation 12 , the network interface 30 may comprise a modem, and may connect to the network 14 through a local access line, such as a telephone line.
Within any given workstation 12 , a system bus 36 may operably interconnect the logic device 16 , the memory devices 18 , the input devices 30 , the output devices 32 , the network interface 34 , and one or more additional ports 38 , such as parallel ports and RS-232 serial ports.
The system bus 36 and a network backbone 40 may be regarded as data carriers. Accordingly, the system bus 36 and the network backbone 40 may be embodied in numerous configurations. For instance, the system bus 36 and the network backbone 40 may comprise wire and/or fiber optic lines, as well as “wireless” electromagnetic links using visible light, infrared, and radio frequencies.
In general, the network 14 may comprise a single local area network (LAN), a wide area network (WAN), several adjoining networks, an intranet, or as in the manner depicted, a system of interconnected networks such as the Internet 42 . The individual workstations 12 may communicate with each other over the backbone 40 and/or over the Internet 42 using various communication techniques. Thus, a communication link may exist in general, between any of the stations 12 .
Different communication protocols, e.g., ISO/OSI, IPX, TCP/IP, may be used within the network 14 , but in the case of the Internet 42 , a single, layered communications protocol (TCP/IP) generally enables communications between the differing networks 14 and workstations 12 .
The workstations 12 may be coupled via the network 14 to application servers 44 , and/or other resources or peripherals 46 , such as printers, scanners, and facsimile machines. External networks may be coupled to the network 14 through a router 48 and/or through the Internet 42 .
Referring to FIG. 2, a block diagram illustrates a database system 200 which provides an environment for operation of the invention. The database system 200 may comprise one more database management systems (DBMS) 202 . The DBMSs 202 are designated DBMS 1 to DBMSn to indicate a variance of DBMSs 202 in the database system 200 . The DBMS 202 may be incorporated on a station 12 illustrated in FIG. 1 . An example of a DBMS 202 suitable for use with the invention is the Information Management System (IMS) previously discussed. One of skill in the art will appreciate that other database management systems may be incorporated into the present invention.
Each DBMS 202 may include a log 204 having log records to track updates to data kept in memory 18 or in a database (DB) 206 . The log 204 is used for reference to track data changes and other events performed by the corresponding database management system 202 . The log 204 may be stored on one or more memory devices 18 of the station 12 .
The database system 200 further includes one or more DBs 206 having one or more database data sets. The DBs 206 are designated as DB 1 to DBn to illustrate a variance in the number of DBs 206 in the system 200 . The DBs 206 may be a hierarchial structured database, such as an IMS database, but may comprise a relational database in an alternative embodiment. Throughout the application, reference to DBs 206 or database data sets is used interchangeably.
Each DBMS 202 may allow access to one or more DBs 206 in order for users to interact with any data maintained on the DBs 206 . One or more DBMSs 202 may also serve a single DB 206 . This is common practice as the size of DBs 206 often require more than one DBMS 202 to efficiently manage the transactions. A sharing session occurs when a plurality of DBMS 202 concurrently access a DB 206 .
The interconnection of the DBMS 202 and DBs 206 is designated by an electrical communication 208 . The electrical communication 208 may be considered a data carrier and may be embodied as the network backbone 40 . Electrical communication 208 does not require that components be physically coupled to each other. The electrical communication 208 may be enabled by electromagnetic, infrared, or other wireless communications. Furthermore, as database systems 200 vary in implementation, FIG. 2 is for illustrative purposes only as not every system 200 will have DBMSs 202 in communication with multiple DBs 206 . For purposes of the invention it is sufficient that there be a plurality of DBMS 202 in electrical communication with one DB 206 .
Database recovery methods require that a DB 206 have a corresponding backup copy 210 which may be a physical or logical copy. In one embodiment, the backup copy 210 is stored on a magnetic tape drive although other means of storage may also be used. The backup copy 210 reflects the contents of the DB 206 up to a certain time and serves as a starting point for the database recovery process. However, the backup copy 210 is not a complete repository of data of the DB 206 and other data is required to complete database recovery as explained below. The backup copy 210 may be in electrical communication 208 with other components of the system 200 as required for recovery.
The database system 200 further includes a repository 212 of recovery related information. The repository 212 is used to store information required to recover lost data if a media failure or another type of inadvertent error occurs. For example, hardware within a system may unexpectedly fail or a user may have accidentally inputted defective data or instructions that led to inconsistency in one or more DBs 206 . The repository 212 comprises data sets containing database recovery related information that may be specific to each DB 206 used in the system 200 . The repository 212 is in electrical communication 208 with other components of the system 200 as required to update and access the data sets in the repository 212 .
Each DB 206 to be recovered may be specified in a recovery list by designating one or more database data sets, designating entire DBs 206 for recovery, or designating groups as defined in the repository 212 for recovery. These groups may comprise, for example, database data set groups or other types of database groups.
The database system 200 comprises one or more CADS 214 designated CADS 1 to CADSn to indicate a variance in the number of CADS 214 in the system 200 . Each CADS 214 contains records reflecting change data from one or more logs 204 for a certain span of time. A single CADS 214 may further reflect updates for one or more databases 206 . The CADS 214 may be in electrical communication 208 with other components as required for recovery of one or more databases 206 .
Referring to FIG. 3, time lines 302 , 304 , 306 illustrating events in various logs corresponding to DBMS 1 - 3 202 are shown. FIG. 3 is used to illustrate the concept and advantages of the present invention. The timelines 302 , 304 , 306 represent allocation of a single database 206 to a plurality of DBMSs 202 . Practice of the invention is contemplated for a sharing session wherein two or more DBMSs 202 concurrently access a database 206 .
At a certain time in the time lines, a change accumulation process 307 is performed to merge log records and create a CADS 214 . In the change accumulation process 307 , a merge end point 308 is required for all logs of DBMSs 202 allocated to a database 206 . A merge end point 308 is a time separating log update records 310 , which may be merged into detail records, and log update records 312 which may not be merged. Unmergeable log update records 312 are written to spill records. Unmergeable log update records 312 must be stored in the CADS 214 with their individual identities as individual update records. Thus, spill records 312 are not as compact as merged detail records 310 . The more spill records 312 in a CADS 214 , the greater amount of time that is required to read and process the CADS 214 . This in turn increases the amount of database recovery time. Reducing the number of spill records 312 reduces the size of the CADS 214 and can improve the efficiency of a database recovery or subsequent change accumulation process.
Conventionally, the merge end points 308 always coincided with sharing session boundaries. The location of the merge end point 308 may be reflected by the DSSN (Data Set (allocation) Sequence Number). The DSSN is updated whenever a DB 206 is allocated for use by a DBMS 202 , unless the DB 206 is in current use by another DBMS 202 . Thus, the merging of updates is only possible for completed sharing sessions.
The present invention reduces the number of updates written to the spill records, comprising unmergeable update data, which are written to a CADS 214 . This is accomplished in part by identifying the latest point to which log records are available to be merged. The invention requires the identification of log volume end-start points 314 in each log 302 , 304 , 306 . A log volume end-start point 314 is the approximate position in a log where the medium storing the log records is filled and must be replaced by another medium. The medium may be a computer readable tape or other computer readable storage medium. Thus, the log volume end-start point indicates where the current medium ends its storage and a new medium starts its storage. The log archive module assigns a time value to each log volume end-start point to indicate their positions
The most recent log volume end-start points 316 are identified for each log 302 , 304 , 306 . Log records transpiring after the most recent log volume end-start point 316 on each log are not available to be processed. Thus, in FIG. 3, log 302 contains the greatest number of unmergeable log records. The merge end point 308 must coincide with all logs 302 , 304 , 306 in the sharing session and allocated to a DB 206 . The minimum time position of the most recent log volume end-start points 316 is the latest point available for the merge end point 308 . In FIG. 3, end-start point 318 is the minimum of the most recent end-start points 316 and is established as the location for the merge end point 308 . All available log records occurring after the end-start point 318 are written to spill records and all log records occurring prior to end-start point 318 are merged in the detail records. In this manner, the mergeable records are obtained as far down stream in the log time lines as possible. The merge end point 308 need no longer be dictated by sharing session boundaries.
Referring to FIG. 4, one embodiment of a system 400 having modules is shown. The memory devices 18 in which the modules of the present invention are located may be located in a single computer station 12 or may be distributed across both local and remote computer stations 12 . Two or more illustrated modules may be integrated into a single module without departing from the scope of the invention.
The system 400 contains one or more DBMSs 202 represented as DBMS 1 - 3 in FIG. 4 . Each DBMS 202 comprises a logger 402 which manages the writing of log data sets 404 . As a log data set 404 is completed it is sent to a log archive 406 . The log archive 406 writes the log data set 404 out to be logged on a log volume 408 . As the log data sets 404 are created, they take space on the log volume 408 . When a log volume 408 is full, the log archive 406 provides an identifier of the log volume end-start point 314 . As referenced herein, the log archive 406 may be specific to a single DBMS 202 or may be utilized by multiple DBMSs 202 . Thus, a log archive module 406 may include one or more modules resident within one or more DBMSs 202 .
The identifier for the log volume end-start point 314 / 316 is a value such as a time stamp to track the current position of log volume end-start point 314 in the log of the corresponding DBMS 202 . In one embodiment, the value is both the current DSSN and Lock Sequence Number (LSN). The LSN is generated by a lock manager 410 and is used to confirm the lock of a log record on a DB 206 for updates to the log record. The lock manager 410 may provide the LSN for a plurality of DBMSs 202 relating to a DB 206 . In the present invention, the LSN is also used to track the log position of the log volume start point 314 . The LSN is only reset to zero in synchronization with an increment of all DSSN values, i.e. when no DB 206 is allocated. The DSSN value is only incremented when a DB 206 is allocated for use by a DBMS 202 when it is not concurrently in use by another DBMS 202 .
The log archive 406 obtains a database synchronization token from the last log data set 404 of an archived log volume 408 . The database synchronization token reflects a DSSN/LSN value. The DSSN/LSN value is sent to a database recovery control (DBRC) 412 . The DBRC 412 obtains the DSSN/LSN values which indicate the log volume end-start point 314 for each log volume 408 . The DBRC 412 stores the DSSN/LSN values in the repository 212 .
The DBRC 412 evaluates the log volume end-start points 314 to select the log volume end-start point 316 which is most recent for each DBMS 202 . The DBRC 412 then selects from the most recent log volume end-start points 316 the minimum volume end point to be the merge end point 308 . The DBRC 412 may update the merge end point 308 each time a log volume end-start point 318 is received. In this manner, the merge end point 308 is available at any time. The DBRC 412 sends the DSSN/LSN value reflecting the merge end point 308 to a change accumulation utility 414 .
Previously, the change accumulation utility 414 received only a DSSN value to reflect the location of the merge end point 308 . In the present invention, the change accumulation utility 414 uses a DSSN/LSN value to determine the merge end point 308 . The change accumulation utility 414 reads in the log volumes 408 and uses the merge end point to distinguish mergeable update records 310 from unmergeable records 312 in the creation of a CADS 214 .
For clarification, the disclosure of the present invention was in reference to a single DB 206 allocated to a plurality of DBMSs 202 . The invention also allows for the DBRC 412 and change accumulation utility 414 to accommodate the allocation of a plurality of DBs 206 to a plurality of DBMSs 202 . The DBRC 412 receives an indication that each log volume end-start point 314 relates to a specific log volume 408 for a specific DB 206 . The change accumulation utility 414 further reads log volumes 408 associated with each DB 206 for which the change accumulation process is to be performed. Thus, when the change accumulation utility 414 performs the change accumulation process for multiple DBs 206 , the DBRC 412 will send multiple merge end points 308 to the change accumulation utility 414 .
Referring to FIG. 5, one embodiment of a method 500 for use with the present invention is shown. In step 502 , the method begins. In step 504 , the log archive 406 provides the log volume end-start points 314 to the DBRC 412 for each completed log volume. Step 504 may be repeated numerous times throughout the process as log volumes are filled. Thus, the DBRC 412 may receive updated information regarding new log volume end-start points 314 .
In step 506 , the change accumulation utility 414 is invoked to commence the change accumulation process for one or more DBs 206 . This may be performed automatically based on preestablished parameters or through initiation by a user.
In step 508 , the user or the DBRC 412 builds a log list of log volumes which are associated with the DBs 206 for which the change accumulation process will be run. The change accumulation utility 414 sends the log list to the DBRC 412 to verify the logs which will undergo the change accumulation process.
In step 510 , the DBRC 412 confirms the logs and sends verification of the logs to the change accumulation utility 414 .
In step 512 , the DBRC 412 determines which of the log volume end-start points 314 associated with a specific DB 206 is the current merge end point 308 for that DB 206 . This step may be performed as new log volume end-start points 314 are received. DBRC 412 determines the current merge end point 308 when a request for the merge end point 308 is received from the change accumulation utility 414 .
In step 514 , the DBRC 412 sends a value reflecting the merge end point 308 to the change accumulation utility 414 for each DB 206 . In the present embodiment, the value is a DSSN/LSN value. Nevertheless, one of skill in the art will appreciate that other time sensitive values which reflect the merge end point 308 position in a log may also be used and are included within the scope of the invention.
In step 516 , the change accumulation utility 414 reads in the log volumes associated with each DB 206 .
In step 518 , the change accumulation utility 414 uses the merge end point 308 to distinguish mergeable and nonmergeable update records 310 , 312 in the creation of a CADS 214 .
In step 520 , the mergeable update records are merged with detail records 310 and unmergeable update records are written to spill records 312 .
In step 522 , the change accumulation utility 414 writes out the CADS 214 . In step 524 , the method concludes.
The present invention reduces the number of unmergeable log records by selecting the lastest merge end point 308 corresponding to the logs of DBMSs 202 . The DSSN/LSN value is used to accurately track the merge end point 308 . In most cases, the present invention will significantly reduce the number of changes written to spill records 312 . The more log records which are processed and merged into the CADS, the fewer which must be read and sorted by a subsequent change accumulation or recovery process. Thus, the present invention increases the number of mergeable updates 310 incorporated into detail records to thereby expedite any future accumulation or recovery.
The present invention may be embodied in other specific forms without departing from its scope or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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The present invention establishes a merge end point in logs reflecting a sharing session with a common database. The merge end point is established at an earlier point to thereby reduce the number of unmergeable records. The system of the present invention includes a log archive module which determines the position of each log volume end-start point in the logs. A database recovery control module receives the positions of the log volume end-start points and determines the most recent log volume end-start point for each log. The database recovery control module next determines which of the most recent log volume end-start points has the earliest time value. This log volume end-start point is the latest identifiable point wherein all log records for all logs will be committed and is selected as the merge end point. A change accumulation utility is able to incorporate the merge end point in a CADS to separate unmergeable and mergeable log records.
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RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP2014/065991, filed Jul. 25, 2014, which claims the benefit of priority under 35 USC 119(a) to European patent application number 13178342.5, filed Jul. 29, 2013, the disclosure of each of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This application relates to a method for differentiating pluripotent stem cells (PSCs) into defined multi-competent renal precursor cells expressing Six2. These renal precursor cells are able to differentiate into fully functional and fully differentiated podocytes. Moreover this application relates to a method for differentiating human embryonic stem cells (ESCs) and induced pluripotent stem cells (iPSCs) into defined renal precursor cells expressing Six2 and podocytes based on linked steps of chemically defined medium inductions.
BACKGROUND
[0003] Renal cells are used in basic research, disease models, tissue engineering, drug screening, and in vitro toxicology. The kidneys have highly differentiated and complicated structures, and have pivotal roles in many physiological processes, such as body fluid osmolality, regulation of fluid and electrolyte balance, regulation of acid-base balance, excretion of metabolic waste products and foreign chemicals, and production of hormones controlling blood pressure and erythropoiesis. Once damaged, kidneys rarely recover their functions. Renal cells (e.g. Podocytes and tubular cells) can regenerate to some extent following acute necrosis. However, kidneys generally do not regenerate in patients with chronic kidney diseases (Humphreys and Bonventre, 2007), leading to end-stage renal insufficiency. Chronic kidney disease (CKD) is a major cause of morbidity and mortality affecting 11% of the adult population in Western countries. People with CKD suffer from a substantial loss of quality of life. The pharmacoeconomic burden caused by this disease is very high, as there is a permanent shortage of donor kidneys for transplantation.
[0004] The mammalian kidney is derived from the intermediate mesoderm (IM), which gives rise to the nephric duct (ND), and the metanephric mesenchyme (MM). The ND gives rise to the collecting duct system, which is composed of two key cell types, principal cells, and intercalated cells. The MM specifies the cap mesenchyme (CM) and also gives rise to the stroma. The CM is the nephron progenitor population and differentiates in the renal vesicle via a mesenchyme-to-epithelial transition.
[0005] The nephron consists of a glomerular tuft or glomerulus, and a renal tubule. The glomerulus is a highly specialized filtration unit that separates waste products for excretion as urine. The filtration barrier between blood and urine in the glomerulus is provided by highly specialized, terminally differentiated cells termed podocytes.
[0006] Converging evidence suggests that damage to the podocytes is one of the key events triggering loss of renal function. Podocyte damage occurs secondary to hyperinsulinemia, hemodynamic mechanisms and other mechanisms. The progressive loss of podocytes leads to broad sclerosis of the glomeruli accompanied by increased proteinuria and reduction in the clearance function (Wiggins, 2007).
[0007] However, the underlying mechanisms of insulin resistance and loss of regenerative properties leading to pathophysiological changes in the nephron of the kidney are not completely understood. Thus there is a need for in vitro cell models to study the biology of renal diseases like CKD and to facilitate the development of new treatments.
[0008] Embryonic stem (ES) cells and patient specific induced pluripotent stem cells (iPSCs) are a potential source for the production of renal precursor cells and podocytes in large scale for regenerative medicine and disease modeling for drug discovery. With the induced pluripotent stem cells (iPSCs) technology (Takahashi, K. & Yamanaka, S., “Induction of pluripotent stem cells from mouse embryonic and adult fibroblast cultures by defined factors”, Cell 126, 663-676 (2006)) somatic cells can be reprogrammed to iPSCs by transduction of four defined factors (Sox2, Oct4, Klf4, c-20 Myc). The iPSC technology enables the generation of patient specific iPSCs, which can be differentiated into patient specific renal cells. These patient specific renal cells are useful for example in vitro modeling of the pathophysiology of renal disease such as Chronic Kidney Disease (CKD), Focal segmental glomerulosclerosis (FSGS), Membranoproliferative glomerulonephritis, Polycystic kidney disease (PKD) and diabetic nephropathy associated with Diabetes Type-2, or for the assessment of drug toxicity. One important prerequisite to attempt such in vitro disease modeling is the implementation of an efficient, robust and scalable differentiation system (Tiscornia et al., 2011).
[0009] Previous efforts to differentiate human PSCs into renal cells have not achieved scales and efficacies relevant for drug discovery campaigns or regenerative cell therapies, neither in humans (Batchelder et al., 2009; Lin et al., 2010; Mae et al., 2013; Narayanan et al., 2013; Song et al., 2012) or mice (Kim and Dressler, 2005; Mae et al., 2010; Morizane et al., 2009; Nishikawa et al., 2012; Ren et al., 2010). In addition, a major concern is the mal-differentiation of the cells into unwanted tissues or even the formation of teratomas. To avoid this danger, one must direct the cells to a state of differentiation that will on the one hand provide them with the potential to regenerate mature kidney cells of interest and on the other hand prevent mal-differentiation. This can be achieved by the controlled activation of the correct network of nephric transcription factors. Unfortunately, attaining this exact state of differentiation in vitro has proven to be quite difficult. Many attempts have been made to induce pluripotent cells in this manner, applying both growth factor combinations [bone morphogenetic protein (BMP)/Activin/Retinoic acid] and genetic approaches. However, most differentiation studies, even after successfully inducing renal lineage genes, failed to pinpoint the exact stage in nephrogenesis (IM, MM, CM) to which ESCs were differentiated along the renal lineage.
[0010] Therefore, a highly efficient and chemically defined method for stimulating the differentiation of human pluripotent stem cells into kidney lineages remains to be developed.
[0011] Mae et al. 2013 describe a protocol to differentiate human pluripotent stem cells into intermediate mesoderm cells which express Osr1 using defined induction steps in serum free media. The authors dissociated the undifferentiated cells with Accutase® to obtain a single layer of cells and induced the differentiation with Activin A, a GSK3 beta inhibitor and a ROCK kinase inhibitor in a first step and BMP7 and the GSK3 beta inhibitor in a second step. The authors obtained 90% Osr1 positive cells on day 11 only. Expression of PAX2, LIM1, WT1, CITED2, EYA1 and SALL1 (marker genes for the developing kidney, gonad and adrenal cortex) was observed after 18 days, indicating that the authors obtained a heterogeneous cell population of different cell types and cells in different differentiation stages.
[0012] Lin et al., 2010 describe the differentiation of human embryonic stem cells into mesodermal renal progenitor lineages by reducing serum concentration and feeder layer density for 14 days. The authors obtained a heterogeneous population of differentiated human embryonic cells which they fractionated by flow cytometry.
[0013] Batchelder et al., 2009 describe the direct differentiation of embryonic stem cells towards the renal lineage by culturing the embryonic stem cells with retinoic acid, activin A, BMP7 or BMP4 on laminin or gelatin substrates in a monolayer. They obtained cells with upregulated intermediate mesoderm marker genes (PAX2, SIX2, WT1 and OSR1) at day 4. However, markers for kidney precursors and markers of undifferentiated cells were also elevated at day 4. Batchelder et al do not show any further differentiation of this heterogeneous population into defined cell types. The differentiation of the embryonic stem cells is achieved through a stage with embryoid bodies, which generally limits reproducibility and standardization of the protocol.
[0014] Hence, prior art protocols for differentiation of human pluripotent stem cells into kidney percursors have major drawbacks: Firstly, most protocols result in a heterogenous population of cells and the absolute yield of defined renal precursor cells stably expressing metanephric mesenchyme markers is very low. In addition, the overall time needed to differentiate pluripotent stem cells into renal precursor cells by most known methods is very long. Many protocols require undefined elements such as medium conditioned with factors secreted by primary cells, co-cultures with feeder layers, which limit the standardization of these methods. In addition, many protocols rely on cell aggregates or embryoid bodies, which due to their heterogeneous nature constrain the reproducibility of these techniques.
[0015] Song et al. 2012 is the first reported protocol to differentiate human induced pluripotent stem cells into kidney podocytes. Following ten days of directed differentiation in medium supplemented with fetal bovine serum and different growth factors (BMP7, Activin-A and retinoic acid), the authors obtained iPS cells with a podocyte phenotype. They obtained cells expressing podocyte specific genes but also still expressing the metanephric mesenchymal genes PAX2 and WT1, indicating that the obtained podocytes are immature and not fully differentiated. Song et al do not describe any of the intermediate stages of the differentiation like the intermediate mesoderm or the metanephric mesenchyme.
[0016] None of the known protocols provide defined renal precursor cells that express Six2, WT1, and SALL1 with downregulation of the expression of PAX2, i.e. defined metanephric mesenchyme cells. None of the known protocols describe the differentiation of the renal precursor cell into podocytes.
[0017] In summary, there is no method that provides a defined population of renal precursor cells expressing metanephric mesenchyme markers at very high yield after only six days. In addition none of the known protocols provides fully functional and fully differentiated podocytes at very high yield after only 13 days.
SUMMARY OF THE INVENTION
[0018] The present invention provides an improved method for differentiating pluripotent stem cells into a defined metanephric mesenchyme renal precursor stage in a shorter amount of time (6 days) and with a significantly increased yield (up to 95% yield of renal precursor cells expressing marker genes SIX2, SALL1 and WT1) compared to prior art protocols. The new method alleviates the necessity of obtaining embryoid bodies or small cell clumps from pluripotent stem cells and removes the major drawback of low reproducibility and standardization of methods known so far. Moreover, the high efficiency allows the use of these defined precursor cells in large scales in drug discovery and safety assessments, in regenerative medicine applications, and in in vitro disease modeling in the pharmaceutical industry. In addition, the new method permits the selective modulation of the metanephric mesenchyme renal precursor cells, which enables shifting lineage commitment into fully differentiated podocytes (˜99%) after 13 days.
[0019] Provided herein is a method for differentiating pluripotent stem cells into renal precursor cells expressing SIX2, the method comprising the steps of:
[0000] a) providing a monolayer of pluripotent stem cells in a pluripotency medium
b) incubating the cells in a priming medium supplemented with a small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b),
c) inducing the differentiation by incubating the primed cells in an induction medium.
[0020] In one embodiment the renal precursor cells express the additional marker genes WT1 and/or SALL1.
[0021] In one embodiment the small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b) is 3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione.
[0022] In one embodiment the pluripotency medium of step a) is a serum-free medium supplemented with an inhibitor of the Rho-associated coiled-coil forming protein serine/threonine kinase family of protein kinases (ROCK kinase inhibitor).
[0023] In one embodiment the ROCK kinase inhibitor is selected from the group of 1-(5-Isoquinolinesulfonyl)homopiperazine), N-Benzyl-2-(pyrimidin-4-ylamino)thiazole-4-carboxamide) and (+)-(R)-trans-4-(1-aminoethyl)-N-(4-pyridyl)cyclo-hexanecarboxamide dihydrochloride).
[0024] In one embodiment the priming medium of step b) is a serum free medium supplemented with insulin, transferrin and progesterone.
[0025] In one embodiment the priming medium of step b) additionally comprises recombinant bone morphogenic protein-4 (BMP4).
[0026] In one embodiment step a) comprises incubating the cells in the pluripotency medium for 18 hours to 30 hours.
[0027] In one embodiment step b) comprises incubating the cells in the priming medium for 2 to 4 days.
[0028] In one embodiment step c) comprises incubating the cells in the induction medium for 18 hours to 48 hours.
[0029] In one embodiment the induction medium is a serum-free medium supplemented with recombinant bone morphogenic protein-7 (BMP7).
[0030] In one embodiment the induction medium is a serum-free medium supplemented with Retinoic Acid.
[0031] In one embodiment the method additionally comprises step
[0000] d) incubating the product of step c) under conditions suitable for proliferation of the podocytes.
[0032] In one embodiment the pluripotent stem cell is an induced pluripotent stem cell.
[0033] In one embodiment the induced pluripotent stem cell is a human cell.
[0034] In one embodiment the induced pluripotent stem cell is obtained from a subject suffering from a renal disease.
[0035] In one embodiment renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments described herein is provided.
[0036] In one embodiment a biobank of renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments described herein is provided.
[0037] In one embodiment use of renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments described herein or of the biobank of of renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments described herein as in vitro model for renal diseases is provided.
[0038] In one embodiment a therapeutic composition comprising renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments described herein or of the biobank of of renal precursor cells expressing SIX2 or differentiated podocytes obtained by a method according to any of the embodiments is provided.
[0039] Any of the above embodiments may be present singly or in combination.
SHORT DESCRIPTION OF THE FIGURES
[0040] FIG. 1 : Quantification BRY+, PAX2+, LIM1+, iPSCs cells by image based high content analysis (HCA). Human iPS cells have been cultured in monolayer conditions. Quantification graph: Percent BRY+, PAX2+, and LIM1+ positive cells at Day 1 in pluripotency medium. These findings were confirmed by whole genome expression profiling (data not shown).
[0041] FIG. 2 : Quantification BRY+, PAX2+, LIM1+, iPSCs derived cells by image based high content analysis (HCA). Human iPS cells have been differentiated in monolayer conditions. Quantification graph: Percent BRY+, PAX2+, and LIM1+ positive cells at Day 4 in priming medium. These findings were confirmed by whole genome expression profiling (data not shown).
[0042] FIG. 3 : Quantification WT1+, SIX2+, SALL1+, and PAX2 low, iPSCs derived multi-competent renal precursors by image based high content analysis (HCA). Human iPS cells have been differentiated in monolayer conditions. Main panel: Quantification graph: Percent WT1+, SIX2+, SALL1+, and PAX2+ positive cells at Day 6 in induction medium. These findings were confirmed by whole genome expression profiling (data not shown).
[0043] FIG. 4 : Quantification WT1+, a-ACTININ4+, NEPRHIN+, PODOCIN+ and SYNAPTOPODIN+, iPSCs derived functional Podocytes by image based high content analysis (HCA). Human iPS cells have been differentiated in monolayer conditions. Main panel: Quantification graph: Percent WT1+, a-ACTININ4+, NEPRHIN+, PODOCIN+ and SYNAPTOPODIN+ positive cells at Day 13 in Podocytes proliferation medium. These findings were confirmed by whole genome expression profiling (data not shown).
[0044] FIG. 5 : Reproducibility of the Podocytes cell differentiation method using as starting hESCs. Image based high content analysis (HCA) quantification of key markers regulated during the Podocytes cell differentiation method. The human embryonic stem cell line (SA001 from Cellartis) has been differentiated in monolayer conditions. Main panel: Quantification graph: Percent PAX2+ positive cells at Day 4 in priming medium; SIX2+ and SALL1+ positive cells at Day 6 in induction medium; WT1+, and a-ACTININ4+ positive cells at Day 13 in Podocytes proliferation medium.
[0045] FIG. 6 : Characterization of monolayer differentiated hPSCs-derived Podocytes cells at Day 13. hiPSCs have been differentiated in monolayer conditions and at Day 13 have been tested for functional response to TGF beta (10 ng/ml) stressor stimulation. The expression of the tight junction marker ZO-1 has been tested by immunocytochemistry analysis and its cellular localization by image based high content analysis (HCA). Upper panel: Representative images ZO-1 immunocytochemistry where it is show a defined ZO-1 localization at the membrane for Day 1 in DMEMF12 Medium without TGF Beta (CTR D1-TGFb1), upon TGF beta stimulation we report a remodeling and translocation of the ZO-1 expression form the membrane to the perinuclear zone already at Day 1 (D1+TGFb1), and it is sustained over time by the continuous stimulation with TGF beta (D2+TGFb1 and (D5+TGFb1). Lower panel: Quantification graph: Percent positive cells for perinuclear translocation of ZO-1 expression in podocytes at different days.
[0046] FIG. 7 : Characterization of monolayer differentiated hPSCs-derived Podocytes cells at Day 13. hiPSCs have been differentiated in monolayer conditions and at Day 13 have been tested for functional response to Angiotensin II (AngII) (100 nM) stressor stimulation. The expression of the tight junction marker ZO-1 has been tested by immunocytochemistry analysis and its cellular localization by image based high content analysis (HCA). Upper panel: Representative images ZO-1 immunocytochemistry where it is show a defined ZO-1 localization at the membrane for Day 1 in DMEMF12 Medium without AngII (CTR D1−AngII), upon AngII stimulation we report a remodeling and translocation of the ZO-1 expression form the membrane to the perinuclear zone already at Day 1 (D1+AngII), and it is sustained over time by the continuous stimulation with AngII (D2+AngII and (D5+AngII). Lower panel: Quantification graph: Percent positive cells for perinuclear translocation of ZO-1 expression in podocytes at different days.
[0047] FIG. 8 a : Pro-inflammatory cytokine response assay. hPSCs-derived Podocytes cells at Day 13 upregulate the expression of pro-inflammatory markers such as IL-8 upon stimulation with TNFα (1 ng/ml and 5 ng/ml) after 24 h in DMEMF12 medium Main panel: Quantification graph: concentration in the harvested supernatant (pg/ml) of the mentioned cytokines. Bio-Plex Pro Cytokine, Chemokine and Growth factor assay was used to measure the activation of hPSCs-derived Podocytes cells in response to TNFα. The secreted cytokines were significantly upregulated (quantification graphs).
[0048] FIG. 8 b : Pro-inflammatory cytokine response assay. hPSCs-derived Podocytes cells at Day 13 upregulate the expression of pro-inflammatory markers such as RANTES upon stimulation with TNFα (1 ng/ml and 5 ng/ml) after 24 h in DMEMF12 medium Main panel: Quantification graph: concentration in the harvested supernatant (pg/ml) of the mentioned cytokines. Bio-Plex Pro Cytokine, Chemokine and Growth factor assay was used to measure the activation of hPSCs-derived Podocytes cells in response to TNFα. The secreted cytokines were significantly upregulated (quantification graphs).
[0049] FIG. 8 c : Pro-inflammatory cytokine response assay. hPSCs-derived Podocytes cells at Day 13 upregulate the expression of pro-inflammatory markers such as MIP1b upon stimulation with TNFα (1 ng/ml and 5 ng/ml) after 24 h in DMEMF12 medium Main panel: Quantification graph: concentration in the harvested supernatant (pg/ml) of the mentioned cytokines. Bio-Plex Pro Cytokine, Chemokine and Growth factor assay was used to measure the activation of hPSCs-derived Podocytes cells in response to TNFα. The secreted cytokines were significantly upregulated (quantification graphs).
[0050] FIG. 8 d : Pro-inflammatory cytokine response assay. hPSCs-derived Podocytes cells at Day 13 upregulate the expression of pro-inflammatory markers such as MCP1 upon stimulation with TNFα (1 ng/ml and 5 ng/ml) after 24 h in DMEMF12 medium Main panel: Quantification graph: concentration in the harvested supernatant (pg/ml) of the mentioned cytokines. Bio-Plex Pro Cytokine, Chemokine and Growth factor assay was used to measure the activation of hPSCs-derived Podocytes cells in response to TNFα. The secreted cytokines were significantly upregulated (quantification graphs).
[0051] FIG. 9 : Schematic representation of the method for differentiating human pluripotent stem cells (PSCs) to Podocytes. Day 0: human PSCs were enzymatically dissociated and plated on pre-coated Matrigel® plates using a concentration of 37000 cells/cm′ in pluripotency medium (mTeSR1™ with Y27631 10 μM). Day 1: Media change with fresh priming medium (N2B27 with Compound 21 (CP21R7) 1 μM and 25 ng/ml BMP4). Day 4: Media change with fresh induction medium (DMEMF12 with 2.5% FBS, 100 nM Retinoic Acid and 50 ng/ml BMP7). Day 6: The cells are detached with Accutase® and after centrifugation plated in collagen I coated plates using a concentration of 50000 cells/cm 2 in Podocytes proliferation medium (DMEMF12 with 10% FBS, 0.1 mM Retinoic Acid and 100 nM Vitamin D3). At Day 13 Podocytes cells are shown.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The present invention provides an improved method for differentiating pluripotent stem cells into a defined metanephric mesenchyme renal precursor stage in a shorter amount of time (6 days) and with a significantly increased yield (up to 95% yield of renal precursor cells expressing marker genes SIX2, SALL1 and WT1) compared to prior art protocols. The renal precursor cells express SIX2, SALL1 and WT1, which are all important markers of the metanephric mesenchyme. SIX2, also known as SIX homeobox 2 (NCBI Gene ID: 10736), is a member of the vertebrate gene family which encode proteins homologous to the Drosophila ‘sine oculis’ homeobox protein. The encoded protein is a transcription factor which has an important role for metanephros development. SIX2 is an important marker of the metanephric mesenchyme (see e.g. Nishinakamura et al, 2011 and Chai et al, 2013). SALL1 (full name: SALL1 sal-like 1 ( Drosophila ) [ Homo sapiens (human)] NCBI Gene ID: 6299), is also known as TBS; HSAL1; Sal-1; ZNF794. The protein encoded by this gene is a zinc finger transcriptional repressor and is highly expressed in multipotent nephron progenitors in the mesenchyme (Nishinakamura et al, 2011). WT1 (full name: Wilms tumor 1, also known as GUD; AWT1; WAGR; WT33; NPHS4; WIT-2; EWS-WT, NCBI Gene ID:7490) encodes a transcription factor that contains four zinc-finger motifs at the C-terminus and a proline/glutamine-rich DNA-binding domain at the N-terminus. It has an essential role in the normal development of the urogenital system, and it is mutated in a small subset of patients with Wilm's tumors. WT1 is an important marker of the metanephric mesenchyme (see e.g. Chai et al, 2013).
[0053] In addition to obtaining defined metanephric mesenchyme renal precursor cells, the new method permits the selective modulation of the metanephric mesenchyme renal precursor cells, which enables shifting lineage commitment into fully differentiated podocytes (˜99%) after 13 days.
[0054] Provided herein is a method for differentiating pluripotent stem cells into renal precursor cells expressing SIX2, the method comprising the steps of:
[0000] a) providing a monolayer of pluripotent stem cells in a pluripotency medium
b) incubating the cells in a priming medium supplemented with a small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b),
c) inducing the differentiation by incubating the primed cells in an induction medium.
In one embodiment the renal precursor cells are metanephric mesenchyme cells. In one embodiment the renal precursor cells express the additional marker genes WT1 and/or SALL1. In one embodiment the renal precursor cells express WT1, SALL1 and SIX2. In another embodiment the renal precursor cells downregulate marker genes of the intermediate mesoderm. Hence, in one embodiment the renal precursor cell express PAX2 only at a very low level. PAX2 (full name Paired Box 2, NCBI Gene ID 5076, also known as PAPRS) encodes paired box gene 2, one of many human homologues of the Drosophila melanogaster gene prd. The central feature of this transcription factor gene family is the conserved DNA-binding paired box domain. PAX2 is an important marker of the intermediate mesoderm (Chai et al, 2013, Nishikawa et al, 2012) and is downregulated in the metanephric mesenchyme. In one embodiment the renal precursor cells do not express LIM1 and/or BRY. LIM1 (official symbol LHX1, full name LIM homeobox 1, NCBI Gene ID 3975) encodes a member of a large protein family which contains the LIM domain, a unique cysteine-rich zinc-binding domain. The encoded protein is a transcription factor important for the development of the renal and urogenital systems: LIM1 is a marker for nephrogenic intermediate mesoderm (Nishikawa et al, 2012). The protein product of the T gene (full name: T, brachyury homolog (mouse) [ Homo sapiens (human)] NCBI Gene ID: 6862, herein referred to as “BRY”), Brachyury, is an embryonic nuclear transcription factor and widely used as the definitive benchmark for mesodermal differentiation (Nishikawa et al, 2012).
[0055] Preferably the media are changed in between each steps, that means that the first medium is discarded e.g. by aspiration before the second medium is added to the cells.
[0056] “A monolayer of pluripotent cells” as used herein means that the pluripotent stem cells are provided in single cells which are attached to the adhesive substrate in one single film, as opposed to culturing cell clumps or embryoid bodies in which a solid mass of cells in multiple layers form various three dimensional formations attached to the adhesive substrate.
[0057] Providing a monolayer of pluripotent stem cells in the initial step is crucial for the reproducibility and efficiency of the method. In one embodiment, monolayers of pluripotent stem cells can be produced by enzymatically dissociating the cells into single cells and bringing them onto an adhesive substrate, such as pre-coated Matrigel® plates (e.g. BD Matrigel® hESC-qualified from BD Bioscience, Geltrex hESC-qualified from Invitrogen, Synthemax from Corning). Examples of enzymes suitable for the dissociation into single cells include Accutase® (Invitrogen), Trypsin 25 (Invitrogen), TrypLe™ Express (Invitrogen). In one embodiment, 20000 to 60000 cells per cm2 are plated on the adhesive substrate. The medium used herein is a pluripotency medium which facilitates the attachment and growth of the pluripotent stem cells as single cells in a monolayer.
[0058] “Pluripotency medium” as used herein refers to any chemically defined medium useful for the attachment of the pluripotent stem cells as single cells on a monolayer while maintaining their pluripotency and are well known in the art. In one embodiment the pluripotency medium comprises at least one of the following growth factors: basic fibroblast growth factor (bFGF, also depicted as Fibroblast Growth Factor 2, FGF2) and transforming growth factor β (TGFβ). In one embodiment, the pluripotency medium is a serum free medium supplemented with a small molecule inhibitor of the Rho-associated coiled-coil forming protein serine/threonine kinase (ROCK) family of protein kinases (herein referred to as ROCK kinase inhibitor).
[0059] Thus, in one embodiment, step a) of the method described above comprises providing a monolayer of pluripotent stem cells in a pluripotency medium, wherein the pluripotency medium is a serum free medium supplemented with a ROCK kinase inhibitor.
[0060] Examples of serum-free pluripotency media suitable for the attachment are mTeSR1™ or TeSR2 from Stem Cell Technologies, Primate ES/iPS cell medium from ReproCELL and StemPro® hESC SFM from Invitrogen, X-VIVO™ from Lonza, Stemline Pluripotent Stem Cell Culture Medium from Sigma Aldrich, NutriStem™ XF/FF Culture Medium from Stemgent, Essential 8™ Medium (prototype) from Invitrogen and STEMium® from ScienCell Research Laboratories.
[0061] Examples of ROCK kinase inhibitor useful herein are Fasudil (1-(5-Isoquinolinesulfonyl)homopiperazine), Thiazovivin (N-Benzyl-2-(pyrimidin-4-10 ylamino)thiazole-4-carboxamide) and Y27632 ((+)-(R)-trans-4-(1-aminoethyl)-N-(4-pyridyl)cyclo-hexanecarboxamide dihydrochloride, e.g. Catalogue Number: 1254 from Tocris bioscience). In one preferred embodiment the ROCK kinase inhibitor is Y27632. In one embodiment, the pluripotency medium is a serum free medium supplemented with 2-20 μM Y27632, preferably 5-10 μM Y27632. In another embodiment the pluripotency medium is a serum free medium supplemented with 2-20 μM Fasudil. In another embodiment the pluripotency medium is a serum free medium supplemented with 0.2-10 μM Thiazovivin.
[0062] In one embodiment step a) of the method described above comprises providing a monolayer of pluripotent stem cells in a pluripotency medium and incubating (growing) the monolayer in the pluripotency medium for one day (24 hours). In another embodiment step a) of the method described above comprises providing a monolayer of pluripotent stem cells in a pluripotency medium and incubating the monolayer in the pluripotency medium for 18 hours to 30 hours, preferably for 23 to 25 hours.
[0063] In another embodiment step a) of the method described above comprises providing a monolayer of pluripotent stem cells in a pluripotency medium, wherein the pluripotency medium is a serum-free medium supplemented with a ROCK kinase inhibitor, and incubating the monolayer in the pluripotency medium for one day (24 hours). In another embodiment step a) of the method described above comprises providing a monolayer of pluripotent stem cells in a pluripotency medium, wherein the pluripotency medium is a serum-free medium supplemented with a ROCK kinase inhibitor, and incubating the monolayer in the pluripotency medium for 18 hours to 30 hours, preferably for 23 to 25 hours.
[0064] A “suitable medium for priming”, also depicted as “priming medium”, as used herein refers to any chemically defined medium useful for priming of the pluripotent stem cells towards renal precursor cells. As used herein, “priming medium” refers to a medium that comprises at least one factor, such as a small molecule that activates the Beta-Catenin (cadherin-associated protein, beta 1; human gene name CTNNB1) pathway and/or the Wnt receptor signaling pathway and/or hedgehog (HH) signaling pathway, that promotes the induction activity of intermediate mesoderm. In one preferred embodiment the priming medium comprises a small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b). In one embodiment the a small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b) is 3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione.
[0065] Upon incubation in priming medium, the pluripotent stem cells start to change cell morphology overtime and the cell proliferation is increased. The “priming” step is defined by the expression of specific genes and markers involved into the intermediate mesoderm transition (e.g. upregulation of BRY, PAX2, LIM1, GATA2, VIMENTIN, SMA, HAND1, KDR and FOXa2 (low expression)) and down regulation of the pluripotency associated genes and markers (e.g. OCT4 (POU5F1), NANOG, SOX2, REX1 (ZFP42), LEFTY1, LEFTY2, TDGF1, DNMT3B, GABRB3, GDF3, TERT, see e.g. Tan et al, 2007).
[0066] In one embodiment the small molecules activating Beta-Catenin (cadherin-associated protein, beta 1; human gene name CTNNB1) pathway and/or the Wnt receptor signaling pathway and/or hedgehog (HH) signaling pathway are selected from the group consisting of small molecule inhibitors of glycogen synthase kinase 3 (Gsk3a-b), small molecule inhibitors of CDC-like kinase 1 (Clk1-2-4), small molecule inhibitors of mitogen-activated protein kinase 15 (Mapk15), small molecule inhibitors of dual-specificity tyrosine-(Y)-phosphorylation regulated kinase (Dyrk1a-b 4), small molecule inhibitors of cyclin-dependent kinase 16 (Pctk1-3 4), Smoothened (SMO) activators and modulators of the interaction between β-catenin (or γ-catenin) 15 and the coactivator proteins CBP (CREB binding protein) and p300 (E1A binding protein p300).
[0067] Preferably the glycogen synthase kinase 3 (Gsk3a-b) inhibitors are pyrrolidindione-based GSK3 inhibitors. “Pyrrolidindione-based GSK3 inhibitor” as used herein relates to selective cell permeable ATP-competitive inhibitors of GSK3α and GSK3β with low IC50 values. In one embodiment the pyrrolidindione-based GSK3 inhibitor is selected from the group comprising 3-(2,4-Dichlorophenyl)-4-(1-methyl-1H-indol-3-yl)-1H-pyrrole-2,5-dione (SB216763), 3-[(3-Chloro-4-hydroxyphenyl)amino]-4-(2-nitrophenyl)-1H-pyrrol-2,5-dione (SB415286), N6-{2-[4-(2,4-Dichloro-phenyl)-5-imidazol-1-yl-pyrimidin-2-ylamino]-ethyl-3-nitro-pyridine-2,6-diamine 2HCl, 3-Imidazo[1,2-a]pyridin-3-yl-4-[2-(morpholine-4-carbonyl)-25 1,2,3,4-tetrahydro-[1,4]diazepino[6,7,1-hi]indol-7-yl]-pyrrole-2,5-dione, 9-Bromo-7,12-dihydro-indolo[3,2-d][1]benzazepin-6(5H)-one (Kenpaullone), 9-Bromo-7,12-dihydro-pyrido[3′,2′:2,3]azepino[4,5-b]indol-6(5H)-one (CHIR99021) and (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione (CP21R7, also referred to as “compound 21” herein; see e.g. L. Gong et al; Bioorganic & Medicinal Chemistry Letters 20 (2010), 1693-1696). In one embodiment the CDC-like kinase 1 (Clk1-2-4) inhibitor is selected from the group comprising benzothiazole and 3-Fluoro-N-[1-isopropyl-6-(1-methyl-piperidin-4-yloxy)-1,3-dihydro-benzoimidazol-(2E)-ylidene]-5-(4-methyl-1H-pyrazole-3-sulfonyl)-benzamide. In one embodiment the mitogen-activated protein kinase 15 (Mapk15) inhibitor is selected from the group comprising 4-(4-Fluorophenyl)-2-(4-methylsulfinylphenyl)-5-(4-pyridyl)-1H-imidazole (SB203580) and, 5-Isoquinolinesulfonamide (H-89).
[0068] In one embodiment the dual-specificity tyrosine-(Y)-phosphorylation regulated kinase 5 (Dyrk1a-b 4) inhibitor is selected from the group comprising 6-[2-Amino-4-oxo-4H-thiazol-(5Z)-ylidenemethyl]-4-(tetrahydro-pyran-4-yloxy)-quinoline-3-carbonitrile.
[0069] In one embodiment the smoothened activator is Purmorphamine (2-(1-Naphthoxy)-6-(4-morpholinoanilino)-9-cyclohexylpurine. Examples of modulators of the interaction between β-catenin (or γ-catenin) and the coactivator proteins CBP (CREB binding protein) and p300 (E1A binding protein p300) are IQ-1 (2-(4-Acetyl-phenylazo)-2-[3,3-dimethyl-3,4-dihydro-2H-isoquinolin-(1E)-ylidene]-acetamide, and ICG-001((6S,9aS)-6-(4-Hydroxy-benzyl)-8-naphthalen-1-ylmethyl-4,7-dioxo-hexahydro-15 pyrazino[1,2-a]pyrimidine-1-carboxylic acid benzylamide (WO 2007056593).
[0070] In one embodiment the priming medium is a serum free medium supplemented with insulin, transferrin and progesterone. In one embodiment the serum free medium is supplemented with 10-50 μg/ml insulin, 10-100 μg/ml transferrin and 10-50 nM progesterone, preferably 30-50 μg/ml insulin, 20-50 μg/ml transferrin and 10-30 nM progesterone. Examples of serum-free media suitable for priming are N2B27 medium (N2B27 is a 1:1 mixture of DMEM/F12 (Gibco, Paisley, UK) supplemented with N2 and B27 (both from Gibco)), N3 medium (composed of DMEM/F12 (Gibco, Paisley, UK), 25 μg/ml insulin, 50 μg/ml transferrin, 30 nM sodium selenite, 20 nM progesterone, 100 nM putrescine (Sigma)), or 25 NeuroCult® NS-A Proliferation medium (Stemcell Technologies). In one embodiment the priming medium is a serum free medium supplemented with insulin, transferrin, progesterone and a small molecule inhibitor of glycogen synthase kinase 3 (Gsk3a-b).
[0071] Preferably the small molecule inhibitor is (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione, also referred to as CP21R7 therein. In one embodiment the priming medium is a serum-free medium comprising 10-50 μg/ml insulin, 10-100 μg/ml transferrin and 10-50 nM progesterone and 0.5-4 μM CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione). In one such embodiment the priming medium comprises 1 μM CP21R7. In one embodiment the priming medium of any of the embodiments described herein additionally comprises recombinant bone morphogenic protein-4 (BMP4). In one preferred embodiment the priming medium is a serum-free medium comprising 10-50 μg/ml insulin, 10-100 μg/ml transferrin, 10-50 nM progesterone, 0.5-4 μM CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione) and 10-50 ng/ml recombinant bone morphogenic protein-4 (BMP4).
[0072] In one embodiment step b) of the method described above comprises incubating the cells in a priming medium for at least 3 days (72 hours). In one embodiment step b) of the method described above comprises incubating the cells in a priming medium for 2 to 4 days (48 hours to 96 hours). In another embodiment step b) of the method described above comprises incubating the cells in a priming medium, wherein the priming medium is a serum-free medium supplemented with CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione). Preferably the priming medium is supplemented with 0.5-4 μM CP21R7 (3-(3-Amino-phenyl)-4-(1-30 methyl-1H-indol-3-yl)-pyrrole-2,5-dione), most preferably 1-2 μM CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione). In one embodiment the priming medium additionally comprises recombinant bone morphogenic protein-4 (BMP4). In another embodiment step b) of the method described above comprises incubating the cells in a priming medium, wherein the priming medium is a serum-free medium supplemented with CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione), and incubating the cells for three days (72 hours). In one such embodiment the priming medium additionally comprises recombinant bone morphogenic protein-4 (BMP4).
[0073] In another embodiment step b) of the method described above comprises incubating the cells in a priming medium, wherein the priming medium is a serum-free medium supplemented with CP21R7 (3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione), and incubating the cells for 2 to 4 days (48 hours to 96 hours). In one such embodiment the priming medium additionally comprises recombinant bone morphogenic protein-4 (BMP4).
[0074] “Induction medium” as used herein refers to any chemically defined medium useful for the induction of primed cells into SIX2 and/or WT1 and/or SALL1 positive renal precursor cells on a monolayer. In one embodiment the renal precursor cells express all three marker genes SIX2, WT1 and SALL1 and are referred to as SWS+ renal precursor cells. In one embodiment the renal precursor cells are metanephric mesenchyme cells. In another embodiment the renal precursor cells downregulate marker genes of the intermediate mesoderm. Hence, in one embodiment the renal precursor cell express PAX2 only at a very low level. In one embodiment the renal precursor cells do not express LIM1 and/or BRY.
[0075] Examples of media suitable for the induction are DEMEM/F12, RPMI 1640 (Invitrogen) or William's E Medium (Invitrogen).
[0076] In one embodiment the induction medium is supplemented with a Bone morphogenetic protein (BMP), like BMP4, BMP7 or other BMPs like BMP2, BMP3, BMP 5, BMP 6, BMP 8a, BMP 8b, or BMP 9.
[0077] Preferably the induction medium is a medium supplemented with BMP7. In one such embodiment the induction medium is supplemented with 20-80 ng/ml BMP7, preferably 50 ng/ml BMP7.
[0078] With the new method presented herein it is now possible to differentiate renal precursor cells expressing SIX2 from pluripotent stem cells with a yield of up to 95%. The product of step c) can be easily identified in a cell culture as SIX2 and WT1 and/or SALL1 positive cells.
[0079] In one embodiment the induction medium additionally comprises Retinoic acid (RA), like all-trans-Retinoic acid or 9-cis Retinoic acid. In another embodiment the induction medium comprises a Retinoic Acid inhibitor or an Retinoic Acid agonist. Retinoic acid inhibitors and Retinoic acid agonists are well known in the art.
[0080] Preferably the induction medium is a medium supplemented with RA. In one such embodiment the induction medium is supplemented with 50-200 nM RA, preferably 100 nM RA.
[0081] In one embodiment the induction medium is supplemented with RA and BMP7.
[0082] In one embodiment the induction medium additionally comprises 1-5% serum, preferably 2.5% serum. Serum useful therein is for example fetal bovine serum, known in the art. In another embodiment the induction medium is supplemented with amino acids, e.g. non essential Aminoacid solution from Sigma-Aldrich (Catalogue number M7145).
[0083] In another embodiment the induction medium additionally comprises beta-mecaptoethanol.
[0084] In one embodiment step c) of the method described above comprises incubating the cells in a induction medium for 2 days (48 hours).
[0085] In one embodiment, steps a) to c) of the method described above together take six days.
[0086] In embodiment the method as described in any the above embodiments is useful for differentiating pluripotent stem cells into podocytes. In one embodiment the method as described in any of the above embodiments additionally comprises step
[0087] d) incubating the product of step c) under conditions suitable for proliferation of podocytes. Typically, the SWS+ cells obtained in step c) are harvested and expanded in a chemically defined proliferation medium. In one embodiment, step d) comprises incubating the cells obtained in step c) for 24-168 h, preferably for 48-96 hours in a proliferation medium.
[0088] Proliferation medium as used herein is a medium supplemented with growth factors and/or small molecules enhancing the proliferation and survival of podocytes cells.
[0089] In one embodiment step the proliferation medium is a chemically supplemented medium (SP medium). SP media useful herein are e.g. DMEM/F12 medium (e.g. Invitrogen or Gibco Cat num. 31331-028) or RPMI 1640 (Gibco Cat num. 61870-010) or DMEM medium). In one embodiment the proliferation medium is supplemented with 2-10% serum, for example 2-10% fetal bovine serum. In one embodiment the proliferation medium is supplemented with a Knock-out serum replacement (e.g. from Invitrogen, Catalogue number 10828028).
[0090] In another embodiment the proliferation medium is supplemented with 0.1-0.5 mM RA, preferably 0.1 mM RA. In another embodiment the proliferation medium is supplemented with 10-200 nM Vitamin D3, preferably 100 nM Vitamin D3. In one embodiment the proliferation medium is supplemented with both RA and Vitamin D3. In one embodiment the proliferation medium further comprises stable glutamine. In a preferred embodiment the proliferation medium is a DMEM/F12 medium supplemented with 10% serum, 100 nM Vitamin D3 and 0.1 mM Retinoic Acid.
[0091] The renal precursor cells and podocytes obtained by the method described herein can be expanded for several passages.
[0092] Any of the above embodiments may be present singly or in combination.
[0093] In one embodiment of the present invention a method for generating patient specific or healthy individual specific renal precursor cells or podocytes is provided. Towards this end, human induced pluripotent stem cells (iPSCs) obtained from a patient or healthy individual are differentiated into renal precursor cells or podocytes with the method described herein. The patient-specific human iPSCs can be obtained by methods known in the art by reprogramming somatic cells obtained from the patients or healthy individuals to pluripotent stem cells. For example, fibroblast cells, keratinocytes or adipocytes may be obtained by skin biopsy from the individual in need of treatment or from a healthy individual and reprogrammed to induced pluripotent stem cells by the methods known in the art. Other somatic cells suitable as a source for induced pluripotent stem cells are leucocytes cells obtained from blood samples or epithelial cells or other cells obtained from urine samples. The patient specific induced pluripotent stem cells are then differentiated to patient specific or healthy individual specific renal precursor cells or podocytes by the method described herein. In another aspect of the invention, a population of renal precursor cells or podocytes produced by any of the foregoing methods is provided. Preferably, the population of renal precursor cells or podocytes is patient specific, i.e. derived from iPSCs obtained from diseased individuals. In another embodiment the population of renal precursor cells or podocytes is obtained from a healthy individual.
[0094] Patient derived renal precursor cell or podocytes represent a disease relevant in vitro model to study the pathophysiology of renal diseases like acute kidney failure/acute kidney injury, Alport syndrome, angiotensin antibodies and focal segmental glomerulosclerosis, APOL1 mutations, CFHR5 nephropathy, Bartter syndrome, collapsing glomerulopathy, diabetes and diabetic kidney disease related to CMV, Fabry's disease, glomerular diseases, HIV-associated nephropathy (HIVAN), lipoprotein glomerulopathy, lupus kidney disease, lupus nephritis, membranoproliferative glomerulonephritis, nodular glomerulosclerosis, post-infectious glomerulonephritis, post-streptococcal glomerulonephritis. In one embodiment the renal precursor cells or podocytes obtained by this method are used for screening for compounds that reverse, inhibit or prevent renal diseases caused by dysfunction of renal cells, e.g. Chronic Kidney Disease (CKD), Focal segmental glomerulosclerosis (FSGS), Membranoproliferative glomerulonephritis, Polycystic kidney disease (PKD) and diabetic nephropathy associated with Diabetes Type-2. Preferably, the renal precursor cells or podocytes obtained by the method of the invention described herein are derived from diseased subjects. In another embodiment the renal precursor cells or podocytes obtained by this method are used for screening and evaluating new targets and compounds for treatment of Diabetes and Diabetic Kidney Disease. Preferably, the renal precursor cells or podocytes obtained by the method of the invention described herein are derived from individuals affected by renal diseases like for example Chronic Kidney Disease (CKD), Focal segmental glomerulosclerosis (FSGS), Membranoproliferative glomerulonephritis, Polycystic kidney disease (PKD) and diabetic nephropathy associated with Diabetes Type-2. Differentiating renal precursor cells and/or podocytes from diseased subjects represents a unique opportunity to early evaluate drug safety in a human background paradigm. In another embodiment the podocytes obtained by this method are used as an in vitro model of the nephron.
[0095] The present invention provides a highly efficient method to supply patient specific podocytes or compatible cells from healthy individuals with the same HLA type suitable for transplantation, both derived in xeno-free conditions. “Xeno-free culture conditions” refers to a medium and a substrate for attachment that comprising components only of human and recombinant origin. Thus the risk of contamination with xenopathogens is circumvented and the renal cells are safe for use in regenerative medicine. Differentiation of patient specific induced pluripotent stem cells (iPSCs) into patient specific podocytes with the method described herein represents an easy accessible and reproducible technology to generate autologous sources of podocytes. The use of autologous and/or compatible cells in cell therapy offers a major advantage over the use of non-autologous cells, which are likely to be subject to immunological rejection. In contrast, autologous cells are unlikely to elicit significant immunological responses.
[0096] In a further preferred aspect of the invention the generation of a BioBank of patient specific renal precursor cells or podocytes is envisaged. In one embodiment, a BioBank comprising different populations of renal precursor cells or podocytes obtained from healthy individuals and/or patients is generated. The term “BioBank” as used herein means a library of biological samples taken from different individuals or species. The archived collection of specimen and associated data is intended for research purposes with the aim of addressing diseases associated with vascular complications. In another embodiment, the BioBank is used for vascular regenerative medicine approaches.
[0097] In another aspect, the invention provides a therapeutic composition comprising renal precursor cells or podocytes produced by any of the foregoing methods or comprising any of the foregoing cell populations. Preferably, the therapeutic compositions further comprise a physiologically compatible solution including, for example, a phosphate-buffered saline with 5% human serum albumin. The therapeutic composition can be used to treat, prevent, or stabilize renal diseases such as for example, Chronic Kidney Disease (CKD), Focal segmental glomerulosclerosis (FSGS), Membranoproliferative glomerulonephritis, Polycystic kidney disease (PKD) and diabetic nephropathy associated with Diabetes Type-2. For example, fibroblast cells, keratinocytes or adipocytes may be obtained by skin biopsy from the individual in need of treatment or from a healthy individual and reprogrammed to induced pluripotent stem cells by the methods known in the art (“Induction of pluripotent stem cells from adult human fibroblasts by defined factors.” Takahashi et al., 2007, Cell 131, 861-72). Other somatic cells suitable as a source for induced pluripotent stem cells are leucocytes cells obtained from blood samples or epithelial cells or other cells obtained from urine samples. The patient specific induced pluripotent stem cells are then differentiated to podocytes by the method described herein, harvested and introduced into the individual to treat the condition. The renal precursor cells or podocytes produced by the method of the invention may be used to replace or assist the normal function of diseased or damaged tissue.
[0098] Another embodiment of the invention is the use of BioBanks of renal precursor cells or podocytes for therapy of renal diseases. The BioBanks preferably comprise renal precursor cells or podocytes obtained from patients or healthy individuals with several HLA types. Transplanting cells obtained from a healthy donor to an individual in need of treatment with a compatible HLA type obviates the significant problem of rejection reactions normally associated with heterologous cell transplants. Conventionally, rejection is prevented or reduced by the administration of immunosuppressants or anti-rejection drugs such as cyclosporine. However, such drugs have significant adverse side-effects, e.g., immunosuppression, carcinogenic properties, kidney toxicity as well as being very expensive. The present invention eliminates, or at least significantly reduces, the need for anti-rejection drugs, such as cyclosporine, imulan, FK-506, glucocorticoids, and rapamycin, and derivatives thereof.
[0099] With respect to the therapeutic methods of the invention, it is not intended that the administration of renal precursor cells or podocytes to a mammal be limited to a particular mode of administration, dosage, or frequency of dosing; the present invention contemplates all modes of administration, including intramuscular, intravenous, intrarticular, intralesional, subcutaneous, or any other route sufficient to provide a dose adequate to prevent or treat a disease. The renal precursor cells or podocytes may be administered to the mammal in a single dose or multiple doses. When multiple doses are administered, the doses may be separated from one another by, for example, one week, one month, one year, or ten years. One or more growth factors, hormones, interleukins, cytokines, small molecules or other cells may also be administered before, during, or after administration of the cells to further bias them towards a particular cell type.
[0100] As used herein the term “differentiating”, “differentiation” refers to one or more steps to convert a less-differentiated cell into a somatic cell, for example to convert a pluripotent stem cell into renal precursor cells or podocytes. Differentiation of a pluripotent stem cell to renal precursor cells or podocytes is achieved by the method described herein.
[0101] The term “stem cell” as used herein refers to a cell that has the ability for self-renewal. An “undifferentiated stem cell” as used herein refers to a stem cell that has the ability to differentiate into a diverse range of cell types. As used herein, “pluripotent stem cells” as used herein refers to a stem cell that can give rise to cells of multiple cell types. Pluripotent stem cells (PSCs) include human embryonic stem cells (hESCs) and human induced pluripotent stem cells (hiPSCs). Human induced pluripotent stem cells can be derived from reprogrammed somatic cells, e.g. by transduction of four defined factors (Sox2, Oct4, Klf4, c-Myc) by methods known in the art. The human somatic cells can be obtained from a healthy individual or from a patient. These donor cells can be easily obtained from any suitable source. Preferred herein are sources that allow isolation of donor cells without invasive procedures on the human body, for example human skin cells, blood cells or cells obtainable from urine samples. Although human pluripotent stem cells are preferred, the method is also applicable to non-human pluripotent stem cells, such as primate, rodent (e.g. rat, mouse, rabbit) and dog pluripotent stem cells.
[0102] As used herein, “renal precursor cells” or “cells in a metanephric mesenchyme renal precursor stage” are cells that differentiated into the metanephric mesenchyme stage and express at least the cellular marker SIX2, and in a preferred embodiment also the cellular markers SALL1 and WT1. Renal precursor cells as used herein are characterized by down-regulation of marker genes of the pluripotent stage and the intermediate mesoderm stage, like for example PAX 2, BRY and/or LIM1. These cells have the potential to differentiate into all renal cells, including the ability to give rise to podocytes.
[0103] As used herein “intermediate mesoderm cells” are cells that express one or more of the cellular markers BRY, LIM1 and PAX2 and which do not express SIX2, SALL1 and WT1, or only at a very low level.
[0104] As used herein “downregulation of a marker” refers to a decrease of an expression level of a marker gene and its gene product. The term can mean that the expression level of a certain marker gene and its gene product in one differentiation stage is decreased compared to another differentiation stage. “Downregulation of a marker” can also refer to a complete abolishment of the expression of a marker gene and its gene product in a cell, e.g. the expression of the marker gene and its gene product is not detectable any more.
[0105] As used herein “upregulation of a marker” refers to an increase of an expression level of a marker gene and its gene product. The term can mean that the expression level of a certain marker gene and its gene product in one differentiation stage is increased compared to another differentiation stage. “Upregulation of a marker” can also refer to a an increase of an expression of a marker gene and its gene product from no (detectable) expression to low, medium or high expression of a marker gene and its gene product.
[0106] “Expression of marker” means that a certain gene is transcribed into mRNA and usually is subsequently translated into a protein (its gene product) which exerts a certain function in a cell. The expression of a marker can be detected and quantified on the RNA level or on the protein level by methods known in the art. Preferred herein is the detection of the expression of a marker on the protein level, e.g. by testing for the presence of a certain protein with antibodies binding to the marker.
[0107] “Podocytes” are a type of cell located in the kidneys and also known as glomerular epithelial cells. Podocytes have a characteristic cell phenotype: They consist of a main body and thin extensions that branch out of it and possess characteristics like long processes, or “foot projections”. As used herein “podocytes” are cells that express at least the specific surface marker podocin and the expression of one or more further surface markers/cellular markers selected from the group of α-actinin-4, WT1, synaptopodin or nephrin. Preferred therein are mature podocytes, i.e. podocytes that do not express the marker PAX2.
[0108] Podocin is a glomerular protein which plays a role in the regulation of glomerular permeability, and acts as a linker between the plasma membrane and the cytoskeleton. It is encoded by NPHS2 (full name nephrosis 2, idiopathic, steroid-resistant (podocin), NCBI Gene ID 7827, also known as PDCN or SRN1).
[0109] Alpha actinins belong to the spectrin gene superfamily which represents a diverse group of cytoskeletal proteins, including the alpha and beta spectrins and dystrophins. Alpha actinin is an actin-binding protein with multiple roles in different cell types. In nonmuscle cells, the cytoskeletal isoform is found along microfilament bundles and adherens-type junctions, where it is involved in binding actin to the membrane. In contrast, skeletal, cardiac, and smooth muscle isoforms are localized to the Z-disc and analogous dense bodies, where they help anchor the myofibrillar actin filaments. This gene encodes a nonmuscle, alpha actinin isoform which is concentrated in the cytoplasm, and thought to be involved in metastatic processes. Mutations in this gene have been associated with focal and segmental glomerulosclerosis. α-actinin-4 is encoded by ACTN4 (full name actinin, alpha 4, NCBI Gene ID 81, also known as FSGS; FSGS1; ACTININ-4).
[0110] Synaptopodin is an actin-associated protein that may play a role in actin-based cell shape and motility. The name synaptopodin derives from the protein's associations with postsynaptic densities and dendritic spines and with renal podocytes. The protein is encoded by SYNPO (NCBI Gene ID 11346).
[0111] Nephrin is a member of the immunoglobulin family of cell adhesion molecules that functions in the glomerular filtration barrier in the kidney. The gene is primarily expressed in renal tissues, and the protein is a type-1 transmembrane protein found at the slit diaphragm of glomerular podocytes. The slit diaphragm is thought to function as an ultrafilter to exclude albumin and other plasma macromolecules in the formation of urine. It is encoded by Nphs1, also known as CNF, NPHN or nephrin (NCBI Gene ID 4868). Mutations in this gene result in Finnish-type congenital nephrosis 1, characterized by severe proteinuria and loss of the slit diaphragm and foot processes.
[0112] As used herein, “renal diseases” relates to any disease caused by injury, loss or dysfunction of renal cells. Examples for renal diseases are Chronic Kidney Disease (CKD), Focal segmental glomerulosclerosis (FSGS), Membranoproliferative glomerulonephritis, Polycystic kidney disease (PKD) and diabetic nephropathy associated with Diabetes Type-2. Further examples are acute kidney failure/acute kidney injury, Alport syndrome, angiotensin antibodies and focal segmental glomerulosclerosis, APOL1 mutations, CFHR5 nephropathy, Bartter syndrome, collapsing glomerulopathy, diabetes and diabetic kidney disease related to CMV, Fabry's disease, glomerular diseases, HIV-associated nephropathy (HIVAN), lipoprotein glomerulopathy, lupus kidney disease, lupus nephritis, membranoproliferative glomerulonephritis, nodular glomerulosclerosis, post-infectious glomerulonephritis, post-streptococcal glomerulonephritis.
REFERENCES
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Ok-Hee Chai, Chang-Ho Song, Sung-Kwang Park, Won Kim and Eui-Sic Cho (2013). Molecular regulation of kidney development. Anat Cell Biol. 2013 March; 46(1): 19-31.
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Lin, S. A., Kolle, G., Grimmond, S. M., Zhou, Q., Doust, E., Little, M. H., Aronow, B., Ricardo, S. D., Pera, M. F., Bertram, J. F., et al. (2010). Subfractionation of differentiating human embryonic stem cell populations allows the isolation of a mesodermal population enriched for intermediate mesoderm and putative renal progenitors. Stem cells and development 19, 1637-1648.
Mae, S., Shirasawa, S., Yoshie, S., Sato, F., Kanoh, Y., Ichikawa, H., Yokoyama, T., Yue, F., Tomotsune, D., and Sasaki, K. (2010). Combination of small molecules enhances differentiation of mouse embryonic stem cells into intermediate mesoderm through BMP7-positive cells. Biochemical and biophysical research communications 393, 877-882.
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Examples
Materials and Methods
[0129] CP21R7: 3-(3-Amino-phenyl)-4-(1-methyl-1H-indol-3-yl)-pyrrole-2,5-dione (also referred to as “compound 21” herein; see e.g. L. Gong et al; Bioorganic & Medicinal Chemistry Letters 20 (2010), 1693-1696).
[0000]
[0130] Cell Culture:
[0131] Pluripotency Medium: TeSR1 supplemented with Y27632 ROCK Kinase inhibitor (commercially available, e.g. Catalogue Number: 1254 from Tocris bioscience).
[0132] Priming Medium: 1:1 mixture of DMEM:F12 (1:1) plus GlutaMAX™ (Invitrogen) and Neurobasal media (N2B27 medium) with N2 and B27 supplements (all Invitrogen), with 1 μM CP21R7 (Roche) and 25 ng/ml BMP4 (Peprotech).
[0133] Induction Medium: DMEM:F12 plus GlutaMAX™ (Invitrogen) medium supplement with 2.5% FBS (Life technologies) 0.1 mM non essential amino acid mix (NEAA), 0.1 mM b-ME, 100 nM Retinoic Acid (Sigma) and 50 ng/ml BMP7 (Prepotech).
[0134] Podocytes Proliferation Medium: DMEM:F12 plus GlutaMAX™ (Invitrogen) supplemented with 10% FBS (Invitrogen), 0.1 mM Retinoic Acid (Sigma) and 100 nM Vitamin D3 (Sigma).
[0135] Human ESCs: SA001, LOT CA001 were isolated on Mar. 20, 2001 at Göteborg University and Cellartis AB Arvid Wallgrens Backe 20, SE-413 46 Göteborg, SWEDEN follows all applicable laws in Sweden and is approved by the Local Research Ethics Committees at Göteborg University and Uppsala University. Embryo source: Frozen, surplus from IVF. Donor confidentiality: In order to protect the privacy and the confidentiality of the donors, all identifiers associated with the embryo donors have been removed. Thus, no information about the donors is accessible. Notably, the donation did not result in any financial gain for the donors. We have the approval to work with hESCs and to derive different cell lines. The responsible ethical committee (Ethikkommission beider Basel) and the Federal office of public health have approved our research project. (Ref-No: R—FP-S-1-0002-0000).
[0136] Human iPSCs: Catalogue Number: SC101A-1 Lot. Number 110218-FF from SBI System Biosciences/Catalogue Number: A13777 from Life technologies Gibco® Episomal hiPSC Line.
[0137] Human pluripotent stem cells are routinely cultured on hESC-qualified Matrigel® (BD Bioscience) in TeSR1 medium (Stem cell Technologies). Cultures are passaged every 4-6 days using StemPro® Accutase® (Invitrogen). For an increased viability TeSR1 medium is supplemented with 10 μM ROCK-inhibitor one hour prior enzymatic dissociation.
[0000] 1. Method for Differentiation of Pluripotent Stem Cells into Podocytes
(i) Before the enzymatic dissociation of hPSC colonies using StemPro® Accutase® (Invitrogen) cells were preincubated for one hour with 10 μM ROCK-Inhibitor Y27632. 37.000 single hPSCs per cm′ were plated onto growth factor reduced Matrigel® (BD bioscience) coated cell culture plates in TeSR1 medium supplemented with 10 μM ROCK-30 Inhibitor.
(ii) On day 1 attachment medium was exchanged to N2B27 (Gibco) medium supplemented with 1 μM Compound 21 (CP21R7) and 25 ng/ml BMP4 (R&D Systems). Cells were cultivated for additional 3 days without media change.
(iii) On day 4 the priming medium was exchanged to DMEMF12 (Gibco) medium supplemented with 100 nM retinoic acid (Sigma, R2625) and 50 ng/ml BMP7 (Peprotech). Cells were cultivated for additional 2 days without media change.
(vi) On day 6 the cells were dissociated with Accutase® solution and plated on collagen I coated plates at a density of 40000-50000 cells/cm′ in DMEMF12 (Gibco) medium supplemented with 0.1 mM retinoic acid (Sigma, 82625) and 100 nM Vitamin D3 (Sigma) for another 7 days. The proliferation medium was changed every other day.
2. Immunocytochemistry Analysis and Image Based High Content Analysis (HCA) for Quantification
[0138] The cells were fixed with PBS containing 4% paraformaldehyde for 20 min at room temperature. After three washing with PBS the cells the cells were then blocked with 5% BSA solution (Blocking buffer) for 60 min. When probing for an intracellular antigen, 0.5% Triton-X was included in the blocking buffer. The samples were stained with the primary antibody diluted in 2% BSA solution overnight at 4° C., followed by incubation with the appropriated secondary antibody for 1 h at room temperature. Nuclei were stained by DAPI for 5 minutes at room temperature. Fluorescence was acquired and analyzed by the Operetta® High Content Imaging System (PerkinElmer) followed by computer-based image analysis (ImageJ, Java-based image processing program). Separate images from the same field were acquired using appropriate filters, and exported as jpg files.
[0000] Table with primary antibody used in the work. Antigen Origin Catalog Number Bry R&D System AF2085 PAX2 Invitrogen 716000 LIM1 Abeam Ab14554 SIX2 Proteintech 11562-1-AP WT1 R&D System AF5729 SALL1 R&D System PP-K9814-00 Actinin-4 Origene TA307264 Podocin Sigma-aldrich P0372 Synaptopodin Abeam Ab101883 ZO-1 Invitrogen 61-7300 P-cad R&D System MAB861 AQP1 Santa-Cruz sc-20810
3. Functional Characterization of iPSCs-Derived Podocytes Cells
[0139] In response to proinflammatory stimuli Podocytes express specific cytokines including IL-8, Rantes, MIP-1b and MCP1. Bio-Plex Pro™ Cytokine, Chemokine and Growth factor assay (Biorad, M50-0KCAF0Y). After overnight serum starvation hiPS derived podocytes were exposed at two different concentrations of TNFα (1 and 5 ng/ml) for 24 hours. After treatment the supernatants were collected and used to quantify the Cytokine, Chemokine and Growth factor release using Bio-Plex Pro™ Cytokine, Chemokine and Growth factor assay kit (Biorad, M50-0KCAF0Y). The assay was performed following the manufacturer's instruction. To determine whether the differentiation system generates bona fide Podocytes, we challenged the iPS-derived Podocytes with proinflammatory TNFα and analyzed for cytokine and chemokine release. Secretome analysis clearly showed an increase of the supernatant concentration of IL-8, Rantes, MIP-1b and MCP1 in a dose dependent manner, upon TNF-α treatment ( FIGS. 8 a , 8 b , 8 c and 8 d ) comparable to primary human podocytes (Saleem et al., JASN, 2002; data not shown).
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This application relates to a method for differentiating pluripotent stem cells (PSCs) into multi-competent renal precursor cells expressing Six2. These renal precursor cells are able to differentiate into fully functional and fully differentiated podocytes. Moreover this application relates to a method for differentiating human embryonic stem cells (ESCs) and induced pluripotent stem cells (iPSCs) into defined renal precursor cells expressing Six2 and podocytes based on linked steps of chemically defined medium inductions.
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The invention relates to a safety or pressure relief valve in particular for pipes conveying abrasive fluids under high pressure, such as the muds utilized for drilling oil or gas wells.
BACKGROUND OF THE INVENTION
Generally speaking, a safety or pressure relief valve comprises, on one hand, a hollow body closed by a plug defining a revolution volume formed from a relatively large central chamber and two relatively narrow opposed chambers and, on the other, a floating piston with its ends engaged in said chambers, one side of this piston being subjected to a reference thrust and the other to the pressure of the fluid to be controlled, the central chamber being in communication with the outside by a release hole.
Such a pressure relief valve is described in the German Pat. No. 1.083.096 (Eddelbutteb 1960) and the French Pat. No. 1.384.817 (SITA-1963).
Such valves suit the canalizations conveying non abrasive fluids subjected to medium pressure.
In the case of high pressure abrasive fluids (mud or cement, of the oil industry, under 700 bars, for example), at the moment the pressure to be controlled undergoes a sudden increase and generates, on the control end of the piston, a force greater than the reference thrust force applied to the other end, the fluid under control escapes at great speed all around the control end of the piston and its pressure drops immediately by lamination.
Due to the solid particles carried at great speed by the fluid, the edges of the chamber under control and those of the concerned end of the piston are rapidly eroded, with the result that, after a small number of discharges, a loss of sealing capacity is produced, at this level, which renders the valve unusable as is and requires it to be repaired.
SUMMARY OF THE INVENTION
The primary object of the invention is to remedy this major fault in the pressure relief valves currently available.
A second object of the invention relates to complementary means enabling the valve to be opened at an increased speed whilst preventing the valve from vibrating.
According to the invention, in a pressure relief valve as described above, the opposing chambers having identical diameters, the floating piston comprises a cylindrical box having a bottom and a wall, said box being arranged to slide in the central chamber of the valve, at least one longitudinal hole being pierced in said bottom and at least one radial hole pierced in said wall, so that, in a closed position of the valve the box's wall closes the discharge hole in a sealed manner and the piston closes the chamber under control in a non-sealed manner and, in an open position of the valve, the piston is clear of the control chamber and the radial hole is placed opposite the release hole.
According to a complementary characteristic of the invention, the box's wall comprises narrow channels connected to the radial hole, said channels being adapted to slide without damage over a seal associated with the release hole, during the initial opening movement of the piston.
Owing to this arrangement, the two basic functions of a pressure relief valve, which have until now been fulfilled by the same components, are separated from each other and assumed by two different components, each being specially adapted to its specific function.
As a result, the first of these functions, namely: to establish a seal in the closed position of the valve between the chamber under control and the release hole, is ensured by the box's wall in co-operation with the seals associated with this hole; whilst the second function, namely: to produce a pressure drop by lamination between this chamber and this hole when the valve starts to open, continues to be assured by the end of the piston engaged, in a non-sealing manner, in the chamber subjected to the pressure of the fluid to be controlled.
The particular adaptation of the sliding box for the repetition of the valve's first function results from the presence of narrow channels (longitudinal slots, for example,) connected to the radial hole. These channels first provide a quick decompression of the central chamber as soon as the sliding box starts its opening movement and, secondly they slide without damage on a seal which has just been released from its sealing function. From this the entire pressure loss by lamination between the chamber under control and the release hole is shifted to the space between this chamber and the concerned end of the piston. Under these conditions, as the end of the piston engaged in the chamber under control does not have to establish a seal, it is possible, by means of a hard metal sleeve placed at the chamber's inlet and a hard metal cap placed at the end of the piston, to obtain an efficient resistance to abrasion for these two components. Until now, this was not possible since these same components had moreover to establish the full sealing of the chamber under control, which is the object of the first function of the valve.
According to a second complementary characteristic of the invention, a stud mounted fixed in the valve is adapted to progressively close the longitudinal hole pierced in the box's wall when the box finishes its opening movement.
Owing to this arrangement, the opening movement of the box starts with a rapidly increasing speed and finishes with a progressively decreasing speed, which has the effect of suppressing the rebound of the piston at the end of the box's opening, while making possible a rapid opening start.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the invention will be apparent in more precise a manner after the following description in the form of a non-limiting example, with reference to the appended drawings in which:
FIGS. 1A and 1B are a first form of implementation of the pressure relief valve constructed according to the invention, in opened and closed positions;
FIG. 2 is a sectional plan view along line II of the valve as shown in FIG. 1.
FIG. 3 is a second implementation form of the valve according to the invention, in a closed postion.
FIG. 4 shows a valve according to the invention, used to control high pressure flows.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to FIGS. 1A and 1B, the valve according to the invention includes a hollow cylindrical body 10 closed by a screw plug 12 equipped with an O-ring seal 14. The body 10 houses a revolution volume formed by a relatively large central chamber 16 and by a relatively narrow chamber under control 18, to which is opposed a reference chamber 20, of the same diameter, fitted in the plug 12. The body 10 further comprises a threaded coupling 22, crossed by the chamber under control 18 and adapted to be fixed on the fluid pipe under pressure, to be controlled.
At mid-height in the central chamber 16, pierced in the body's wall 10, are two diametrically opposed release holes 24, the insides of these holes being slanted and their outsides machined into tapered threads.
The body 10 and the plug 12 enclose a floating piston 26 whose cylindrical ends 28 and 30 are adapted to be engaged respectively in the chamber under control 18 with a very slight, but not zero, clearance and in the reference chamber 20, in an sealed manner owing to the presence of an O-ring seal 32.
The piston 26 comprises a cylindrical box 34, in its median portion, formed by a bottom 36 and a wall 38, adapted to slide in the central chamber 16. When the valve is in a closed position, (FIG. 1A) the edge of the wall 38 of the box 34 is close to the base of the central chamber 16, contiguous with the chamber under control 18 and the end 28 of the piston 26 is engaged in said chamber 18. When the valve is in an open position (FIG. 1B) the bottom 36 of the box 34 bears on the base of the central chamber 16 contiguous with the reference chamber 20 and the end 28 of the piston 26 is entirely disengaged from the control chamber 18. In the closed position of the valve, the end 30 of the piston 26 is slightly engaged beyond the seal 32 and, in the open position, more deeply engaged.
The wall 38 of the box 34 works in co-operation with two seals 40 and 42, lodged in two grooves cut into the wall of the central chamber 16, so that, in its closed position, the central chamber 16 and the release holes 24 are totally isolated from each other.
Two diametrically opposed logitudinal holes 44 are pierced in the bottom 36 of the box 34 and, in the vicinity of the edge of the wall 38 of the box 34, two radial holes 48 are pierced to face each other, the external edges of these radial holes being slanted. Furthermore, as is apparent on FIG. 2, a ring 52 of narrow longitudinal slots (3 to 4 tenths of a millimeter wide) directly or indirectly connected to the radial holes 48, is fitted in the wall 38 of the box 34 and their length is determined so that, in a closed position, this ring of slots 52 does not reach the edge of the groove in which the seal 40 is lodged.
In the base of the central chamber 16 contiguous with the reference chamber 20, two conical studs such as 54 are fixed, these studs being adapted to progressively seal the longitudinal holes 44 of the bottom 36 of the box 34, as this box finishes opening.
In the reference chamber 20 the reference end of a piston 58 is also engaged, coming to bear on the end 30 of the floating piston 26. The reference piston 58 comprises a shoulder 60 adapted to bear on the outside of the plug 12 when the valve is in its closed position. The plug 12 comprises an annular groove whose external wall 62 is threaded to the interior and exterior. Inside this annular groove is set an elastic metal sleeve comprising, on one hand, a collar 64 fitted with a bearing flange 65 and, on the other, a multiplicity of elastic blades 66 separated from each other by a longitudinal slot, each blade being finished by a locking hook 67. This sleeve is held fixed in its groove by means of an annular screw 68 screwed into the external wall 62 of this groove, the height of the screw 68 determining the stiffness of the elastic blades 66 of the sleeve. The hooks of these blades 66 bear on a ramp 69 fitted onto the shoulder 60 of the piston 58.
A helicoidal spring 70 is mounted to be compressed between the shoulder 60 of the piston 58 and a circular bearing plate 72. This plate 72 is pierced by a central hole crossed by the second end of the piston 58 and held by the internal ledge 74 of a protection cylinder 76 screwed to lock on the outside of the plug 12.
In the vicinity of the base of the central chamber 16, the wall of the valve body 10 comprises two holes 78 and 80 fitted with detachable plugs. These holes enable the central chamber 16 to be emptied and filled with clean oil after each opening of the valve.
According to FIG. 3, the reference end 30 of the control piston 26 emerges into a reference chamber 20 to be filled with oil under pressure, a filling hole 80 having been planned to this effect. In the chamber 20 slides a floating piston 82 equipped with a seal 84. The head 86 of the piston 82 has a section several times greater (5 times, for example) than the base of this piston engaged in the chamber 20. the head 86 of the piston 82 slides in such a way as to create a seal, in an auxiliary chamber 88, filled with a gas under adjustable pressure by means of a control tap 89. The space 90 allowed between the head 86 of the piston 82 and the external edge of the plug 12 emerges by a passage 92 cut into the wall of the chamber 88.
According to FIG. 4, the floating piston 26 comprises an axial passage 100 emerging, at its end 30, into a transversal passage 102, the end 30 otherwise comprising at least one external longitudinal groove 104. At the end 30 of the piston 26 is a manual push rod 106 crossing the refernce chamber 20 by the cap 108 of this chamber 20 screwed on the plug 12.
The valve according to the invention being connected with a pipes in which abrasive fluid under very high pressure circulates, this high pressure is constantly applied to the chamber under control 18. When this high pressure generates a thrust on the end 28 of the control piston 26 lower than the reference thrust to which the other end 30 of this piston is subjected, the valve is closed. In this case, the central chamber 16 previously filled with clean oil is subjected to the pressure of the fluid to be controlled since no sealing is assured around the end 28 of the control piston 26 engaged in the control chamber central chamber 16 and the seals 40 and 42 set out on both sides of the release holes 24 in cooperation with the box 34 totally isolate the chamber 16 and the holes 24. In this closed position of the valve, the shoulder 60 of the reference piston 58 is blocked against the outside of the plug 12, the reference thrust to which is thereby subjected the control piston 26 is the force capable to move the shoulder 60.
In the present case, this detaching force is determined, on one hand, by the force maintaining the hooks 67 of the elastic blades 66 in a locked position on the ramp 69 of the shoulder 60 and, on the other hand, by the compression force of the helicoidal spring 70.
By way of example, let us suppose that the pressure of adjustment of the valve being 500 bars, a maintaining force corresponding to a pressure of 300 bars applied to the end 30 of the control piston 26 is developed by the calibrated hooks 67, the remaining adjustment pressure (200 bars) corresponding to the initial compression force of the spring 70.
The moment a sudden overpressure is produced, in the piping of fluid to be controlled, which is greater (for example, 100 bars) than the adjustment pressure of the valve, a force greater than the reference thrust is applied to the end 28 of the control piston 26 engaged in the chamber under control 18. Some abrasive fluid under excessive pressure thus penetrates into the central chamber 16 escaping all around the end 28 of the piston 26. The piston 26 is therefore subjected to an acceleration proportional to the difference in the forces applied to its two ends, whilst a relatively slow movement and small displacement of the piston 26 result. During this short time interval, the circulation of the abrasive fluid around the end 28 of the piston 26 and along the edge of the chamber under control 18, does not bring about detrimental erosion due to the very slight clearance (hundredths of a millimeter, for example) in which this circulation is established, which produces only a slight flow.
With great rapidity, this small displacement is sufficient to cause the ring of longitudinal slots 52, cut in the wall 38 of the box 34 of the piston 26, to engage progressively above the seal 40. As the total passage section of these slots is, by construction, far greater (by at least ten times) than the existing passage section between the end 28 of the piston 26 and the wall of the chamber under control 18, the move of these slots above the seal 40 has the effect of abruptly decompressing the oil contained in the central chamber 16, the pressure drop then being immediately referred to the area around the end 28 of the piston 26. Before and during this decompression, the ring of longitudinal slots slides, without damage, on the seal 40, as a result no perceptible deformation is produced along these particularly narrow slots (3 to 4 tenths of a millimeter) which pass progressively above a seal which is no longer required to fulfill its sealing function. Equally rapidly, this small displacement has the effect of making the hooks 67 of the blades 66 slide on the ramp 69 and of abruptly reducing the adjustment pressure of the valve by 300 bars. The control piston 26 then undergoes a sudden acceleration which causes it to rapidly pick up speed until the radial hole 48, cut in the box's wall 34, begins to be opposite the release hole 24. As this rapid displacement progresses, the clean oil contained in the central chamber 16 on the side of the reference chamber 20 flows out without particular difficulty (the ends 28 and 30 of the piston 26 have the same diameter) through the longitudinal holes cut through the bottom of the box 34. Consequently, the radial hole 48 can arrive, in a few milliseconds, at the point where it is almost entirely opposite the release hole 24. The overpressure to which the chamber under control 18 was subjected the preceeding instant disappears progressively as the oil initially contained in the central chamber 16 and, in case of need, a certain quantity of abrasive fluid, escape through the release hole 24.
The movement of the box 34 does not lessen, for all that, until the conical studs 54 begin to engage in the holes 44 in the bottom of the box 34. From this moment, the movement of the box 34 is strongly decelerated by the lamination of the oil in these holes 44 which are progressively sealed, and no vibration of piston 26 can be generated. When the movement of the box 34 is stopped and the pressure of the fluid in the pipes to be controlled has descended below the adjustment pressure corresponding to the force produced by the spring 70 at that moment, the control piston 26 and the box 34 begin a return movement and the valve, according to the invention, progressively takes up its closed position again, the hooks 67 engaged on the ramp 69.
Owing to the fact that the overpressure thus compensated by the valve is the consequence of an unfortunate accident, the operator will decide to stop the injection system of the abrasive fluid (mud or cement, for example) and will immediately try to master the cause of this accident. At this juncture, he will empty the central chamber 16 of the mud and cement contained in it, by circulating the clean oil via the previously opened apertures 78 and 80. Then he will again close these aperture. The pressure relief valve, according to the invention, is thus again ready for service.
The invention is not, of course, limited to the form of the construction described above. Numerous modifications may be made without departing from the spirit of the invention.
One of these modifications, as illustrated in FIG. 3, consists of replacing the reference piston 58, the spring 70 and the elastic blades 66, by a variable pressure hydraulic accumulator. Such an accumulator is known in the art. In the reference chamber 20, filled with oil, the pressure produced by the narrow base of the piston 82 is much higher than the adjustable pneumatic pressure applied to the large head 86 of said piston. the operation of a safety valve so modified is similar to that of the valve on FIG. 1. It has the advantage of having an adjustable reference pressure and the drawback of a somewhat less rapid opening.
It is worth noting that it is easy, as illustrated on FIG. 4, to transform the pressure relief valve, so modified, into a regulating valve without reaction. To do this, the reference chamber 20 is in direct communication with the fluid to be controlled through the passages 100, 102 and 104 pierced in the control piston 26. By means of a control rod 106 passing through the base of the reference chamber 20, it is easy to displace the control piston 26 in such a way as to obtain, smoothly, a more or less significant opening of the valve thus constructed, whatever the value of the concerned fluid's pressure. As a matter of fact, according to the relative position of the piston end 28 and the edge of the chamber 18, an adjustable pressure drop is generated, so that the pressure in chamber 18 is controlled.
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Constructed in a cylindrical body (10) are a central chamber (16) fitted with a release hole (24) and two opposing chambers (18, 20). The ends of a floating piston (26) are engaged in these opposed chambers and subjected to both the pressure to be controlled and a reference pressure. A cylindrical box (34) integral to the piston (26) slides in the central chamber (16). In the closed position, the box (34) closes the release hole (24) to form a seal and the piston (26) closes the chamber under control (18) without forming a sealed closure. In the open position, a radial hole (48) cut in the wall of the box (34) is opposite the release hole (24). A decompression of the central chamber (16) is obtained as the valve starts to open (narrow channels 52) and a deceleration of the box (34) is obtained at the end of this opening (hole 44 and stud 54). Applications: Pressure relief valve for the oil industry, reactionless valve, pressure control nozzle.
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FIELD
[0001] The present disclosure relates to engine diagnostic systems, and more specifically to intake air temperature sensor diagnostic systems.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Internal combustion engines combust a fuel and air mixture to produce drive torque. More specifically, air is drawn into the engine through a throttle. The air is mixed with fuel and the air and fuel mixture is compressed within a cylinder using a piston. The air and fuel mixture is combusted within the cylinder to reciprocally drive the piston within the cylinder, which in turn rotationally drives a crankshaft of the engine.
[0004] Engine operation is regulated based on several parameters including, but not limited to, intake air temperature (IAT), manifold absolute pressure (MAP), throttle position (TPS), engine RPM and barometric pressure (P BARO ). With specific reference to the throttle, the state parameters (e.g., air temperature and pressure) before the throttle may be used for engine control and diagnostic systems. Traditional internal combustion engines include an IAT sensor that directly measures the IAT. In some instances, however, the IAT sensor can become inaccurate as a result of damage, wear and/or a number of other factors. Accordingly, the IAT sensor should be monitored to determine whether the IAT that is determined based on the IAT sensor reading is accurate.
[0005] Traditional internal combustion engine systems may additionally include a second IAT sensor, the reading from which is compared to that of the first IAT sensor in order to determine whether the first IAT sensor is accurate. This additional IAT sensor increases cost and complexity and itself must be monitored for accuracy.
SUMMARY
[0006] A method of evaluating intake air temperature (IAT) sensor rationality may include measuring a first intake air temperature associated with an engine using an IAT sensor when the engine is in a non-operating condition, determining a second intake air temperature associated with the engine using a hot wire air flow meter when the engine is in the non-operating condition, and indicating an IAT sensor fault when a difference between the first and second intake air temperatures exceeds a predetermined temperature limit.
[0007] The method may further include determining a mass air flow (MAF) rate into an engine during operation thereof using the hot wire air flow meter.
[0008] A control module may include an intake air temperature (IAT) sensor temperature determination module, a mass air flow (MAF) sensor temperature determination module, an intake temperature evaluation module, and an IAT sensor fault determination module. The IAT sensor temperature determination module may determine a first intake air temperature measurement associated with an engine using an IAT sensor when the engine is in a non-operating condition. The MAF sensor temperature determination module may determine a second intake air temperature associated with the engine using a hot wire air flow sensor when the engine is in a non-operating condition. The intake temperature evaluation module may be in communication with the IAT sensor temperature determination module and the MAF sensor temperature determination module and may determine a difference between the first and second intake air temperatures. The IAT sensor fault determination module may be in communication with the intake temperature evaluation module and may indicate an IAT sensor fault when the difference exceeds a predetermined temperature limit.
[0009] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0010] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0011] FIG. 1 is a schematic illustration of a vehicle according to the present disclosure;
[0012] FIG. 2 is a control block diagram of the control module shown in FIG. 1 ; and
[0013] FIG. 3 is a flow diagram illustrating steps for control of the vehicle of FIG. 1 .
DETAILED DESCRIPTION
[0014] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term “module” refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
[0015] Referring to FIG. 1 , a vehicle 10 may include an engine assembly 12 and a control module 14 . Engine assembly 12 may include an engine 16 , an intake system 18 , an exhaust system 20 , and a fuel system 22 . Intake system 18 may be in communication with engine 16 and may include an intake manifold 24 , a throttle 26 , and an electronic throttle control (ETC) 28 . ETC 28 may actuate throttle 26 to control an air flow into engine 16 . Exhaust system 20 may be in communication with engine 16 and may include an exhaust manifold 30 . Fuel system 22 may provide fuel to engine 16 . Exhaust gas created by combustion of the air/fuel mixture may exit engine 16 through exhaust system 20 .
[0016] Control module 14 may be in communication with fuel system 22 , ETC 28 , an intake air temperature (IAT) sensor 32 , a mass air flow (MAF) sensor 34 , and a manifold absolute pressure (MAP) sensor 36 . IAT sensor 32 may provide a signal to control module 14 indicative of an intake air temperature, MAF sensor 34 may provide a signal to control module 14 indicative of a mass air flow into engine 16 , and MAP sensor 36 may provide a signal to control module 14 indicative of a manifold absolute pressure. The signal provided by MAF sensor 34 may additionally be used to determine an intake air temperature.
[0017] MAF sensor 34 may be a hot wire balanced bridge air flow sensor commonly used for MAF sensor applications. MAF sensor 34 may include a wheatstone thermocouple bridge 38 positioned in the intake air flow path provided to intake manifold 24 and may include a first side having a heated sensing element and calibration resistors and a second side having an air temperature sensitive resistor and calibration resistors.
[0018] The heated element may be in the form of a wire or a film. A voltage may be applied to the heated element to maintain a predetermined temperature and balance the bridge 38 . As air flow across the heated element increases, the electric power required to maintain the predetermined temperature increases. As air flow across the bridge decreases, the electric power required to maintain the predetermined temperature decreases. The voltage across bridge 38 , therefore, provides an indication of the mass flow rate of air across bridge 38 . The temperature sensitive resistor may compensate the air flow determination based on an ambient air temperature.
[0019] The bridge output voltage may be converted to a pulse modulated signal which may be sent to control module 14 . The frequency of the pulse modulated signal may be interpreted by control module 14 as an air flow value. The frequency may additionally be used to determine an air temperature.
[0020] More specifically, when engine 16 is in a non-operating condition, there may be generally zero flow into engine 16 through intake manifold 24 . As such, there is generally no flow across MAF sensor 34 , and therefore bridge 38 . During this no-flow condition, the heat from the heated element is dissipated into the air surrounding the heated element in intake system 18 . In this no-flow condition, bridge 38 outputs a low voltage and is balanced mainly based on the temperature of the surrounding air in intake system 18 .
[0021] During this no-flow condition, a generally linear relationship may exist between the frequency provided by the bridge output voltage and the temperature of the surrounding air in intake system 18 . More specifically, the frequency provided by the bridge output voltage may be inversely proportional to the air temperature in intake system 18 . It is understood that MAF sensor 34 may alternatively provide a frequency that is directly proportional to the air temperature in intake system 18 .
[0022] Referring to FIG. 2 , control module 14 may include an engine-off evaluation module 40 , an IAT sensor temperature determination module 42 , a MAF sensor temperature determination module 44 , an intake temperature evaluation module 46 , and an IAT sensor fault determination module 48 . Engine-off evaluation module 40 may determine when engine 16 is in a non-operating state and may determine an elapsed time of the non-operating state. Engine-off evaluation module 40 may be in communication with IAT sensor temperature determination module 42 and MAF sensor temperature determination module 44 and may provide the elapsed time of the non-operating state of engine 16 thereto.
[0023] IAT sensor temperature determination module 42 may determine the temperature (T IAT ) of air in intake system 18 provided by IAT sensor 32 . IAT sensor temperature determination module 42 may be in communication with intake temperature evaluation module 46 and may provide T IAT thereto. MAF sensor temperature determination module 44 may determine the temperature (T MAF ) of air in intake system 18 based on the frequency of the signal provided by MAF sensor 34 . MAF sensor temperature determination module 44 may include a look-up table and/or a function to convert the frequency to a temperature. MAF sensor temperature determination module 44 may be in communication with intake temperature evaluation module 46 and may provide T MAF thereto.
[0024] Intake temperature evaluation module 46 may determine a temperature difference (ΔT) between T IAT and T MAF (ΔT IAT −T MAF |). Intake temperature evaluation module 46 may be in communication with IAT sensor fault determination module 48 and may provide ΔT thereto. IAT sensor fault determination module 48 may determine whether ΔT exceeds a predetermined limit and may indicate an IAT sensor fault when ΔT exceeds the predetermined limit.
[0025] With reference to FIG. 3 , control logic 100 generally illustrates operation of an IAT sensor diagnostic system. Control logic 100 may begin at block 102 where an engine operating state may be evaluated by engine-off evaluation module 40 . If engine 16 is in an operating state, control logic 100 may return to block 102 . If engine 16 is in a non-operating state, control logic 100 may proceed to block 104 .
[0026] Block 104 may include evaluation of an elapsed time that engine 16 has been in the non-operating state by engine-off evaluation module 40 . If engine 16 has been in the non-operating state for a time less than or equal to a predetermined time limit, control logic 100 may return to block 102 . If engine 16 has been in the non-operating state for a time period greater than the predetermined time limit, control logic 100 may proceed to block 106 . The predetermined time limit may generally correspond to a time after engine shutdown sufficient to provide a steady state condition within intake system 18 . For example, the predetermined time limit may include a time period of greater than 15 minutes after engine shutdown.
[0027] Block 106 may determine T IAT with IAT sensor temperature determination module 42 . Control logic 100 may then proceed to block 108 where T MAF is determined using MAF sensor temperature determination module 44 . Control logic 100 may then proceed to block 110 where difference (ΔT) between T IAT and T MAF is determined by intake temperature evaluation module 46 . Control logic 100 may then proceed to block 112 where ΔT is evaluated by IAT sensor fault determination module 48 .
[0028] Block 112 may compare ΔT to a predetermined temperature limit. If ΔT is less than or equal to the predetermined temperature limit, control logic 100 may terminate. If ΔT is greater than the predetermined temperature limit, control logic 100 may proceed to block 114 where an IAT sensor fault condition may be indicated. Control logic 100 may then terminate.
[0029] Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without departing from the spirit and scope of the disclosure as defined in the following claims.
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A method of evaluating intake air temperature (IAT) sensor rationality may include measuring a first intake air temperature associated with an engine using an IAT sensor when the engine is in a non-operating condition, determining a second intake air temperature associated with the engine using a hot wire air flow meter when the engine is in the non-operating condition, and indicating an IAT sensor fault when a difference between the first and second intake air temperatures exceeds a predetermined temperature limit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of U.S. patent application Ser. No. 10/384,110 filed on Mar. 7, 2003.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
FIELD OF THE INVENTION
[0003] The present invention relates generally to an epiluminescence device used in dermoscopy. More particularly, the invention comprises an improved apparatus for illuminating the skin for medical examination by providing cross-polarized and parallel-polarized light to aid in viewing internal structures as well as the skin surface.
BACKGROUND OF THE INVENTION
[0004] Dermoscopy is the term used to describe methods of imaging skin lesions. Skin is the largest organ in the body and it is the most easily accessible organ for external optical imaging. For early detection of cancers, it is important that the skin be medically examined for lesions.
[0005] With over forty (40%) percent of the cancers occurring on the skin (American Cancer Society Statistics 2001, Perelman 1995), and incidence of skin cancer increasing each year, tools and methods of imaging skin lesions are becoming increasingly important. Most of the cancers detected on the skin are Basal Cell Carcinoma (BCC) and Squamous Cell Carcinoma (SSC), which are differentiated from melanoma, a more deadly form of skin cancer. The early detection of skin cancer allows for inexpensive treatment before the cancer causes more severe medical conditions. Thus, there is a great need in the art for simple inexpensive instruments that allow for the early screening for skin cancer.
[0006] Because skin is partially translucent, dermoscopy utilizes tools for visualization of the pigmentation of the skin below the surface. In this regard, when attempting to visualize the deeper structure of the skin, it is important to reduce the reflection of light from the skin which may obscure the underlying structures. Methods used to reduce the surface reflection from the skin are referred to as epiluminescence imaging. There are three known methods for epiluminescence imaging of the skin, oil-immersion, cross-polarization, and side-transillumination. Oil-immersion and cross-polarization methods have been extensively validated for early skin cancer detection while side transillumination methods are currently undergoing study and clinical validation.
[0007] Oil-immersion devices are generally referred to as Dermatoscopes. Dermatoscopes permit increased visualization of sub surface pigmentation by using a magnification device in association with a light source. In operation, oil is placed between the skin and a glass faceplate. The placement of oil and a glass interface between the eye and the surface of the skin reduces the reflected light from the skin, resulting in deeper visualization of the underlying skin structure.
[0008] While oil-immersion has proved to be an excellent method of epiluminescence imaging of the skin, demonstrating improved sensitivity for melanoma detection, it is messy and time consuming for the physician. As a result, the Dermatoscope is used mostly by physicians that specialize in pigmented lesions and for evaluation of suspicious lesions that cannot be diagnosed visually. Also, the oil-immersion of the Dermatoscope has been found to be less effective for BCC and SCC imaging. The pressure created by the compression of the glass faceplate causes blanching of blood vessels in the skin resulting in reduced capability of the Dermatoscope for imaging the telangiectesia that is often associated with BCC or other malignent lesions.
[0009] Cross-polarization or orthogonal polarization is another method of reducing the reflection of the light from the surface of the skin to aid in the medical examination of the skin. Light emanating from a light source is first linearly polarized, so that the orientation of the light falling on the skin surface is in the same plane of polarization. As the light enters the skin, its polarization angle changes such that the light is reflected from a deeper structure. However, the light reflected from the surface of the skin is still polarized in the same plane as the incident light. By including a second polarizer in the path of the reflected light from the skin, a selective filtering of light can be achieved.
[0010] Most of the light directed to the skin's surface is reflected as the refractive index of skin is higher than that of air. The reflection of light, off of the skin, is analogous to the reflection of light off of the surface of water. Accordingly, the information received by the eye carries mostly information about the contour of the skin surface rather than the deeper structures. Remaining light enters the skin and is absorbed or is reflected back in a scattered fashion. By polarizing the incident light with a second of polarizer, the specular component of the reflected light is blocked by the viewing polarizer, thus producing an enhanced view below the skin surface. Accordingly, inflammation, color, pigmentation, hair follicles and blood vessels may be viewed.
[0011] When the incident light and the second polarizer are parallel, the surface topography and properties of the skin are highlighted and enhanced. In this regard, if the polarizer in the path of the light from the skin to the eye is polarized in the same orientation of the incident light, only the light from its polarization angle will be allowed to pass through the lens. Cross-polarization imaging of the body was originally described by R. R. Anderson (“Polarized light examination and photography of the skin.” Archives Dermatology 1991; 127; 1000-1005). Later, Binder introduced the MoleMax manufactured by Derma Instruments (Vienna, Austria) for the examination and mapping of pigmented lesions. Binder further developed the no-oil cross-polarization epiluminescence method. MoleMax, however, while validating clinically the improved diagnosis and accuracy without the use of oil, still used a glass faceplate and video imaging system to execute skin examinations.
[0012] In light of many of the difficulties associated with prior dermoscopy systems, a simple and cost-effective diagnostic systems remained unavailable for general dermatologists to use on a routine clinical basis. Dermoscopy, until recently, remained generally a research tool utilized in special clinical cases.
[0013] More recently, however, a substantial advancement in skin cancer detection occurred through a simple device identified as DermLite®, manufactured and marketed by 3Gen, LLC. of Monarch Beach, Calif. With this low cost and easy to use DermLite® Device, screening for cancer by dermatologists in routine clinical examination of skin disease has become a reality. The DermLite® device uses cross-polarization epiluminescence imaging through use of white light emitting diodes (LEDs), a high magnification lens (10×), and a lithium ion battery contained in a small lightweight device.
[0014] In the DermLite® device, a window is incorporated into a compact housing, and a plurality of white light LEDs encircle a magnifying lens. The DermLite® device incorporates cross-polarization filters that reduce the reflection of light from the surface of the skin and permits visualization of the deeper skin structures. Light from eight (8) LEDs is polarized linearly by a polarizer, which is annular in shape and located in front of the LEDs. The imaging viewed through the magnifying lens is also linearly polarized by using a polarizer that is located in front of the lens. The LEDs have a narrow beam angle that concentrates the light into a small area, pointing the incident light to the center to increase the brightness of the area being viewed. Thus, light from the LEDs passes through the polarizer which enters the skin and reflects back through the viewing polarizer to create cross-polarization allowing examination to look deeper within the skin structure. Although, the DermLite® product has been recognized as a major advancement in the art of routing clinical diagnosis and analysis of skin cancer lesions, DermLite® device does not provide a mechanism for enabling the user to additionally view parallel-polarized light, or a combination of cross-polarized light and parallel-polarized light.
[0015] The DermLite® Platinum® product, also manufactured by 3Gen, LLC. was developed to provide variable polarization. Variable polarization is achieved by a rotating dial. Rotation of the polarizer to a cross-polarization cancels out the surface reflection for an in-depth look at the deeper pigmentation in lesion structure. Rotation to parallel polarization allows a clear view of the skin surface. The DermLite® Platinum® product requires manual manipulation of the dial which may cause user to lose the viewing spot, or otherwise interfere with examination. Further, DermLite Platinum® does not provide a user the ability to view the skin with an instantaneous switch over from cross-polarization to parallel polarization.
[0016] Recent discoveries in optical fluorescence imaging have identified several molecules having fluorescence properties that are useful in medicine. In dermatology, simple applications such as delta-aminolaevulinic acid (ALA) applied topically have been found to enhance the visualization of basal cell cancer from normal tissue, when illuminated with UV/Blue light. Fluorescein is another fluorescent compound that has been in clinical use in opthamology for several years and has great potential for use in dermatological applications. Indocyanine green (ICG), Methylene Blue, and ethyl nile blue are contrast agents that are used to increase light absorption in blood vessels. There are several FDA approved optical fluorescence tracers already approved for clinical use, and several more new probes may be applicable in the future. However, the use of fluorescence imaging of the skin has been illusive for clinical dermatologist because of the complexity and costs of the associated equipment.
[0017] In current applications, such as in the application of ALA topically to a basal cell carcinoma to a BCC, conventional white light visual images of the BCC are displayed next to the fluorescence excited images of ALA in the BCC. The ALA is taken up by the active areas of cancer, converted to porphyrin IX, and fluoresces when exposed to UV/Blue light. It becomes apparent that the fluorescent areas of the BCC may not coincide with the anatomical features of the BCC as shown in white light. Currently the side-by-side comparison is only available by taking two separate images and co-registering these images later in the computer.
[0018] Thus, there is a great need in the art for a device that will allow clinical viewing of skin lesions which provides on demand switching from cross-polarized imaging to parallel-polarized imaging and a combination of both. Further there is a great need in the art for a clinical viewing of skin lesions that can toggle back and forth from a white light to a colored or UV light in order to contrast and compare images.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention relates to a dermoscopy epiluminescence device used in the medical diagnosis of skin lesions. The device is a hand held modular housing incorporating a magnification lens and associated lighting scheme for examining the epidermis on humans. The light sources of the lighting scheme are powered by an on board lithium battery and are controlled by a three way switch which provides on demand cross-polarized, parallel-polarized and a combination thereof for epiluminescence.
[0020] More particularly, a first embodiment of the present invention comprises a generally circular optical lens incorporated into the housing of the device. The lens produces a magnified image of the skin to be observed by a viewer. In the first embodiment the lens is a 15 mm diameter Hastings lens with a 10× optical gain. The viewer observes the magnified skin through the lens window of the housing. The viewing is aided by a plurality of luminous diodes positioned within the housing and about the circumference of the lens. The diodes direct light upon the skin to be viewed. The LEDs are white high light output Indium Gallium Nitride LEDs. Two light circuits form first and second illumination sources forming a ring of alternating diodes about the lens. A switch is provided that when not in operation has a normal OFF mode. In operation the switch has a first ON mode for initiating the first illumination source (i.e. every other diode on the first light circuit), a second ON mode for initiating the second illumination source (i.e. every other diode on the second light circuit) and a third ON mode for initiating both said first and second illumination sources simultaneously (i.e. all diodes).
[0021] A first polarizer filter comprises a planar annular ring defining a generally circular center opening and an outer ring. The center opening of the annular ring of the first polarizer is positioned in alignment with the circular optical lens to provide an unobstructed view of the skin through the lens and the housing. The outer ring of the first polarizer includes a plurality of openings sized and positioned to correspond to the diodes of the second illumination source (i.e. every other diode of the second light circuit) such that light emitted from the diodes of the second illumination source passes through the openings unfiltered by the first polarizer. Because there are no corresponding openings for the diodes of the first illumination source (i.e. every other diode on the first light circuit) light emitted from first source diodes is polarized by the outer ring of the first polarizer filter.
[0022] A second polarizer filter comprises a planar annular ring defining a generally circular center opening and an outer ring. The center opening of said annular ring of the second polarizer is positioned in alignment with the circular optical lens to provide an unobstructed view of the skin through the lens and housing. The second polarizer is 90 degrees out of phase with the first polarizer. The outer ring of the second polarizer has a plurality of openings sized and positioned to correspond to the diodes of the first illumination source (i.e. every other diode on the first light circuit) such that light emitted from the diodes of the first illumination source passes through the openings unfiltered by the second polarizer. Because there are no corresponding openings for the diodes of the second illumination source (i.e. every other diode on the second light circuit) light emitted from second source diodes is polarized by the outer ring of the second polarizer filter.
[0023] A viewing polarizer is also provided positioned in the housing in line with viewing corridor of the optical lens. The viewing polarizer filters light reflected back from the skin and is cross-polarized relative to said first polarizer and is parallel-polarized relative to said second illumination source. The cross-polarization aids the examiner in viewing deeper structures of the skin while the parallel polarization aids in viewing the topography of the skin.
[0024] In a second embodiment of the invention, the ring of diodes that surround the lens incorporate alternating light wavelengths of differing colors. In operation, a user initiates the first light circuit by operating the first ON mode of the housing switch to light every other diode of a first color. The user then can initiate the second ON mode to light every other diode of a second color. Finally the user can initiate a third ON mode and light both sets of diodes to emit both colors simultaneously. For example, one set of lights could be white light LEDs and the second set of light can be a UV/Blue LEDs. Fluorescence imaging provides functional information about the disease, while the standard white light epiluminescence imaging provides the anatomical information that the physician is familiar with in viewing skin disease. Combining the UV/Blue light image with the standard white light image, into a device that is simple and easy to use can be achieved by using a “flicker” method of image integration in the eye, whereby two sets of images are presented one after the other. Switching back and forth between the two sets of images allows the brain to “co-register” the two different images without the need for computers. A third embodiment employs the alternating colored diodes of the second embodiment as well as the cross and parallel polarization of the light from the diodes as found in the first embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:
[0026] FIG. 1 is a is a top perspective view of the device of the present invention;
[0027] FIG. 2 is a bottom perspective view of the device of the present invention;
[0028] FIG. 3 is an exploded top view of a first embodiment of the present invention;
[0029] FIG. 4 is and exploded bottom view of a first embodiment of the present invention;
[0030] FIG. 5 is a cross-sectional view of the device of a first embodiment of the present invention;
[0031] FIG. 6 is and exploded bottom view of a second embodiment of the present invention; and
[0032] FIG. 7 is and exploded bottom view of a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The detailed description as set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of the present invention, and does not represent the only embodiment of the present invention. It is understood that various modifications to the invention may be comprised by different embodiments and are also encompassed within the spirit and scope of the present invention.
[0034] Referring particularly to FIGS. 1 and 2 , there are shown a top and bottom perspective views, respectively, of the dermoscopy epiluminescence device 12 of the present invention. The device 12 is lightweight and compact, and can easily fit within the shirt pocket of a user. The outer structure of the device 12 can be utilized in association with the first embodiment ( FIGS. 3-5 ), the second embodiment ( FIG. 6 ) and third embodiment ( FIG. 7 ). The exterior appearance of the device for each of the first, second and third embodiments would be identical as shown in FIGS. 1 and 2 .
[0035] FIG. 1 shows the top perspective view of the device 12 showing the viewing port of the lens 14 incorporated into a housing 20 . A battery cover 22 may be removeably secured to the housing 20 to provide access to an interior compartment for insertion and removal of a battery.
[0036] Also shown is a switch 16 for initiating a first light source and a switch 18 for initiating the second light source.
[0037] Referring particularly to FIG. 2 , a bottom perspective view of the device 12 is shown. A light portal is incorporated into the housing 20 to expose a viewing polarizer 24 . A plurality of diodes (not shown) encircle the viewing polarizer within the housing 20 and direct light though a multiple layer filter ring 25 . Light from the diodes (not shown) is directed onto the skin surface to aid lighting the magnified area to be viewed.
[0038] Referring particularly to FIGS. 3 and 4 , there is shown a first embodiment of the present invention. FIG. 3 is an exploded top view of the device 12 and FIG. 4 is an exploded bottom view of the device 12 . The housing 20 includes top component 20 a and bottom component 20 b . The top component 20 a , bottom component 20 b and battery cover 22 are formed from molded lightweight durable plastic. The plastic is a PVC derivative material and may be formed from acrylic or lexan. Additionally, the housing may be formed from metal such as aluminum. Components 20 a , 20 b and cover 22 are interconnected to form the outer housing 20 as shown in FIGS. 1 and 2 .
[0039] The top housing component 20 a includes an aperture 26 for receiving the combination of the optical lens 14 inserted within the lens sleeve 28 . Shown best in FIG. 4 , the underside of the top housing component 20 a is shown wherein the aperture 26 incorporates a downwardly protruding collar for receiving the lens 14 within the lens sleeve 28 . The lens sleeve 28 incorporates an annular lip 29 which engages the sloped sides of the aperture 26 to complete the exterior of the viewing port of the housing 20 . The lens sleeve 28 operates to securely hold the lens 14 in place within the aperture 26 . The lens 14 in the first embodiment is preferably a 15 mm diameter Hastings lens with a 10× optical gain. Although the first embodiment employs a Hastings lens, the lens may be a single convex lens, a combination of two or more lenses, a double achromat lens, or a combination of double achromat lenses. In addition, the lens may incorporate aspherical lenses to accommodate better optics and lower distortion. The lenses coated with an antireflection coating may be used and may additionally include a color filter to selectively filter light passing through the lens.
[0040] Although the invention shows a hand held unit without imaging equipment attached, it is contemplated by the present invention that the same could be used with a camera, and that the size and shape of the lens would be modified to accommodate the same.
[0041] The protruding collar 30 is part of the unitary structure of the upper housing component 20 a . The cylinder 30 protrudes through the interior components of the housing 20 , including a printed circuit board (PCB) 32 having an opening 33 to extend to the light portal of bottom component 20 b . A battery 34 nests within a battery chamber formed by the top component 20 a and bottom component 20 b . PCB 32 includes electrical contacts 36 a and 36 b for interfacing with the battery 34 contacts 38 a and 38 b . The upper housing 20 a includes slots 40 a and 40 b to allow the PCB contacts 36 a and 36 b to protrude from the circuit board 32 into the battery chamber and contact the battery leads 38 a and 38 b . In all embodiments of the present invention, the battery 34 is an extended charge lithium battery, however, it is understood and contemplated by the present invention that the battery could be any suitable battery package such as a one-time lithium battery or rechargeable lithium battery. The invention additionally contemplates use of a DC power supply that may have a suitable DC output to drive the LEDs.
[0042] The bottom component 20 b includes a viewing aperture 42 . The viewing polarizer 24 and sleeve 44 cap off the opening of the collar 30 . Viewing polarizer 24 is composed of acrylic plastic with polarization material embedded within the polarizer. It is contemplated by the invention that the viewing polarizer 24 may be constructed of glass, also with material embedded or coated on the glass. In addition, the viewing polarizer 24 may be coated with a filter material that can selectively filter out some of the light frequencies emanating from the object. Alternatively, the secondary filter assembly made of plastic or glass with the capability of filtering the light may be placed in the path of the viewing lens to filter out some of the light. Bottom housing component 20 b includes a bottom collar 46 formed therein. A lip 48 incorporating a plurality of guide tabs, is formed between the collar 46 and the aperture 42 . The lip 48 and guide tabs are adapted to engage bottom annular polarizer 50 and a top annular polarizer 52 . The top 52 and bottom 50 polarizers are 90 degrees out of phase. The bottom 50 polarizer is in cross polarization with the viewing polarizer 24 and top polarizer 52 is in parallel polarization with the viewing polarizer 24 . The top 52 and bottom 50 polarizers are composed of acrylic plastic and include polarization at different angles. The polarizers 50 and 52 may also be coated with a special material to filter out some of the light emanating from the LEDs, or alternatively the annular polarizer 50 and 52 may be sandwiched with a color filter acrylic material. The aperture 42 is wide enough to permit a viewing corridor from the lens sleeve 28 through the housing 20 to the aperture 42 while allowing portions of the top 52 and bottom 50 polarizers to be exposed and to filter light emitting diodes inside the housing 20 .
[0043] Sixteen light emitting diodes 58 ring the circuit board. The diodes are preferably white high light output Indium Gallium Nitride LEDs, however any suitable lighting diodes are appropriate. The even diodes are on a single circuit and the odd diodes are an a separate single circuit. In the shown embodiment, the LEDs 58 are a standard white LED made with phosphorescence phosphors to create white light. It is additionally contemplated by the present invention that tri-colored LEDs, with individual red, green and blue LEDs that can combine form white light may be utilized. It is contemplated by the present invention that the LEDs may have focusing lenses to concentrate the light into a smaller and tighter beam. The LEDs may additionally be comprised of indium gallium arsenide material, or any other like semiconductor material. The PCB board 42 incorporates switch contacts 54 and 56 . The polarizing parallel switch 16 engages switch contact 56 and the parallel-polarizing switch 18 engages with contact 54 . Thus, engaging switch 16 initiates a first light source, which are the eight even diodes 58 and the switch 18 initiates the second light source, which are the other eight odd diodes. Both switches 56 and 54 may be operated simultaneously to light all sixteen diodes 58 simultaneously. It is contemplated by the present invention that the device may employ three or more switches operative to initiate three or more sets of diodes.
[0044] A first polarizer filter 50 comprises a planar annular ring defining a generally circular center opening and an outer ring. The center opening of the annular ring of the first polarizer 50 is positioned in alignment with the circular optical lens 14 to provide an unobstructed view of the skin through the lens 14 and the housing 20 . The outer ring of the first polarizer 50 includes a plurality of openings sized and positioned to correspond to the diodes 58 of the second illumination source (i.e. every other diode 58 of the second light circuit) such that light emitted from the diodes 58 of the second illumination source passes through the openings unfiltered by the first polarizer 50 . Because there are no corresponding openings for the diodes of the first illumination source (i.e. every other diode on the first light circuit) light emitted from first source diodes is polarized by the outer ring of the first polarizer filter 50 .
[0045] A second polarizer filter 52 comprises a planar annular ring defining a generally circular center opening and an outer ring. The center opening of said annular ring of the second polarizer 52 is positioned in alignment with the circular optical lens 14 to provide an unobstructed view of the skin through the lens 14 and housing 20 . The second polarizer 52 is 90 degrees out of phase with the first polarizer 50 . The outer ring of the second polarizer 52 , like the first polarizer 50 , has a plurality of openings sized and positioned to correspond to the diodes of the first illumination source (i.e. every other diode on the first light circuit) such that light emitted from the diodes of the first illumination source passes through the openings unfiltered by the second polarizer 52 . Because there are no corresponding openings for the diodes 58 of the second illumination source (i.e. every other diode on the second light circuit) light emitted from second source diodes is polarized by the outer ring of the second polarizer 52 . While the switches of the first embodiment 16 and 18 shows only two light sources (i.e. two sets of diodes) three are more sets of diodes are contemplated by the present invention.
[0046] Referring particularly to FIG. 5 , there is shown a cross-sectional view of the device 12 of the first embodiment of the present invention. FIG. 5 shows an optional spacer 60 which can engage the viewing portal of the housing 20 . The spacer includes glass 62 to provide a transparent barrier. The spacer can aid in achieving the optimal viewing distance between the device 12 and the skin 64 . Also, the spacer 60 can prevent contamination of the lens 14 during examination.
[0047] FIG. 5 illustrates the angle of mounting of the LEDs 58 upon the PCB 32 . The light from the LEDs 58 is angled to concentrate the light onto a focused area are represented by the angled lines shown in phantom. The light from the LEDs 58 is focused into a smaller area, so as to increase the brightness of the LEDs. All of the LEDs 58 in the circle are pointed toward the central area of the region of interest, so as to increase multifold the amount of light directed into the region. It is additionally contemplated by the present invention that some of the LEDs may be directed slightly off center to enlarge the viewing field and to make for uniform lighting.
[0048] FIG. 6 is a bottom exploded view of a second embodiment of the present invention. The assembly and structure of the device shown in FIG. 6 is identical to that shown in FIGS. 1-5 of the first embodiment of the present invention (and thus the description is not repeated herein), except that the device shown in FIG. 6 does not include two annular filters 50 and 52 and the LEDs 66 and 68 are of different colors. Preferably, the even diodes 66 are of a particular green wavelength and odd diodes 68 are white diodes. The colored LEDs may be different LEDs available at the time such as 370 nm UV, 470 nm blue, 500 nm aqua, 525 nm green, 570 nm orange, 630 nm red, etc. The combination of different colors will provide different imaging capabilities. As an example, the blue light is more absorbed in skin pigmentation and therefore better visualization of pigmentation is achieved with the blue light. Similarly, the green light is more absorbed by the blood and so it is better for visualizing blood vessels. Some compounds also fluoresce at different wavelength light. An example of this is the multiple fluorescence compounds used in research and medicine such as fluorescein, which fluoresces green when illuminated with a blue light. While the second embodiment herein shows green and white diodes, it is understood that the second embodiment could employ any desirable combinations of colors. Likewise, while the switch contemplates only two light sources (i.e. two sets of diodes) three are more sets of diodes are contemplated by the present invention, employing multiple combinations of colors.
[0049] FIG. 7 is a bottom exploded view of a third embodiment of the present invention. The assembly and structure of the device shown in FIG. 7 is identical to that shown in FIGS. 1-5 of the first embodiment of the present invention (and thus the description is not repeated herein), except that the device shown in FIG. 7 includes LEDs 70 and 72 are of different colors. Preferably, the even diodes 70 are of a particular green wavelength and odd diodes 72 are white diodes. The two annular polarizers provide cross polarization and parallel polarization identical to that described with respect to the first embodiment. While the third embodiment herein contemplates green and white diodes, it is understood that the third embodiment could employ any desirable combinations of colors. Likewise, while the switches may only initiate two light sources (i.e. two sets of diodes), three are more sets of diodes are contemplated by the present invention, employing multiple combinations of colors.
[0050] It should be noted and understood that with respect to the embodiments of the present invention, the materials suggested may be modified or substituted to achieve the general overall resultant high efficiency. The substitution of materials or dimensions remains within the spirit and scope of the present invention.
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The present invention is a hand held dermoscopy epiluminescense device with a magnification lens and an associated ring of luminous diodes powered by an on board battery. Every other diode in the ring operates as first and second light sources. The even diodes are filtered by a first polarization ring and the odd diodes are filtered by a second polarization ring. Each polarization ring has an open center for the lens and openings sized and positioned to correspond to the even or odd diodes to only filter one set. A viewing polarizer is provided and is cross-polarized relative to the first polarization ring and is parallel-polarized with the second polarization ring. A three way switch which provides on demand cross-polarized, parallel-polarized and a combination thereof for epiluminescence. A second embodiment provides even diodes of a first color and odd diodes of a second color. A third embodiment employs the alternating colored diodes of the second embodiment as well as the cross and parallel polarization of the light from the diodes as found in the first embodiment.
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TECHNICAL FIELD
[0001] The present invention relates to a control apparatus and method for a construction machine. More particularly, the present invention relates to such a control apparatus and method for a construction machine in which when a combined operation of a boom and an arm of an excavator is performed, a loss in the flow rate of the hydraulic fluid discharged from the hydraulic pump can be prevented from occurring.
BACKGROUND OF THE INVENTION
[0002] A conventional flow control apparatus for a construction machine in accordance with the prior art as shown in FIG. 1 includes:
[0003] an engine 1 ;
[0004] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ;
[0005] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ;
[0006] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state;
[0007] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state; and
[0008] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 due to an attachment (including a boom, an arm, or a bucket)'s own weight, and a regeneration valve 13 installed in the regeneration flow path 10 .
[0009] As shown in FIG. 1 , when a spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot signal pressure from a pilot pump (not shown) through the manipulation of a manipulation lever (not shown), hydraulic fluid discharged from the hydraulic pump 2 is supplied to a small chamber of the first hydraulic cylinder 3 via a meter-in flow path 12 of the first control valve 6 . In this case, hydraulic fluid discharged from a large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 and the return flow path 11 . Thus, the first hydraulic cylinder 3 is driven to be retracted so that the boom can be driven to perform a boom-down operation.
[0010] In addition, when the spool of the first control valve 6 is shifted to the left on the drawing sheet through the manipulation of a manipulation lever (not shown), hydraulic fluid discharged from the hydraulic pump 2 is supplied to the large chamber of the first hydraulic cylinder 3 via the first control valve 6 . In this case, hydraulic fluid discharged from the small chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 and the return flow path 11 a . Thus, the first hydraulic cylinder 3 is driven to be extended so that the boom can be driven to perform a boom-up operation.
[0011] Meanwhile, when the hydraulic fluid from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T due to the retractable drive of the first hydraulic cylinder 3 , a back pressure is formed in the regeneration flow path 10 by a back pressure check valve 18 installed in the return flow path 11 . For this reason, when a pressure within the small chamber of the first hydraulic cylinder 3 is low, the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be supplementarily supplied to the small chamber of the first hydraulic cylinder 3 through the regeneration flow path 10 .
[0012] In other words, when there is a shortage in the hydraulic fluid supplied to the small chamber during the retractable drive of the first hydraulic cylinder 3 , the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be recycled and supplementarily supplied to the small of the first hydraulic cylinder 3 through the regeneration flow path 10 .
[0013] In the meantime, when a combined operation of a boom and an arm is performed by a user, i.e., when the first hydraulic cylinder 3 is driven to be retracted to perform the boom-down operation of the boom and the second hydraulic cylinder 4 is driven to be retracted to perform the arm-out operation of the arm, a load pressure generated in the second hydraulic cylinder 4 is relatively higher than that generated in the first hydraulic cylinder 3 . In this case, the hydraulic fluid discharged from the hydraulic pump 2 is much more supplied to the first hydraulic cylinder 3 whose load pressure is relatively low through the meter-in flow path 12 in terms of the characteristics of the hydraulic fluid.
[0014] In other words, the conventional flow control apparatus entails a problem in that since the hydraulic fluid discharged from the hydraulic pump 2 is much more supplied to the first hydraulic cylinder 3 through the meter-in flow path 12 , the efficiency of the recycled hydraulic fluid is degraded. Besides, there is a problem in that the hydraulic fluid from the hydraulic pump 2 is introduced into the small chamber of the first hydraulic cylinder 3 , which causes a loss of the hydraulic fluid, thus leading to a decrease in the energy efficiency of the machine.
SUMMARY OF THE INVENTION
[0015] Accordingly, the present invention has been made to solve the aforementioned problems occurring in the prior art, and it is an object of the present invention to provide a flow control apparatus and method for a construction machine, which can limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to a boom cylinder whose load pressure is relatively low during a combined operation of a boom and an arm so that an unnecessary loss of the hydraulic fluid can be prevented.
Technical Solution
[0016] To achieve the above object, in accordance with an embodiment of the present invention, there is provided a flow control apparatus for a construction machine, including:
[0017] an engine;
[0018] a variable displacement hydraulic pump connected to the engine;
[0019] a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump;
[0020] a first control valve installed in a center bypass path of the hydraulic pump, the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump to be returned to a hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state;
[0021] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump, the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump to be returned to the hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state;
[0022] a regeneration flow path configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank during a retractable drive of the first hydraulic cylinder, and a regeneration valve installed in the regeneration flow path; and
[0023] a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders.
[0024] The pressure compensation type flow control valve may include a spool having a first position in which the meter-in flow path is opened by a pressure passing through a meter-in orifice installed in the meter-in flow path and an elastic force of a valve spring, and a second position in which the meter-in flow path is closed when the spool is shifted by a pressure in the meter-in flow path.
[0025] The pressure compensation type flow control valve may include a spool having a first position in which the meter-in flow path is opened by a pressure passing through a meter-in orifice installed in the meter-in flow path and an elastic force of a valve spring, and a second position in which the flow rate of the hydraulic fluid is limited through the shift of the spool in a direction in which an opening portion of the meter-in orifice is reduced if the pressure in the meter-in flow path is higher than the elastic force of the valve spring.
[0026] The first hydraulic cylinder 3 may be a boom cylinder, and the second hydraulic cylinder 4 may be an arm cylinder.
[0027] To achieve the above object, in accordance with another embodiment of the present invention, there is provided a flow control apparatus for a construction machine, including:
[0028] an engine;
a variable displacement hydraulic pump connected to the engine; a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump;
[0031] a first control valve installed in a center bypass path of the hydraulic pump, the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump to be returned to a hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state;
[0032] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump, the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump to be returned to the hydraulic tank in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state;
[0033] a regeneration flow path configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank during a retractable drive of the first hydraulic cylinder, and a regeneration valve installed in the regeneration flow path;
[0034] a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders;
[0035] at least one pressure detection sensor configured to detect a pilot pressure that is input to the first and second control valves to shift the first and second control valves;
[0036] a controller configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor and output a control signal that corresponds to the calculated required flow rate; and
[0037] an electronic proportional valve configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump.
[0038] To achieve the above object, in accordance with still another embodiment of the present invention, there is provided a flow control method for a construction machine which includes:
[0039] a variable displacement hydraulic pump connected to an engine;
[0040] a first hydraulic cylinder and a second hydraulic cylinder, which are connected to the hydraulic pump;
[0041] a first control valve installed in a center bypass path of the hydraulic pump and configured to control a start, a stop, and a direction change of the first hydraulic cylinder in its shifted state;
[0042] a second control valve installed on a downstream side of the center bypass path of the hydraulic pump and configured to control a start, a stop, and a direction change of the second hydraulic cylinder in its shifted state;
[0043] a regeneration flow path configured to reuse the hydraulic fluid that returns to a hydraulic tank by an attachment's own weight and a regeneration valve;
a pressure compensation type flow control valve installed in a meter-in flow path of a spool of the first control valve and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first hydraulic cylinder during a combined operation of the first and second hydraulic cylinders;
[0045] at least one pressure detection sensor configured to detect a pilot pressure that is input to the first and second control valves to shift the first and second control valves;
[0046] a controller configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor and output a control signal that corresponds to the calculated required flow rate;
[0047] an electronic proportional valve configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump, the flow control method including:
[0048] a first step of allowing the pressure detection sensor to detect the pilot pressure that is input to the first and second control valves to shift the first and second control valves through a manipulation of a manipulation lever;
[0049] a second step of calculating the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever; and
[0050] a third step of outputting an electrical control signal that corresponds to the calculated required flow rate to the electronic proportional valve,
[0051] wherein the flow rate of the hydraulic fluid supplied from the hydraulic pump to the first and second hydraulic cylinders by the shifting of the first and second control valves is set to be equal to or lower than the flow rate of the hydraulic fluid passing through the pressure compensation type flow control valve.
Advantageous Effect
[0052] The flow control apparatus and method for a construction machine in accordance with the present invention as constructed above has the following advantages.
[0053] The flow control apparatus and method can limit the flow rate of the hydraulic fluid supplied from the hydraulic pump to the boom cylinder whose load pressure is relatively low during a combined operation of the boom and the arm so that an unnecessary loss of the hydraulic fluid can be prevented, thereby increasing the energy efficiency and thus the fuel efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
[0055] FIG. 1 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with the prior art;
[0056] FIG. 2 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention;
[0057] FIG. 3 is an enlarged view showing a pressure compensation type flow control valve shown in FIG. 2 ;
[0058] FIG. 4 is an exemplary view showing a modification of a pressure compensation type flow control valve shown in FIG. 2 ;
[0059] FIG. 5 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention;
[0060] FIG. 6 is a flowchart showing a process for controlling the flow rate of the hydraulic fluid from the hydraulic pump in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention; and
[0061] FIG. 7 is a graph showing the relationship between a manipulation amount and a required flow rate of hydraulic fluid in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention.
EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS
[0000]
1 : engine
2 : variable displacement hydraulic pump
3 : first hydraulic cylinder
4 : second hydraulic cylinder
5 : center bypass path
6 : first control valve
7 : second control valve
8 : first manipulation lever
9 : second manipulation lever
10 : regeneration flow path
11 , 11 a : return flow path
12 : meter-in flow path
13 : regeneration valve
14 : pressure compensation type flow control valve
15 : valve spring
16 : meter-in orifice
17 : spool
DETAILED DESCRIPTION OF THE INVENTION
[0079] Now, a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter.
[0080] In order to definitely describe the present invention, a portion having no relevant to the description will be omitted, and through the specification, like elements are designated by like reference numerals.
[0081] In the specification and the claims, when a portion includes an element, it is meant to include other elements, but not exclude the other elements unless otherwise specifically stated herein.
[0082] FIG. 2 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention, FIG. 3 is an enlarged view showing a pressure compensation type flow control valve shown in FIG. 2 , FIG. 4 is an exemplary view showing a modification of a pressure compensation type flow control valve shown in FIG. 2 , FIG. 5 is a hydraulic circuit diagram showing a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention, FIG. 6 is a flowchart showing a process for controlling the flow rate of the hydraulic fluid from the hydraulic pump in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with another preferred embodiment of the present invention, and FIG. 7 is a graph showing the relationship between a manipulation amount and a required flow rate of hydraulic fluid in a hydraulic circuit diagram of a flow control apparatus for a construction machine in accordance with a preferred embodiment of the present invention.
[0083] Referring to FIGS. 2 to 4 , the flow control apparatus for a construction machine in accordance with an embodiment of the present invention includes:
[0084] an engine 1 ;
[0085] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ;
[0086] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ;
[0087] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state;
[0088] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state;
[0089] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 due to an attachment (including a boom, an arm, or a bucket)'s own weight, and a regeneration valve 13 installed in the regeneration flow path 10 ; and
[0090] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 .
[0091] The pressure compensation type flow control valve 14 includes a spool having a first position I in which the meter-in flow path is opened by a pressure passing through a meter-in orifice 16 installed in the meter-in flow path 12 and an elastic force of a valve spring 15 , and a second position II in which the meter-in flow path 12 is closed when the spool is shifted by a pressure in the meter-in flow path 12 .
[0092] The pressure compensation type flow control valve 14 includes a spool having a first position I in which the meter-in flow path 12 is opened by a pressure passing through a meter-in orifice 16 installed in the meter-in flow path 12 and an elastic force of a valve spring, and a second position II in which the flow rate of the hydraulic fluid is limited through the shift of the spool in a direction in which an opening portion of the meter-in orifice 16 is reduced if the pressure in the meter-in flow path 12 is higher than the elastic force of the valve spring 15 .
[0093] The first hydraulic cylinder 3 is a boom cylinder, and the second hydraulic cylinder 4 is an arm cylinder.
[0094] In this case, a configuration of the flow control apparatus for a construction machine in accordance with an embodiment of the present invention is the same as that of the conventional flow control apparatus for a construction machine as shown in FIG. 1 , except the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 in order to limit the supply of a relatively large amount of the hydraulic fluid from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 . Thus, the detailed description of the same configuration and operation thereof will be omitted to avoid redundancy, and the same hydraulic parts are denoted by the same reference numerals.
[0095] In accordance with the configuration as described above, when a spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot signal pressure from a pilot pump (not shown) through the manipulation of a manipulation lever, hydraulic fluid discharged from the hydraulic pump 2 is supplied in a limited amount to a small chamber of the first hydraulic cylinder 3 by a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of the first control valve 6 . In this case, hydraulic fluid discharged from a large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the first control valve 6 , the return flow path 11 and the back pressure check valve 18 . Thus, the first hydraulic cylinder 3 is driven to be refracted so that the boom can be driven to perform a boom-down operation.
[0096] Meanwhile, when the hydraulic fluid discharged from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T due to the retractable drive of the first hydraulic cylinder 3 , a back pressure is formed in the regeneration flow path 10 by the back pressure check valve 18 installed in the return flow path 11 . For this reason, when a pressure within the small chamber of the first hydraulic cylinder 3 is low, the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T can be supplementarily supplied to the small chamber of the first hydraulic cylinder 3 through the regeneration flow path 10 .
[0097] In the meantime, when a combined operation of a boom and an arm is performed by a user, i.e., when the first hydraulic cylinder 3 generating a relatively lower pressure is driven to be retracted to perform the boom-down operation of the boom and the second hydraulic cylinder 4 generating a relatively high load pressure is driven to be retracted to perform the arm-out operation of the arm, the supply of the hydraulic fluid from the hydraulic pump 2 to the small chamber of the first hydraulic cylinder 3 is limited by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 . Thus, the hydraulic fluid discharged from the hydraulic pump 2 is supplied in a reduced amount to the first hydraulic cylinder 3 after passing through the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 (indicated by a line “b” in the graph of the FIG. 7 ), and the remaining hydraulic fluid discharged from the hydraulic pump 2 is supplied to the second hydraulic cylinder 4 (indicated by a line “a” in the graph of the FIG. 7 ).
[0098] For this reason, even during a combined operation in which the boom-down operation of the boom is performed by the retractable drive of the first hydraulic cylinder 3 and the arm-out operation of the boom is performed by the retractable drive of the second hydraulic cylinder 4 , the hydraulic fluid discharged from the hydraulic pump 2 can be prevented from being much more supplied to the first hydraulic cylinder 3 in which a relatively low load pressure is generated than in the second hydraulic cylinder 4 .
[0099] Meanwhile, as in the pressure compensation type flow control valve 14 shown in FIG. 4 , if a pressure of the hydraulic fluid which is formed in the meter-in flow path 12 is higher than an elastic force of the valve spring 15 , a spool of the pressure compensation type flow control valve 14 is shifted to the left on the drawing sheet. In other words, the spool of the pressure compensation type flow control valve 14 is shifted to the second position II to further reduce an opening portion of the meter-in orifice 16 so that the supply of the hydraulic fluid from the hydraulic pump 2 to the first hydraulic cylinder 3 can be further limited.
[0100] Referring to FIG. 5 , the flow control apparatus for a construction machine in accordance with another embodiment of the present invention includes:
[0101] an engine 1 ;
[0102] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to the engine 1 ;
[0103] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ;
[0104] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 , the first control valve being configured to allow hydraulic fluid discharged from the hydraulic pump 2 to be returned to a hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state;
[0105] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 , the second control valve being configured to allow the hydraulic fluid discharged from the hydraulic pump 2 to be returned to the hydraulic tank T in its neutral state and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state;
[0106] a regeneration flow path 10 configured to supplement and reuse the hydraulic fluid that returns to the hydraulic tank T from a large chamber of the first hydraulic cylinder 3 during a retractable drive of the first hydraulic cylinder 3 , and a regeneration valve 13 installed in the regeneration flow path 10 ;
[0107] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 ;
[0108] at least one pressure detection sensor Pa, Pb, Pc, Pd configured to detect a pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 ;
[0109] a controller 20 configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor Pa, Pb, Pc, Pd and output a control signal that corresponds to the calculated required flow rate; and
[0110] an electronic proportional valve 22 configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller 20 , to a pump regulator 21 that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump 2 .
[0111] In accordance with still another embodiment of the present invention, there is provided a flow control method for a construction machine which includes:
[0112] a variable displacement hydraulic pump (hereinafter, referred to as “hydraulic pump”) 2 connected to an engine 2 ;
[0113] a first hydraulic cylinder 3 and a second hydraulic cylinder 4 , which are connected to the hydraulic pump 2 ;
[0114] a first control valve 6 installed in a center bypass path 5 of the hydraulic pump 2 and configured to control a start, a stop, and a direction change of the first hydraulic cylinder 3 in its shifted state;
[0115] a second control valve 7 installed on a downstream side of the center bypass path 5 of the hydraulic pump 2 and configured to control a start, a stop, and a direction change of the second hydraulic cylinder 4 in its shifted state;
[0116] a regeneration flow path 10 configured to reuse the hydraulic fluid that returns to a hydraulic tank T from the first hydraulic cylinder 3 by an attachment's own weight and a regeneration valve installed in the regeneration flow path 10 ;
[0117] a pressure compensation type flow control valve 14 installed in a meter-in flow path 12 of a spool of the first control valve 6 and configured to limit the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first hydraulic cylinder 3 during a combined operation of the first and second hydraulic cylinders 3 and 4 ;
[0118] at least one pressure detection sensor Pa, Pb, Pc, Pd configured to detect a pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 ;
[0119] a controller 20 configured to calculate a required flow rate of hydraulic fluid, which corresponds to the pressure detected by the pressure detection sensor Pa, Pb, Pc, Pd and output a control signal that corresponds to the calculated required flow rate; and
[0120] an electronic proportional valve 22 configured to output, as a control signal, a secondary pressure generated therefrom to correspond to the control signal applied thereto from the controller, to a pump regulator 21 that controls a flow rate of the hydraulic fluid discharged from the hydraulic pump 2 , the flow control method including:
[0121] a first step S 10 of allowing the pressure detection sensor to detect the pilot pressure that is input to the first and second control valves 6 an 7 to shift the first and second control valves 6 and 7 through a manipulation of a manipulation lever;
[0122] a second step S 20 of calculating the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 ; and
[0123] a third step S 30 of outputting an electrical control signal that corresponds to the calculated required flow rate to the electronic proportional valve,
[0124] wherein the flow rate of the hydraulic fluid supplied from the hydraulic pump 2 to the first and second hydraulic cylinders 3 and 4 by the shifting of the first and second control valves 6 and 7 is set to be equal to or lower than the flow rate of the hydraulic fluid passing through the pressure compensation type flow control valve 14 using the relational expression between the manipulation amount and the required flow rate. For this reason, in the case where the first hydraulic cylinder 3 or the second hydraulic cylinder 4 is driven alone, an excessive pressure can be prevented from being generated due to an increase in the flow rate of the hydraulic fluid discharged from the hydraulic pump 2 .
[0125] According the configuration as described above, the spool of the first control valve 6 is shifted to the right on the drawing sheet by a pilot pressure input upon the manipulation of the manipulation lever in order to perform a single boom-down operation of the boom by the retractable drive of the first hydraulic cylinder 3 . In this case, the pressure detection sensors Pa and Pb detect the pilot pressure that is input to the first control valve 6 to shift the first control valve 6 (see S 10 ), and outputs a detection signal to the controller 20 . The controller 20 calculates the required flow rate (Q 1 ) of the hydraulic fluid relative to the manipulation amount of the manipulation lever to correspond to the detected pilot pressure using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 (see S 20 ). Then, when the controller 20 outputs a control signal corresponding to the calculated required flow rate of the hydraulic fluid to the electronic proportional valve 22 (see S 30 ), the electronic proportional valve 22 outputs, a secondary pressure generated therefrom to correspond to the control signal input thereto output from the controller 20 , to a pump regulator 21 .
[0126] Thus, the hydraulic fluid discharged from the hydraulic pump 2 is reduced in the flow rate when passing through the first control valve 6 by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 of the first control valve 6 . In other words, the hydraulic fluid from the hydraulic pump 2 whose flow rate is reduced by the pressure compensation type flow control valve 14 is supplied to the small chamber of the first hydraulic cylinder 3 . At this point, the hydraulic fluid discharged from the large chamber of the first hydraulic cylinder 3 is returned to the hydraulic tank T via the return flow path 11 and the back pressure check valve 18 .
[0127] In this case, when there is a shortage in the hydraulic fluid supplied to the small chamber during the retractable drive of the first hydraulic cylinder 3 , the hydraulic fluid returned from the large chamber of the first hydraulic cylinder 3 to the hydraulic tank T is recycled and supplementarily supplied to the small of the first hydraulic cylinder 3 through the regeneration valve 13 of the regeneration flow path 10 . For this reason, even in the case where the supply of the hydraulic fluid to the small chamber of the first hydraulic cylinder 3 is limited, a phenomenon can be prevented in which the hydraulic fluid is deficient in the small chamber of the first hydraulic cylinder 3 by the regeneration flow path 10 and the regeneration valve 13 .
[0128] In the meantime, a spool of the second control valve 7 is shifted to the left or the right on the drawing sheet by the manipulation of the manipulation lever to simultaneously perform the boom-down and arm-out operations. In this case, the pressure detection sensors Pc and Pd detect the manipulation amount of the manipulation lever and output a detection signal to the controller 20 . The controller 20 calculates the required flow rate of the hydraulic fluid, which corresponds to the detected manipulation amount of the manipulation lever using a relational expression between the manipulation amount and the required flow rate that is previously stored in the controller 20 . Then, the controller 20 calculates the required flow rates of the hydraulic fluid of the first control valve 6 and the second control valve 7 , respectively, and outputs a control signal corresponding to the calculated required flow rate of the hydraulic fluid to the pump regulator 21 through the electronic proportional valve 22 .
[0129] In this case, when a combined operation of the first and second hydraulic cylinders 3 and 4 is performed, the flow rate of the hydraulic fluid required for the arm-out operation of the second hydraulic cylinder (i.e., the arm cylinder) 4 is higher than that of the hydraulic fluid required for the boom-down operation of the first hydraulic cylinder (i.e., the boom cylinder) 3 , and thus the hydraulic pump 2 discharges a maximum amount of the hydraulic fluid. Thus, even in the case where the combined operation of the first and second hydraulic cylinders 3 and 4 is performed to cause the a large amount of the hydraulic fluid is discharged from the hydraulic pump 2 , the supply of the hydraulic fluid from the hydraulic pump 2 to the small chamber of the first hydraulic cylinder 3 is limited by the pressure compensation type flow control valve 14 installed in the meter-in flow path 12 of the first control valve 6 (indicated by a line “b” in the graph of FIG. 7 ). On the other hand, the remaining hydraulic fluid discharged from the hydraulic pump 2 can be used to drive the second hydraulic cylinder 4 (indicated by a line “a” in the graph of FIG. 7 ).
[0130] As described above, in the case where a combined operation of the first and second hydraulic cylinders 3 and 4 is performed, a load pressure generated during the drive of the second hydraulic cylinder 4 (i.e., the arm-out operation) is relatively higher than that generated during the drive of the first hydraulic cylinder 3 (i.e., the boom-down operation). For this reason, the hydraulic fluid discharged from the hydraulic pump 2 can be prevented from being much more supplied to the first hydraulic cylinder 3 in whose load pressure is relatively low, thereby avoiding an unnecessary loss of the hydraulic fluid from the hydraulic pump 2 .
INDUSTRIAL APPLICABILITY
[0131] In accordance with the flow control apparatus and method for a construction machine of the present invention as constructed above, the supply of the hydraulic fluid from the hydraulic pump to a boom cylinder whose load pressure is relatively low can be limited during a combined operation of a boom and an arm so that an unnecessary loss of the hydraulic fluid can be prevented, thereby improving the energy efficiency.
[0132] While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
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Disclosed are a flow control device and a flow control method for a construction machine for preventing the loss of fluid exhausted from a hydraulic pump when a boom and an arm of an excavator are operated in combination. The flow control device for a construction machine according to the present invention includes: an engine; a variable capacity hydraulic pump connected to the engine; a first hydraulic cylinder and a second hydraulic cylinder connected to the hydraulic pump; a first control valve disposed in a center bypass channel of the hydraulic pump, the first control valve, in neutral, returning the fluid exhausted from the hydraulic pump to a hydraulic tank and, when switched, controlling the driving, stopping, and direction change of the first hydraulic cylinder; a second control valve disposed downstream of the center bypass channel of the hydraulic pump, the second control valve, in neutral, returning the fluid exhausted from the hydraulic pump to the hydraulic tank and, when switched, controlling the driving, stopping, and direction change of the second hydraulic cylinder; a regeneration fluid channel for supplementing and reusing fluid returned to the hydraulic tank during a compression stroke of the first hydraulic cylinder, and a regeneration valve disposed in the regeneration fluid channel; and a pressure-compensated flow control valve which is disposed in a meter-in fluid channel of a spool of the first control valve and limits the quantity of working fluid supplied from the hydraulic pump to the first hydraulic cylinder when the first hydraulic cylinder and the second hydraulic cylinder are operated in combination.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/400,045, filed Mar. 25, 2003, which is a continuation of U.S. application Ser. No. 09/724,588, filed Nov. 28, 2000, now U.S. Pat. No. 6,536,922, which is a divisional of U.S. application Ser. No. 09/711,355, filed Nov. 9, 2000, now U.S. Pat. No. 6,601,974, which is a divisional of U.S. application Ser. No. 09/108,263, filed Jul. 1, 1998, now U.S. Pat. No. 6,220,730.
TECHNICAL FIELD
[0002] The present disclosure describes a special image obscurement device for a light source.
BACKGROUND
[0003] In live dramatic performances controlled lighting is often used to illuminate a performer or other item of interest. The illuminated area for live dramatic performance is conventionally a circular beam of light called a “spot light.” This spot light has been formed from a bulb reflected by a spherical, parabolic, or ellipsoidal reflector. The combination forms a round beam due to the circular nature of reflectors and lenses.
[0004] The beam is often shaped by gobos. FIG. 1 shows a light source 100 with reflector 101 projecting light through a triangular gobo 108 to the target 105 . The metal gobo 108 as shown is a sheet of material with an aperture 110 in the shape of the desired illumination. Here, that aperture 110 is triangular, but more generally it could be any shape. The gobo 108 restricts the amount of light which passes from the light source 100 to the imaging lenses 103 . As a result, the pattern of light 106 imaged on the stage 105 conforms to the shape of the aperture 110 in the gobo 108 .
[0005] Light and Sound Design, the assignee of this application, have pioneered an alternate approach of forming the gobo from multiple selected reflective silicon micromirrors. One such array is called a digital mirror device (“DMD”) where individual mirrors are controlled by digital signals. See U.S. Pat. No. 5,828,485 the disclosure of which are herein incorporated by reference. DMDs have typically been used for projecting images from video sources. Because video images are typically rectangular, the mirrors of DMDs are arranged in a rectangular array of rows and columns.
[0006] The individual mirrors 370 of a DMD are rotatable. Each mirror is mounted on a hinge 372 such that it can rotate in place around the axis formed by the hinge 372 . Using this rotation, individual mirrors 370 can be turned “on” and “off” to restrict the available reflective surface.
[0007] FIG. 2 shows an example of using a DMD 400 to project a triangular illumination by turning “off” some of the mirrors in the DMD 400 . The surface of the DMD 400 exposed to a light source 402 comprises three portions. The individual mirrors which are turned “on” (toward the light source 402 ) make up an active portion 404 . In FIG. 3A , the active portion 404 is triangular. The individual mirrors which are turned “off” (away from the light source 402 ) make up an inactive portion 406 . These pixels are reflected. The third portion is a surrounding edge 408 of the DMD 400 . Each of these portions of the DMD 400 reflects light from the light source 402 to different degrees.
[0008] FIG. 3A shows a resulting illumination pattern 410 with the active area 404 inactive area 406 and cage 408 .
SUMMARY
[0009] The inventors recognize that light reflected from the inactive portion 406 of the DMD 400 generates a dim rectangular penumbra 418 area surrounding the bright desired area 404 . Light reflected from the edge 408 of the DMD 400 generates a dim frame area. The inventors recognized that this rectangular penumbra 418 is not desirable.
[0010] The inventors also recognized that a circular penumbra is much less noticeable in the context of illumination used in dramatic lighting.
[0011] Accordingly the inventors have determined that it would be desirable to have a device which would provide a circular illumination without a rectangular penumbra while using a rectangular arrayed device as an imaging surface. The present disclosure provides such capabilities.
[0012] This disclosure describes controlling illumination from a light source. The disclosed system is optimized for use with a rectangular, arrayed, selective imaging device.
[0013] In a preferred embodiment, a rotatable shutter with three positions is placed between a DMD and the imaging optical system. The first position of the shutter is a mask, preferably a circle, placed at a point in the optical system to be slightly out of focus. This circle creates a circular mask and changes any unwanted dim reflection to a circular shape. The second position of the shutter is completely open, allowing substantially all the light to pass. The third position of the shutter is completely closed, blocking substantially all the light from passing.
[0014] An alternate embodiment for blocking the rectangular penumbra by changing any penumbra to round uses an iris shutter placed between a DMD and increases optics. The iris shutter creates a variable aperture which ranges from completely closed to completely open. Intermediate settings include circles of varying diameter, resulting in similar projections as with the first position of the shutter embodiment.
[0015] Another alternate embodiment for blocking the rectangular penumbra by changing any penumbra to round uses two reflective surfaces. The first reflective surface is a DMD. The second reflective surface is preferably a light-sensitive reflective surface such as a polymer. If the light striking a portion of the reflective surface is not sufficiently bright, that portion will not reflect the full amount of that light.
[0016] By controlling the penumbra illumination surrounding the desired illumination, DMDs and other pixel-based rectangular elements can be used in illumination devices without creating undesirable rectangular penumbras.
DESCRIPTION OF DRAWINGS
[0017] FIG. 1 shows a conventional illumination device including a gobo.
[0018] FIG. 2 shows an illumination device including a DMD.
[0019] FIGS. 3A-3G shows a illumination patterns.
[0020] FIG. 4 show the optical train.
[0021] FIG. 5 shows a three position shutter according to a preferred embodiment of the present invention.
[0022] FIG. 6A shows an illumination device including a three position shutter according to a preferred embodiment of the present invention which is set to a mask position.
[0023] FIG. 6B shows an illumination pattern resulting from the device shown in FIG. 6A .
[0024] FIG. 7 shows an iris-type shutter.
[0025] FIGS. 8A and 8B show use of the adjustable iris in a DMD system.
[0026] FIG. 9 shows a three-position shutter with an iris system.
[0027] FIG. 10 shows an embodiment with a light.
DETAILED DESCRIPTION
[0028] The structure and operational parameters of preferred embodiments will be explained below making reference to the drawings.
[0029] The present system uses two different operations to minimize the viewable effect of the unintentional illumination, or penumbra, discussed previously. A first operation forms the optics of the system in a way which prevents certain light from being focused on the DMD and hence prevents that light from being reflected. By appropriately masking the incoming light to the DMD, certain edge portions of the penumbra can be masked. A second part of the system uses a special illumination shutter to provide different shaped penumbras when desired.
[0030] The overall optical system is shown in FIG. 4 . The bulb assembly 200 includes a high wattage bulb, here an MSR 1200 SA Xenon bulb 202 and retroreflectors 204 which capture some of the output from that bulb. The output of the bulb is coupled to a dichroic or “cold” mirror 206 which reflects the visible light while passing certain portions of the infrared. The first focus of the reflector is at Point 208 . A DMD mask is located at that point. The DMD mask is preferably rectangular, and substantially precisely the shape of the inner area 418 of the DMD. The image of the mask is also focused onto the DMD: such that if one were looking at the mask from the position of the DMD, one would see the mask clearly and in focus.
[0031] A first color system includes an RGB system 210 and a parameter color system 212 . The light passes through all of these elements and is then further processed by an illumination relay lens 214 and then by an imaging relay lens 216 . The image relay lens 216 has an aperture of 35 millimeters by 48 millimeters. The output is focused through a field lens 218 to the DMD 400 . The off pixels are coupled to heat sink 220 , and the on pixels are coupled via path 222 back through the imaging relay 216 folded in the further optics 224 and finally coupled to zoom elements 230 . The zoom elements control the amount of zoom of the light beam. The light is colored by a designer color wheel 232 and finally focused by a final focus element 235 controlled by motor assembly 236 .
[0032] The way in which the outer penumbra is removed will be explained with reference to FIGS. 3A and 8B .
[0033] FIG. 3B shows the front surface of the DMD. This includes a relatively small inner active portion 350 which includes the movable mirrors. Active portion 350 is surrounded by a white inactive portion 352 which is surrounded by packaging portion 354 , a gold package 356 , and a ceramic package 358 . Light is input at a 20° angle from the perpendicular. The reason why becomes apparent when one considers FIG. 3C . The mirrors in the DMD tip by 10°.
[0034] FIG. 3C shows two exemplary mirrors, one mirror 360 being on, and the other mirror 361 being off. Input light 362 is input at a 20° angle. Hence, light from the on mirror emerges from the DMD perpendicular to its front surface shown as 364 . However, the same light 362 impinging on an off mirror emerges at a different angle shown as 366 . The difference between those two angles forms the difference 367 between undesired light and desired light. However, note in FIG. 3C what happens when the incoming light 362 hits a flat surface. Note the outgoing beam 368 is at a different angle than either the off position or the on position. The hypothetical beam 366 from an off mirror is also shown.
[0035] The inventors recognize, therefore, that a lot of this information falls within an undesired cone of light. All light which is input (e.g. 362 rays) can be filtered by removing the undesired cone. This is done according to the present disclosure by stopping down the cone of light to about 18° on each side. The final result is shown in FIG. 3D . The incoming light is stopped down to a cone of 18° by an F/3.2 lens. The incoming light is coupled to the surface of the DMD 400 , and the outgoing light is also stopped to a cone of 18°. These cones in the optical systems are identified such that the exit cone does not overlap with the undesired cone 367 shown in FIG. 3C .
[0036] This operation is made possibly by appropriate two-dimensional selection of the incoming light to the digital mirror. FIG. 3E shows the active portion 350 of the digital mirror. Each pixel is a rectangular mirror 370 , hinged on axis 372 . In order to allow use of this mirror and its hinge, the light needs to be input at a 45° angle to the mirror, shown as incident light ray 374 . The inventors recognized, however, that light can be anywhere on the plane defined by the line 374 and perpendicular to the plane of the paper in FIG. 3E . Hence, the light of this embodiment is input at the FIG. 3F which represents a cross section along the line 3 E- 3 F. This complex angle enables using a plane of light which has no interference from the undesired portions of the light. Hence, by using the specific desired lenses, reflections of random scattered illumination is bouncing off the other parts is removed. This masking carried out by at least one of the DMD mask 208 and the DMD lens 218 . By appropriate selection of the input light, the output light has a profile as shown in FIG. 3G . 350 represents the DMD active area, 356 represents the package edge, and 358 represents the mount. The light output is only from the DMD active area and is stopped and focused by appropriate lenses as shown in FIG. 3G .
[0037] FIG. 5 shows a planar view of a shutter 500 according to a preferred embodiment of the invention. The preferred configuration of the shutter 500 is a disk divided into three sections. Each section represents one position to which the shutter 500 may be set. The shutter 500 is preferably rotated about the center point 502 of the shutter. The gate of the light is off center, to allow it to interact with one of the three sections. Rotation is preferred because rotation allows efficient transition between positions. Alternately, the shutter 500 may slide vertically or horizontally to change from one position to another. A round shape is preferred because of efficiency in material and space use. Alternately, the shutter 500 may be rectangular or some other polygonal shape.
[0038] Three positions are preferred because each position is rotatably equidistant from the other positions. However, a shutter 500 with three positions provides more positions than a shutter 500 with only two positions.
[0039] In a preferred embodiment, a first position is a mask position 504 . The mask position 504 includes an open or transparent aperture 506 and an opaque mask portion 508 which is not permeable to light. Preferably, material is removed from the shutter 500 leaving a shaped aperture 506 and a mask portion 508 .
[0040] The second position is an open position 510 . The open position 510 includes an opening 512 . Preferably the opening 512 is formed by removing substantially all material from the shutter 500 in the section of the open position 510 .
[0041] The third position is a closed position 514 . The closed position 514 includes a opaque barrier portion 516 . Preferably, the barrier portion 516 is just a solid block of material.
[0042] FIG. 6A shows a preferred embodiment of an illumination system. A shutter 500 of the type shown in FIG. 5 is rotatably mounted between a light source 602 /DMD 604 such that substantially all the light from the light source 602 strikes only one section of the shutter 500 at a time. The shutter 500 is rotatably positioned to the mask position 504 . Thus, when the light source 602 is activated, light from the light source 602 reflected by DMD 604 strikes only the mask position 504 of the shutter 500 .
[0043] Using digital control signals, the DMD 604 is set so that an active portion 404 of the individual mirrors are turned “on” and an inactive portion 406 of the individual mirrors are turned “off” (see FIG. 3A ). The shape of the active portion 404 is set to conform to the desired shape of the bright portion of the illumination reflected by the DMD 604 shown in FIG. 6B , described below.
[0044] FIG. 6B shows an illumination pattern generated by the illumination device 600 configured as shown in FIG. 6A .
[0045] Returning to FIGS. 3A and 3B , when the shutter 500 is not interposed between the DMD 400 and the stage. All portions of the DMD 400 reflect the light and create the undesirable illumination pattern shown in FIG. 3A . In particular, the bright triangular area 404 is surrounded by an undesirable dim rectangular penumbra 418 and slightly brighter frame 422 .
[0046] As described above, the illumination pattern shown in FIG. 6B does not include a dim rectangular penumbra 418 and a slightly brighter frame 422 . These undesirable projections are substantially eliminated by using the shutter 500 and the aperture 506 . A dim penumbra illumination is generated by light reflecting from the inactive portion of the DMD 604 . This dim circular penumbra illumination is more desirable than the dim rectangular penumbra and slightly brighter frame 422 of FIG. 3A because the shape of the dim penumbra illumination is controlled by the shape of the aperture 506 . Accordingly, the dim penumbra illumination can be conformed to a desirable shape.
[0047] FIG. 7 shows an alternate embodiment for an iris shutter 900 . Preferably, a series of opaque plates 902 are arranged inside a ring 904 to form an iris diaphragm. By turning the ring 904 the plates 902 move so that an iris aperture 906 in the center of the iris shutter 900 varies in diameter. The iris aperture 906 preferably varies from closed to a desired maximum open diameter. Preferably the iris shutter 900 can transition from closed to a maximum diameter (or the reverse) in 0.1 seconds or less.
[0048] FIG. 8A shows an illumination device 1000 including an iris shutter 900 as shown in FIG. 7 . The iris shutter 900 is positioned between a DMD 1004 and a stage 1002 . In FIG. 8A , the iris shutter 900 is partially open such that the iris aperture 906 allows part of the light 1006 , 1008 from the light source 1002 to pass through, similar to the mask position 504 of the three position shutter 500 shown in FIG. 5 . One difference between the mask position 504 and the iris shutter 900 is that the iris aperture 906 is variable in diameter while the aperture 506 of the mask position 504 is fixed. The remainder of the light 1010 from the light source 1002 is blocked by the plates 902 of the iris shutter 900 . The light 1006 , 1008 which passes through the iris aperture 906 strikes the DMD 1004 in a pattern 1012 which is the same shape as the shape of the iris aperture 906 . Through digital control signals, some of the individual mirrors of the DMD 1004 are turned “on” to form an active portion 1014 , and some of the individual mirrors are turned “off” to form an inactive region 1016 . Preferably, the pattern 1012 is at least as large as the active portion 1014 of the DMD.
[0049] FIG. 8B shows an illumination pattern 1018 generated by the illumination device 1000 shown in FIG. 8A . Similar to FIGS. 6A and 6B , a bright illumination 1020 is generated by light 1022 , 1020 reflected from the active portion 1014 of the DMD 1004 . A dim penumbra illumination 1024 is generated by light 1026 reflected from the inactive portion 1016 of the DMD 1004 . By varying the diameter of the iris aperture 906 , the size of the pattern 1012 on the DMD 1004 changes. As the pattern 1012 changes the amount of the inactive portion 1016 of the DMD 1004 which is struck by light 1008 from the light source 1002 changes and so the dim penumbra 1024 changes as well.
[0050] FIG. 9 shows an alternate embodiment of a shutter 1100 which combines features of a three position shutter 500 with an iris shutter 900 . The overall configuration of this shutter 1100 is that of the three position shutter 500 . However, instead of the mask portion 504 as shown in FIG. 5 and FIG. 6A , one of the positions is an iris portion 1102 . The iris portion 1102 has an iris diaphragm 1104 inserted into the material of the shutter 1100 . Similar to the iris shutter 900 of FIG. 7 , the iris diaphragm 1104 is made from a series of opaque plates 1106 arranged inside a ring 1108 . By turning the ring 1108 the plates 1106 move so that an iris aperture 1110 in the center of the iris diaphragm 1104 varies in diameter. This configuration operates in most respects similarly to the three position shutter 500 as shown in FIG. 5 and FIG. 6A . Because of the iris diaphragm 1104 , the amount of light blocked by the iris portion 1102 is variable.
[0051] FIG. 10 shows an alternate embodiment of an illumination device 1200 which includes a second reflective surface 1220 . A light source 1204 projects light onto a DMD 1206 which has an active portion 1208 and an inactive portion 1210 . Light reflects off the DMD 1206 and strikes the second reflective surface 1220 . The second reflective surface 1220 acts to reduce the dim penumbra and frame created by the inactive 1210 and edge 1212 of the DMD 1206 (recall FIGS. 3A and 3B ), leaving the active portion 1222 , to project image 1246 .
[0052] In the embodiment shown in FIG. 10 , the second reflective surface 1220 is a light sensitive surface such as an array of light trigger cells. Only light of a certain brightness is reflected. If the light striking a cell is insufficiently bright, substantially no light is reflected by that cell. Alternately, the second reflective surface 1220 may be made of a polymer material that only reflects or passes light of sufficient brightness. Light 1224 reflected from the active portion 1208 of the DMD 1206 is preferably bright enough to be reflected from the second reflective surface 1220 . Light 1230 reflected from the inactive portion 1210 and the edge 1214 of the DMD 1206 is preferably not bright enough to be reflected from the second reflective surface 1220 . Thus, only light 1224 from the active portion 1208 of the DMD 1206 will be reflected from the second reflective surface 1220 . As described above, the undesirable dim rectangular penumbra 418 and slightly brighter frame 422 (recall FIG. 3A ) would be created by light 1230 reflected from the inactive portion 1210 and edge 1212 of the DMD 1206 . The second reflective surface 1220 does not reflect this dim light 1230 and so wholly eliminates the dim penumbra and frame from the resulting illumination.
[0053] A number of embodiments of the present invention have been described which provide controlled obscurement of illumination. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, filters or lenses might be introduced to the illumination device 600 shown in FIG. 6A between the shutter 500 and the DMD 604 . Alternately, the light source might be a video projection device or a laser.
[0054] While this disclosure describes blocking the light before impinging on the DMD, it should be understood that this same device could be used anywhere in the optical train, including downstream of the DMD. Preferably the blocking is at an out of focus location to soften the edge of the penumbra, but could be in-focus.
[0055] The light reflecting device could be any such device, including a DMD, a grating light valve (“GLV”), or any other arrayed reflecting device which has a non-circular shape.
[0056] All such modifications are intended to be encompassed in the following claims.
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An illumination obscurement device for controlling the obscurement of illumination from a light source which is optimized for use with a rectangular, arrayed, selective reflection device. In a preferred embodiment, a rotatable shutter with three positions is placed between a light source and a DMD. The first position of the shutter is a mask, preferably an out of focus circle. This out of focus circle creates a circular mask and changes any unwanted dim reflection to a circular shape. The second position of the shutter is completely open, allowing substantially all the light to pass. The third position of the shutter is completely closed, blocking substantially all the light from passing. By controlling the penumbra illumination surrounding the desired illumination, DMDs can be used in illumination devices without creating undesirable rectangular penumbras.
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This is a continuation of application Ser. No. 08/307,749, filed Sept. 26, 1994, now U.S. Pat. No.5,502,890.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method and apparatus for checking the position of leads on an electrical component.
2. Description of the Related Art
Process for determining the position and/or checking the separation and/or checking the coplanarity of the leads of components, and planting head for the automatic planting of components.
In the automatic equipping of printed circuit boards or ceramic substrates with SMD components, the individual components are removed from a magazine or a feeding device by means of a equipping head and are then positioned in a predetermined position on the printed circuit board or the ceramic substrate. Since the components exhibit, in the magazine Or in the collection position of a feeding device, a position tolerance of approximately 1 mm, but must be positioned on the printed circuit board or the ceramic substrate with high accuracy, an automatic determination of position and correction are necessary. Furthermore, especially in the case of SMD components with a large number of pins, the separation and the coplanarity of the leads must be checked. The determination of position and the checking of separation and coplanarity should in this case take as little time as possible, in order to permit a high degree of equipping performance of the automatic equipping system. Increasing component dimensions of up to 70×70 mm, decreasing separation of the leads of down to 0.3 mm and stringent requirements placed upon the speed of equipping create considerable difficulties in achieving the mentioned objects.
Known arrangements for determining the position and checking the separation of the leads of components obtain the image of the component or sections of the component, by means of an objective lens, onto a planar CCD camera and ascertain, using digital image processing, the position of the component leads and the separation of the leads. With such arrangements, a coplanarity check is not possible.
In other known arrangements for determining the position and checking the separation of the leads of components, the components are placed onto an optically transparent plate, on which a shadow of the illuminated leads is generated. The shadow edges of the leads are then imaged from below by means of an objective lens onto a planar CCD camera, so that in this case also, again, the position of the component leads and the separation of the leads can be ascertained using digital image processing. A coplanarity check is made possible using these arrangements in that the leads are successively illuminated from two different directions (cf. European Patent Application 0 425 722 and PCT Published Application 91/15104).
As a result of the increasing component size as well as the more stringent requirements imposed on accuracy and the required short determination times, significant limits are placed on use of the known arrangements for determining the position, checking the separation and possibly checking the coplanarity of the leads of components, since:
In the case of a dimensioning of the components of for example 70×70 mm, a CCD camera having 4000×4000 pixels would be necessary.
The read-out time of the corresponding information, at approximately 1 s, lasts far too long and is far too great for rapid processing.
It is necessary to provide objective lenses which while having a field of view of 70×70 mm exhibit a freedom from distortion of 5 micrometers. Such objectives can be produced only at high cost and are heavy and large.
On account of weight and size of the illuminating device and of the objective lens, the known arrangements for determining the position and checking the separation can scarcely be integrated into the equipping head of an automatic equipping system; in this case, such an integration is definitely to be ruled out with respect to a certain size of the components. The solution which is optimal with regard to the equipping time, involving a determination of position and checking during the shortest equipping path between component removal and component positioning, cannot then be implemented.
German Patent Application 35 46 216 discloses an arrangement for determining the position of components, in which arrangement the equipping head brings up an image sensor, such as for example a television camera, and the image sensor then records an image of the component at the suction pipette of the equipping head. According to a variant, it is also to be possible to fit the image sensor on the equipping head. Having regard to the overall volume and the weight of the image sensor, this variant could however at best be feasible for the equipping of small components.
German Patent Document 33 40 084 discloses a device for the equipping of printed circuit boards or ceramic substrates with components, in which device the equipping head brings up a position pickup device, in which a relative displacement of the component in relation to a theoretical position related to the positioning axis of the equipping head is ascertained. The position pickup device includes a frame, which is provided along one frame side with a series of mutually adjacent, radiation-emitting elements and along the opposite frame side with a series of mutually adjacent elements receiving the mentioned radiation. If now a component held at the suction pipette of the equipping head is transported into the frame, then the centrally disposed receiving elements lie in the shadow of the component. The ratio of the left-hand and the right-hand receiving elements, which receive a beam, forms a measure of the eccentricity of the component in the corresponding direction.
SUMMARY OF THE INVENTION
The invention is based on the problem of reducing the constructional effort required for determining the position and/or checking the separation and/or checking the coplanarity of the leads of components and of permitting a rapid processing.
The solutions to this problem are based on the common concept of generating on the photosensitive surface of a local resolution optoelectronic transducer a direct shadow of the region of the leads at one side of a component. As a result of this direct shadow, it is possible to entirely dispense with an optical imaging system.
In the case of the first solution parallel light is used for the generation of the direct shadow. The position of the shadow edges of the leads on the local resolution optoelectronic transducer then permits a rapid determination of position and checking of separation. The process can be used for the checking of the separation of the leads in quality control or for determining the position and checking the separation in the automatic planting of components.
According to the second solution and which is especially suitable for SMD planting, parallel light is again used for the generation of the direct shadow, but in this case the local resolution optoelectronic sensor is secured to the equipping head. The light source generating the parallel light can then be brought up by the equipping head or alternatively can likewise be secured to the equipping head.
According to the third solution in each case one direct shadow of the region of the leads at one side of a component is generated successively by illumination from two different directions on the photosensitive surface of the local resolution optoelectronic transducer. Besides the determination of position and checking of separation, this additionally also permits a checking of the coplanarity of the leads. The process can be used for checking the separation and checking the coplanarity in quality control or for determining the position, checking the separation and checking the coplanarity in the automatic equipping of components.
According to the fourth solution and which is especially suitable for SMD planting, in each case one direct shadow of the region of the leads at one side of a component is generated successively again by illumination from two different directions on the photosensitive surface of the local resolution optoelectronic transducers; in this case, however, the local resolution optoelectronic transducer is secured to the equipping head. The illumination from two different directions can be undertaken by a device which is to be brought up by the equipping head or by a device fitted to the equipping head.
According to the sixth solution an equipping head for the automatic equipping of printed circuit boards or ceramic substrates with components is equipped with a suction pipette, a local resolution optoelectronic transducer and at least one light source; in this case, using the light source, in each case one direct shadow of the region of the leads at one side of a component is generated successively on the photosensitive surface of the local resolution optoelectronic transducer from two different directions. As a result of the described constructional measures, a determination of position, checking of the separation and coplanarity of the leads of the components picked up by the suction pipette are made possible, in which case these procedures can are carried out in the path from the component preparation device to the equipping position in the equipping head and thus do not require any additional time. Further advantageous refinements of the processes according to the invention and advantageous refinements of the equipping head according to the invention are set out below.
The local resolution optoelectronic transducer can be formed just by one single photodiode, provided that the latter is displaceable in two mutually perpendicular directions.
The further development of the process concerns a particularly preferred formation of the local resolution optoelectronic transducer by a line of photodiodes which is displaceable perpendicular to the line direction. Since lines of photodiodes are commercially available, even in the length required for particularly large components, this solution is feasible with a particularly low expenditure. It is in this case expedient to use a line of photodiodes, the individual photodiodes of which have rectangular photosensitive surfaces which are arranged so that the long edge of the rectangle is perpendicular to the line direction. Such lines of photodiodes are particularly insensitive to dust.
A photodiode matrix can also be used as a local resolution optoelectronic transducer, i.e. in this case it is possible to dispense with movement of individual photodiodes or of a line of photodiodes.
Another refinement permits a determination of position, checking of separation and checking of coplanarity of the leads of components by central projection from two different directions. In this case, a particularly low expenditure is required if two point light sources disposed at a spacing from one another are used for the central projection from two different directions.
An additional refinement concerns the use of a laser diode as point light source. Such laser diodes are economical and moreover are distinguished by low weight and by a good point characteristic.
If the point light source is fitted to the equipping head, then determination of position, checking of separation and checking of coplanarity of the leads of the components can be carried out without delay on the shortest equipping path between component removal and component positioning. It is then particularly favorable if the point light source is displaced synchronously with the line of photodiodes perpendicular to its line direction. As a result of this measure, a precise shadow of the entire region of the leads at one side of a component is guaranteed with a small expenditure.
Yet another refinement permits, by a simple rotation of the respective component in steps of 90° and 180°, an encompassing of all lead regions. This rotation can then be undertaken without additional expenditure with the aid of the suction pipette of a equipping head.
More refinements concern the fitting of a line of photodiodes which is displaceable perpendicular to its line direction to the equipping head. As has already been mentioned, lines of photodiodes are commercially available even in the length required for particularly large components, so that the realization of the local resolution optoelectronic transducer in this case requires a particularly low expenditure. In these circumstances, in this case also again, a design which is particularly resistant to dust is obtained if the individual photodiodes of the line of photodiodes exhibit a rectangular photosensitive surface which is elongate perpendicular to the line direction.
It is particularly favorable to fit to the equipping head a point light source, preferably two point light sources which are disposed at a spacing from one another. In this case, here also again two laser diodes disposed at a spacing from one another are to be preferred having regard to the low expenditure on cost, the low weight and the good point characteristic to other point light sources.
A further refinement permits a particularly simple synchronous displacement of the point light sources and of the line of photodiodes.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown in the drawings and are described in greater detail hereinbelow.
In the drawings:
FIG. 1 shows the basic principle for determining the position and checking the separation of the leads of components, in the case of which basic principle a direct shadow of the region of the leads at one side of a component is generated by illumination with parallel light on the photosensitive surface of a local resolution optoelectronic transducer,
FIG. 2 shows the basic principle of a first embodiment for determining position, checking separation and checking coplanarity of the leads of components, in the case of which basic principle in each case one direct shadow of the region of the leads at one side of a component is generated successively by illumination with parallel light from two different directions on the photosensitive surface of a local resolution optoelectronic transducer,
FIG. 3 shows the basic principle of an embodiment for determining position, checking separation and checking coplanarity of the leads of components, in the case of which embodiment in each case one shadow of the region of the leads at one side of a component is generated successively by central projection from two different directions on the photosensitive surface of a local resolution optoelectronic transducer,
FIG. 4 shows a variant of the embodiment shown in FIG. 3, in the case of which a line of photodiodes which is displaceable perpendicular to the line direction is used as local resolution optoelectronic transducer,
FIG. 5 and FIG. 6 show the arrangement of the line of photodiodes and point light sources corresponding to the variant shown in FIG. 4 in the checking procedure and in the planting procedure, and
FIGS. 7 and 8 show the ascertainment of the spatial position of the leads of a component according to the variant shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows, in greatly simplified diagrammatic representation, an equipping head BK1, the suction pipette SP of which carries a component B. The shown component B comprises a quad flat pack, which possesses ten leads A on each side of the component. A local resolution optoelectronic transducer W is secured to the equipping head BK1 in such a manner that by illumination with a parallel light PL1 a direct shadow of the region of the leads at one side of the component is generated on its photosensitive surface. From the position of the shadow edges of the leads A on the local resolution optoelectronic transducer W1 it is then possible to ascertain the position of the leads A, for example, in relation to the axis of symmetry of the suction pipette SP and also to check the separation of the leads A. By rotation of the component B relative to the local resolution optoelectronic transducer W1 in steps of 90°, the regions of the leads of the remaining three sides of the component can be encompassed for position determination and separation checking. This rotation, indicated by a double arrow D, of the component B is undertaken by a corresponding rotation of the suction pipette SP.
The photosensitive surface of the local resolution optoelectronic transducer W1 shown in FIG. 1 extends in the direction of the double arrow Pf1 parallel to the pertinent component edge over the region of the leads A and perpendicularly thereto in the direction of the double arrow Pf2. The extent of the photosensitive surface in the direction of the double arrow Pf2 is necessary having regard to any possible rotations of the component B, since such rotations prevent a precise parallel alignment of the component edge and transducer W1.
The photosensitive surface of the local resolution optoelectronic transducer W1 can be generated by a single photodiode FD, which is correspondingly displaced in the direction of the double arrows Pf1 and Pf2. The photosensitive surface of the local resolution optoelectronic transducer W1 can however also be generated by a line of photodiodes which extends in the direction of the double arrow Pf1 and which is displaced in the direction of the double arrow Pf2. Furthermore, the photosensitive surface of the local resolution optoelectronic transducer W1 can be formed by a photodiode matrix, the lines and columns of which extend in the direction of the double arrows Pf1 and Pf2.
The parallel light PL1 for the generation of a direct shadow of the region of the leads at one side of a component on the photosensitive surface of the local resolution optoelectronic transducer W1 is indicated in FIG. 1 by a plurality of arrows, which are aligned in matrix fashion corresponding to the directions Pf1 and Pf2. The generation of the parallel light PL1 can in this case also be realized by movement of a single light source in the direction of the double arrows Pf1 and Pf2 or by movement of a linear arrangement, extending in the direction of the double arrow Pf1, of light sources in the direction of the double arrow Pf2. The device which generates the parallel light PL1 can be either brought up by the equipping head BK1 or directly secured to the equipping head BK1.
FIG. 2 shows, in greatly simplified diagrammatic representation, an equipping head BK2, the suction pipette SP of which carries a component B. A local resolution optoelectronic transducer W2 is secured to the equipping head BK2 in such a manner that by illumination with parallel light PL2 and PL3 from two different directions in each case one direct shadow of the region of the leads at one side of the component is generated on its photosensitive surface successively. From the differing position of corresponding shadow edges of the leads A on the photosensitive surface of the local resolution optoelectronic transducer W2, it is then possible to compute the spatial position of the leads A. The computation of the spatial position of the leads A comprises a determination of position as well as a checking of separation and coplanarity.
By rotation D of the component B relative to the local resolution optoelectronic transducer W2 in steps of 90°, the regions of the leads at the remaining three sides of the component can be encompassed for determination of position as well as checking separation and coplanarity. This rotation D of the component B is in this case also again undertaken with the aid of the suction pipette SP.
With respect to the construction and the mode of operation of the local resolution optoelectronic transducer W2, reference is made to the statements concerning the local resolution optoelectronic transducer W1 of the equipping head BK1 shown in FIG. 1.
The parallel light PL2 and PL3 is indicated in FIG. 2 by two groups of arrows of differing direction. The generation of the parallel light PL2 and PL3 can for example be undertaken by a linear arrangement of corresponding light sources, which are possibly moved in the direction of the double arrow Pf2. The corresponding light sources can either be brought up by the equipping head BK2 or be directly secured to the equipping head BK2.
FIG. 3 shows, in greatly simplified diagrammatic representation, an equipping head BK3, the suction pipette SP of which carries a component B. A local resolution optoelectronic transducer W3 is secured to the equipping head BK3 in such a manner that by central projection from two different directions in each case one direct shadow of the region of the leads at one side of the component is generated successively on its photosensitive surface. From the differing position of corresponding shadow edges of the leads A on the photosensitive surface of the local resolution optoelectronic transducer W3 it is then possible to compute the spatial position of the leads A by using the laws of geometrical optics. This computation is explained later in detail with reference to FIGS. 7 and 8. The computation of the spatial position of the leads A then comprises, in this case also again, a determination of position as well as a checking of separation and coplanarity.
By rotation D of the component B relative to the local resolution optoelectronic transducer W3 in steps of 90°, the regions of the leads at the remaining three sides of the component can be encompassed for determination of position as well as checking of separation and coplanarity. This rotation D of the component B is, in this case also again, undertaken with the aid of the suction pipette SP.
With respect to the construction and the mode of operation of the local resolution optoelectronic transducer W3, reference is made to the corresponding statements concerning the local resolution optoelectronic transducer W1 of the planting head BK1 shown in FIG. 1.
The abovementioned central projection from two different directions is effected by two laser diodes LD1 and LD2 disposed at a spacing from one another. These laser diodes LD1 and LD2 which are fitted to the planting head BK3 are--as is indicated by arrows S--to generate successively in each case one direct shadow of the region of the leads at one side of the component on the photosensitive surface of the local resolution optoelectronic transducer W3. Since the laser diodes LD1 and LD2 comprise point light sources, there is here in each instance a shadow due to central projection.
FIG. 4 shows a variant of the equipping head shown in FIG. 3. The equipping head, designated here by BK4, carries at mutually opposite sides in each case one local resolution optoelectronic transducer W4. The two local resolution optoelectronic transducers W4 are in each instance formed by a line of photodiodes which is displaceable perpendicular to its line direction, i.e. in the direction of the double arrows Pf2. In each instance, two laser diodes LD1 and LD2 which are disposed at a spacing from one another are associated with the two lines of photodiodes.
In the embodiment shown in FIG. 4, by a once-only rotation D of the component B relative to the two local resolution optoelectronic transducers W4 through 90°, the remaining two component sides can also be encompassed for determining the position as well as checking the separation and coplanarity of the leads.
FIGS. 5 and 6 show, in greatly simplified diagrammatic representation for the equipping head BK4 shown in FIG. 4, the arrangement of lines of photodiodes and light sources in the checking procedure and in the equipping procedure. It can be seen that the local resolution optoelectronic transducers W4 and the two associated laser diodes LD1 and LD2, lying one behind the other perpendicular to the plane of the drawing, are secured in each instance to a common mounting H. The mutually opposite mountings H are displaceable by means of shifting devices VE in the direction of the double arrows Pf2, i.e. in the course of the checking procedure the local resolution optoelectronic transducers W4 are displaced synchronously with the associated laser diodes LD1 and LD2 relative to the leads A to be encompassed. The shifting devices VE are fitted to a longitudinal guide LF, in which the suction pipette SP is mounted to be raisable and lowerable in the direction of the double arrow Pf3 and rotatable in the direction of the double arrow D.
After the position determination and checking procedure shown in FIG. 5, the two mountings H are displaced radially outwardly according to FIG. 6, so that the component B can be deposited without obstruction at the predetermined equipping position of a printed circuit board LP by lowering the suction pipette SP. In the course of this positioning of the component B on the printed circuit board LP, the result of the previously performed determination of position is taken into account, as appropriate, by a corresponding correction. This correction can include both a displacement and a rotation of the component B relative to the printed circuit board LP.
FIGS. 7 and 8 show, for the equipping head BK4 described hereinabove with reference to FIGS. 4, 5 and 6, the ascertainment of the spatial position of the leads A of a component B. FIG. 7 shows the local resolution optoelectronic transducer W4 which is formed by a line of photodiodes, the component B, disposed immediately therebelow, with the leads A and, below the same, the two laser diodes LD1 and LD2 disposed at a spacing from one another. The length, designated in FIG. 8 by L, of the line of photodiodes is in this case coordinated with the length of the component B.
In the vertical direction, the spacing between the lower side of the line of photodiodes and the two laser diodes LD1 and LD2 is designated by A. In the horizontal direction, the spacing between the laser diodes LD1 and LD2 and the margin R, on the left in FIG. 7, of the line of photodiodes is designated D1 and D2 respectively. The shadow edges, generated successively by the radiation S of the laser diodes LD1 and LD2 on the line of photodiodes, of a specified lead A exhibit a spacing d1 and a spacing d2 respectively from the left-hand margin R of the line of photodiodes in the horizontal direction. The horizontal spacing of this specified lead A from the left-hand margin R is shown by the coordinate x, while in the vertical direction the spacing of the leads A from the lower side of the line of photodiodes is shown by the coordinate z. As a result of the ascertainment of the coordinates x, a determination of position and a checking of separation of the leads A can be performed, while the coordinates z of the leads A permit a check of coplanarity.
With the aid of the predetermined dimensions A, D1 and D2 and of the dimensions d1 and d2 recorded by the line of photodiodes, it is possible to compute for the determination of position, checking of separation and coplanarity the coordinates x and z with the aid of the relations ##EQU1##
It can also be seen from FIG. 8 that the transducer W4 formed by a line of photodiodes exhibits rectangular photodiodes FD and is displaceable in the direction of the double arrows Pf2. As a result of this displaceability, an unambiguous shadow of the leads A is guaranteed, even in the event of a rotation of the component B. Moreover, the displacement of the line of photodiodes also permits the ascertainment of the rotation of a component B, so that also any possible rotations can be corrected in the course of the positioning on a printed circuit board.
In the case of the preferred embodiment described hereinabove with reference to FIGS. 4 to 8, lines of photodiodes from the company Reticon, Sunnyvale, Calif., USA with the designation RL 4096 N are used as the local resolution optoelectronic transducers W. These lines of photodiodes comprise in each instance 4096 individual photodiodes disposed in a row; in this case, the photosensitive surfaces of the individual photodiodes exhibit dimensions of 15×16 micrometers. The length of a line of photodiodes is 60 mm. Laser diodes from the company Hitachi Ltd, Tokyo, Japan with the designation HL 6711 C are used as the point light sources or laser diodes LD1 and LD2. These laser diodes exhibit a power of 5 mW and emit light having a wavelength of 670 nm. As a result of the large number of individual photodiodes in the line of photodiodes, it is guaranteed that at high resolution only the necessary information is recorded and can be read out in the shortest time of, for example, 2 ms.
By way of departure from the described embodiments, in the case of specified equipping heads it can also be expedient to exchange the arrangement of lines of photodiodes and laser diodes. In this case, the laser diodes are fitted to the equipping head above the component and the lines of photodiodes are fitted to the equipping head below the component.
Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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In order to determine the position and/or to check the separation of the leads (A) of components (B), a direct shadow of the region of the leads at one side of the component is generated on the photosensitive surface of a local resolution optoelectronic transducer (W4). If in each case one shadow is generated successively from two different directions, the coplanarity of the leads (A) may also be checked. Preferably, the local resolution optoelectronic transducer (W4) and the light sources for casting the shadow are directly secured to the equipping head (BK4). By integrating the determination system into the equipping head, the lead position can be determined and the separation and coplanarity of the leads can be checked without delay.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. nonprovisional application Ser. No. 13/633,281, filed Oct. 2, 2012, which is a continuation of U.S. nonprovisional application Ser. No. 12/622,776, filed Nov. 20, 2009, which is a continuation-in-part of international patent application number PCT/US2008/065245, filed May 30, 2008, which claims priority to and the benefit of U.S. provisional application Ser. Nos. 60/941,310 and 60/953,822 filed in the U.S. Patent and Trademark office Jun. 1, 2007 and Aug. 3, 2007 respectively. U.S. nonprovisional application Ser. No. 12/622,776 also claims priority to and the benefit of U.S. provisional application Ser. No. 61/254,086, filed Oct. 22, 2009. The contents of each of which are hereby incorporated by reference herein in their entireties.
GOVERNMENT SUPPORT
[0002] The present invention described herein was support at least in part by the Department of Homeland Security (grant number: HSHQPA-05-9-0033). The government has certain rights in the invention.
TECHNICAL FIELD
[0003] The invention generally relates to an improvement to ion introduction to mass spectrometers.
BACKGROUND
[0004] The atmospheric pressure interface (API) of a mass spectrometer is used to transfer ions from a region at atmospheric pressure into other regions at reduced pressures. It allows the development and use of a variety of ionization sources at atmospheric pressure for mass spectrometry, including electrospray ionization (ESI) (Fenn, J. B.; Mann, M.; Meng, C. K.; Wong, S. F.; Whitehouse, C. M. Science 1989, 246, 64-71; Yamashita, M.; Fenn, J. B. J. Phys. Chem. 1984, 88, 4451-4459), atmospheric pressure ionization (APCI) (Carroll, D. I.; Dzidic, I.; Stillwell, R. N.; Haegele, K. D.; Horning, E. C. Anal. Chem. 1975, 47, 2369-2373), and atmospheric pressure matrix assisted laser desorption ionization (AP-MALDI), (Laiko, V. V.; Baldwin, M. A.; Burlingame, A. L. Anal. Chem. 2000, 72, 652-657; Tanaka, K.; Waki, H.; Ido, Y.; Akita, S.; Yoshida, Y.; Yoshida, T.; Matsuo, T. Rapid Commun. Mass Spectrom. 1988, 2, 151-153) etc. An API not only allows the coupling of a mass spectrometer with various sample separation and sample pretreatment methods, such as liquid chromatograph, but also enables ambient preparation and treatment of ions using a variety of desirable conditions, such as the thermal production of the ions, (Chen, H.; Ouyang, Z.; Cooks, R. G. Angewandte Chemie, International Edition 2006, 45, 3656-3660; Takats, Z.; Cooks, R. G. Chemical Communications (Cambridge, United Kingdom) 2004, 444-445) ion-ion reactions (Loo, R. R. O.; Udseth, H. R.; Smith, R. D. Journal of the American Society for Mass Spectrometry 1992, 3, 695-705) or ion fragmentation, (Chen, H.; Eberlin, L. S.; Cooks, R. G. Journal of the American Chemical Society 2007, 129, 5880-5886) before sending them into vacuum for mass analysis. Without an API, it is also not possible to take advantage of the recent development of a new category of direct ambient ionization/sampling methods, including desorption electrospray ionization (DESI) (Takats, Z.; Wiseman, J. M.; Gologan, B.; Cooks, R. G. Science 2004, 306, 471-473), direct analysis in real time (DART) (Cody, R. B.; Laramee, J. A.; Durst, H. D. Anal. Chem. 2005, 77, 2297-2302), Atmospheric Pressure Dielectric Barrier Discharge Ionization (DBDI), and electrospray-assisted laser desoption/ionization (ELDI) (Shiea, J.; Huang, M. Z.; Hsu, H. J.; Lee, C. Y.; Yuan, C. H.; Beech, I.; Sunner, J. Rapid Commun. Mass Spectrom. 2005, 19, 3701-3704).
[0005] Since the ESI source was first successfully demonstrated for mass spectrometry (Yamashita, M.; Fenn, J. B. J. Phys. Chem. 1984, 88, 4451-4459), the configuration of API used for ESI was widely adopted and has not changed significantly. Nowadays a typical API has a constantly open channel involving a series of differential pumping stages with a capillary or a thin hole of small ID to allow ions to be transferred into the first stage and a skimmer for access to the second stage. A rough pump is usually used to pump the first region to about 1 ton and multiple turbomolecular pumps or a single pump with split flow used for pumping the subsequent regions with a base pressure in the final stage used for the mass analysis, which is usually 10 −5 ton or below. Ion optical systems, including static electric lenses and RF guides, are also used to preserve the ion current while the neutrals are pumped away. To maximize the number of ions transferred into the final region for mass analysis, large pumping capacities are always desirable so that larger orifices can be used to pass ions from region to region. As an example, a Finnigan LTQ (Thermo Fisher Scientific, Inc., San Jose, Calif.) ion trap mass spectormeter has two 30 m 3 /hr rough pumps for the first stage and a 400 l/s turbomolecular pump with two drag pumping stages for the next 3 stages. The highest loss in ion transfer occur at the first stage and the second stage, corresponding to a 2 orders and a 1 order of magnitude, respectively, which results in an overall efficiency lower than 0.1% for the ion transfer through an API. When an attempt is made to implement this kind of API on a portable instrument, the ion transfer efficiency is further reduced by the fact that much lower pumping capacity must be used to achieve the desirable weight and power consumption of the instruments. A recently developed Mini 10 handheld rectilinear ion trap mass spectrometer weighs only 10 kg and has miniature rough and turbo pumps of only 0.3 m 3 /hr and 11 l/s, respectively. (Gao, L.; Song, Q.; Patterson, G. E.; Cooks, R. G.; Ouyang, Z. Anal. Chem. 2006, 78, 5994-6002)
[0006] Many efforts have been made to increase the ion transfer efficiency in laboratory scale mass spectrometers. The ion transfer through the second stage has been successfully improved by a factor of ten by replacing the skimmer with an ion funnel. (Shaffer, S. A.; Tang, K. Q.; Anderson, G. A.; Prior, D. C.; Udseth, H. R.; Smith, R. D. Rapid Communications in Mass Spectrometry 1997, 11, 1813-1817) Air-dynamic ion focusing devices (Zhou, L.; Yue, B.; Dearden, D. V.; Lee, E. D.; Rockwook, A. L.; Lee, M. L. Anal. Chem. 2003, 75, 5978-5983; Hawkridge, A. M.; Zhou, L.; Lee, M. L.; Muddiman, D. C. Analytical Chemistry 2004, 76, 4118-4122) have been employed in front of API's of mass spectrometers. Though the efficiency of API itself was not improved, the ultimate ion current reaching the mass analyzer was significance increased. However, the possibility of arcing inside the vacuum increases at high pressure, which results in high noise and short lifetime of the electron multiplier and power supplies.
[0007] There is a need for atmospheric interfaces that increase ion transfer efficiency to a mass spectrometer.
SUMMARY
[0008] An aspect of the invention herein provides a device for controlling movement of ions and the body of air or other gas in which the ions are maintained, the device including: a valve aligned with an exterior portion of a tube, in which the valve controls movement of ions through the tube; and a first capillary inserted into a first end of the tube and a second capillary inserted into a second end of the tube, in which neither the first capillary nor the second capillary overlap with a portion of the tube that is in alignment with the valve.
[0009] In a related embodiment of the device, a proximal end of the first capillary is connected to a trapping device, in which the trapping device is below atmospheric pressure. In another related embodiment, a distal end of the second capillary receives the ions from an ionizing source, in which the ionizing source is at substantially atmospheric pressure.
[0010] In certain embodiments of the device, the tube is composed of an inert plastic, for example silicone plastic. In other embodiments, the first and second capillary are composed of an inert metal, for example stainless steel. In other embodiments of the device, the first and second capillaries have substantially the same outer diameter. In alternative embodiments, the first and second capillaries have different outer diameters. In another embodiment of the device, the first and second capillaries have substantially the same inner diameter. Alternatively, the first and second capillaries have different inner diameters. In another embodiment of the device, the second capillary has a smaller inner diameter than the inner diameter of the first capillary.
[0011] In another embodiment of the devices, the valve is selected from the group consisting of a pinch valve, a thin plate shutter valve, and a needle valve.
[0012] Another aspect of the invention herein provides a device for controlling movement of ions, the device including a valve aligned with an exterior portion of a tube, in which the valve controls movement of ions through the tube. In a related embodiment, a proximal end of the tube is connected to a trapping device, in which the trapping device is below atmospheric pressure. In another related embodiment, a distal end of the tube receives the ions from an ionizing source, in which the ionizing source is at substantially atmospheric pressure. In certain embodiment, a distal end of the tube receives the ions at a first pressure, and a proximal end of the tube is connected to a trapping device at a pressure reduced from the first pressure.
[0013] Another aspect of the invention herein provides a discontinuous atmospheric pressure interface system including: an ionizing source for converting molecules into gas phase ions in a region at about atmospheric pressure; a trapping device; and a discontinuous atmospheric pressure interface for transferring the ions from the region at about atmospheric pressure to at least one other region at a reduced pressure, in which the interface includes a valve for controlling entry of the ions into the trapping device such that the ions are transferred into the trapping device in a discontinuous mode.
[0014] In a related embodiment, the system further includes at least one vacuum pump connected to the trapping device. In another related embodiment of the system, the atmospheric pressure interface further includes: a tube, in which an exterior portion of the tube is aligned with the valve; and a first capillary inserted into a first end of the tube and a second capillary inserted into a second end of the tube, such that neither the first capillary nor the second capillary overlap with a portion of the tube that is in alignment with the valve. In another embodiment of the system, the atmospheric pressure interface further includes a tube, in which an exterior portion of the tube is aligned with the valve.
[0015] In certain embodiments of the system, ions enter the trapping device when the valve is in an open position. In another embodiment of the system, ions are prevented from entering the trapping device when the valve is in a closed position. The closed position refers to complete closure of the valve, and also includes quasi-closure of the valve, i.e, the valve is substantially closed such that pumping significantly exceeds ingress of gas or vapor. Substantially closed includes at least about 70% closed, at least about 80% closed, at least about 90% closed, at least about 95% closed, or at least about 99% closed.
[0016] In another embodiment, the system further includes a computer operably connected to the system. In another embodiment, the computer contains a processor configured to execute a computer readable program, the program controlling the position of the valve. In another embodiment, the computer contains a processor configured to execute a computer readable program, the program implementing a selected waveform inverse Fourier transformation (SWIFT) isolation algorithm to separate ions.
[0017] In certain embodiments of the system, the ionizing source operates by a technique selected from the group consisting of: electrospray ionization, nano-electrospray ionization, atmospheric pressure matrix-assisted laser desorption ionization, atmospheric pressure chemical ionization, desorption electrospray ionization, atmospheric pressure dielectric barrier discharge ionization, atmospheric pressure low temperature plasma desorption ionization, and electrospray-assisted laser desorption ionization. In another embodiment of the system, the trapping device is selected from the group consisting of a mass analyzer of a mass spectrometer, a mass analyzer of a handheld mass spectrometer, and an intermediate stage storage device.
[0018] In another embodiment of the system, the mass analyzer is selected from the group consisting of: a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, and an orbitrap. In another embodiment of the system, the intermediate storage device is coupled with a mass analyzer of a mass spectrometer or a mass analyzer of a handheld mass spectrometer. In a related embodiment, the mass analyzer is selected from the group consisting of: a mass filter, a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, an orbitrap, a time of flight mass spectrometer, and a magnetic sector mass spectrometer. In yet another embodiment, the system further includes an ion accumulating surface connected to a distal end of the second capillary. In yet another embodiment, the system further includes an ion accumulating surface connected to a distal end of the tube. In another embodiment of the system, the tube of the atmospheric interface is composed of an inert plastic, for example silicone plastic. In another embodiment of the system, the first and second capillary of the atmospheric interface are composed of an inert metal, for example stainless steel.
[0019] In certain embodiments of the system, the valve operates to control entry of ions in a synchronized manner with respect to operation of the mass analyzer. In another embodiment of the system, the configuration of the discontinuous atmospheric pressure interface and the mass analyzer is off-axis. In another embodiment of the system, an ion optical element, for example, a focusing tube lens, is located between the discontinuous atmospheric pressure interface and the mass analyzer to direct the ions into the mass analyzer. In another embodiment, the system further includes an ion optical element located between the ionization source and the discontinuous atmospheric pressure interface to direct the ions into the mass analyzer.
[0020] Another aspect of the invention provides a kit including the above devices and a container. Another aspect of the invention provides a kit including the above system and a container. In certain embodiments, the kits include instructions for use.
[0021] Another aspect of the invention provides a method of discontinuously transferring ions at atmospheric pressure into a trapping device at reduced pressure, the method including: opening a valve connected to an atmospheric pressure interface, such that opening of the valve allows for transfer of ions substantially at atmospheric pressure to a trapping device at reduced pressure; and closing the valve connected to the atmospheric pressure interface, such that closing the valve prevents additional transfer of the ions substantially at atmospheric pressure to the trapping device at reduced pressure.
[0022] In certain embodiments, prior to opening the valve, the method further includes converting molecules to gas phase ions. In other embodiments, the converting step is selected from the group consisting of: electrospray ionization, nano-electrospray ionization, atmospheric pressure matrix-assisted laser desorption ionization, atmospheric pressure chemical ionization, desorption electrospray ionization, atmospheric pressure dielectric barrier discharge ionization, atmospheric pressure low temperature plasma desorption ionization, and electrospray-assisted laser desorption ionization.
[0023] In another embodiment of the method, the opening and the closing of the valve is controlled by a computer operably connected to the atmospheric pressure interface. In another embodiment of the method, the trapping device is selected from the group consisting of a mass analyzer of a mass spectrometer, a mass analyzer of a handheld mass spectrometer, and an intermediate stage storage device. In another embodiment of the method, the mass analyzer is selected from the group consisting of: a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, and an orbitrap. In another embodiment of the method, the intermediate storage device is coupled with a mass analyzer of a mass spectrometer or a mass analyzer of a handheld mass spectrometer. In a related embodiment, the mass analyzer is selected from the group consisting of: a mass filter, a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, an orbitrap, a time of flight mass spectrometer, and a magnetic sector mass spectrometer.
[0024] In certain embodiments of the method, electrical voltage of the mass analyzer is set to ground when the valve is open. In other embodiments of the method, subsequent to the ions being transferred into the mass analyzer and the valve being closed, the ions are retained by the mass analyzer for further manipulation. In another embodiment of the method, prior to further manipulation, the ions are cooled and the pressure is further reduced. In yet another embodiment of the method, further manipulation includes mass analysis of the ions.
[0025] In certain embodiments of the method, the computer synchronizes the opening and the closing of the valve with a sequence of mass analysis of the ions in the mass analyzer. In a related embodiment of the method, the computer synchronizes the opening and the closing of the valve with a sequence of steps that allow tandem mass analysis of the ions in the mass analyzer.
[0026] In another embodiment of the method, the atmospheric pressure interface further includes: a tube, in which an exterior portion of the tube is aligned with the valve; and a first capillary inserted into a first end of the tube and a second capillary inserted into a second end of the tube, such that neither the first capillary nor the second capillary overlap with a portion of the tube that is in alignment with the valve. In another embodiment of the method, the atmospheric pressure interface further includes: a tube, in which an exterior portion of the tube is aligned with the valve. In related embodiments of the method, the valve is selected from the group consisting of a pinch valve, a thin shutter plate valve, and a needle valve.
[0027] In another embodiment of the method, after converting the molecules to ions, the ions are stored on a functional surface connected to the distal end of the second capillary at atmospheric pressure, in which the functional surface is continuously supplied with ions from a continuously operated ion source. In another embodiment of the method, after converting the molecules to ions, the ions are stored on a functional surface connected to the distal end of the tube at atmospheric pressure, in which the functional surface is continuously supplied with ions from a continuously operated ion source. In related embodiments, the ions stored on the functional surface are subsequently transferred by the atmospheric pressure interface to the trapping device.
[0028] In another embodiment of the method, the first and second capillary of the atmospheric interface have substantially the same outer diameter. Alternatively, the first and second capillary of the atmospheric interface have different outer diameters. In another embodiment of the method, the first and second capillary of the atmospheric interface have substantially the same inner diameter. Alternatively, the first and second capillary of the atmospheric interface have different inner diameters. In another embodiment of the method, the second capillary has a smaller inner diameter that the inner diameter of the first capillary.
[0029] Another aspect of the invention provides a method of discontinuously transferring ions into a mass spectrometer, the method including: opening a valve connected to an atmospheric pressure interface, such that opening of the valve allows for transfer of ions substantially at atmospheric pressure to a mass analyzer at a reduced pressure in the mass spectrometer; and closing the valve connected to the atmospheric pressure interface, such that closing the valve prevents additional transfer of the ions substantially at atmospheric pressure to the mass analyzer at the reduced pressure in the mass spectrometer.
[0030] In a related embodiment of the device, two devices for controlling the movement of ions and the body of air or other gas in which the ions are maintained are present: a first valve is aligned with an exterior portion of a first tube, in which the first valve controls movement of ions through the first tube; and a first capillary inserted into a first end of the tube in which the first capillary does not overlap with a portion of the first tube that is in alignment with the first valve, and a second valve aligned with an exterior portion of a second tube, in which the second valve controls movement of ions through the second tube; and a second capillary inserted into a first end of the second tube and a third capillary inserted into a second end of the second tube, in which neither the second capillary nor the third capillary overlap with a portion of the first second tube that is in alignment with the second valve.
[0031] In one embodiment of the invention, the first discontinuous atmospheric pressure interface is connected to a trapping device and the second discontinuous atmospheric pressure interface connected to the opposite side of the trapping device. In a related embodiment of the device, a proximal end of the first capillary is connected to a trapping device, in which the trapping device is below atmospheric pressure. In another related embodiment of the device, a proximal end of the second capillary is connected to a trapping device, in which the trapping device is below atmospheric pressure. In another related embodiment, a distal end of the first tube receives the ions from an ionizing source, in which the ionizing source is at substantially atmospheric pressure.
[0032] In certain embodiments of the device, the first and second tubes are comprised of an inert plastic, for example silicone plastic. In other embodiments, the first, second, and third capillaries are comprised of an inert metal, for example stainless steel. In other embodiments of the device, the first, second, and third capillaries have substantially the same outer diameter. In alternative embodiments, the first, second, and third capillaries have different outer diameters. In another embodiment of the device, the first, second, and third capillaries have substantially the same inner diameter. Alternatively, the first, second, and third capillaries have different inner diameters. In another embodiment of the device, the third capillary has a smaller inner diameter than the inner diameter of the second capillary. In another embodiment of the devices, the first and second valves are selected from the group consisting of a pinch valve, a thin plate shutter valve, and a needle valve.
[0033] Another aspect of the invention herein provides a discontinuous atmospheric pressure interface system including: an ionizing source for converting molecules into gas phase ions in a region at about atmospheric pressure; a trapping device; and two discontinuous atmospheric pressure interfaces for transferring the ions from the region at about atmospheric pressure to at least one other region at a reduced pressure, in which each interface includes a valve for controlling entry of the ions into the trapping device such that the ions are transferred into the trapping device in a discontinuous mode.
[0034] In a related embodiment, the system further includes at least one vacuum pump connected to the trapping device. In another related embodiment of the system, the first atmospheric pressure interface further includes: a first tube, in which an exterior portion of the first tube is aligned with the first valve; and a first capillary inserted into a first end of the first tube such that the first capillary does not overlap with a portion of the first tube that is in alignment with the valve; and the second atmospheric pressure interface further includes: a second tube, in which an exterior portion of a second valve aligned with an exterior portion of a second tube, and a second capillary inserted into a first end of the second tube and a third capillary inserted into a second end of the second tube, in which neither the second capillary nor the third capillary overlap with a portion of the first second tube that is in alignment with the second valve. In another embodiment of the system, the first atmospheric pressure interface further includes a tube, in which an exterior portion of the tube is aligned with the valve. In another embodiment of the system, the second atmospheric pressure interface further include a tube, in which an exterior portion of the tube is aligned with the valve.
[0035] In certain embodiments of the system, ions enter the trapping device when the valves are in an open position. In another embodiment of the system, ions are prevented from entering the trapping device when the valves are in a closed position. The closed position refers to complete closure of the valves, and also includes quasi-closure of the valves, i.e, the valves are substantially closed such that pumping significantly exceeds ingress of gas or vapor. Substantially closed includes at least about 70% closed, at least about 80% closed, at least about 90% closed, at least about 95% closed, or at least about 99% closed.
[0036] In another embodiment, the system further includes a computer operably connected to the system. In another embodiment, the computer contains a processor configured to execute a computer readable program, the program controlling the positions of the valves. In another embodiment, the computer contains a processor configured to execute a computer readable program, the program implementing a selected waveform inverse Fourier transformation (SWIFT) isolation algorithm to separate ions.
[0037] In certain embodiments of the system, the ionizing source operates by a technique selected from the group consisting of: electrospray ionization, nano-electrospray ionization, atmospheric pressure matrix-assisted laser desorption ionization, atmospheric pressure chemical ionization, desorption electrospray ionization, atmospheric pressure dielectric barrier discharge ionization, atmospheric pressure low temperature plasma desorption ionization, and electrospray-assisted laser desorption ionization. In another embodiment of the system, the trapping device is selected from the group consisting of a mass analyzer of a mass spectrometer, a mass analyzer of a handheld mass spectrometer, and an intermediate stage storage device.
[0038] In another embodiment of the system, the mass analyzer is selected from the group consisting of: a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, and an orbitrap. In another embodiment of the system, the intermediate storage device is coupled with a mass analyzer of a mass spectrometer or a mass analyzer of a handheld mass spectrometer. In a related embodiment, the mass analyzer is selected from the group consisting of: a mass filter, a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, an orbitrap, a time of flight mass spectrometer, and a magnetic sector mass spectrometer. In yet another embodiment, the system further includes an ion accumulating surface connected to a distal end of the first tube. In another embodiment of the system, the tubes of the atmospheric interfaces are comprised of an inert plastic, for example silicone plastic. In another embodiment of the system, the first, second, and third capillary of the atmospheric interface are comprised of an inert metal, for example stainless steel.
[0039] In certain embodiments of the system, the valves operate to control entry of ions in a synchronized manner with respect to operation of the mass analyzer. In another embodiment of the system, the configuration of the discontinuous atmospheric pressure interface and the mass analyzer is off-axis. In another embodiment of the system, an ion optical element, for example, a focusing tube lens, is located between first discontinuous atmospheric pressure interface and the mass analyzer to direct the ions into the mass analyzer. In another embodiment, the system further includes an ion optical element located between the ionization source and the first discontinuous atmospheric pressure interface to direct the ions into the mass analyzer.
[0040] In another embodiment of the invention, the first discontinuous atmospheric pressure interface is optimized with respect to capillary size, capillary distance from the mass analyzer and optional ion optical element, then the second discontinuous atmospheric pressure interface is implemented on the opposite side of the mass analyzer.
[0041] Another aspect of the invention provides a kit including the above devices and a container. Another aspect of the invention provides a kit including the above system and a container. In certain embodiments, the kits include instructions for use.
[0042] Another aspect of the invention provides a method of discontinuously transferring ions at atmospheric pressure into a trapping device at reduced pressure, the method including: opening a valve connected to an atmospheric pressure interface, such that opening of the valve allows for transfer of ions substantially at atmospheric pressure to a trapping device at reduced pressure; and closing the valve connected to the atmospheric pressure interface, such that closing the valve prevents additional transfer of the ions substantially at atmospheric pressure to the trapping device at reduced pressure.
[0043] In certain embodiments, prior to opening a valve, the method further includes converting molecules to gas phase ions. In other embodiments, the converting step is selected from the group consisting of: electrospray ionization, nano-electrospray ionization, atmospheric pressure matrix-assisted laser desorption ionization, atmospheric pressure chemical ionization, desorption electrospray ionization, atmospheric pressure dielectric barrier discharge ionization, atmospheric pressure low temperature plasma desorption ionization, and electrospray-assisted laser desorption ionization.
[0044] In another embodiment of the method, the opening and the closing of the valves are controlled by a computer operably connected to the atmospheric pressure interface. In another embodiment of the method, the trapping device is selected from the group consisting of a mass analyzer of a mass spectrometer, a mass analyzer of a handheld mass spectrometer, and an intermediate stage storage device. In another embodiment of the method, the mass analyzer is selected from the group consisting of: a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, and an orbitrap. In another embodiment of the method, the intermediate storage device is coupled with a mass analyzer of a mass spectrometer or a mass analyzer of a handheld mass spectrometer. In a related embodiment, the mass analyzer is selected from the group consisting of: a mass filter, a quadrupole ion trap, a rectalinear ion trap, a cylindrical ion trap, a ion cyclotron resonance trap, an orbitrap, a time of flight mass spectrometer, and a magnetic sector mass spectrometer.
[0045] In certain embodiments of the method, electrical voltage of the mass analyzer is set to ground when a valve is open. In other embodiments of the method, subsequent to the ions being transferred into the mass analyzer and a valve being closed, the ions are retained by the mass analyzer for further manipulation. In another embodiment of the method, prior to further manipulation, the ions are cooled and the pressure is further reduced. In yet another embodiment of the method, further manipulation includes mass analysis of the ions.
[0046] In certain embodiments of the method, the computer synchronizes the opening and the closing of the valves with a sequence of mass analysis of the ions in the mass analyzer. In a related embodiment of the method, the computer synchronizes the opening and the closing of the valves with a sequence of steps that allow tandem mass analysis of the ions in the mass analyzer.
[0047] In another embodiment of the method, the first atmospheric pressure interface further includes: a first tube, in which an exterior portion of the first tube is aligned with the first valve; and a first capillary inserted into a first end of the first tube such that the first capillary does not overlap with a portion of the first tube that is in alignment with the valve; and the second atmospheric pressure interface further includes: a second tube, in which an exterior portion of a second valve aligned with an exterior portion of a second tube, and a second capillary inserted into a first end of the second tube and a third capillary inserted into a second end of the second tube, in which neither the second capillary nor the third capillary overlap with a portion of the first second tube that is in alignment with the second valve. In related embodiments of the method, the valves are selected from the group consisting of a pinch valve, a thin shutter plate valve, and a needle valve.
[0048] In another embodiment of the method, after converting the molecules to ions, the ions are stored on a functional surface connected to the distal end of the first tube at atmospheric pressure, in which the functional surface is continuously supplied with ions from a continuously operated ion source. In related embodiments, the ions stored on the functional surface are subsequently transferred by the atmospheric pressure interface to the trapping device.
[0049] In another embodiment of the method, the first, second, and third capillaries of the atmospheric interfaces have substantially the same outer diameter. Alternatively, the first, second, and third capillaries of the atmospheric interfaces have different outer diameters. In another embodiment of the method, first, second, and third capillaries of the atmospheric interfaces have substantially the same inner diameter. Alternatively, the first, second, and third capillaries of the atmospheric interfaces have different inner diameters. In another embodiment of the method, the third capillary has a smaller inner diameter that the inner diameter of the secondary capillary.
[0050] Another aspect of the invention provides a method of discontinuously transferring ions into a mass spectrometer, the method including: opening a valve connected to an atmospheric pressure interface, such that opening of the valve allows for transfer of ions substantially at atmospheric pressure to a mass analyzer at a reduced pressure in the mass spectrometer; and closing the valve connected to the atmospheric pressure interface, such that closing the valve prevents additional transfer of the ions substantially at atmospheric pressure to the mass analyzer at the reduced pressure in the mass spectrometer.
[0051] In another embodiment of the method, the second valve is open during the ionization period together with the first valve. In a further embodiment of the method, the second valve is open after the ionization period.
[0052] In another embodiment of the method, the first and second valves can be opened or closed at various times during ionization and ion cooling in order to introduce gas flow into the trapping device. In a related embodiment of the invention, this gas flow can induce collisional dissociation for some compounds. In a related embodiment, these compounds are small organic compounds.
[0053] In another aspect of the invention, ions and/or molecules can react in a device with two discontinuous atmospheric pressure interfaces. In a related embodiment, an ion can be introduced into the trapping device by opening valve 1 and reactive ions or molecules can subsequently be introduced into the trapping device by opening valve 2.
[0054] In yet another embodiment of the device, a fourth capillary is connected to the distal end of the first tube. In a related embodiment of the method, after converting the molecules to ions, the ions are stored on a functional surface connected to the distal end of the fourth capillary connected first tube at atmospheric pressure, in which the functional surface is continuously supplied with ions from a continuously operated ion source.
[0055] In another embodiment of the device, more than two discontinuous atmospheric pressure interfaces can be connected to the trapping device. In a related embodiment, such discontinuous atmospheric pressure interfaces would have the same properties as described above.
[0056] In an other embodiment of the method, ions and/or molecules can react in a device with more than two discontinuous atmospheric pressure interfaces. In a related embodiment, an ion can be introduced into the trapping device by opening one valve and reactive ions or molecules can subsequently be introduced into the trapping device by opening at least one of the other valves.
[0057] In yet another embodiment of the device, the discontinuous atmospheric pressure interface is comprised of a valve aligned with an exterior portion of a tube, in which the valve controls the movement of ions through the tube. In a related embodiment, the tube is connected to a trapping device. These embodiments may have the same properties as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] FIG. 1 is a schematic view of a discontinuous atmospheric pressure interface coupled in a miniature mass spectrometer with rectilinear ion trap.
[0059] FIG. 2A is a horizontal time graph of a typical scan function used for mass analysis using a discontinuous atmospheric pressure interface.
[0060] FIG. 2B is a horizontal time graph of a manifold pressure measured during scanning, with an open time of 20 ms and a close time of 800 ms for the DAPI.
[0061] FIG. 3A is a nano ESI mass spectrum recorded using a DAPI for a 5 ppm solution of caffeine and cocaine, 20 ms ion introduction time and 500 ms cooling time.
[0062] FIG. 3B is a detail of a portion of the spectrum of FIG. 3A .
[0063] FIG. 3C is a nano ESI mass spectrum recorded using a DAPI for a 50 ppb mixture solution of methylamphetamine, cocaine and heroin, 25 ms ion introduction time and 500 ms cooling time.
[0064] FIG. 4A is a nano ESI mass spectrum of a 500 ppb mixture solution of methylamphetamine, cocaine and heroin.
[0065] FIG. 4B is a MS/MS mass spectra of molecular ions of methylamphetamine m/z 150, SWIFT notch 300 to 310 kHz and excitation AC at 100 kHz.
[0066] FIG. 4C is a MS/MS mass spectra of molecular ion of cocaine m/z 304, SWIFT notchth 300 to 310 kHz and excitation AC at 100 kHz.
[0067] FIG. 4D is a MS/MS mass spectra of molecular ion of heroin m/z 370, SWIFT notch 300 to 310 kHz and excitation AC at 100 kHz.
[0068] FIG. 5A is a ESI mass spectrum with 20 ms ion introduction of a 500 ppb lysine solution.
[0069] FIG. 5B is a detail of a portion of the spectrum of FIG. 5A .
[0070] FIG. 5C is a APCI mass spectrum with 20 ms ion introduction of a 50 ppb DMMP in air.
[0071] FIG. 6 is a DESI mass spectrum of cocaine on Teflon surface with 15 ms ion introduction time and 500 ms cooling time, background subtracted.
[0072] FIG. 7A is a DESI mass spectrum of direct analysis of black ink from BIC Round Stic ballpoint pen.
[0073] FIG. 7B is a DESI mass spectrum of direct analysis of blue ink from BIC Round Stic ballpoint pen.
[0074] FIG. 8 is a nano ESI mass spectrum of a 400 ppt mixture solution of methamphetamine, cocaine and heroin.
[0075] FIG. 9A is a schematic elevation view of a discontinuous atmospheric pressure interface coupled with a miniature mass spectrometer and nano electrospray ionization source.
[0076] FIG. 9B is a schematic elevation view of a discontinuous atmospheric pressure interface coupled with a miniature mass spectrometer and atmospheric pressure chemical ionization using corona discharge.
[0077] FIG. 10 is an APCI mass spectrum of naphthalene vapor.
[0078] FIG. 11 a schematic elevation view of an off-axis configuration for the combination of discontinuous API and RIT, which avoids direct gas jet into RIT. A focusing tube lens is used to direct the ion beam into the RIT.
[0079] FIG. 12 is a schematic elevation view of a discontinuous atmospheric pressure interface coupled via a tubing with an functional inner surface for ion accumulation and release. The Ions are accumulated for a given time on this inner surface before they are sent through the discontinuous atmospheric pressure interface into the mass analyzer.
[0080] FIG. 13 is a schematic view of a dual discontinuous atmospheric pressure interfaced ion trap mass spectrometer which uses a rectilinear ion trap (DAPI-RIT-DAPI).
[0081] FIG. 14 is a horizontal time graph of a scan function used for the DAPI-RIT-DAPI mass spectrometer.
[0082] FIG. 15 is a mass spectrum of a Lysine/Cytochrome C mixture recorded using a DAPI-RIT-DAPI mass spectrometer.
[0083] FIG. 16A is a pumping systems test comparing: a 30 m 3 /h roughing pump together with a 345 l/s turbo pump; a 307 m 3 /h roughing pump together with a 345 l/s turbo pump and a 307 m 3 /h roughing pump together with two turbo pumps, 345 l/s and 210 l/s.
[0084] FIG. 16B is a gas dynamic simulation of the gas flow for the DAPI-RIT interface from 760 torr to 10 ton.
[0085] FIG. 16C is a gas dynamic simulation of the gas flow for the DAPI-RIT interface from 760 torr to 0.4 torr.
[0086] FIG. 16D is the optimization of ion focusing lens voltage.
[0087] FIG. 16E is the depicts the effect of the distance between capillary 1 and the RIT endcap on ion transfer intensity.
[0088] FIG. 17A is horizontal time graph of a scan function used for counter gas flow in the DAPI-RIT-DAPI mass spectrometer.
[0089] FIGS. 17B-C depict the effects of the counter gas flow on ion capture for MRFA. 17 B is with no counter gas and 17 C is with counter gas.
[0090] FIG. 18A is horizontal time graph of a scan function wherein the second pinch valve is also opened during the cooling period.
[0091] FIGS. 18B-D depict the effects of gas blow effects on the mass spectra of WAGGDApSGE (SEQ ID NO.: 1). 18 B is with no gas bLow, 18 C is with 45 ms gas blow, and 18 D is with 75 ms gas blow.
[0092] FIGS. 18E-G compare the gas flow effects under various conditions: ( 18 E) different analytes; ( 18 F) with and without isolation before gas flow; and ( 18 G) different amounts analyte sprayed out of the nano-ESI tip.
[0093] FIGS. 19A-C depict the linear dynamic range of detection for 10 ng/uL bradykinin ( 19 A) as well as the single shot mass spectra for 2.9 attomole ( 19 B) and 5.8 attomole of bradykinin ( 19 C).
[0094] FIGS. 19D-F depict the linear dynamic range of detection of 50 ng/uL of myoglobin ( 19 D) as well as the single shot mass spectra for 260 attomole ( 19 E) and 77.8 attomole ( 19 F) of myoglobin.
[0095] FIG. 20A is horizontal time graph of a scan function for gas flow assisted collisional induced dissociation.
[0096] FIGS. 20B-D depict tandem mass spectra for 5 ng/uL of cocaine with respect to different gas flow durations. 20 B is with 16 ms gas flow, 20 C is with 56 ms gas flow, and 20 D is with 25 ms+25 ms gas flow.
[0097] FIGS. 20E-G depict tandem mass spectra for 5 ng/uL of methamphetamine with respect to different gas flow duration and compared to conventional CID. 20 E is with 22 ms gas flow, 20 F is with 56 ms gas flow, and 20 G is with normal CID.
[0098] FIG. 21A is horizontal time graph of a scan function for ion-molecule and ion-ion reactions.
[0099] FIG. 21B depicts the mass spectra of the proton transfer between angiotensin 1 cation and azobenzene molecule.
[0100] FIG. 21C is a detail of a portion of the spectrum of FIG. 21B .
[0101] FIG. 21D depicts the electron transfer disassociation between KGAILKGAILR (SEQ ID NO: 2) cation and m-dinitrobenzene anion.
[0102] FIG. 21E is a detail of a portion of the spectrum of FIG. 21D .
[0103] FIGS. 22A-B show the LOD (absolute amount) for LTQ (Thermo, Calif.) mass spectrometer. In the test, pulsed nano-ESI source is coupled with LTQ. FIG. 22A shows a single MS scan for 54.4 attomole bradykinin (10 ng/uL). FIG. 22B shows a tandom MS scan of 136 attomole bradykinin (10 ng/uL).
[0104] FIG. 23 shows the gas dynamic simulation of gas flow speed from atmosphere to vacuum (0.4 Torr) through capillary 1. Secondary ion acceleration is observed at the hole of the RIT endcap.
DETAILED DESCRIPTION OF THE INVENTION
[0105] For ion trap type mass spectrometers, the pumping capability is not efficiently used with a traditional constantly open API. The ions are usually allowed to pass into the ion trap for only part of each scan cycle but neutrals are constantly leaked into the vacuum manifold and need to be pumped away to keep the pressure at the low levels typically needed for mass analysis. Although the mass analysis using an ion trap usually requires an optimal pressure at several milli-torr or less, ions can be trapped at a much higher pressure. (Shaffer, S. A.; Tang, K. Q.; Anderson, G. A.; Prior, D. C.; Udseth, H. R.; Smith, R. D. Rapid Communications in Mass Spectrometry 1997, 11, 1813-1817) Taking advantage of this characteristic of an ion trap, an alternative atmospheric pressure interface, discontinuous atmospheric pressure interface (DAPI), is proposed here to allow maximum ion transfer at a given pumping capacity for mass spectrometers containing an ion trapping component. The concept of the discontinuous API is to open its channel during ion introduction and then close it for subsequent mass analysis during each scan. An ion transfer channel with a much bigger flow conductance can be allowed for a discontinuous API than for a traditional continuous API. The pressure inside the manifold temporarily increases significantly when the channel is opened for maximum ion introduction. All high voltages can be shut off and only low voltage RF is on for trapping of the ions during this period. After the ion introduction, the channel is closed and the pressure can decrease over a period of time to reach the optimal pressure for further ion manipulation or mass analysis when the high voltages can be is turned on and the RF can be scanned to high voltage for mass analysis.
[0106] A discontinuous API opens and shuts down the airflow in a controlled fashion. The pressure inside the vacuum manifold increases when the API opens and decreases when it closes. The combination of a discontinuous atmospheric pressure interface with a trapping device, which can be a mass analyzer or an intermediate stage storage device, allows maximum introduction of an ion package into a system with a given pumping capacity.
[0107] Much larger openings can be used for the pressure constraining components in the API in the new discontinuous introduction mode. During the short period when the API is opened, the ion trapping device is operated in the trapping mode with a low RF voltage to store the incoming ions; at the same time the high voltages on other components, such as conversion dynode or electron multiplier, are shut off to avoid damage to those device and electronics at the higher pressures. The API can then be closed to allow the pressure inside the manifold to drop back to the optimum value for mass analysis, at which time the ions are mass analyzed in the trap or transferred to another mass analyzer within the vacuum system for mass analysis. This two-pressure mode of operation enabled by operation of the API in a discontinuous fashion maximizes ion introduction as well as optimizing conditions for the mass analysis with a given pumping capacity.
[0108] The design goal is to have largest opening while keeping the optimum vacuum pressure for the mass analyzer, which is between 10 −3 to 10 −10 ton depending the type of mass analyzer. The larger the opening in an atmospheric pressure interface, the higher is the ion current delivered into the vacuum system and hence to the mass analyzer.
[0109] A device of simple configuration was designed to test the concept of the discontinuous API with a Mini 10 handheld mass spectrometer. A Mini 10 handheld mass spectrometer is shown in Gao, L.; Song, Q.; Patterson, G. E.; Cooks, R. G.; Ouyang, Z. Anal. Chem. 2006, 78, 5994-6002. In comparison with the pumping system used for lab-scale instruments with thousands watts of power, the Mini 10 has a 18 W pumping system with only a 5 L/min (0.3 m 3 /hr) diaphragm pump and a 11 L/s turbo pump. The discontinuous API was designed to connect the atmospheric pressure region directly to the vacuum manifold without any intermediate vacuum stages. Due to the leakage of a relatively large amount of air into the manifold during ion introduction, traps with relatively good performance with air as buffer gas are preferred as the mass analyzer for the discontinuous API. A rectilinear ion trap was used in Mini 10 for mass analysis, for which the performance with air buffer gas had been demonstrated previously. (Gao, L.; Song, Q.; Patterson, G. E.; Cooks, R. G.; Ouyang, Z. Anal. Chem. 2006, 78, 5994-6002) Various atmospheric pressure ionization methods, including ESI, APCI and DESI, were coupled to the Mini 10 and limit of detection (LOD) comparable with lab-scale instruments was achieved while unit resolution and tandem mass spectrometry efficiency were also retained.
[0110] A first embodiment is shown in FIG. 1 , in which a pinch valve is used to open and shut off the pathway in a silicone tube connecting the regions at atmospheric pressure and in vacuum. A normally-closed pinch valve (390NC24330, ASCO Valve Inc., Florham Park, N.J.) was used to control the opening of the vacuum manifold to atmospheric pressure region. Two stainless steel capillaries were connected to the piece of silicone plastic tubing, the open/closed status of which is controlled by the pinch valve. The stainless steel capillary connecting to the atmosphere is the flow restricting element, and has an ID of 250 μm, an OD of 1.6 mm ( 1/16″) and a length of 10 cm. The stainless steel capillary on the vacuum side has an ID of 1.0 mm, an OD of 1.6 mm ( 1/16″) and a length of 5.0 cm. The plastic tubing has an ID of 1/16″, an OD of ⅛″ and a length of 5.0 cm. Both stainless steel capillaries are grounded. The pumping system of the mini 10 consists of a two-stage diaphragm pump 1091-N84.0-8.99 (KNF Neuberger Inc., Trenton, N.J.) with pumping speed of 5 L/min (0.3 m 3 /hr) and a TPD011 hybrid turbomolecular pump (Pfeiffer Vacuum Inc., Nashua, N.H.) with a pumping speed of 11 L/s.
[0111] When the pinch valve is constantly energized and the plastic tubing is constantly open, the flow conductance is so high that the pressure in vacuum manifold is above 30 ton with the diaphragm pump operating. The ion transfer efficiency was measured to be 0.2%, which is comparable to a lab-scale mass spectrometer with a continuous API. However, under these conditions the TPD 011 turbomolecular pump can not be turned on. When the pinch valve was de-energized, the plastic tubing was squeezed closed and the turbo pump could then be turned on to pump the manifold to its ultimate pressure in the range of 1×10 −5 torr.
[0112] The sequence of operations for performing mass analysis using ion traps usually includes, but is not limited to, ion introduction, ion cooling and RF scanning. After the manifold pressure is pumped down initially, a scan function shown in FIG. 2A was implemented to switch between open and close modes for ion introduction and mass analysis. During the ionization time, a 24 V DC was used to energize the pinch valve and the API was open. The potential on the RIT end electrode I was also set to ground during this period. A minimum response time for the pinch valve was found to be 10 ms and an ionization time between 15 ms and 30 ms was used for the characterization of the discontinuous API. A cooling time between 250 ms to 500 ms was implemented after the API was closed to allow the pressure to decrease and the ions to cool down via collisions with background air molecules. The high voltage on the electron multiplier was then turned on and the RF voltage was scanned for mass analysis.
[0113] During the operation of the discontinuous API, the pressure change in the manifold can be monitored using the micro pirani vacuum gauge (MKS 925C, MKS Instruments, Inc. Wilmington, Mass.) on Mini 10. With an open time of 20 ms and a close time of 850 ms, the reading of the pirani gauge was recorded and is plotted as shown in FIG. 2B . A pressure variation between 8×10 −2 ton to 1×10 −3 torr was measured. Capillaries with different flow conductance were tested as the flow restricting element, including 10 cm capillaries with a 127 μm ID and 500 μm ID. It was found that the sensitivity significantly decreased with the former and a much longer cooling time, 2 to 3 s, was required for pressure to drop with the latter.
[0114] Different atmospheric ionization sources were used with the min 10 mass spectrometer to verify the performance of this discontinuous atmospheric pressure interface. A scan speed of 5000 m/z per second was used for mass analysis with a resonance ejection AC of 350 kHz and an electron multiplier voltage of −1600V was used for ion detection. Sample solutions used for ESI and nano ESI were prepared using 1:1 methanol water with 0.5% acetic acid. A 250 ppm standard acetonitrile drug mixture solution (Alltech-Applied Science Labs, State College, Pa.) of methamphetamine, cocaine and heroin was diluted for preparation of samples at various concentrations.
[0115] The discontinuous API on the Mini 10 was first characterized with a nano ESI source, which was set up using a nano spray tip prepared in house. (Wilm, M.; Mann, M. Anal. Chem. 1996, 68, 1-8; Pan, P.; Gunawardena, H. P.; Xia, Y.; Mckuckey, S. A. Anal. Chem. 2004, 76, 1165-1174) A spray voltage between 1.3 and 2.5 kV was applied. A sample solution containing ppm caffeine and cocaine were analyzed using the Mini 10 with the discontinuous API. The RF voltage was set at a low mass cut-off (LMCO) of m/z 60 corresponding to about 160 V 0-p , during the 20 ms ion introduction of the DAPI and was scanned to m/z 450 (1200 V 0-p ) to record a spectrum as shown in FIGS. 3A and 3B . The protonated molecules m/z 195 from caffeine and m/z 304 from cocaine were observed. Though the ion introduction was at much higher pressure, the mass analysis was performed at about 5 milli-torr and unit resolution was obtained. Another sample solution containing 50 ppb methamphetamine, heroine and cocaine was also analyzed with a 20 ms ion introduction time ( FIG. 3C ). The signal-to-noise ratio is lower for this sample due to the much lower concentration used but a LOD lower than 50 ppb was indicated to be achievable for this sample. Another sample solution containing 400 ppt methamphetamine, cocaine and heroin was also analyzed ( FIG. 8 ), indicating the limit of detection is lower than 400 ppt.
[0116] Tandem mass spectrometry can also be performed with a discontinuous API using an altered scan function with two additional periods for ion isolation and ion excitation between the cooling and the RF scan. The ions was first isolated by applying a SWIFT waveform and subsequently fragmented via collision induced dissociation (CID) by applying an excitation AC. (Gao, L.; Song, Q.; Patterson, G. E.; Cooks, R. G.; Ouyang, Z. Anal. Chem. 2006, 78, 5994-6002) After 20 ms ion introduction and a 500 ms cooling period, the pressure inside the manifold is in the milli-ton range, a condition for CID that is identical to what was previously used without an atmospheric pressure interface. (Gao, L.; Song, Q.; Patterson, G. E.; Cooks, R. G.; Ouyang, Z. Anal. Chem. 2006, 78, 5994-6002) No additional collision gas was added and the air left in the manifold was used as the collision gas. A sample solution containing 500 ppb methamphetamine, cocaine and heroin was analyzed using MS/MS with nano ESI source and discontinuous API. A waveform with a notch window between 300 to 310 kHz was used for the isolation of the precursor ions and an excitation AC at 100 kHz was used for CID. The MS spectrum for the mixture and the MS 2 spectra for each of the component were recoded and shown in FIG. 4 . Typical fragment patterns were observed for the protononated molecular ions of these three compounds.
[0117] For tandem mass analysis, additional operations including ion isolation, ion excitation and ion cooling are added between the ion introduction and final RF scanning steps. The operation of the pinch valve is synchronized with the operation of the ion optics and the RIT scan. The pinch valve is open for around 20 ms in this particular case, during which time ions are allowed to enter the vacuum manifold by setting the voltage on end electrode I of the RIT to ground to allow the ions to enter RIT; during this time the pressure inside the manifold increases. After the pinch valve is shut off, the ions are trapped in the RIT for hundreds of milliseconds and the pressure inside the manifold graduate decreases to optimum values for mass analysis. The high voltages for ion detectors are then turned on, the RF applied on RIT is scanned to mass selectively eject ions and the auxiliary AC for resonance ejection can also be applied at the same time. This sequence of mass analysis steps can be repeated.
[0118] The analysis of amino acids was performed with an ESI source using the discontinuous API and Mini 10. The spray direction was angled at 30° with respect to the stainless steel tubing of the interface to minimize the introduction of the neutral droplets into the vacuum system. The sample was sprayed at a flow rate of 0.50/min with a high voltage of 3 kV applied and a sheath gas pressure was 80 psi. An ESI-MS spectrum was recorded with 20 ms ion introduction for a solution containing 500 ppb lysine, as shown in FIGS. 5A and 5B . The protonated molecule [M+H] + (m/z 147) and protonated dimer [2M+H] + (m/z 293) were observed.
[0119] In addition to ESI ( FIG. 9A ), this experiment setup can also be used with other ionization methods. An atmospheric pressure chemical ionization source using a platinum wire for corona discharge was used with the discontinuous atmospheric pressure interface, as shown in FIG. 9B . The vapor from a moth ball was the sample and a spectrum of naphthalene and other chemicals was recorded as shown in FIG. 10 .
[0120] Gas sample analysis with the discontinuous API was demonstrated using the chemical warfare simulant dimethyl methylphosphonate (DMMP) and an APCI source, which was set up for use with the Mini 10 using a stainless steel corona discharge pin as previously described. (Carroll, D. I.; Dzidic, I.; Stillwell, R. N.; Haegele, K. D.; Horning, E. C. Anal. Chem. 1975, 47, 2369-2373; Laughlin, B. C.; Mulligan, C. C.; Cooks, R. G. Anal. Chem. 2005, 77, 2928-2939) The discharge pin was placed about 5 mm away from the stainless steel capillary inlet with 3 kV voltage applied on it. A 10 ml flask containing 50 ppb DMMP in air was place under the discharge pin and the stopper was removed from the flask to allow the sample to escape. A spectrum was recorded with a 20 ms ion introduction as shown in FIG. 5C . The protonated molecule [M+H] + (m/z 125) and proton-bound dimer [2M+H] + (m/z 249) were observed. Good signal-to-noise ratio was obtained for the analysis of this sample at a concentration of 50 ppb. In another experiment, a signal-to-noise ratio of 50 was observed for an air sample containing 10 ppb DMMP, based on which the LOD is estimated to be below 1 ppb.
[0121] As a demonstration of the use of the discontinuous API for the direct ambient sampling methods, a DESI source was set up for analysis of samples directly from surfaces. A sample was prepared by depositing 5 μl methanol/water (1:1) solution containing 5 ppm cocaine onto a 2×3 mm area on a Teflon surface. After the sample had dried in air, it was analyzed using Mini 10 with DESI and the discontinuous API. Methanol water solvent at a ratio of 1:1 was sprayed at a flow rate of 10 ml/min with a spray voltage of 3 kV to generate the sampling charged droplets. A spray angle of 55° and a take-off angle of 10° were applied and a sheath gas pressure 120 psi was used. The distance between the spray tip and the Teflon surface is about 2 mm and the sampling area was estimated to be 1 mm 2 . The sample area and a blank area on the Teflon surface were analyzed with 15 ms ion introduction and the spectrum recorded for latter was used for background subtraction. The solid cocaine on surface was desorbed and ionized by DESI and the protonated molecule m/z 304 was observed ( FIG. 6 ).
[0122] Direct ink analysis from surface was also carried as a demonstration of the fast in-situ analysis using an instrument package of DESI, discontinuous API and Mini 10. Two 2 mm×3 mm dots were drawn on a piece of printer paper (Xerox Corporation, Rochester, N.Y.) using BIC Round Stic black ball pen and blue ball pen, respectively. The experimental condition for DESI was identical to that described above except the methanol water ratio of the solvent was 9:1. The two sample areas on the paper were analyzed with a 15 ms ion introduction and the spectra were recorded as shown in FIG. 7 . Basic violet 3, corresponding to the peak m/z 372, was found in the black ball pen ink ( FIG. 7A ) while both basic violet 3 and basic blue 26 (m/z 470) were found in the blue ball pen ink ( FIG. 7B ). The peak m/z 358 and 344 observed for both black and blue ball pen ink were reported to be the products of oxidative demethylation of basic violet 3. (Ifa, D. R.; Gumaelius, L. M.; Eberlin, L. S.; Manicke, N. E.; Cooks, R. G. Analyst 2007, 132, 461-467; Grim, D. M.; Siegel, J.; Allison, J. J. Forensic Sci. 2002, 47, 1265-1273).
[0123] Various arrangements of a discontinuous atmospheric pressure interface can be used to transfer ions between two regions at different pressures that opens to allow ions to be transferred and shuts off after the ion transfer to allow different pressures to be established thereby achieving high efficiency ion transfer between differential pressure regions with limited pumping capacity.
[0124] Another embodiment is shown in FIG. 13 , which consists of a pulsed nano-ESI source and two DAPI interfaced ion trap mass spectrometer, which uses a rectilinear ion trap (RIT) as the mass analyzer. The whole system is controlled by a central computer.
[0125] A 10×8×40 mm 3 rectilinear ion trap is placed in a 35×25×25 cm 3 vacuum chamber to serve as the mass analyzer. The RIT has a stainless steel endcap on one side (left side in FIG. 13 ) with an ion introduction hole ( 1/16 th inch in diameter) and mesh electrode on the other side. The mesh electrode has a grid size about 1 mm.
[0126] The embodiment shown in FIG. 13 has a vacuum chamber with one pressure stage, and two DAPI interfaces are used to maintain the base pressure inside the vacuum chamber. The first DAPI interface is on the left side of the RIT. Capillary 1 connects the vacuum chamber with a 3 cm long silicone tubing (˜350 Ohm resistance, with 1/16 th inch ID and ⅛ th inch OD). Pinch valve 1, purchased from ASCO Scientific (Florham Park, N.J.), is then used to control the open and close stages of the silicone tubing. Several different ID capillaries were tested, including 125 mm, 250 mm, 1 mm and 1.5 mm ID capillaries with the same length (10 cm). The 1 mm ID capillary (capillary 1) is chosen for the current setup. Capillary 2, pinch valve 2 and capillary 3 constitute the second DAPI interface on the right side of the RIT.
[0127] A single phased RF (910 kHz) is applied on the pair of electrodes without ejection slits (y electrodes, FIG. 13 ), and the dipolar resonance ejection AC (244 kHz with q=0.685, otherwise specified) is applied on the pair of electrodes with ejection slits (x electrodes, FIG. 13 ). A 120 V DC is also applied on the endcaps to provide additional trapping field along the z direction.
[0128] A high voltage DC power supply, a fast, high voltage solid state switch and a nano-ESI needle comprise the pulsed nano-ESI source. 205B-05R purchased from Bertan (Hicksville, N.Y.), which can provide a DC voltage up to 5 kV, is used as the high voltage DC power supply. The high voltage solid state switch is a PVX-4140 high voltage pulse generator purchased from Directed Energy Inc. (Fort Collins, Colo.). The PVX-4140 can output a flat single ended pulse from ground to +/−3500 V with the pulse rise and fall time less than 25 ns. To make the nano-ESI needle, 0.85 mm ID (inner diameter), 1.5 mm OD (outer diameter) glass capillaries are pulled by the P-97 flaming/brown micropipette puller (Sutter Instrument Co. Novato, Calif.) to give a tip diameter from 1 to 10 um.
[0129] The pulsed nano-ESI sprays can then be generated. First a constant 2.5 kV DC voltage is generated by the high voltage DC power supply, and then this high DC voltage is outputted to the PVX-4140 switch. The PVX-4140 can be triggered by a low voltage pulse signal. When a 4-6 V pulse signal is sent into the gate of the PVX-4140, a high voltage pulse with the same width will be generated and outputted. The voltage of this output pulse is determined by the high voltage input of the PVX-4140, which is 2 kV in our case. This high voltage pulse is then connected to the nano-ESI needle to have the pulsed nano-ESI sprays.
[0130] The pulsed nano-ESI source, DAPI and waveforms on the ion trap are synchronized and controlled by the central computer. The scanning function consists of three parts: a 12 ms ionization period, a 400 to 600 ms cooling period and a 150 ms RF scanning period ( FIG. 14 ). A 24 V, 12 ms control signal pulse is sent from the computer to pinch valve 1 to open the silicone tubing during the ionization period to let analyte ions/molecules in, while pinch valve 2 is kept closed all time (unless specified). The pulsed nano-ESI source is enabled for a short time of period (t e ) during this 12 ms to ionize and spray a very small amount of analytes. The pinch valve open time and the ion source enable time are synchronized and optimized, so that maximum ion transfer efficiency is achieved, resulting in a 10 ms delay of the pulsed nano-ESI with respect to the pinch valve open time. The duration of the pulsed nano-ESI (t e ) can be controlled and varied from 300 ns to 3 ms. FIG. 15 shows a mass spectrum obtained from 4 ng/uL Lysine and 300 ng/uL Cytochrome C mixture, with a 500 us nano-ESI pulse.
[0131] Different pumping systems are also tested and optimized. The pressure inside the vacuum chamber will increase (>>10 mTorr) when the pinch valve is opened for a short time. To perform mass analysis in RIT, mTorr range of pressure is preferred, so a pumping system which can quickly pump down the vacuum chamber is desired. Three different pumping systems are tested to find the best combination of turbo and roughing pumps. The use of a 30 m 3 /h roughing pump (Pfeiffer UNO-030M) together with a 345 l/s turbo pump (TurboVac 361); a 307 m 3 /h roughing pump (Edwards 275 E2M275) together with a 345 l/s turbo pump and a 307 m 3 /h roughing pump together with two turbo pumps, 345 l/s and 210 l/s (Pfeiffer TMH262P) are tested (see FIG. 16A ). In all cases, pinch valve 1 is opened for 12 ms, while keeping pinch valve 2 closed all time. Then the pressure inside the vacuum chamber is monitored by a MKS 925C microPirani transducer (MKS Instrument, Andover, Mass.). Measured results show that the three pumping systems provide very similar characteristic pressure drop curves with respect to time. As shown in FIG. 16 , after pinch valve 1 is closed, it takes about 300 ms to pump the pressure down to 2 mTorr, and the pressure drop will be much slower after 2 mTorr in all cases. The 30 m 3 /h roughing pump (Pfeiffer UNO-030M) together with a 345 l/s turbo pump (TurboVac 361) is chosen as the pumping system in the embodiment depicted in FIG. 13 .
[0132] By using the ideal gas law (Equation 1), more than 59 micro-mole of air (together with trace amount of analyte molecules/ions) will be sucked into the vacuum chamber during the pinch valve open time.
[0000]
n
=
pV
RT
Equation
1
[0000] n is the amount of gas, p is the absolute pressure of the gas, V is the volume of the gas, R is gas constant and T is the absolute temperature. Also, when the gas mixture entered the vacuum chamber, big expansion of the gas flow is expected to happen at the capillary exit due to the high pressure difference. Gas dynamic simulation in ANSYS (Canonsburg, Pa.) shows this expansion effects at different vacuum chamber base pressures. In the simulation, capillary 1 is used to connect the atmosphere and vacuum chamber with a RIT placed inside the vacuum chamber with dimensions kept same as the instrument setup. When the vacuum chamber base pressure is high (10 Torr), streamline plot of the gas velocity shows that relatively big portion of gas will be injected into the RIT through the hole on the endcap. However, when the vacuum chamber base pressure drop down to 400 mTorr, the gas expansion effect will become stronger and smaller portion of the gas can enter the ion trap through the hole on the endcap ( FIGS. 16B and C).
[0133] To maximize the ion transfer efficiency from the first DAPI into the ion trap, a 4 cm long, 2 cm diameter cylindrical electrode is placed between the capillary and the endcap of the RIT ( FIG. 13 ). With the help of this electrode (will be referred to as the ion focusing lens), better ion transfer efficiency from atmosphere to the RIT is observed through experiment. In the experiment, five mass spectra of 25 ng/uL of atrazine and 25 ng/uL spinosad are recorded for every different voltage on the focusing lens. Results indicate that the focusing lens can significantly improve the ion transfer efficiency, and an optimized voltage (410 V) is found (shown in FIG. 16D ).
[0134] Capillary 1 is aligned with the holes on the RIT endcaps and its distance from the endcap is optimized too. FIG. 16E depicts the effect of the capillary distance (d) on ion transfer efficiency. In the experiment, 50 ng/uL of bradykinin is used as the analyte. As the capillary distance is varied, the ion focusing lens voltage is also tuned to maximize the ion signal in the mass spectrum. When the capillary is too close to the endcap (<3 mm), ions entering the ion trap will possess high kinetic energy due to gas flow acceleration, which will be hard for the ion trap to capture ions. On the other hand, when the capillary is too far away from the endcap (>1 cm), the gas expansion effect will spread the ion beams into bigger diameter when it reaches the hole on the endcap, which results in lower amount of ions transferred into the ion trap. Therefore, an optimized distance is chosen at around 6 mm.
[0135] The second DAPI interface was also used to improve the performance of the system. First, pinch valve 2 is opened during the ionization period to increase ion trapping efficiency. When ions are introduced through pinch valve 1, gas flow will accelerate the ion stream and push them into the ion trap. Although the RF and DC potential well are designed to slow down the ions and trap them inside the ion trap, ion molecule collisional cooling also performs important role. By opening pinch valve 2 together with pinch valve 1 during ionization period, a counter gas flow can be formed inside the ion trap. This counter gas flow can effectively reduce the ion stream speed and increase the ion molecule collision probability, which results in a higher ion trapping efficiency. Ion signal intensity can be increased by 2 to 3 times by using this counter gas flow method, which was observed in the chemicals we have tested (10 ng/uL of MRFA, 100 ng/uL of WAGGDApSGE (SEQ ID NO.: 1), 10 ng/uL of bradykinin, mixture of 4 ng/uL lysine and 300 ng/uL cytochrome C) and with the mass spectrum of MRFA shown in FIGS. 17B and C.
[0136] Pinch valve 2 is also opened during the ion cooling period to improve the ion trapping and desolvation. As plotted in FIG. 18A , pinch valve 2 is opened during the ion cooling period to let the gas blow into the ion trap through the mesh electrode. The ion signal intensity can be increased significantly as this gas blow time increase from 15 to 75 ms. FIGS. 18B-D show a 40 times signal intensity increase by using 100 ng/uL of WAGGDApSGE (SEQ ID NO.: 1). Other chemicals like 50 ng/uL of heroin, 10 ng/uL of bradykinin and 300 ng/uL of cytochrome C were also tested with their signal intensity increase ratio (signal intensity with gas blow over signal intensity without gas blow) plotted in FIG. 18E .
[0137] To better understand this gas blow effect, doubly charged bradykinin is isolated first (by using a 30 ms SWIFT waveform with a 10 kHz notch) and then experienced the gas blow. After isolation, the ion intensities are also enhanced by the gas blow ( FIG. 18F ), which can be assigned to the ion trapping efficiency increase at high pressure. The rest of the ion intensity increase in the full mass spectrum cases may then be assigned to the desolvation effect. After ions and charged solvent clusters are sprayed out of the nano-ESI tip, they experience a relatively short path (<15 cm) before they enter the ion trap. So some charged solvent clusters may not be well desolved, extra gas blow can help the desolvation of these water clusters and improve the ion intensity.
[0138] Furthermore, the gas blow effect on ion intensity increase is tested with respect to different amounts of analytes sprayed out of the nano-ESI tip. 100 ng/uL of bradyknin 1-7 is loaded into the nano-ESI tip. By varying the pulse width of the nano-ESI, different amounts of analytes are sprayed into the ion trap. As the amount of analytes decrease, this gas blow effect also decreases as shown in FIG. 18G . First space charge effect will be minimized with very few ions in the trap; second the amount of solvent cluster in the trap may also decrease as the total amount of analytes decrease.
[0139] Peptide (bradykinin) and proteins (cytochrome C and myoglobin) are used in the experiments to test the performances of the instrument. Absolute limit of detection for peptide (MS and MS/MS) and mass range extension for large protein are performed.
[0140] A 10 ng/uL bradykinin sample is used as an example of peptide detection. 5 uL of the sample is first loaded into the nano-ESI tip. By varying the duration of the nano-ESI pulse, different amount of solutions were sprayed towards the inlet of the mass spectrometer. This amount of sprayed solution is a function of the voltage and duration of the pulse, and it is also a function of the distance of the electrode from the reference ground (in our case the mass spectrometer metal capillary inlet), which is about 1 cm (high voltage probe to the silicone tubing inlet)+3 cm (silicone tubing length).
[0141] By applying a high voltage (2.0 kV) pulse from 1 us to 1 ms on a 10 ppm bradykinin solution in the nano-ESI tip, different amount of analytes are sprayed out of the nano-ESI tip. A linear relationship between the amount of sprayed analyte with the pulse width can be assumed. The linear dynamic range with respect to absolute amount for bradykinin is tested from 29 attomole to 2900 attomole ( FIG. 19A ) (10 us to 1 ms pulse). Five mass spectra were recorded for each data point in FIG. 19A , and the integrate peak area for the doubly protonated bradykinin molecule is calculated. A relatively good linearity range of about 2 orders of magnitude is achieved with a 0.98512 R 2 value and standard deviation varies from 5.9%-12.2%.
[0142] As the pulse width decrease from 10 us to 1 us, the linearity of the signal intensity versus pulse width changes as shown in the inset of FIG. 19A , and the signal intensity decrease much faster. If we assume the nano-ESI tip has the same spray speed (pL/us) in this time range (1 to 10 us) as in the 10 us to 1 ms time range, about 0.29 pL of the solution will be sprayed out of the tip for a 1 us pulse. FIG. 19B shows the mass spectrum obtained for 2.9 attomole (1 us pulse) bradykinin without any data processing such as averaging, smoothing or filtering. For bradykinin, doubly protonated molecule ([M+2H] 2+ , m/z 531) shows the dominant peak in the mass spectrum, singly charged molecule ([M+H] 1+ , m/z 1060) can also be observed ( FIG. 19B ). The doubly protonated peak has a signal to noise ratio about 2.5.
[0143] The MS/MS capability is an important tool for indentifying biomolecules from complex mixtures. The low absolute amount MS/MS capability of the instrument is also demonstrated by using bradykinin ( FIG. 19C ). First, 5.4 attomole of bradykinin (2 us pulse) is sprayed by the nano-ESI tip towards the inlet of the mass spectrometer. After ions are trapped in the RIT, a SWIFT (stored waveform inversion Fourier transform) waveform with an 8 kHz wide isolation window is used to isolate the doubly protonated bradykinin molecule. During the ion excitation and CID period, the RF voltage is set on a value such that the m/z 531 ions experience a q z value of 0.25. A single frequency AC signal with amplitude 1.13 V is then applied for 80 ms to excite parent ions (m/z 531) and induce CID via collisions with background air molecules. The fragmented y″ and b ions are observed and shown in FIG. 19C .
[0144] To analyze larger proteins, the mass range of the system is extended to 2000. This is done by first elevate the trapping voltage of the RF signal from 350 V to 550 V during the ionization and cooling periods. During the mass analysis period, the dipolar resonance ejection AC signal frequency is also lowered from 244 kHz (q=0.685) to 115 kHz (q=0.35).
[0145] To explore the performance of the new setup, 50 ng/uL myoglobin (molecular weight 16700 daltons) sample is tested. FIG. 19D shows the linear response of myoglobin (by using the [M+17H] + peak for ion intensity calculation) from 77.8 to 4150 attomole with a 0.91433 R 2 value. The mass spectrum of 260 attomole myoglobin (500 us pulse) (apomyoglobin groups) is plotted in FIG. 19E with a good signal to noise ratio. By shortening the pulsed nano-ESI ionization time, less amount of myoglobin solution can be sprayed and the ALOD of the new setup for myoglobin can be studied. As low as 77.8 attomole myoglovin (150 us pulse) can be identified with the mass spectrum obtained and plotted in FIG. 19F .
[0146] The gas flow can also induce the collisional dissociation for some small organic compounds. For the gas blow CID, pinch valve 2 was opened to let gas flow into the ion trap and induce the ion dissociation ( FIG. 20A ). First 5 ng/uL of cocaine is isolated and tested under the gas blow CID. Fragmentation peak (m/z 182) can be observed with a 16 ms gas blow ( FIG. 20B ). As the gas blow duration increases (56 ms; FIG. 20C ), the fragmentation efficiency can be improved. To further enhance the fragmentation efficiency, pinch valve 2 can be opened twice (25 ms each time) ( FIG. 20D ). Opening the pinch valve twice with shorter duration each time can increase the gas blow speed as they enter the ion trap. Because cooling periods in front of each open pinch valve will allow the pumping system to pump down the pressure inside the vacuum chamber, and the gas flow will experience a big pressure difference.
[0147] 4 ng/uL of methamphetamine is also tested. Methamphetamine can be fragmented easily by this gas blow CID method ( FIGS. 20E-G ). 56 ms gas blow can achieve over 95% fragmentation efficiency. However, the fragmentation pattern of methamphetamine is different from that in conventional CID, wherein the AC field is used to excite ions for collisional dissociation. The m/z 119 peak which appears in conventional CID mass spectrum does not appear in the gas blow CID spectra.
[0148] Ion/molecule and ion/ion reaction capabilities of the setup are also demonstrated. Since the instrument setup has two DAPI interfaces, ion/molecule and ion/ion reactions can be performed. As shown in FIG. 21A , first cations can be introduced into the ion trap through pinch valve 1. After cations are cooled down, anions or reactive molecules can be introduced into the ion trap through pinch valve 2. During and after the anions are introduced into the ion trap, the DC voltage on the endcaps are lowered down to zero to trap both cations and anions. First an ion/molecule reaction (proton transfer) is demonstrated. 200 ng/uL angiotensin 1 is loaded into a nano-ESI tip put in front of pinch valve 1 and azobenzene crystals in front of pinch valve 2. After angiotensin 1 is ionized and introduced into the ion trap, SWIFT waveform is used to isolate the triply charged cations ([M+3H] 3+ ). Then vaporized azobenzene is sucked into the ion trap through pinch valve 2. After about 600 ms cooling time, part of the triply charged angiotensin will lose one proton to azobenzene, and doubly charged angiotensin appeared in the mass spectrum ( FIGS. 21B and 21C ).
[0149] Ion/ion reaction is performed between 100 ng/uL KGAILKGAILR (SEQ ID NO.: 2) and m-dinitrobenzene. KGAILKGAILR (SEQ ID NO.: 2) is loaded into a nano-ESI tip and put in front of pinch valve 1. A constant −3.2 kV is applied on an atmosphere pressure chemical ionization (APCI) needle which is placed in front of capillary 3. A small bottle of M-dinitrobenzene powder is then placed right under the APCI needle. After triply charged KGAILKGAILR (SEQ ID NO.: 2) is trapped and isolated in the ion trap, m-dinitrobenzene anions will then be sucked into the ion trap through pinch valve 2. During a 900 ms cooling time, both proton transfer and electron transfer dissociation (ETD) happened as shown in FIG. 21D .
[0150] FIGS. 22A-B show the LOD (absolute amount) for LTQ (Thermo, Calif.) mass spectrometer. In the test, pulsed nano-ESI source is coupled with LTQ. FIG. 22A shows a single MS scan for 54.4 attomole bradykinin (10 ng/uL). FIG. 22A shows a tandom MS scan of 136 attomole bradykinin (10 ng/uL).
[0151] FIG. 23 shows the gas dynamic simulation of gas flow speed from atmosphere to vacuum (0.4 Torr) through capillary 1. Secondary ion acceleration is observed at the hole of the RIT endcap.
[0152] While these features have been disclosed in connection with the illustrated preferred embodiments, other embodiments of the invention will be apparent to those skilled in the art that come within the spirit of the invention as defined in the following claims. All references, including issued patents and published patent applications, are incorporated herein by reference in their entireties.
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A method of interfacing atmospheric pressure ion sources, including electrospray and desorption electrospray ionization sources, to mass spectrometers, for example miniature mass spectrometers, in which the ionized sample is discontinuously introduced into the mass spectrometer. Discontinuous introduction improves the match between the pumping capacity of the instrument and the volume of atmospheric pressure gas that contains the ionized sample. The reduced duty cycle of sample introduction is offset by operation of the mass spectrometer under higher performance conditions and by ion accumulation at atmospheric pressure.
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The use of membranes to separate aromatics from saturates has long been pursued by the scientific and industrial community and is the subject of numerous patents.
U.S. Pat. No. 3,370,102 describes a general process for separating a feed into a permeate stream and a retentate stream and utilizes a sweep liquid to remove the permeate from the face of the membrane to thereby maintain the concentration gradient driving force. The process can be used to separate a wide variety of mixtures including various petroleum fractions, naphthas, oils, hydrocarbon mixtures. Expressly recited is the separation of aromatics from kerosene.
U.S. Pat. No. 2,958,656 teaches the separation of hydrocarbons by type, i.e., aromatic, unsaturated, saturated, by permeating a portion of the mixture through a non-porous cellulose ether membrane and removing permeate from the permeate side of the membrane using a sweep gas or liquid. Feeds include hydrocarbon mixtures, e.g., naphtha (including virgin naphtha, naphtha from thermal or catalytic cracking, etc.).
U.S. Pat. No. 2,930,754 teaches a method for separating hydrocarbons, e.g., aromatic and/or olefins from gasoline boiling range mixtures, by the selective permeation of the aromatic through certain non-porous cellulose ester membranes. The permeated hydrocarbons are continuously removed from the permeate zone using a sweep gas or liquid.
U.S. Pat. No. 4,115,465 teaches the use of polyurethane membranes to selectively separate aromatics from saturates via pervaporation.
The present invention relates to a process for the separation of aromatics from saturates.
Compared to distillation, membrane permeation can lead to considerable energy savings. A membrane can separate a mixture of aromatics and saturates, e.g., a heavy cat naphtha, into a high-octane, mainly aromatic permeate and a high-cetane, mainly saturated retentate. Both permeate and retentate are more valuable than the starting heavy cat naphtha.
SUMMARY OF THE INVENTION
The present invention is a method for separating mixtures of aromatics and non-aromatics into aromatic-enriched and non-aromatic-enriched streams by contacting the aromatics/non-aromatics mixture with one side of a polyphthalatecarbonate membrane, and selectively permeating the aromatic components of the mixture through the membrane. Both crosslinked and uncrosslinked polyphthalatecarbonate membranes can be used for the aromatics/non-aromatics separation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a method for the separation of aromatics from saturates using crosslinked and uncrosslinked polyphthalatecarbonate membranes. Polyphthalatecarbonates are commercially available. Examples are General Electric's PPC 4501 and PPC 4701; Mobay's APEC DP 9-9308 and APEC DP 9-9310. They are polyesters of Bisphenol A (4,4'-isopropylidenebiphenol) with variable proportions of carbonic, isophthalic and terephthalic acids.
In the present invention, membranes are used to separate a mixture of aromatics and non-aromatics into an aromatic-enriched fraction and a non-aromatic-enriched fraction.
The membranes are useful for the separation of aromatics from saturates in petroleum and chemical streams and are particularly useful for the separation of large substituted aromatics from saturates as are encountered in heavy cat naphtha streams. Other streams which are also suitable feed streams for aromatics from saturates separation are intermediate cat naphtha streams boiling at 93°-160° C, light aromatics content streams boiling in the C 5 -150° C. range, light catalytic cycle oil boiling in the 200°-345° C. range as well as streams in chemical plants which contain recoverable quantities of benzene, toluene, xylenes (BTX) or other aromatics in combination with saturates. The separation techniques which may successfully employ the membrane of the present invention include perstraction and pervaporation.
Perstraction involves the selective dissolution of particular components contained in a mixture into the membrane, the diffusion of those components through the membrane and the removal of the diffused components from the downstream side of the membrane by the use of a liquid sweep stream. In the perstractive separation of aromatics from saturates in petroleum or chemical streams, the aromatic molecules present in the feedstream dissolve into the membrane film due to similarities between the membrane solubility parameter and those of the aromatic species in the feed. The aromatics then permeate (diffuse) through the membrane and are swept away by a sweep liquid which is low in aromatics content. This keeps the concentration of aromatics at the permeate side of the membrane film low and maintains the concentration gradient which is responsible for the permeation of the aromatics through the membrane.
The sweep liquid is low in aromatics content so as not to itself decrease the concentration gradient. The sweep liquid is preferably a saturated hydrocarbon liquid with a boiling point much lower or much higher than that of the permeated aromatics. This is to facilitate separation, as by simple distillation. Suitable sweep liquids, therefore, would include, for example, C 3 to C 6 saturated hydrocarbons and lube basestocks (C 15 -C 20 ).
The perstraction process is run at any convenient temperature, preferably as low as possible.
The choice of pressure is not critical since the perstraction process is not dependent on pressure, but on the ability of the aromatic components in the feed to dissolve into and migrate through the membrane under a concentration driving force. Consequently, any convenient pressure may be employed, the lower the better to avoid undesirable compaction, if the membrane is supported on a porous backing, or rupture of the membrane, if it is not.
If C 3 and C 4 sweep liquids are used at 25° C. or above in liquid state, the pressure must be increased to keep them in the liquid phase.
Pervaporation, by comparison, is run at generally higher temperatures than perstraction and relies on vacuum on the permeate side to evaporate the permeate from the surface of the membrane and maintain the concentration gradient driving force which drives the separation process. As in perstraction, the aromatic molecules present in the feed dissolve into the membrane film, migrate through said film and emerge on the permeate side under the influence of a concentration gradient. Pervaporative separation of aromatics from saturates can be performed at a temperature of about 25° C. for the separation of benzene from hexane but for separation of heavier aromatic/saturate mixtures, such as heavy cat naphtha, higher temperatures of at least 80° C and higher, preferably at least 100° C. and higher, more preferably 120° C. and higher should be used. Temperatures of about 190.C have been successfully used with crosslinked polyphthalatecarbonate membranes of the present invention, the maximum upper limit being that temperature at which the membrane is physically damaged. Vacuum on the order of 1-50 mm Hg is pulled on the permeate side. The vacuum stream containing the permeate is cooled to condense out the highly aromatic permeate Condensation temperature should be below the dew point of the permeate at a given vacuum level.
The membrane itself may be in any convenient form utilizing any convenient module design. Thus, sheets of membrane material may be used in spiral wound or plate and frame permeation cell modules. Tubes and hollow fibers of membrane may be used in bundled configurations with either the feed or the sweep liquid (or vacuum) in the internal space of the tube or fiber; the other material obviously being on the other side.
When the membrane is used in a hollow fiber configuration with the feed introduced on the exterior side of the fiber, the sweep liquid flows on the inside of the hollow fiber to sweep away the permeated highly aromatic species, thereby maintaining the desired concentration gradient. The sweep liquid, along with the aromatics contained therein, is passed to separation means, typically distillation means, however, if a sweep liquid of low enough molecular weight is used, such as liquefied propane or butane, the sweep liquid can be permitted to simply evaporate, the liquid aromatics being recovered and the gaseous propane or butane (for example) being recovered and reliquefied by application of pressure or lowering of temperature.
Crosslinked polyphthalatecarbonate films can be obtained by preparing a solution in a suitable solvent, e.g., chloroform, casting on a glass plate or a porous support, adjusting the thickness with a casting knife and drying the membrane first at room temperature, then at high temperatures, e.g., 120° C. and 230° C., etc., possibly in the presence of an additive, e.g., cupric acetylacetonate. Uncrosslinked polyphthalatecarbonate films can be prepared in the same way except no crosslinking additive is used and drying temperatures are not higher than about 120° C.
The present invention will be better understood by reference to the following examples which are offered by way of illustration and not limitation.
In the following examples, membranes are used to separate aromatics from saturates in a pervaporation apparatus. The pervaporation apparatus is a cell, separated into two compartments by a porous metal plate, on which the membrane is supported. During a pervaporation experiment the aromatics/saturates mixture is circulated through the upper compartment at the desired temperature. The lower compartment is kept at reduced pressure. The permeate is collected in a trap, cooled with dry ice-acetone or dry iceisopropanol and periodically analyzed by gas chromatography. The following examples illustrate the invention.
EXAMPLE 1
20.25 g of a polyphthalatecarbonate containing 42 moles of isophthalic acid, 4 moles of terephthalic acid and 54 moles of carbonic acid for 100 moles of Bisphenol A was dissolved in 100 ml of chloroform at room temperature. When dissolution was complete, 0.187 g of cupric acetylacetonate was added. About 50 ml of chloroform was allowed to evaporate in order to have a sufficiently thick solution for casting. After centrifugation, four membranes were cast on glass plates under nitrogen. After two days the membranes were removed by immersing the glass plates in warm water. After drying, square pieces were cut and the sides were clamped between stainless-steel holders which lay on a small table covered with Gore-tex (porous Teflon) sheet. The distance between the membrane and the Gore-tex sheet was about 1/2 inch. Weights attached to the clamp kept the membranes suspended above the Gore-tex sheets. The membranes were crosslinked by heating them in an oven under the following conditions.
______________________________________120° C. 17 hours in nitrogen160° C. 24 hours in air230° C. 5 hours in air______________________________________
The resulting membranes were insoluble in chloroform, i.e., crosslinked.
One of the membranes was used in the pervaporation apparatus described above for the separation of a mixture containing 10 wt% toluene, 40% p-xylene, 20% isooctane and 30% n-octane. The following table gives the results.
______________________________________ Aromatics/T Toluene/n-Octane Saturates Normalized Flux(°C.)Selectivity Selectivity (Kg · μM/M.sup.2 ·______________________________________ D)150 6.1 9 500170 5.2 7.5 950190 4.9 6 2000______________________________________
EXAMPLE 2
40 g of polyphthalatecarbonate containing 71 moles of isophthalic acid, 7 moles of terephthalic acid and 21 moles of carbonic acid per 100 moles of Bisphenol A was dissolved in 240 g of chloroform. When dissolution was complete, 0.38 g of cupric acetylacetonate was added. Four membranes were cast on glass plates under nitrogen. After drying, the membranes were suspended above Gore-tex sheets as described in Example 1. The heating cycle was:
______________________________________120° C. 17 hours in nitrogen160° C. 24 hours in air190° C. 24 hours in air230° C. 5 hours in air______________________________________
At the end the membranes were flexible and insoluble in CHCl 3 , i.e., crosslinked.
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The present invention describes a method for separating mixtures of aromatics and non-aromatics into aromatic-enriched and non-aromatic-enriched streams by contacting the mixture with one side of a polyphthalate-carbonate membrane and selectively permeating the aromatic components of the mixture through the membrane.
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BACKGROUND OF THE INVENTION
The present invention generally relates to a vacuum cleaner housing having a coarse separator into which dust laden air is drawn by means of a vacuum source from a nozzle connected to the vacuum cleaner, a cyclone with a cyclone chamber arranged after the coarse separator as seen in the flow direction, and a collecting container for particles separated by the cyclone.
Vacuum cleaners of the type mentioned above are previously known, see for instance U.S. Pat. No. 5,779,745. In these vacuum cleaners the lower part of the coarse separator and the cyclone each constitute a collecting container that can be emptied via an opening in each container. The openings are covered by a common lid. A disadvantage with this arrangement is that it is difficult to clean the coarse separator, the cyclone and the other air channels unless extensive disassembly is carried out. Disassembly of the machine is dirty and unhygienic.
It is also previously known, see GB 2321181, in a similar arrangement to empty the two integrated collecting containers by removing the container part from the vacuum cleaner and turning the container part up-side-down, which means that a grating covering the coarse separator is opened and that the contents of the cyclone falls out through a separate emptying opening. The liner may also be manually removed from the cyclone before the container is turned right-side-up. With this arrangement it is also cumbersome and unhygienic to empty and clean the containers.
It is also previously known in vacuum cleaners having two concentric cyclones that are connected in series, see for instance EP 636338, to use an arrangement having two containers being separated by means of a liner that is manually removed during emptying. Also, in this case, an extensive unhygienic disassembly operation is required in order to clean the two cyclones and the gratings and container walls belonging to them.
SUMMARY OF THE INVENTION
The present invention is directed toward an emptying system for a cyclone vacuum cleaner in which the emptying is simplified and more hygienic to undertake than in previously-known systems. The present invention is further directed toward a cyclone vacuum cleaner wherein all the parts of the cyclone system are uncovered during emptying, thereby rendering all the internal surfaces of the cyclone, the container and the coarse separator accessible for cleaning.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features of the invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 schematically shows a vacuum cleaner with accessories;
FIG. 2 is a side view of the vacuum cleaner according to the invention being provided with a liner;
FIG. 3 is a vertical section of the vacuum cleaner shown in FIG. 2, but with the liner removed;
FIG. 4 is a vertical section through the liner with a cover plate, which serves as an end wall, removed;
FIG. 5 is an end view of the liner as seen from the right hand side in FIG. 4, but with the cover plate secured to the liner;
FIG. 6 is the same end view as that of FIG. 5, but with the cover plate removed;
FIG. 7 is a cross-sectional view as seen along line VII—VII in FIG. 4;
FIG. 8 is a vertical section through the cover plate; and,
FIG. 9 is the cover plate in a front view from the left hand side in FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a vacuum cleaner has a nozzle 5 connected to a tube shaft 6 that, via a tube handle 7 and a hose 8 with a hose connection 9 , is secured to a vacuum cleaner housing 10 . The vacuum cleaner housing 10 is supported by a front pivot wheel 11 and two rear wheels 12 .
With reference to FIGS. 2-3, the housing 10 defines a recess 13 in which a liner 14 is removably secured. The vacuum cleaner housing 10 , in a traditional manner, encloses a vacuum source such as a fan unit 15 . The fan unit 15 has an inlet side that, via openings 16 , is connected to an air inlet part 17 . The air inlet part 17 is surrounded by an inclined, angled sealing surface 18 on which the liner 14 rests. The vacuum cleaner housing 10 also includes a replaceable outlet filter 19 , through which the outlet air from the fan unit 15 leaves to atmosphere, and control means 20 , other electric means, a cable reel, and other conventional features.
The vacuum cleaner housing 10 has a front end wall 22 extending upwardly from a bottom wall 21 of the housing, the bottom wall 21 defining a lower limit of the recess 13 . The front wall 22 is provided with a through-tube section 23 to which the hose connection 9 can be secured. The side of the tube section 23 facing the recess is provided with an annular sealing 24 in order to seal against the liner 14 .
With reference to FIGS. 4-7, the liner 14 includes three elongated, horizontal, parallel chambers that are separated from one another. These three chambers are referred to hereinafter as a coarse separator 25 , a cyclone with a cyclone chamber 26 , and a collecting container 27 .
The coarse separator 25 has an end wall 28 with an inlet opening 29 that, when the liner 14 is placed in the vacuum cleaner housing 10 , is coaxial with the tube section 23 . The coarse separator 25 is surrounded by a first wall part 30 , which serves as a separating wall toward the cyclone chamber 26 , and a second wall part 31 , which serves as a separating wall toward the collecting container 27 . At the end of the coarse separator 25 remote from the end wall 28 , there is an opening 32 in the first wall part 30 (FIGS. 4 and 6 ). The opening 32 continues into an inlet channel 33 to the cyclone chamber 26 , the channel 33 being arranged near one end of the cyclone chamber 26 . One wall 34 of the inlet channel 33 is curved and arranged such that a mainly tangentially-directed air inlet flow is created in the cylinder-shaped cyclone chamber 26 .
The cyclone chamber 26 is provided with a first end wall 35 and a second end wall 36 . The first end wall 35 is a part of a cover plate 37 , which will be more fully discussed hereinafter. The cyclone chamber 26 is also provided with an intermediate part 38 that is disposed between the end walls 35 , 36 . Preferably, the intermediate part 38 is either cylinder-shaped or is shaped as a truncated cone directed such that the smaller cone opening faces the second end wall 36 . The intermediate part 38 has an opening 39 (whose diameter in the embodiment shown in FIG. 4 is identical to a diameter of the intermediate part 38 ) that leads to a separation part 40 positioned close to the second end wall 36 .
With reference to FIGS. 4 and 7, the separation part 40 has an opening 41 in the side wall. The opening 41 extends almost over the complete length of the separation part 40 and is connected to a channel 42 leading to the collecting container 27 . One wall 43 of the channel 42 is spiral-shaped and forms a generally tangential particle outlet opening for particles leaving the cyclone. The particles leaving through the opening 41 have a direction component that is generally perpendicular to the axis of rotation R of the vortex created in the cyclone chamber 26 .
The collecting container 27 is, with the exception of the previously-mentioned wall part 31 and cover plate 37 , surrounded by an end wall 44 , a bottom wall 45 , and side walls 46 . One side wall merges with the spiral-shaped wall 43 of the channel 42 , as illustrated in FIG. 7 . The bottom wall 45 , at its external side, is provided with a locking shoulder 47 , the function of which will be explained below.
The coarse separator 25 , the cyclone chamber 26 , and the collecting container 27 are each provided with a completely open end wall that is normally covered by the cover plate 37 . The cover plate 37 is normally secured on the liner 14 and is removed when the collecting container 27 is to be emptied.
With reference to FIGS. 5, 8 , and 9 , the cover plate 37 includes an angled plate 37 a having two lugs 48 and a spring-loaded latching hook 49 . The lugs 48 are inserted into recesses (not shown) in the liner 14 whereas the latching hook 49 engages the locking shoulder 47 on the liner 14 in order to releasably lock the cover plate 37 to the liner 14 .
The cover plate 37 also has a circular tube 50 extending from the angled plate 37 a . The tube 50 is provided with a rounded portion 51 at one tube end interconnecting the tube 50 and the angled plate 37 a . The cover plate 37 has, at the opposite side of the angled plate 37 a relative to the tube 50 , a wall portion 52 surrounding a filter cassette 53 that receives a so-called deep filter 54 . The deep filter 54 is, for example, a thick, coarse filter that can be picked out from the cassette 53 and cleaned, for instance, in a dishwasher. The filter 54 is spaced from the angled plate 37 a , thereby creating a space 55 for the distribution of air flowing through the tube 50 to the complete area of the filter 54 . The filter cassette 53 is retained on the cover plate 37 by cooperation between a locking mechanism 56 on the cover plate 37 and lugs 57 arranged on the cassette.
In order to decrease the creation of noise, the tube 50 has, at its internal side, an axially-directed flange or rib 58 preventing the creation of a vortex within the tube 50 . The angled plate 37 a is, at the side from which the tube 50 extends, provided with a soft material layer 59 that serves as a sealing member when the cover plate 37 is secured to the liner 14 .
With reference to FIGS. 4 and 6, the liner 14 includes a handle 60 that also serves as a handle for the complete vacuum cleaner. The handle 60 includes a knob or button 61 that is operable to release the liner 14 from the vacuum cleaner housing 10 . The knob 61 is under the influence of a spring 62 and is, via an arm 63 , connected to a yoke member 64 . The yoke member 64 is supported for turning motion about shafts 65 arranged at each side of the liner 14 . Each side of the yoke member 64 is provided with a hook 66 that engages a shoulder or the like (not shown) in the vacuum cleaner housing 10 . The liner 14 is also provided with a holder 67 cooperating with, and partly surrounding, the end wall 22 of the vacuum cleaner housing 10 .
In order to get proper particle separation conditions, the diameter of the cyclone chamber 26 is preferably within the range of 50-100 mm, the length of the cyclone is within the range of about 100-300 mm, and the distance between the opening 39 and the second end wall 36 is more than 20 mm. The length of the tube 50 is preferably 20-50% of the length of the cyclone.
The vacuum cleaner described above operates and is used in the following manner. Dust-laden air taken up by the vacuum cleaner nozzle 5 flows through the tube shaft 6 and the hose 8 into the tube section 23 . The air flows via the inlet opening 29 into the coarse separator 25 and continues toward the end that is covered by the cover plate 37 . Heavier particles are separated from the air flow in the coarse separator 25 because of the reduction of the air velocity and the air deflection at the opening 32 . The separated particles are collected on the wall part 31 that serves as a bottom of the coarse separator 25 . After deflection, the air flow continues through the opening 32 and further through the inlet channel 33 toward the cyclone chamber 26 .
Air flows tangentially into the cyclone chamber 26 and near the first end wall 35 between the side wall of the cyclone chamber 26 and the tube 50 , the tube 50 being indicated by dash-dotted lines in FIG. 4 . This means that a vortex is created about the central axis of rotation R in the intermediate part 38 of the cyclone chamber 26 . Due to centrifugal forces, dust particles are distributed toward the second end wall 36 , pass through the opening 38 , and into the separation part 40 . The particles are thrown out mainly perpendicular to the rotational axis through the opening 41 and the channel 42 into the collecting container 27 , which is placed outside the separation part 40 , and collect on the bottom 45 of the collecting container 27 .
The air at the central part of the vortex, which is substantially free of large particles, is drawn out via the tube 50 of the cover plate 37 and flows through the space 55 and the filter 54 in which further particles are separated. The air continues through the inlet part 17 and the openings 16 into the motor fan unit 15 , and then leaves to atmosphere via the outlet filter 19 in which smaller particles are separated.
When the vacuum cleaner is emptied, the liner 14 is first removed from the vacuum cleaner housing 10 by depressing the knob 61 on the handle 60 . Depressing the knob 61 causes the yoke member 64 to pivot about the shafts 65 such that the hook 66 disengages from the shoulder (not shown) in the vacuum cleaner housing 10 . Thus, the liner 14 can be turned somewhat about the front part and then lifted out of the recess 13 in the vacuum cleaner housing 10 . The cover plate 37 is then removed from the liner 14 by depressing the latching hook 49 , which means that the plate 37 disengages from the locking shoulder 47 on the liner 14 to permit the cover plate to be tilted and the fastening lugs 48 drawn out from the recesses (not shown).
Turning the liner 14 up-side-down simultaneously empties all the material that was collected in the cavities, i.e. the collecting container 27 , the coarse separator 26 and the cyclone chamber 25 , into a bin or the like. The arrangement also allows all the cavities 25 , 26 , 27 to be easily cleaned since the end walls (cover plate 37 ) of the cavities are completely removed and, hence, all parts of the cavities are accessible without further disassembly or the need for special cleaning tools.
If necessary, the filter cassette 53 can be released from the cover plate 37 and then the filter 54 can be picked out and cleaned. After cleaning, the filter 54 and the filter cassette 53 are again secured to the cover plate 37 . Then the cover plate 37 is fixed to the liner 14 which is placed in the recess 13 such that the filter cassette 53 abuts the inclined sealing plane 18 . Application of additional pressure will then allow the hooks 66 to engage the shoulders (not shown) in the vacuum cleaner housing 10 .
An optional emptying ring (not shown) may be used to facilitate emptying of the cavities 25 , 26 , 27 . Such an emptying ring is shaped such that it corresponds to the part of the liner 14 on which the cover plate 37 is normally secured. The cover plate 37 is removed from the liner 14 and a conventional plastic bag is placed within the emptying ring. The open end of the bag is folded about the ring after which the emptying ring is manually pressed toward the liner. The liner 14 with the emptying ring and the bag is then turned up-side-down such that the dust falls down into the bag. The bag and the emptying ring can then be separated from the liner 14 and from one another after which the bag can be closed and thrown away.
While the preferred embodiment of the present invention is shown and described herein, it is to be understood that the same is not so limited but shall cover and include any and all modifications thereof which fall within the purview of the invention.
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A vacuum cleaner assembly including a vacuum cleaner housing ( 10 ) and an air filtration unit removably installed in the housing. The unit includes a coarse separator ( 25 ), a cyclone with a cyclone chamber ( 26 ), a collecting container ( 27 ), and a releasable cover plate ( 37 ). The coarse separator ( 25 ) receives dirt-laden air. Air is tangentially introduced into the cyclone chamber ( 26 ), which is downstream the coarse separator ( 25 ). The collecting chamber ( 27 ) receives particles separated from the air stream in the cyclone chamber ( 26 ). The cover plate ( 37 ) serves as a wall part for each of the coarse separator, cyclone, and collecting container whereby, after the unit ( 14 ) has been removed from the housing ( 10 ), the cover plate is removed to simultaneously reveal the coarse separator, cyclone, and collecting container to permit emptying thereof.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a nationalization of International Application PCT/EP2012/069755 filed Oct. 5, 2012 and claims priority from German Application DE 102011054358.9 filed Oct. 10, 2011 both of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention concerns a method of reshaping a workpiece, in particular an upsetting riveting method, and a device for reshaping a workpiece.
[0003] In the reshaping operation, that is to say upon specifically targeted plastic deformation of a workpiece, a force is applied to the workpiece by way of a reshaping tool and the workpiece is thereby reshaped. A distinction is drawn between pressure reshaping, tension-pressure reshaping, tension reshaping, bending reshaping and thrust reshaping.
[0004] Particularly in the pressure reshaping process the reshaping tool has an upsetting surface of a contour which substantially corresponds to the desired outside contour of the workpiece to be reshaped. During the reshaping operation that upsetting surface is brought into contact with the workpiece to be reshaped and a force is applied to the workpiece so that it is thereby reshaped.
[0005] In the case of many materials it is advantageous if the workpiece to be reshaped is heated during or immediately prior to the reshaping operation.
[0006] For heating the workpiece it is possible for example for an ultrasonic vibration, that is to say a vibration between about 16 kHz and about 10 GHz, to be applied to the workpiece. That ultrasonic vibration is absorbed in the workpiece and the workpiece is heated thereby.
[0007] Thus it is known for example for a rivet to be reshaped by means of a closing head shaper in the form of a sonotrode. FIGS. 1 a through 1 c diagrammatically show the method steps applied in a known reshaping method.
[0008] The known riveting method is used to join two materials or two elements together. Firstly the rivet 1 comprising a plastic is passed through an opening arranged in the riveting material 2 . The rivet 1 is either connected to one of the two elements to be joined or it has a prefabricated setting head which prevents the rivet from being able to be pressed completely through the opening in the riveting material 2 .
[0009] As can be seen from FIG. 1 in that situation the sonotrode 3 , that is to say an element which is acted upon with an ultrasonic vibration, is moved in the direction of the riveting material 2 so that firstly the edges of the end face of the rivet 1 come into contact with the sonotrode 3 . The contact of the sonotrode 3 with the rivet 1 means that an ultrasonic vibration is transmitted into the rivet. The ultrasonic vibration is absorbed in the material. The proportion of the absorbed ultrasonic energy depends on the damping constant or the absorption coefficient of the material.
[0010] In general the amplitude of the ultrasonic vibration will decrease in the workpiece so that the greatest amplitude is reached at the contact surface relative to the sonotrode and becomes progressively smaller, the further the ultrasonic wave moves away from the sonotrode.
[0011] The absorption effect results in heating of the rivet 1 . As in the known method the rivet 1 comprises a plastic the material will begin to melt, as shown in FIG. 1 b and finally, as shown in FIG. 1 c , the material is reshaped by the closing head. Basically, it is possible by means of ultrasound for the workpieces to be shaped to be heated very quickly and in particular only locally so that the desired hot reshaping can take place.
[0012] With some materials however the introduction of heat by the ultrasonic vibration is limited to a close region in the proximity of the contact surface relative to the sonotrode That is due on the one hand to the absorption which generally falls exponentially with the spacing relative to the sonotrode. On the other hand those materials exhibit only a low level of thermal conductivity so that the heating effect firstly remains restricted substantially to a portion in the immediate proximity of the sonotrode. If now in addition the workpiece to be reshaped comprises a material which has a heavily temperature-dependent absorption coefficient such that the absorption coefficient becomes greater with temperature, absorption in the region directly in the proximity of the sonotrode is still further increased by the local heating effect, which results in even more greatly localized heating.
[0013] In the known method therefore it is only possible for a region in the immediate proximity relative to the sonotrode to be adequately heated, so that it is also only in those regions that effective reshaping take place.
[0014] As can be seen in particular from FIG. 1 c the closing head 5 produced in that way has cylindrical constriction recesses 4 and very large regions which are actually not homogeneously connected to the rivet, but are only placed around the cylinder. Those regions reduce the stability of the closing head 5 . In practice therefore the closing heads produced in that way have to be of larger dimensions than would actually be necessary in consideration of their geometry. Nonetheless even then this does not guarantee adequate strength.
[0015] Therefore, based on the described state of the art, the object of the present invention is to provide a method of and a device for reshaping a workpiece, which particularly when reshaping materials with a heavily temperature-dependent damping constant, avoids the above-mentioned disadvantages.
BRIEF SUMMARY OF THE INVENTION
[0016] In regard to the method that object is attained in that before the reshaping force is applied to the workpiece at least a first portion of the workpiece is brought to a temperature which differs from the temperature of a second portion of the workpiece, that comes into contact with the reshaping tool.
[0017] The invention comprises a method of reshaping a workpiece, in which a reshaping force is exerted on the workpiece by means of a reshaping tool and the workpiece is heated during or before reshaping of the workpiece, wherein heating of the workpiece is effected by at least partial absorption of an ultrasonic vibration in the workpiece where before the reshaping force is applied to the workpiece at least a first portion of the workpiece is brought to a temperature which differs from the temperature of a second portion of the workpiece, that comes into contact with the reshaping tool.
[0018] In one embodiment, before the reshaping force is applied to the workpiece the first portion is brought to a temperature which is higher than the temperature of the second portion, preferably by at least 10° C. and particularly preferably by at least 20° C. and best by at least 30° C.
[0019] The workpiece to be reshaped is usually of plastic and preferably a part-crystalline plastic.
[0020] The workpiece may be in the form of a rivet is reshaped to form a closing head and the rivet may be a hollow rivet and preferably a part-hollow rivet.
[0021] In accordance with the method, an ultrasonic vibration may be applied to the first portion to heat the first portion to a temperature higher than the temperature of the second. portion.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] FIGS. 1 a through 1 c show a reshaping method according to the state of the art,
[0023] FIG. 2 shows a sonotrode according to the invention of a first embodiment of the invention,
[0024] FIG. 3 shows a rivet according to the invention of the first embodiment of the invention,
[0025] FIGS. 4 a through 4 c show diagrammatic views of the individual steps in the method according to the invention, and
[0026] FIGS. 5 through 7 show alternative embodiments of sonotrodes according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] If for example in the situation shown in FIG. 1 a the rivet 1 is heated in the region in which it is passed through the riveting material 2 , then, when using a suitable material, when applying an ultrasonic vibration to the rivet 1 by means of the sonotrode, the ultrasonic vibration can be absorbed to an increased degree in the heated portion an that reshaping is effected not or not just in the region of the sonotrode, but also in the heated region.
[0028] The underlying idea of the invention is to utilize the temperature-dependent absorption coefficient for more uniform heating of the workpiece by means of ultrasound.
[0029] The provision of a temperature gradient within the workpiece to be reshaped, that is to say the provision of a first portion of the workpiece, which is at a different temperature from the second portion which comes into contact with the reshaping tool, provides that it is possible to specifically targetedly select the portion which is intended to present particularly high or optionally particularly low absorption of ultrasonic vibrations so that certain portions of the workpiece can be heated in quite specifically targeted fashion by means of the sonotrode.
[0030] In most cases it is advantageous if the first portion, before the reshaping force is applied to the workpiece, is brought to a temperature higher than the temperature of the second portion. In that case the temperature difference is preferably at least 10° C. and particularly preferably at least 20° C. In that respect it will be appreciated that neither the first nor the second portion involve a homogeneous temperature as, by virtue of the finite thermal conductivity, there is always a certain temperature difference within the portion as soon as temperature heating from the exterior is initiated.
[0031] The optimum temperature difference to be set depends on the material of the workpiece to be processed. Particularly preferably therefore the first portion of the workpiece is brought to a temperature which differs from the temperature of the first portion so that the damping factor or absorption coefficient in the first portion differs by at least 5% from the damping factor or absorption coefficient of the second portion.
[0032] The method according to the invention has great advantages, in particular in reshaping workpieces of plastic, preferably part-crystalline plastic. Examples in that respect are PA6, PA12 and PA66. In principle however the described method according to the invention enjoys great advantages in relation to all part-crystalline high-performance materials.
[0033] In principle the first portion can be brought to a temperature higher than the temperature of the second portion, in any desired fashion. In a particularly preferred embodiment however it is provided that the first portion is brought to a higher temperature by means of an impressed ultrasonic vibration.
[0034] Thus for example in FIG. 1 a the riveting material 2 could be acted upon with a ultrasonic vibration so that, in the portion arranged in the through opening in the riveting material 2 , the rivet 1 is heated at its peripheral surface. If then in a further step the sonotrode 3 is moved in a direction towards the rivet 1 , an ultrasonic vibration introduced into the rivet 1 by the sonotrode 2 is absorbed to an increased degree in the first portion which was brought to a higher temperature, so that effective reshaping can take place here.
[0035] As an alternative thereto the workpiece can also be in the form of a hollow rivet and best in the form of a part-hollow rivet as then heating of the first portion can be effected substantially in the interior of the rivet, more specifically by way of the opening which extends over a part or over the complete rivet.
[0036] For example the reshaping tool can have an upsetting surface, by way of which the reshaping force is applied to the workpiece, and a bar which projects beyond the upsetting surface and by way of which heat is introduced into the first portion of the workpiece. That bar can either have a heating device or it can be subjected to the action of an ultrasonic vibration no that heat can be transmitted into the workpiece by way of the ultrasonic vibration.
[0037] In regard to the device the foregoing object is attained by a device for reshaping a workpiece comprising a reshaping tool which is in the form of a sonotrode and which is so designed that it can be brought into contact with a workpiece to be reshaped and a reshaping force can be applied to the workpiece. In that case the device has a transducer for producing an ultrasonic vibration, which is possibly connected to the reshaping tool by way of an amplitude transformer. Furthermore in accordance with the invention there is provided a device for heating and/or cooling a first portion of the workpiece to be reshaped and for producing a temperature gradient between the first portion and a second portion of the workpiece that comes into contact with the reshaping tool.
[0038] The transducer converts an electric ac voltage into a mechanical vibration. Piezoelectric elements are generally used here. In principle ultrasonic vibration units comprising a transducer and a sonotrode connected thereto possibly by way of an amplitude transformer are known so that there is no need for a detailed description at this juncture.
[0039] The reshaping tool preferably has an upsetting surface, by way of which a reshaping force can be applied to the workpiece to be reshaped.
[0040] In addition in a preferred embodiment it is provided that the reshaping tool has a bar which preferably projects beyond the upsetting surface, wherein the bar can be heated or acted upon with an ultrasonic vibration. In that case the bar serves as a device for heating the first portion of the workpiece to be reshaped.
[0041] The reshaping tool can be in the form of a closing head shaper for reshaping a workpiece in the form of a rivet.
[0042] In addition there can be provided a part-hollow rivet which at its side forming the closing head has a recess which does not extend through the entire rivet. Basically the part-hollow rivet forms a kind of pocket, into which the bar is introduced so that the bar heats the inside surfaces of the pocket and the regions adjoining same before the upsetting surface exerts a reshaping force on the workpiece.
[0043] In the known upsetting riveting method the upsetting surface of the sonotrode, that is to say the rivet shape, must always be exactly adapted to the material. If that is not done, the situation involves ejection or rivet heads which are not completely shaped out, without strength.
[0044] Ejection is a major problem in many sectors as particles can cause damage to other critical components like for example electronic components or switching elements.
[0045] In addition the optical impression in regard to visible parts is also not to be disregarded. A poorly shaped rivet head and a rivet head with too much ejection is frequently not accepted in visible situations for purely optical reasons.
[0046] The described method makes it possible to almost completely avoid ejection, even un the case of an upsetting surface which is not properly adapted.
[0047] In that way the sonotrode can be more easily produced.
[0048] Further advantages, features and possible uses of the present invention will be clearly apparent from the description hereinafter of preferred embodiments.
[0049] FIG. 2 shows a specific embodiment of a sonotrode 6 . The sonotrode 6 has an upsetting surface 7 and a bar 8 projecting beyond the upsetting surface 7 . The bar 8 is substantially cylindrical but it has a conical tip.
[0050] FIG. 3 shows a rivet 9 of a configuration according to the invention. The rivet 9 has a setting head 10 and a recess 11 which does not extend through the entire rivet 9 .
[0051] It will be appreciated that, instead of the provision of a setting head 10 , the rivet 9 can also be connected directly to a material which is to be joined to the riveting material 12 by the riveting method. As can be seen from FIGS. 4 a through 4 c the rivet 9 is firstly passed through an opening in the riveting material 12 until the setting head 10 bears against the riveting material 12 .
[0052] The sonotrode 6 is then moved in the direction of the rivet 9 so that the bar 8 passes into the recess 11 in the rivet 9 . In the situation shown in FIG. 4 a it is only at its conical tip that the bar 8 is in contact with the rivet, more specifically at the bottom of the recess 11 . As the sonotrode 6 performs an ultrasonic vibration that ultrasonic vibration is transmitted in the point of contact between the bar on the one hand and the bottom of the recess in the rivet 9 of the other hand, into the rivet 9 . That therefore involves local heating of the rivet 9 in the immediate proximity to the contact surface.
[0053] As can be seen from FIG. 4 b the sonotrode 6 is hen moved further in the direction of the rivet 9 so that the bar 8 penetrates into the rivet and ultrasonic vibrations are now also transmitted to the rivet 9 with a part of the outside surface of the bar so that then a relatively large portion within the rivet is heated.
[0054] If now, as shown in FIG. 4 c , the sonotrode 6 comes into contact with its upsetting surface 7 with the rivet 9 and a reshaping force is applied then reshaping preferably occurs in the regions in which a higher temperature prevails, which according to the invention is the region in the immediate proximity with the bar 8 . The closing head can now be formed by the measure according to the invention, without constriction recesses being produced.
[0055] The view in FIGS. 4 a through 4 c is only diagrammatic. The bar which is fixed to the sonotrode 6 can be of different geometries, thus for example stepped configurations as shown in FIG. 5 , frustoconical configurations as shown in FIG. 6 , as well as bars with stepped portions and a conical tip, as shown in FIG. 7 , are also considered.
[0056] Depending on the respective geometry used for the bar it may be advantageous if the corresponding recess in the part-hollow rivet is also of a stepped and/or conical configuration.
LIST OF REFERENCES
[0000]
1 rivet
2 riveting material
3 sonotrode
4 constriction
5 closing head
6 sonotrode
7 upsetting surface
8 bar
9 rivet
10 setting head
11 recess
12 riveting material
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The present invention relates to a method for reshaping a workpiece, in which a reshaping force is exerted on the workpiece by means of a reshaping tool and the workpiece is heated during or before the reshaping of the workpiece, wherein the heating of the workpiece is performed by the at least partial absorption of an ultrasonic vibration in the workpiece. In order to provide a method and a device for reshaping a workpiece that avoids the aforementioned. disadvantages, in particular when reshaping materials with a highly temperature-dependent damping constant, it is proposed according to the invention that, before the reshaping force is applied to the workpiece, at least a first portion of the workpiece is brought to a temperature which differs from the temperature of a second portion of the workpiece that comes into contact with the reshaping tool.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/098,382, filed Sep. 19, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of Invention
[0004] The present invention relates generally to buoyant cushions for use in a pool and being adaptable for use as outdoor furniture or in cooperation with outdoor furniture.
[0005] 2. Description of the Related Art
[0006] Conventional floatation devices for use at a swimming pool, a river, or a lake are typically inflatable. These inflatable floatation devices, although fully capable of supporting the weight of a person, suffer from numerous shortcomings. A user of these conventional floatation devices is essentially required to inflate the device before each use. Conventional floatation devices having insufficient air pressure often results in the device sinking or suspending the user underwater. In order to inflate these floatation devices the user is required to bring an air pump to the desired location. Furthermore, these conventional floatation devices are typically being manufactured from thin plastic materials that are prone to scratches and punctures that consequently render them useless as a floatation device. Resultingly, these conventional floatation devices can only be used in the pool and cannot be used as outdoor furniture or in conjunction with outdoor furniture.
BRIEF SUMMARY
[0007] The present invention relates generally to a buoyant cushion for use in a pool and being adaptable for use as outdoor furniture or in cooperation with outdoor furniture. The buoyant cushion having physical properties that include buoyancy, weather-resistance, and malleability that allow the buoyant cushion to be used dually as a lounging floatation device, in bodies of water such as pools, lakes, or the ocean, and as a cushion adapted to compliment outdoor furniture or to be used independently.
[0008] The buoyant cushion includes a mechanically compliant exterior covering and defines a mechanically compliant chamber. The chamber containing a plurality of buoyant beads. These buoyant beads enabling the buoyant cushion to support the weight of a subject in a body of liquid to the extent that at least a portion of the subject is maintained above the surface of the liquid. Additionally, because of the properties of the buoyant cushion the cushion is adapted to serve as a weatherproof cushion that compliments a piece of outdoor furniture or to serve as an independent furniture-type device when the buoyant cushion is not being used as a flotation device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The above-mentioned features of the invention will become more clearly understood from the following detailed description of the invention read together with the drawings in which:
[0010] FIG. 1 illustrates one embodiment of the buoyant cushion in accordance with the various features of the present invention;
[0011] FIG. 2 illustrates an alternate embodiment of the buoyant cushion having a plurality of grommets at opposing ends of the buoyant cushion;
[0012] FIG. 3 illustrates a sectional view of the buoyant cushion of FIG. 2 taken at lines 3 - 3 ;
[0013] FIG. 4 illustrates one embodiment of the buoyant cushion defining a cup holder and a cooler; and
[0014] FIG. 5 illustrates one embodiment of the buoyant cushion cooperating with a lounge chair.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention relates generally to a buoyant cushion for use in a pool and being adaptable for use as outdoor furniture or in cooperation with outdoor furniture. More specifically, the buoyant beads enable the buoyant cushion to support the weight of a subject in a body of liquid to the extent that at least a portion of the subject is maintained above the surface of the liquid. Additionally, the buoyant cushion is adapted to serve as a weatherproof cushion that compliments a piece of outdoor furniture or to serve as an independent furniture-type device. One embodiment of the buoyant cushion constructed in accordance with the various features of the present invention is illustrated generally at 10 in FIG. 1 .
[0016] FIG. 1 illustrates one embodiment of the buoyant cushion 10 having a substantially rectangular contour. The buoyant cushion 10 includes a mechanically compliant exterior covering 12 and defines a mechanically compliant chamber. In accordance with one embodiment, the buoyant cushion 10 includes an internal covering and an external covering. More specifically, the internal covering defines a mechanically compliant chamber while the exterior covering provides protection to the internal covering. The internal covering and external covering may be permanently joined together or releasably coupleable such that said exterior covering may be replaced. The exterior covering 12 is constructed of a compliant or flexible material that is water repellant and otherwise weather-resistant. For example, in one embodiment, the exterior covering 12 is constructed of an acrylic fabric, rendering the exterior covering 12 not only weather-resistant, but also UV-resistant and mildew-resistant. One example of such an acrylic fabric is the Sunprella® Fabrics manufactured by Glen Raven Mills, Inc. Additionally, the buoyant cushion 10 may be contoured and dimensioned to function as a seating cushion, small neck-supporting pillow, throw pillow, or roll-type pillow to be used, for example, at poolside.
[0017] FIG. 2 illustrates one embodiment of the buoyant cushion 10 that defines a rim 14 about the perimeter of the chamber. In the illustrated embodiment, the rim 14 includes a reinforced seam defined by the exterior covering 12 . In accordance with one embodiment of the present invention, the rim 14 extends from the exterior covering 12 by two inches and thereafter includes additional seams to reinforce the rim 14 . The rim 14 provides a user with a handle for maneuvering and/or transporting the buoyant cushion 10 in and around a body of water.
[0018] Furthermore, FIG. 2 illustrates one embodiment of the buoyant cushion 10 that includes at least one grommet 16 at the rim 14 . In one embodiment, the grommet 16 is defined by reinforced stitching so as not to include an additional eyelet made of, for example, metal, plastic, or rubber. In another embodiment, the buoyant cushion 10 including a first grommet and a second grommet enables a user to tether the buoyant cushion 10 to a stationary object, such as a dock, and to fold and bind the buoyant cushion 10 , for example using a fastener, for compact transportation.
[0019] In another embodiment, the grommets 16 allow the buoyant cushion 10 to function as a hammock. More specifically, this embodiment of the buoyant cushion 10 has a contour that is substantially that of a hammock such that the buoyant cushion 10 includes a first end 18 and a second end 20 , the first end 18 being opposite the second end 20 with respect to the buoyant cushion 10 . Additionally, in the illustrated embodiment, the buoyant cushion 10 includes a plurality of grommets 16 at the first end 18 and a plurality of grommets 16 at the second end 20 . The grommets 16 are adapted to receive suspension devices, such as ropes, such that when the suspension devices are secured to a structural support, such as a tree or hammock stand, the buoyant cushion 10 is suspended in the same manner as would be a conventional hammock.
[0020] FIG. 3 illustrates one embodiment of the chamber 22 defined by the buoyant cushion 10 housing a plurality of buoyant beads 24 . The buoyant beads 24 provide the buoyant cushion 10 with its buoyancy, enabling the buoyant cushion 10 to support a subject, such as a human, in a body of water to the extent that at least a portion of the human is maintained above the surface of the water, as discussed above. In one embodiment, the buoyant beads 24 are constructed of a virgin polystyrene material. The virgin polystyrene beads do not absorb water or resins and do not expand to the extent that the beads define cracks or separations. As a result, the beads are not prone to collecting moisture or debris, which reduces the probability of mold or mildew developing in or on the beads. The buoyant beads are small in size, such as having a 3 mm diameter, such that the buoyant cushion 10 is substantially conformable and malleable. Because the buoyant beads 24 provide the buoyant cushion 10 with its buoyancy, the buoyant cushion 10 cannot be deflated, such as by way of a puncture to the exterior covering 12 .
[0021] FIG. 4 illustrates another embodiment of the buoyant cushion 10 . In accordance with one embodiment of the present invention, the outer covering 12 defines at least one cup holder 26 and a cubby 28 for holding a small cooler or personal items, such as keys. The chamber defines the cup holder 26 and the cubby 28 by defining a recess that extends within the chamber. As a result, the buoyant beads substantially surround the recess such that the buoyant beads provide thermal insulation for the cup holders 26 and the cubby 28 . In accordance with another embodiment of the present invention, the cup holders 26 and the cubby 28 extend past the chamber thereby allowing the cups to obtain some thermal insulation from the liquid below the buoyant cushion 10 . In another embodiment of the present invention, the outer covering 12 and the chamber define a cooler having a lid.
[0022] FIG. 5 illustrates yet another embodiment of the buoyant cushion 10 contoured and dimensioned as a lounge pillow to cooperate with conventional poolside and outdoor furniture. Because the buoyant cushion 10 is malleable and weather-resistant, it is capable of cooperating with and withstanding the environmental exposure associated with outdoor furniture. In accordance with one embodiment of the present invention, illustrated in FIG. 5 , the outer covering 12 being amendable such that the buoyant cushion 10 conforms to the lounge chair, namely a rectangular portion of the lounge chair where a person is received. In alternate embodiments of the present invention, the buoyant cushion 10 may be easily contoured and dimensioned to cooperate with a platform bed, an outdoor bed having table tops 46 and a storage compartment, a standard chair, a hanging chair frame, a porch swing, and a bench seat cabana.
[0023] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.
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The present invention relates generally to buoyant cushions for use in a pool and being adaptable for use as outdoor furniture or in cooperation with outdoor furniture. The physical properties of the buoyant cushion having physical properties that include buoyancy, weather-resistance, and malleability that allow the buoyant cushion to be used dually as a lounging floatation device, in bodies of water such as pools, lakes, or the ocean, and as a cushion adapted to compliment outdoor furniture or to be used independently.
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BACKGROUND OF INVENTION
Cosmetic applicators, particularly those for eye make-up such as mascara and eye liner, generally comprise a container having a reservoir of cosmetic into which a wand is inserted for loading. The wand normally has a tip portion adapted to function as an applicator for different areas of the body. Quite often this wand is an integral part, or at least attached to, the cap of the container such that, when the cap is in place closing the container, the wand extends into the reservoir and is in contact with the cosmetic. In this condition cosmetic collects on the applicator in excess of that required for use and must be removed before application. Preferably, this is done by a wiping mechanism in the form of a collar within the neck of the container through which the wand passes. As the cap is removed and the wand withdrawn from the container, the collar removes the excess cosmetic that has collected on both the wand and the applicator tip.
The wand in these applicators is commonly round in cross-section and fixedly attached to the inside of the cap. The applicator tip is usually a brush or a pad, also having a generally round cross-section, longitudinally co-extensive with the longitudinal axis of the wand. Furthermore, to achieve a good sea and thereby prevent drying out or contamination of the cosmetic the securing of the cap to the container is usually by means of cooperating threads between the inside of the cap and the outside of the container neck.
U.S. Pat No. 4,922,934 to Gatti discloses a mascara applicator having a means within the cap to rotate the wand and its attached brush when a friction member is released.
Recently, different types of applicator tips for use with these devices have become popular, particularly flat combs and brushes. Such tips do not receive sufficient wiping from the wiping collars used with round tips. Accordingly, wiping collars having rectangular apertures have been devised. However, in order to allow the cap to rotate for application to and removal from the container, the wands of such applicators have remained round which complicates the manufacture of these devices. Particularly in the case of comb type applicators it would be preferred to form the comb on the end of a wand having a flat or irregular shape corresponding to that of the comb. However, such a shape would then prevent cap rotation thereby precluding the use of cooperating threads and the high degree of sealing achieved by that means.
Applicants have devised a method whereby applicators with flat or irregularly shaped wands may be used in conjunction with cosmetic containers having threaded caps wherein the wand extends outward from the inside of the cap along a longitudinal axis so as to depend into the container when the cap is in place.
SUMMARY OF THE INVENTION
The present invention relates to a mascara or similar cosmetic applicator comprising a container and a cooperating cap from the inside of which extends a wand in such a manner as to be inserted into the container when the cap is in place. The end of the wand remote from the cap is provided with an applicator tip having a substantially rectangular form such as a comb or flattened brush or other irregular shape. Similarly, the wand is of a flattened or irregular shaped cross-section.
Within the neck of the container is a wiping collar for the removal of excess cosmetic from the applicator wand and tip as they are removed. This wiping collar has a wiping element and an associated access aperture through which the wand passes. The aperture is formed in a shape to correspond to the shape of the wand and its tip. Thus, where the wand and tip are substantially flattened and rectangular, the aperture in the wiping collar and the wiping element are formed in a corresponding shape. Similarly, where the wand and tip are another substantially irregular shape the aperture and element will be formed to correspond to that shape.
In order to permit rotation of the cap for threading and unthreading from the container, the wand is assembled to the cap in a manner so as to be relatively rotatable thereto about their common longitudinal axis. Alternatively, the cap and wand are fixed and the wiping collar is adapted to be rotatable relative to and within the neck of the container about their common longitudinal axis. In this manner a wiping collar having an aperture and wiping element corresponding to the irregular shape or the wand and applicator may be used in conjunction with threaded attachment of the cap to the container. The continued use or cooperating threads with mascara applicators of this type is preferred because of its superior sealing which prevents drying out or contamination of the cosmetic.
It is therefore an object of this invention to provide a device for the application of cosmetics having means permitting an irregularly shaped shaft and applicator tip to be employed in combination with a threaded closure means and a wiping collar.
It is a further object of this invention to provide a cosmetic applicator in the nature of a mascara brush or comb of irregular shape attached to a wand of equally irregular shape and extending from within a threaded cap through a wiping collar having an opening of the same irregular shape and located in the neck of a container whereby relative rotation between the wand and the cap permit threaded attachment and removal of the cap to and from the container.
It is a still further object of this invention to provide a cosmetic applicator in the nature of a mascara brush or comb of irregular shape attached to a wand of equally irregular shape and extending from within a threaded cap through a wiping collar having an opening of the same irregular shape and located in the neck of a container whereby relative rotation between the wiping collar and the container permit threaded attachment and removal of the cap to and from the container.
Further objects and advantages will become evident from the accompanying drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross section of a mascara applicator cap and container incorporating a first embodiment of the present invention.
FIG. 1a is a horizontal cross-section of the wand of FIG. 1 taken along line E--E.
FIG. 2 is a perspective view of a wiper collar as used in a first embodiment of the present invention.
FIG. 3 is a longitudinal cross-section of figure two taken along line B--B.
FIG. 4 is a longitudinal cross-section of figure two taken along line A--A.
FIG. 5 is a longitudinal cross-section of an alternative construction of the cap portion of the embodiment in FIG. 1.
FIG. 6 is a perspective view of a wiper collar as used in a second embodiment of the present invention.
FIG. 7 is a longitudinal cross-section of the neck portion of a mascara container incorporating a second embodiment of the present invention along line C--C of FIG. 6.
FIG. 8 is a longitudinal cross-section of the neck portion of a mascara container incorporating a second embodiment of the present invention along line D--D of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Cosmetics are often packaged in a bottle with a screw cap to which an applicator is attached such that it extends into the bottle when the cap is screwed on. Mascara and eye liner are particularly packaged this way. In such packaging, the applicator is attached to or is part of an elongated wand which is mounted within the cap and extends longitudinally from the open, threaded end of the cap.
This arrangement is illustrated in FIG. 1 which also shows a first embodiment of the invention.
In this invention, the bottle 1 and the cap 2 are analogous to the common bottle and cap structure of a mascara product. Bottle 1 and cap 2 attach by means of cooperating threads 3a on the outer surface of the bottle neck 4 and threads 3b on the inner surface of the cap 2 and towards its open end 5.
Preferred applicators according to this invention are of a shape other than round and are particularly combs or flattened brushes on the end of a wand having a comparable shape which extend outwardly from within the cap 2. Of particular interest to this invention are applicators having a flattened wand such that they are substantially rectangular in cross-section as shown in FIG. 1a. This figure shows the horizontal cross-section of wand 6 of FIG. 1 taken at line E--E.
Where, as here, the wand 6 is of a shape other than round means must be provided to permit cap 2 to rotate relative to bottle 1. Since the wand 6 must have a wiper configured to its shape for proper and effective wiping, cap rotation would not be possible in the conventional construction of such devices. Accordingly, either the wand must be permitted to rotate relative to the cap or the wiper must be rotatable relative to the bottle. The present invention provides embodiments for both of these conditions.
Wands of this type require a wiper configured to their other than round shape. In the case of the rectangular wand 6, a wiper collar having a slit wiper is preferred. Such a collar 7 is shown in FIG. 1 installed within the neck 4 of bottle 1 and individually in FIGS. 2, 3 and 4.
Wiping collar 7 is a subassembly made up of a collar body 8 a wiping element 9 and a metal disk 10. The collar body 8 comprises a planar top 11 with a depending cylindrical skirt 12. Planar top 11 has a diameter corresponding to the outside diameter of the bottle neck 4 such that it forms a flange 13 about the skirt 12. When wiper 7 is inserted into the bottle neck 4, the lower surface of this flange sits on top of the upper edge of the neck 4. Circumferentially about the skirt 12 is an annular bead 14 which cooperates with a corresponding annular recess 15 within the bottle neck 4 to hold the wiper 7 in place in neck 4.
Through the planar top 11 of collar 7 is an aperture 16 of shape that corresponds to the shape of the wand 6. In the illustrated embodiment, aperture 16 is rectangular to correspond to the rectangular shape and size of wand 6. Furthermore, aperture 16 is preferably diametrically centered in the planar top 11.
Collar body 8 is also provided with a vertical key lug 17 extending downward from flange 13. Key lug 17 cooperates with a corresponding key way (not shown) cut in the inside surface of bottle neck 4 to prevent rotation of collar 7 after its insertion into bottle neck 4. FIG. 2 illustrates key lug 17 as being in line with aperture 16 for convenience. Key lug 17 may be located at any position around the circumference of collar body 8.
At the lower edge of the skirt 12 is wiping element 9 which is held in place by metal disk 10 which is crimped in place around the lower edge of skirt 12. Disk 10 has a central aperture 10' that corresponds to the inside diameter of skirt 12 and functions to hold wiping element 9 in place. Wiping element 9 is preferably a disk of flexible, elastomeric material such as natural or synthetic rubber and is provided with an elongated slit 9' allowing the wand 6 to pass through it and be wiped upon withdrawal of the wand and applicator from the bottle.
It is important that aperture 16 be aligned with slit 9' in wiping element 9 as one purpose of aperture 16 is to ensure that wand 6 is properly aligned when it is inserted and withdrawn so that adequate wiping of wand 6 and its attached applicator tip is achieved. Accordingly, the assembly of wiping element 9 to collar body 8 by disk 10 should be made so that the axis of slit 9' corresponds to that of aperture 16 as shown by cross-section FIGS. 3 and 4.
In order for cap 2 to be threaded onto and off of bottle 1 by means of cooperating threads 3a and b, cap 2 must be able to rotate relative to bottle 1. The embodiment shown in FIG. 1 incorporating a fixed wiping collar 7 achieves this by making the wand 6 rotatable relative to the cap 2. In this manner while the wand 6 is engaged by the wiping collar 7 it is held against rotation and its connection with cap 2 is such as to permit the cap 2 to rotate relative to both the wand 6 and bottle 2. Although this rotation is required for removal and replacement of cap 2, the relative rotation of cap 2 and wand 6 should not be such as to allow wand 6 to freely rotate relative to cap 2 upon complete removal from Bottle 1. Too free a rotatability would render usage of the applicator extremely difficult as it would tend to rotate away from the desired point of application.
FIG. 1 illustrates one construction of the cap 2 and wand 6 whereby the desired relative rotation may be achieved.
As with conventional applicators, cap 2 comprises a top 2 with a cylindrical skirt 2" depending from its periphery. Within the open lower end 5 are cut threads 3b which cooperate with threads 3a on neck 4. Wand 6 extends into cap 2 through open end 5. A length of wand 6 sufficient for insertion into bottle 1 to reach the cosmetic contained therein when cap 2 is applied to bottle 1 extends beyond the open end 5.
At the end of wand 6 opposite applicator tip 6' is a cup 18 which may be a separate piece to which wand 6 is attached but which is preferably integrally molded as part of wand 6. Cup 18 comprises a base 18' and an upstanding skirt 18". Connection between cup 18 and wand 6 is made via block 19 between cup base 18' and end 6" of wand 6. Preferably the entire assembly of wand 6, cup 18 and block 19 is a single molded piece.
Cup 18 is preferably frustoconical in shape tapering from a wider open top end 20 to a narrower base 18". The outside diameter of the open top end 20 is such that it fits snuggly within the inside diameter of cap 2. Block 19 is circular in plan and has a diameter smaller than that of base 18' such that a circumferential ledge 21 surrounds block 19.
The wand/cup combination is inserted into cap 2 until the open top end 20 butts against the inner surface of cap top 2'. The assembly is held in place by a collar 22 that fits around the lower end of cup 18 and has an aperture 22' through which wand 6 and block 19 may extend. An annular bead 23 on collar 22 cooperates with an annular groove 24 on the inside of cap skirt 2" to lock collar 22 in place. A shelf 22" circumferential about aperture 22' cooperates with ledge 21 of cup 18 to securely hold the wand/cup combination within cap 2.
The position of annular groove 24 within cap 2 is such that, when collar 22 is in place, it forces end 20 of cup 18 against the inner surface of cap top 2' with sufficient pressure such that friction prevents rotation of wand 6 when used to apply cosmetic. However, the friction between cup 18 and cap 2 is not so great that it cannot be overcome when wand 6 is held by wiping collar 7 and cap 2 is rotated to screw it on or off bottle 1.
An alternative construction for this embodiment is shown in FIG. 5. Here, cup 18 is substantially cylindrical with an outside diameter at least equal to the inside diameter of cap 2. Wand 6 connects directly to cup base 18' without intervening block 19 of the first construction. Securement of the wand/cup combination within cap 2 is by means of annular bead 25 on cup 18 uniting with groove 26 within cap 2. Preferably, bead 25 is located circumferentially about base 18'. In this manner, the nee for collar 22 is eliminated and the required level of friction is achieved by a tight fit between cup 18 and cap 2.
In an alternative embodiment relative rotation between cap 2 from which extends applicator wand 6, and bottle 1 is achieved eve where wand 6 is fixedly attached to cap 2, by means of a wiping collar mounted within neck 4 of bottle 1 so as to be relatively rotatable thereto. FIGS. 6, 7 and 8 illustrate a wiping collar according to this embodiment.
In this embodiment cap 2 and wand 6 are substantially a described above with the exception that wand 6 is fixed within cap 2 so as to be non-rotatable. Such fixation may be by any means currently used in the manufacture of cap mounted applicators.
Wiper 30 comprises a wiper body 31 and a mounting collar 32 which are assembled in a telescopic relationship and inserted into neck 4 of bottle 1. Wiper body 31 is substantially cylindrical with a longitudinal through channel 33 which has a shape corresponding to the shape of wand 6. The entrance of through channel 33 in the upper surface of wiper body 31 is preferably formed with angled sides 33' to provide guidance for insertion of wand 6. Circumferentially about the upper end of wiper body 31 is a flange 34 which extends outward to a diameter equal to the outer diameter of bottle neck 4 forming a shelf by which wiper body 31 is supported in neck 4 with mounting collar 32 therebetween.
Wiper body 31 is inserted into mounting collar 32 which, in turn, is inserted into bottle neck 4. Mounting collar 32 comprises a cylindrical skirt 35 depending from an annular flange 36 and includes an annular bead 37 circumferentially about the outer surface of skirt 35. Bead 37 cooperates with an annular groove 38 in the inner surface of neck 4 to lock mounting collar 32 in place. The relative positioning of bead 37 and groove 38 is such that flange 36 sits on the top edge of neck 4 and serves as a bearing surface for wiper body flange 34.
The fit between mounting collar 32 and bottle neck 4 is sufficiently tight to prevent rotation of collar 32. Additional means to prevent such rotation may be employed such as a key lug and corresponding key way as in the previous embodiment. However, the fit between collar 32 and wiper body 31 is not tight and should be sufficiently loose so that wiper body 31 may freely rotate.
As shown in FIGS. 7 and 8, wiper body 31 has a length greater than that of mounting collar 32 and extends beyond the lower edge 32' of collar 32. At the bottom end of wiper body 31 is located a wiping element 39 which corresponds to wiping element 9 of the previous embodiment and has a slit 39' allowing passage of wand 6. Wiping element 39 is held in place against the end of upper body 31 by means of a retainer cup 40. Retainer cup 40 has a central aperture 40' corresponding in shape and at least as large as the area of through channel 33. Cup 40 is positioned so that aperture 40' is in line with through channel 33 and wiper slit 39' to allow passage of wand 6. Between the bottom edge of wiper body 31 and the level of the lower edge 32' of collar 32, an annular notch 41 is cut in the outer surface of wiper body 31. Retainer cup 40 is provided with indented spring legs 42 which engage notch 41 when cup 40 is placed thereon to hold both wiping element 39 and cup 40 in place. The upper edge 40" of cup 40, when in place, is in close proximity to lower edge 32' of mounting collar 32 and is of sufficient thickness to prevent wiper body 31 from being withdrawn from mounting collar 32. This relationship between cup 40 and mounting collar 32 is such as to not bind during rotation or wiper body 31 within collar 32.
In an alternative embodiment, which would be the counterpart to the alternative construction of the rotating wand embodiment, mounting collar 32 may be dispensed with as long as the materials from which bottle 1 and wiper body 31 are made have relatively low coefficients of friction so that wiper body 31 may freely rotate. In this alternative construction, annular bead 37 would be formed about wiper body 31 at a vertical level thereon to result in flange 34 resting on the top edge of neck 4. Since the bead 37 will serve to hold wiper body 31 in neck 4, retainer cup 40 may be modified to be a metal disk crimped around the lower end of wiper body 31 in the manner of disk 10 of the embodiment in FIGS. 1-4.
While the foregoing describes preferred embodiments of the present invention it is considered to include obvious variations that would occur to one skilled in the art.
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An improved cosmetic package, particularly for eye make-up such as mascara, comprising a container, a cap having an applicator extendable into the container and a wiping body within the neck of the container. The package is particularly suited for applicators having an irregular cross-section and provides for threaded cooperation between the cap and container by a construction wherein the cap and applicator are relatively rotatable about their common longitudinal axis. An alternative construction provides for the applicator to be fixed within the cap and the wiping body to be relatively rotatable with the container about their common longitudinal axis. These constructions allow applicators with irregular cross-sections to be used in containers where the cap and container attach by means of cooperating threads.
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SUMMARY OF THE INVENTION
Computers and other modern business machines frequently employ multiple folded paper, the paper having edge margins with perforations or sprocket holes therein, the perforations mating with drive sprockets or tractors which move the paper through a processing machine. In many applications, the margins containing the perforations are not needed after the paper passes through the machine and are slit off so that the desired record paper will occupy the minimum amount of storage space. Slitters have been employed for many years in this application but the slitters produce a long, tape-like cutting and this cutting is difficult to dispose of. It will not automatically fall neatly into a bin but instead it is ordinarily necessary to provide some manual means for dealing with the long tapes that are cut off. Further, such long tapes are not easy to store or to dispose of.
In accordance with the present invention, a chopper device is provided which follows a slitter; the chopper chops or tears the tape into a series of short, irregular pieces. These pieces will fall into a bin or the like and occupy a minimum space and are easy to handle.
In the past, attempts have been made to cut the tapes into short lengths but such cutting devices did not prove successful since the perforated tape would bend at the end of the hole, making it difficult to cut.
In contrast, the device of the present invention has a series of staggered, tearing blades, so that a plurality of the spaced, staggered blades enter the tape and literally tear it apart either at the perforations or between them.
In accordance with one aspect of the invention, a plurality of chopper blades are used which are not rigidly mounted on a shaft but are maintained in spaced alignment with some give or leeway so that the machine has little tendency to bind.
Various additional features of the invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of a paper processing machine showing a paper drive mechanism, an edge slitting mechanism, and the chopper which constitutes the gist of the present invention.
FIG. 2 is an exploded view of the fixed cutting blade, one of the chopper blades, a spacer washer, and a supporting arbor.
FIG. 3 is an enlarged side view of the machine on the line 3--3 of FIG. 1.
FIG. 4 is a section on the line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings by reference characters, there is shown a manifold paper 5 having margin edges 7 and 9, each of which has spaced perforations 11 therein. The paper is driven through the machine by sprockets, or preferably, by so-called tractors, which have an endless belt 13 having a series of lugs 15 thereon which engage the sprocket holes 11. Ordinarily, two such tractors would be employed, one on each side of the sheet, but only one is shown in FIG. 1.
Although the margin edges with their sprocket holes are necessary for driving paper through the various processing machines, it is highly desirable that these margins be cut off so that the paper can be stored in a minimum amount of space. For this purpose, margin cutters such as those generally designated 17 and 19 are employed on either side of the sheet. These consist of rotary knives 21 and 23 mounted on shafts 25 and 27 respectively, driven by motor means, not shown. These rotary knives are well known to those skilled in the art so that they will not be described in detail. When the knives encounter the sheet 5, an edge 7 is cut off which drops away as is best seen in FIG. 3, while the balance of the sheet continues through the machine as is shown in 5A.
The margin 7 comes off as a long, tape-like strip and, as has been pointed out above, it is difficult to deal with such material. In accordance with the present invention, highly-effective chopper units are employed, one being mounted under each pair of rotary knives. Since these devices are mirror images of each other, only one will be described in detail. The chopping device fits within a housing generally designated 29 and this holds a shaft 31 mounted for rotation. Shaft 31 has a pulley 33 at the end thereof and it is driven by belt 35 from pulley 37 mounted on shaft 27. Pulley 35 is considerably smaller than pulley 37 so that shaft 31 is driven at a substantially higher speed than the shaft 27. Mounted on one side of the housing 29 is a fixed cutter 39 and a series of teeth 41 formed across one entire side. Shaft 31 carries a series of knives 43, each of which has two teeth 45 and 47 extending on opposite sides. Between each of the knives 43 is a spacer 48 and a shaft support member 49. Shaft support member 49 is pivoted through holes 51 on rod 53. It will be understood that there are a plurality of the knives, spacers, and support members across the width of the chopper as is best seen in FIGS. 3 and 4. The choppers are staggered around 180° so that one chopper is just leaving the chopping grooves as the next approaches and so on. Thus, referring now to FIGS. 3 and 4, successive teeth have been designated 45A, 45B and so on to illustrate how the blades are arranged. Shaft 32 has a spline 33 cut therein and each of the knives 43 has an inwardly extending tooth 42 adapted to engage the spline. The teeth 42 of the knives are offset with respect to the teeth 45 and 47 from one knife to the next to yield the helical configuration of the teeth best seen in FIG. 3.
Knives 43 are not held rigidly on the shaft but some leeway is provided so that they can shift back and forth slightly. Also, it will be seen that the holders 49 which support shaft 31 are not held rigidly in place but can move to some extent on shaft 53. Thus, as the tape enters the space between the rotating knives 43 and the fixed cutter 39, a first rotating knife will engage the margin 7 adjacent one edge thereof and will begin to tear the margin from said one side. An adjacent knife subsequently engages the margin spaced inwardly from said one edge and continues the tear, and so on, until the margin is torn across its width and highly irregular pieces are produced. Since the blaces can move slightly from side-to-side and also the entire holder can move up-and-down slightly, there is substantially no possibility of the chopper jamming.
Although the device was specifically designed for use with a machine for processing paper business forms, it is obvious that it is applicable to any device wherein it is desired to chop a tape or similar material into a plurality of small, irregular pieces which are easy to handle. The device of the present invention is capable of handling heavy materials such as cardboard or plastic.
Although a specific embodiment of the invention has been described, it will be obvious to those skilled in the art that many deviations can be made from the exact structure shown without departing from the spirit of this invention.
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A chopper for severed margins of multi-folded paper is provided wherein the margins are slit off the sheet and then chopped into small pieces which occupy a minimum amount of space and which present a simplified disposal problem.
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BACKGROUND OF THE INVENTION
The present invention generally relates to a method & design of cutting and cutting rotative bits, which can be used for excavation, planing and drilling of rock and soil and other non-metallic brittle materials, for destruction or production of construction materials, and be mounted on corresponding equipment, intended for cutting and crushing of the above mentioned materials.
Generally, the cutting process mechanism is as shown in FIG. 1. Cutting of a material, like rock, is carried out by thrust force T and normal component C n of the cutting force, generated by an equipment drive. Under the action of these forces, the tool simultaneously moves in horizontal and vertical directions generating complicated stresses that overwhelm rock resistance.
Under the action of the force C n , transmitted by the bit front face, compressive stresses are formed in the rock which are not large enough for destruction but preload the rock to resist further strain.
Under the action of the force T, shear stress is produced in the rock due to the high level of load concentration created by the bit's cutting edge. This shear stress provokes generation and development of destructive cracks in the brittle material.
At the same time, both forces C n and T generate a confined zone of super pressurized rock, located next to the bit cutting edge. This so-called kernel is an accumulator of energy that can discharge in an explosive way when accumulated energy exceeds ultimate rock resistance.
Because the previously mentioned destructive cracks propagate from the cutting edge in the direction of lowest resistance, they initially tend toward the open surface of the rock. However, these cracks can not bypass the enhanced resistance of the volume of the rock compressed by C n . Consequently, the destructive cracks pass around the compressed rock and reach the open surface at a distance L from bit front face, isolating the stressed volume of rock and separating the chip from entire rock massif.
Under continuous combined action of compressive and shear stresses,successive rock chips are separated from the rock mass in a whole or nearly whole condition chiefly due to wide and active destructive cracks or by kernel explosion after sufficient energy is accumulated to overcome crack shortfall.
Therefore, in an effective rock cutting process, it is obligatory to maintain a significant load concentration at the bit cutting edge, which is provided by the positive rear angle δ of the bit.
Consequently, the effective cutting bit must have an optimal combination of high cutting ability and high durability of the cutting element, reliable protection from overloading, preservation of both a sharp cutting edge and the bit positive rear angle, and maintain other initial parameters throughout the life of the cutting bit.
A plurality of tools have been developed with the objective to achieve some of the above mentioned parameters. The first group of the tools are bits with non-rotatable cutting elements. U.S. Pat. No. 1,174,433 discloses a cutter with a convex front face; however, the angle between its longitudinal axis and the cut surface behind the bit (defined as the attack angle) is less than 90° and the cutter is not protected from overloading or fast dulling of the cutting edge. U.S. Pat. Nos. 4,538,691 and 4,678,237 disclose destructive tools having elements with flat front face, oriented at a substantial negative front angle, that protects from overloading by providing a lifting force, but reduces the bit's cutting ability. The bits are not protected from fast dulling of the cutting edge. The attack angle here does not exceed 90°. U.S. Pat. Nos. 4,538,690; 4,558,753; and 4,593,777 disclose bits with a concave front face, oriented at a large negative front angle, which provides protection from overloading but decreases bit cutting ability. The attack angle also does not exceed 90°. The bit cutting edge is not protected from intensive dulling.
The second group of tools are rotative conical bits with a rock destructive element which can rotate around its own longitudinal axis. In the first sub-group of these tools, the cutting element has a conical shape (direct cone) and destroys the rock by its side surfaces, as disclosed for example in U.S. Pat. Nos. 3,650,565; 3,807,804; and 4,804,231.
These tools are bits of the crushing type that operate without generation of long destructive cracks. The bits are oriented at an attack angle which does not exceed 90° and, as a rule, is no more than 60° and bits are not protected from overloading. They have zero negative rear angle, their rotation around their longitudinal axis is not continuous and reliable. Therefore, their self-sharpening is not reliable, and if it occurs, the cutting element's initial angular parameters are not preserved.
The second group of the rotative bits includes tools which destroy rock with their end concave surfaces, as disclosed, for example, in U.S. Pat. No. 5,078,219. The bit here is a cutting tool, oriented with a small attack angle and is not protected from overloading. Its concave front face does not have a sufficient self-rotating and self-sharpening ability. Its rear angle has zero or negative value, and the bit quickly looses its cutting ability as it wears.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of cutting and a cutting rotative bit, which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a method of cutting and a cutting rotative bit which ensures maintenance of the bit's high initial cutting ability for the whole service lifetime, independent of normal bit wear along engagement surfaces.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method of cutting in accordance with which a cutting rotative bit is used with a body and a cutting annular element, connected with the body wherein the cutting element has a front convex face, and in the inventive method the cutting rotative bit is oriented so that an attack angle of the bit and the cutting element exceeds 90°. (Attack angle is the angle between the longitudinal axis of the bit and the cut surface behind the bit).
When the method is performed and the tool is designed in accordance with the present invention, the following advantages are provided:
Significant cutting ability of the bit, that provides high destruction efficiency of the rock and other similar material;
Continuous forced self-rotation of the bit around its own longitudinal axis, that provides increase of the bit cutting edge length and uniform wear long its rear face;
Continuous forced self-sharpening of the bit, that provides renewal and maintenance of the initial positive rear angle of the bit along its whole cutting edge;
Self-protection of the bit's cutting element against overloading caused by working material hard spots thereby increasing the bit's reliability;
Increased durability of the bit resulting in high bit reliability and longevity and increased range of working material that may be engaged; due to rational cutting force transmission through the elements of the bit.
Effective operation of the bit until nearly the entire cutting element is consumed by normal wear providing long bit service lifetime.
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 DRAWINGS
FIG. 1 is a view schematically showing a mechanism of rock destruction;
FIG. 2 is a view showing a cutting device provided with that cutting rotative bit in accordance with the present invention;
FIG. 3a is a view showing the inventive cutting rotative bit with cutting element having the front face of a cylindrical shape and rear face of a flat shape;
FIG. 3b is a view showing the inventive cutting rotative bit cutting element having the front face of an inverse conical shape and rear face of a flat shape;
FIG. 3c is a view showing the inventive cutting rotative bit cutting element having the front face of a direct conical shape and rear face of a flat shape;
FIG. 3d is a view showing the inventive cutting rotative bit cutting element having the front face of a cylindrical shape and rear face of a convex shape;
FIG. 3e is a view showing the inventive rotative bit cutting element having front face of a cylindrical shape and rear face of a convex shape;
FIG. 4a is a plan view of the inventive cutting rotative bit;
FIG. 4b is a view showing a longitudinal section of the cutting rotative in accordance with the present invention;
FIG. 4c is a transverse cross-section of the inventive cutting rotative bit; and
FIG. 5 is a perspective view of a bit in accordance with the present invention during cutting.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A cutting tool (FIGS. 2, 3, and 5) in accordance with present invention has a body which is identified with reference numeral 1 and a cutting element or an insert which is identified with reference numeral 2. The body is further provided with a tail part 3 which contributes to rotation of the bit about its longitudinal axis.
As can be seen from FIG. 2, the tail part of the bit is arranged in a tool holder 4 and retained by a retainer 5. The tool holder or a plurality of tool holders are aligned with respect to each other and attached to a cutter support 6. The main angles of each cutting rotative bit are determined by mounting of the tool holder to the cutter support as will be discussed hereinbelow. The tail portion of the bit 3 and therefore the cutting rotative bit are held in the tool holder rotatably around its longitudinal axis and fixed in the axial direction.
The cylindrical or conical body is made, as a rule, from alloyed steel, which has a substantial elasticity and a thermal expansion coefficient which is close to that of the insert.
The insert 2 is ring-shaped and can be formed as a solid ring or a composite ring, composed of individual segments. The inner opening of the ring can be cylindrical or conical while its upper surface, which is in contact with the body, may be flat or conical or curved to match the body shape.
The lower end or surface of the insert can be flat, as shown in FIGS. 3a, 3b, 3c. It can also concave, as shown in FIG. 3d or convex, as shown in FIG. 3e. The outer surface of the ring which is the front face of the bit always has a convex shape formed by a generatrix of a cylinder, as shown in FIGS. 3a, 3d, and 3c, or direct cone, as shown in FIG. 3b or inverse cone, as shown in FIG. 3c. The insert, as a rule, is made of hard and brittle wear resistant materials, preferably sintered hard alloys of the tungsten carbide group. The convex shape of the front face of the insert is preferable, since the cutting forces are directed toward the center of the ring and are resolved into mainly safe compressive stresses, instead of tensile stresses which are very dangerous for brittle materials like the hard alloys the insert is composed of.
The convex shape of the front face of the bit also contributes to more efficient removal of the destroyed rock from the cutting zone due to dispersing of cuttings to both sides of the bit.
The connection of the insert to the body can be performed by brazing, in particular for the composite ring, with use of high temperature brazing filler metal, or performed with interference or press fit. The ring-shaped insert provides semi-closed containment of brazing materials to ensure durable and reliable joining of the body and insert which is particularly important in condition of dynamic loads. The press fitting on the other hand, eliminates residual thermal stresses which are characteristic of high temperature brazing due to different expansion coefficients of the joined elements.
The solid bits which are not subdivided into the body and insert are recommended for cutting of non-abrasive materials. It has to be subjected to a special thermal treatment, for example, isothermic quenching to provide different hardness of the body portion and cutting element portion of the bit.
The main new feature of the present invention is that the inventive method is performed so that the cutting rotative bit is oriented to the surface of the rock to be cut at an attack angle β which exceeds 90°, as shown in FIGS. 2 and 4b.
The attack angle, in accordance with the present invention imparts to the tool a new quality and provides favorable conditions for its efficient operation due to optimization of the main parameters specified hereinabove and producing efficient destruction of the rock.
The skew angle α, shown in FIGS. 4a and 4c, is the angle measured in a horizontal plane between the projection of the longitudinal axis of the tool and the direction of the tool motion. The skew angle determines the force Q rot , which produces a rotary moment (torque) on the tool M rot around its longitudinal axis (or in other words causes rotation of the tool on the rock) as well determining the angular parameters of the tool such as a front angle ψ, and rear angle δ, as shown in FIG. 4b at the point of its self-sharpening, the point E in FIG. 4c.
The front angle ψ of the tool, shown in FIG. 4b, determines durability of the tool, the magnitude and direction of the thrust force T and normal component C n of total cutting force, as shown in FIG. 1. The rear angle δ shown in FIG. 4b, determines the cutting properties of the tool and its durability. The edge angle ρ, shown in FIG. 4b, determines the durability of the tool.
The spatial orientation of the tool which is determined by the attack angle β and the skew angle α imparts the following properties:
The front face of the tool is the convex surface of the insert, while the rear face of the tool is the end surface of the insert;
Each point of the cutting edge of the tool (arc AE in FIG. 4c) has the front angle ψ i and the rear angle δ i which are different from those of the remaining points on this cutting edge;
The rotation of the tool around its longitudinal axis (FIGS. 4b and 4c) is caused due to rolling of the front face of tool along the corresponding surface of the rock under the action of the rotary moment M rot formed by the force Q rot ;
The direction of the rectilinear moving of the tool does not coincide with the direction of cutting (breaking) of the rock, which is different for each point of the cutting edge of the tool, as shown in FIG. 4c.
In the point B in FIG. 4c, the rear angle δ b has its maximum positive value. Moving away from the point B to the right and to the left, this angle reduces (sin δ i =sin δ b ·cos ε i ) and assumes its zero value at point D and a negative value at point E. The geometrical correction of the rear face of the tool by introducing the positive angle Δδ in FIG. 4b (|Δδ|≧|δ e |) provides a positive rear angle along the whole cutting edge of the bit (the arc AE in FIG. 4c). Therefore, this condition, necessary for high rock stress concentrations at the cutting edge, is maintained.
Under the condition |Δδ|=|δ e |, the rear angle of the tool at the point E is zero. Therefore, on the radial line at E, self-sharpening occurs to provide continuous renewal and maintaining of the positive rear angle along the whole cutting edge of the tool despite continuous wearing out of the tool along its rear face.
At the point B in FIG. 4c, the front angle ψ b has its maximum negative value. Moving from point B to the right or to the left increases this angle (sin ψ i =sin ψ b ·cos ε i ) so as to assume its zero value at the point D and its positive value at the point E. Therefore, at the point E the specific thrust force will be maximal, when compared with remaining points of the cutting edge of the tool over the arc AE in FIG. 4c. This contributes to the continuous efficient self-sharpening of the tool and, in combination with the zero value of the rear angle, creates conditions which are close to machine tool sharpening. The introduction of the positive angle of correction Δψ, FIG. 4b, the effect of self-sharpening is further increased.
The negative front angle of the tool, which is maximal in central part of the cutting edge of the tool, contributes to the self-protection of the tool against overloading, due to the generation of a lifting force which lifts the tool from the rock. Such overloading is usually caused by the increase of the hardness of the rock to be broken.
The continuous rotation of the tool around its longitudinal axis is reliable due to the following factors:
Absence of substantial resistance to the rotation along the rear face of the tool due to the positive rear angle; and
Use of substantial cutting force Q (as compared with the thrust force), which is produced by the drive of the cutting equipment to form the required friction force along the front face of the tool and preventing slippage between the front face of the tool and the rock.
The nature and the axial direction of wear of the tool along the rear face in combination with the continuous renewal by self-sharpening to initial values of the rear angle along the whole cutting edge of the tool provides for efficient operation of the tool in the cutting mode until the wear completely consumes the insert.
The skew angle in accordance with the present invention can be within the range of 0° to 90°, preferably 25°±5°. The front angle can be within the range of plus 30° to minus 15°, preferably minus 7.5°,±2.5°. The rear angle can be within the range from 0° to 30°, preferably 12.5°±2.5°. The edge angle can be within the range of 45°-120°, preferably 75°±15°.
It will be understood that, each of the elements described above, or two or more together, may also find a useful application in other types of methods and constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a method of cutting and a cutting rotative bit, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic aspects of this invention.
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A rotating cutting tool has a cutting annular element which is mounted and displaced so that the cutting annular element has an attack angle exceeding 90°. The cutting element has a convex cutting front face and a skew angle between 0° and 90°.
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FIELD OF THE INVENTION
This invention relates to an apparatus for concurrent gaming, more particularly, to an apparatus for concurrently playing a game of chance and, more specifically, to an apparatus for playing a variation of a game of poker. The invention extends to a method for concurrent gaming.
BACKGROUND TO THE INVENTION
A well-known variation of the game of poker is called Caribbean Stud.
This game is a game of poker between each one of a number players and a dealer. During a turn of the game, each player is required to make an initial wager called an ante. After wagering the ante, each player and the dealer receive five cards dealt from a single deck of 52 playing cards. The playing cards are dealt to each player face down, while the dealer receives one card face up and the remainder face down. Each player must not, at this stage, disclose the playing cards that have been dealt to him.
Each player is then required to decide, on the basis of the playing cards which have been dealt to him, and the dealer's exposed playing card, whether to continue with his participation in this turn of the game (that is, to “play”) or to terminate his participation in the turn (that is, to “fold”). If a player folds, he loses his ante wager. If a player decides to play, he must make a further wager, known as the main wager, which is equal to twice the amount of the ante wager.
Once the main wager has been made in this manner by all players who have decided to play in the particular turn of the game, the dealer and the players all reveal their hands. In order to participate in the game (that is, “to qualify”) is, the dealer's hand must contain an Ace and a King, or better, in a conventional ranking of poker hands. If the dealer does not qualify, each player who has not folded wins the ante wager at even money and has the main wager is returned to him. If the dealer qualifies, the dealer's hand is compared to that of each player. If a player has a better poker hand than that of the dealer, the player wins the ante bet at even money and wins the main bet according to a predetermined table of odds. If a player has a worse poker hand than that of the dealer, both the ante wager and the main wager are lost.
A problem with this game of Caribbean Stud is that each player may only play one hand at the time. The reason for this is that if more than one hand was to be played, a player could swap playing cards between the two or more hands, thereby gaining an advantage over the dealer. Even in the absence of cards swapping, a player could, potentially, gain an advantage by playing multiple hands and adjusting his playing strategy in accordance with a collective knowledge of the playing cards in the multiple hands that have been dealt to him in a particular turn of the game.
OBJECT OF THE INVENTION
It is an object of this invention to provide an apparatus for concurrent gaming and a method for concurrent gaming that will, at least partially, alleviate the above-mentioned difficulties and disadvantages whilst allowing a player to play multiple simultaneous hands of Caribbean Stud.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided a method for concurrent gaming, which includes the step of:
dealing multiple concurrent hands of playing cards to a player in a turn of a game of Caribbean Stud poker, wherein each one of the multiple concurrent hands of playing cards is dealt from a separate deck of playing cards, each of the separate decks of playing cards having an identical composition.
Further features of the invention provide for each one of the separate decks of playing cards to be a single deck of cards, preferably 52 in number, and for each one of the concurrent hands to be a poker hand consisting of five dealt playing cards.
Still further features of the invention provide for the method to also include the step of dealing a further hand of playing cards associated with a dealer, for the further hand of playing cards associated with the dealer to be dealt from a further separate deck of playing cards, for dealing the further hand of playing cards associated with the dealer prior to dealing the multiple concurrent hands of playing cards to the player, and for removing from each of the separate decks of playing cards those cards contained in the dealer's hand prior to dealing the multiple concurrent hands to the player.
Yet further features of the invention provide for the method to include the still further step of dealing multiple concurrent hands of playing cards to each one of a plurality of different players in a manner as described above.
The invention extends to a method of operating a gaming server, comprising the steps of:
randomly selecting multiple concurrent hands of playing cards for a player playing a turn of a game of Caribbean Stud poker, wherein each one of the multiple concurrent hands of playing cards is randomly selected from a separate deck of playing cards, each of the separate decks of playing cards having an identical composition;
and
transmitting, along a communication network, a signal containing data representative of the composition of the selected multiple concurrent hands.
There is further provided for each one of the separate decks of playing cards to be a single deck of cards, preferably 52 at most, and for each one of the concurrent hands to be a poker hand consisting of five randomly selected playing cards.
There is still further provided for randomly selecting a further hand of playing cards associated with a dealer, for transmitting, along the communication network, a signal containing data representative of the composition of the randomly selected further hand, for randomly selecting the further hand of playing cards associated with the dealer from a further separate deck of playing cards, for randomly selecting the further hand of playing cards associated with the dealer prior to randomly selecting the multiple concurrent hands of playing cards for the player, and for removing, from each of the separate decks of playing cards, the cards contained in the dealer's hand prior to randomly selecting the multiple concurrent hands of playing cards for the player.
There is yet further provided for randomly selecting multiple concurrent hands of playing cards for each one of a plurality of different players in a manner as described above.
The invention extends further to a method of operating a client computer, comprising the steps of:
transmitting, along a communication network, a request to a gaming server, to randomly select multiple concurrent hands of playing cards for a player playing a turn of a game of Caribbean Stud poker, wherein each one of the multiple concurrent hands of playing cards is randomly selected from a separate deck of playing cards, each of the separate decks of playing cards having an identical composition;
receiving, along the communication network, a response from the gaming server containing data representative of the composition of the selected multiple concurrent hands;
and
displaying the selected multiple concurrent hands as part of a simulation of the game of Caribbean Stud poker.
There is also provided for requesting the gaming server to randomly select a further hand of playing cards associated with a dealer, wherein the further hand is randomly selected from a further separate deck of playing cards, receiving a response from the gaming server containing data representative of the composition of the further hand of playing cards associated with the dealer, and displaying the further hand as part of the simulation of the game.
The invention extends still further to a system for concurrent gaming, comprising:
dealing means instructable to deal multiple concurrent hands of playing cards to a player in a turn of a game of Caribbean Stud poker, wherein each one of the multiple concurrent hands of playing cards is dealt from a separate deck of playing cards, each of the separate decks of playing cards having an identical composition; and
a player terminal responsive to the dealing means to display the multiple concurrent dealt hands.
There is also provided for each one of the separate decks of playing cards to be a single deck of playing cards, preferably 52 in number, and for each one of the concurrent hands to be a poker hand consisting of five dealt playing cards.
There is also provided for the dealing means to also deal a further hand of playing cards associated with a dealer, for the dealing means to deal the further hand of playing cards associated with the dealer from a further separate deck of playing cards, for the dealing means to deal the further hand of playing cards associated with the dealer prior to dealing the multiple concurrent hands of playing cards to the player, and for the dealing means to remove from each of the separate decks of playing cards those cards contained in the dealer's hand prior to dealing the multiple concurrent hands to the player.
There is also provided for the dealing means to deal multiple concurrent hands of playing cards to each one of a plurality of different players in a manner as described above.
The invention extends yet further to a computer generated message containing data representative of the composition of multiple, randomly selected, concurrent hands of playing cards for a player playing a turn of a game of Caribbean Stud poker, wherein each one of the multiple concurrent hands of playing cards is randomly selected from a separate deck of playing cards, each of the separate decks of playing cards having an identical composition.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention is described below, by way of example only, and with reference to the accompanying drawings, in which:
FIG. 1 is a functional representation of a system for playing a game of chance, according to the invention.
FIG. 2 is a flowchart depicting a set of functions in accordance with an exemplary embodiment.
FIG. 3 is a flowchart depicting a set of functions in accordance with another exemplary embodiment.
FIG. 4 is a flowchart depicting a set of functions in accordance with another exemplary embodiment.
FIG. 5 is a flowchart depicting a set of functions in accordance with another exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the invention for playing a game of chance includes means for placing a wager on an outcome of a turn of a game of Caribbean Stud poker, in the form of a playing surface having multiple bet placement locations enabling a player to place separate wagers on an outcome of each one of multiple simultaneous hands of the game of Caribbean Stud poker. In this particular embodiment, the playing surface has five bet placement locations enabling the player to place wagers on up to five simultaneous hands of the game. The bet placement locations are arranged in a substantially arcuate configuration, similar to the layout of bet placement locations on a table in a conventional game of blackjack.
In a turn of the game, a player is able to make an ante wager on any one or more of the bet placement locations on the playing surface. The player is not required to place an ante wager on all of the bet placement locations on the playing surface.
One the player has placed one or more ante wagers as described above, the player is dealt a separate hand of playing cards corresponding to each one of the bet placement locations on which he has placed an ante wager. Each such separate hand consists of five playing cards dealt from a complete conventional deck of 52 laying cards. A further hand of five playing cards is dealt to a dealer representing a “house”. A first one of the cards in the dealer's hand is dealt face up, while the remaining four cards are dealt face down. It is an essential aspect of this invention that each one of the hands dealt to the player that corresponds to a bet placement location, as well as the dealer's hand, is dealt from a separate, complete deck of 52 playing cards.
Once the player's and the dealer's hands have been dealt in this manner, the player is required to decide, in turn, in respect of each one of his dealt hands, whether to continue with his participation in, or to withdraw from, the turn of the game of Caribbean Stud poker, that is, to “play” or to “fold” the hand. If the player folds a hand, the ante wager associated with that particular hand is forfeited. If the player decides to play any particular hand, he is required to make a further wager, the main wager, equal to twice the amount of the ante wager associated with that particular game.
When the player has decided whether to play or to fold each of the dealt hands, the dealer's hand is revealed. If the dealer's hand does not qualify, meaning that the dealer's hand does not contain an Ace-King combination, or better, in a conventional poker sense, all of the player's hands that he has not already folded, win for the player the ante wager at even money and a return of the main wager, irrespective of the cards in the hands. If the dealer's hand does indeed qualify, it is compared, separately and in turn, with each one of the player's unfolded hands in order to determine which of the two hands is of higher rank according to conventional poker rankings. Where the dealer and player hands are of equal ranking, conventional rules in respect of tied poker hands apply; namely, the high cards in the dealer and player hands are used as tiebreakers. If the player and dealer hands are thereafter still tied, the entire hand is tied and the ante wager and the main wager are returned to the player. It is possible to obtain identical tied hands since the cards in the dealer's and player's hands are dealt from different complete decks of playing cards.
Where the dealer's hand does qualify and is outranked by the player's hand, the player wins the ante wager at even money, together with odds on the main wager according to the following table:
Ace/King
2 to 1
One Pair
2 to 1
Two Pair
2 to 1
Three of a kind
4 to 1
Straight
6 to 1
Flush
10 to 1
Full House
10 to 1
Four of a kind
150 to 1
Straight Flush
250 to 1
Royal Flush
1000 to 1
In a slight variation of this embodiment, the dealer's hand is dealt prior to the multiple hands that are dealt to the player, and the cards in the dealer's hand are removed from each one of the remaining different decks of playing cards prior to dealing the multiple simultaneous hands to the player. In this variation, the possibility of a tie between a player's hand and the dealer's hand is reduced.
In a further slight variation of this embodiment, the playing surface is divided into multiple clusters of bet placement locations, thereby enabling multiple players to each play multiple simultaneous hands of Caribbean Stud poker as described above.
It will be appreciated by those skilled in the art that these embodiments of the invention solve the problem of enabling a player to play multiple simultaneous hands of Caribbean Stud poker. Further, the use of a separate complete deck of playing cards to deal each of the multiple hands of Caribbean Stud prevents a player from gaining an advantage by playing multiple simultaneous hands and adjusting his playing strategy as a function of a collective knowledge of the playing cards that have been dealt to him in the multiple hands in a particular turn of the game. Whilst these are significant advantages of the invention, there remains the problem of card swapping described above. Further, the use of separate physical complete decks of playing cards to deal the multiple hands when the game of Caribbean Stud poker is played as a table game can rapidly become tedious and cause a player to lose interest in the game. In order to overcome this problem, a further embodiment of the invention is described below.
In this embodiment, a system for playing a game of Caribbean Stud poker is indicated generally by reference numeral ( 1 ). The system ( 1 ) comprises a gaming server ( 2 ) and a player terminal ( 3 ) in the form of a computer workstation with an associated display monitor ( 4 ) and a pointing device ( 5 ) such as a mouse, touchpad or a trackball. The computer workstation ( 3 ) is located remotely from the gaming server ( 2 ) and is connected thereto by means of a communication network ( 6 ) that is, in this embodiment, the World Wide Web of the Internet.
The computer workstation ( 3 ) is a conventional personal computer operating under a Windows 2000 operating system, which is well known and commercially available from Microsoft Corporation of Seattle, Wash., USA. The computer workstation ( 3 ) executes a stored simulation software program that simulates the progress of a game of Caribbean Stud poker. The operation of the simulation program will be described in more detail in the description that follows.
The gaming server ( 2 ) includes a computer program for generating random events that determine the progress of the game of Caribbean Stud poker. In particular, the random event generation program is executable on the on the gaming server ( 2 ) to “deal”, on a random basis, cards that make up hands that are dealt to a player and to a dealer in the game of Caribbean Stud poker. The operation of such a random event generation programs is well known in the art and will not be described here in detail.
A player wishing to play a game of Caribbean Stud poker is first required to register and to create an account on the gaming server ( 2 ). The player is then required to pre-fund the account by purchasing credit that will, for convenience, be denominated in this description in “units”. The gaming server stores a credit balance corresponding to the player's account at all times.
In order to commence, the player uses the computer workstation ( 3 ) to log onto the gaming server ( 2 ) and initiates execution of the simulation program, which causes a playing surface having five bet placement locations to be displayed on the monitor ( 4 ), each bet placement location representing a hand of Caribbean Stud poker that can be played by the player. An associated bet placement icon is displayed adjacent to each bet placement location. The simulation program also causes a dialogue box to be displayed with information stating that each hand in the game will be dealt from a separate, complete deck of 52 playing cards. The player now enters a betting phase of the game by activating a bet placement icon in order to place an ante wager on a hand to be played. The size of the ante wager is displayed is displayed on the bet placement location. There must be sufficient credit in the player's account to cover any wager that is made. The player may elect to play more than on hand by activating further bet placement icons on the display monitor ( 4 ) and making corresponding ante wagers. The player can make ante wagers of differing amounts on each of the bet placement locations that are activated by the player in this manner. Data relating to the size of each such ante wager made by the player is transmitted by the computer workstation ( 3 ) across the communication network ( 6 ) to the gaming server ( 2 ) for storage on an associated storage device (not shown)
The simulation program also causes a “Deal” icon to be displayed on the display monitor ( 4 ) that, when activated by the player by means of the pointing device ( 5 ), begins a playing phase of the game in which all the player's hands on which he has placed ante wagers, and the dealer's hand, are dealt by the gaming server ( 2 ) and displayed by the simulation program on the display monitor ( 4 ). A first one of the playing cards in the dealer's hand is displayed face-up, while the remaining cards are displayed facedown. Activation of the “deal” icon by the player causes a message to be transmitted to the gaming server ( 2 ) across the communication network ( 6 ), which causes the execution of the event generation program on the gaming server to randomly select playing cards making up the player's and the dealer's hands. Each hand, whether belonging to the player or to the dealer, is selected randomly by the event generation program from an independent, identically distributed, logical deck of playing cards. The gaming server transmits the composition of the randomly selected hands across the communication network ( 6 ) back to the computer workstation ( 3 ) where the simulation program displays the individual playing cards in the player and dealer's dealt hands. The simulation program displays the cards as being dealt from a card shoe and all the cards are dealt simultaneously in order to speed up play and to provide a fast-paced game.
During this playing phase of the game, the simulation program also displays “Play” and “Fold” icons on the display monitor ( 4 ) that can be selectively activated by the player to make desired game play decisions, that is, whether to play or to fold, respectively, each one of the multiple hands dealt to the player. The simulation program causes the cards of any dealt hand that is folded by the player to be displayed in low lighting to indicate that that particular hand is no longer in play. The player is required to make a main wager on each hand that he does not fold, the main wager being equal to twice the corresponding ante wager. As is the case with ante wagers, data relating to the size of each such main wager made by the player is transmitted by the computer workstation ( 3 ) across the communication network ( 6 ) to the gaming server ( 2 ) for storage on the storage device (not shown).
Once the player has either folded or elected to play each one of the multiple dealt hands, the simulation program causes the face down cards in the dealer's hand to be displayed. The dealer's face down cards are revealed slowly, one at a time, in order to heighten tension and excitement of the game. The player's hands that are determined as being winning hands are highlighted on the display monitor ( 4 ) and the gaming server ( 2 ) settles the player's ante and main wagers as described above.
The gaming server ( 2 ) transmits the player's credit account balance across the communication network ( 6 ) to the computer workstation ( 3 ) from time to time. The simulation program displays this balance to the player in real time on the display monitor ( 4 ) to indicate a quantity of credit that is available to the player for playing the game. The credit balance is adjusted with each turn of the game in accordance with wagers placed and won or lost by the player.
Once the player's ante and main wagers have been settled as described above, the turn of the game of Caribbean Stud poker is complete and the player may begin a further turn of the game by making other ante wagers one or more of the bet placement locations displayed on the display monitor ( 4 ).
In this embodiment of the invention, the player is not required to handle physical playing cards of any kind. The playing cards on which the game is based are displayed electronically, thereby eliminating the problem of potential card swapping described above. The embodiment also allows multiple players, each having their own computer workstation ( 3 ) and associated display monitor ( 4 ) to communicate with the gaming server ( 2 ) to each play, at the same time, multiple hands of Caribbean Stud poker.
In order that the invention may be more fully understood, a number of examples of player and dealer hands, and accompanying wagers, are discussed below.
Example 1
The player makes an ante wager of 1 unit and the player is dealt a Royal Flush. The player decides to play the hand, requiring a main wager of 2 units. The dealer's hand does not qualify. In this situation, the main wager of 2 units is returned to the player, together with twice the ante wager. The net profit to the player on this hand is thus 1 unit.
Example 2
The player makes an ante wager of 1 unit and contains none of the above listed card combinations. The player nevertheless decides to play the hand, requiring a main wager of 2 units. The dealer's hand qualifies. The player thus loses both the ante and the main wagers, resulting in a net loss of 3 units.
Example 3
The player makes an ante wager of 1 unit and the player is dealt an Ace-King. The player decides to play the hand, requiring a main wager of 2 units. The dealer's hand does not qualify. In this instance, the main wager of 2 units is returned to the player, together with twice the ante wager. The net profit to the player, as in Example 1, is 1 unit.
Example 4
The player makes an ante wager of 1 unit and the player is dealt an Ace-King. The player decides to play the hand, requiring a main wager of 2 units. The dealer's hand also contains an Ace-King. The remaining cards in the player's and dealer's hands are compared and the highest-ranking card is contained in the player's hand. The player thus wins the hand and is paid twice the ante wager together with twice the main wager, resulting in a net profit of 3 units.
Example 5
The player makes an ante wager of 1 unit and is dealt a Royal Flush. The player decides to play the hand, requiring a main wager of 2 units. The dealer's hand qualifies, but does not contain a Royal Flush. The player thus wins the hand and is paid twice the ante wager, together with 1000 times the main wager, totalling 2002 units and resulting in a net profit of 1999 units.
The technical problem solved by this invention is that of transforming the game of Caribbean Stud poker into a multiplayer game and, further, also enabling each one of such multiple players to play, simultaneously, multiple hands of Caribbean Stud poker. At the same time, the embodiment of the system described above eliminates the possibility of fraud by such players. This is made possible by providing that the multiple hands of the game are played with electronically generated playing cards instead of physical ones. In addition, the invention removes any element of player skill from such a multiple hand game by ensuring that any hand is dealt from a separate deck of cards, thereby transforming the game into one of pure chance.
The invention therefore provides a novel variation of a conventional game of Caribbean Stud poker that will enable one or more players to play multiple simultaneous hands in a turn of the game.
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A system for concurrent gaming comprises a gaming server and a client computer connected to the gaming server by means of an open communication network. The gaming server is instructable by the client to randomly select multiple, concurrent hands of playing cards to a player in a turn of a game of Caribbean Stud poker. The compositions of the multiple, randomly selected concurrent hands is transmitted by the gaming server along the communication network to the client computer where they are displayed to the player, under program control as part of a simulation of the game of Caribbean Stud poker. Gaming server also generates the gaming server also randomly selects a hand associated with a dealer in the game, the composition of the dealer's hand being also transmitted by the gaming server to the client computer and displayed as part of the simulation. The player then makes desired game play decisions, in turn, as a function of each one of the, multiple concurrent hands and the dealer's hand.
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BACKGROUND OF THE PRESENT INVENTION
This invention relates to the repair and maintenance of indoor or outdoor recreational surfaces and, particularly, to the resurfacing of tennis courts.
In the past, acrylic resurfacing material typically employed for tennis courts, has been applied manually and thereafter spread about by a number of individuals working with hand-held, squeegee-like spreaders. The resulting surface coating often varies in thickness and exhibits unsightly streaks resulting from the uneven application and multi-directional spreading techniques common in the prior art. The surface coating can range from thin to thick and, as a result, often shows noticeable deterioration even within one year after resurfacing.
The prior art method is also labor intensive, time consuming and therefore very costly. More importantly, a quality-result is not assured.
According to the present invention, apparatus and a process for resurfacing recreational surfaces, particularly tennis courts, are presented herein which have several advantages over the prior art.
The present invention relates to a mobile, self-propelled device which can uniformly spread and smooth resurfacing material at a predetermined thickness. In addition, the self-propelled device of this invention can resurface a regulation size tennis court in a fraction of the time required by conventional techniques.
According to one exemplary embodiment of the invention, an elongated box-shaped frame, preferably constructed in three separable sections, is supported on a plurality of directionally adjustable wheels, or casters, for movement in any one of a plurality of selectively chosen directions. The total length of the three-section frame may be varied as desired but preferably exceeds the width of a regulation size tennis court.
A variable speed, reversible drive motor, preferably a gasoline or diesel internal combustion engine, provides power input to a pair of drive wheels which can be moved by way of a manually operated handle from an inoperable position wherein the wheels are held above ground, to an operable position where the wheels are in contact with the ground so as to move the machine in the selected direction.
It will be appreciated that since the machine is designed to operate in either of two opposite directions, and since the structure on both longitudinal sides of the machine is essentially identical, the terms front and rear, and forward and reverse, have no particular meaning absent some point of reference. For ease of discussion herein, the "front" of the machine merely refers to that side facing in the direction of movement, and the "rear" of the machine refers to that side which faces away from the direction of movement. Mounted to lower horizontal beam members of the box-like frame, along both front and rear sides of the apparatus, are flexible rubber spreading and smoothing blades, as well as flexible bristle brush means. Adjustable mounting brackets along both longitudinal sides of the machine enable the machine operator to rotate either the blade or brush means into operable position on either side of the machine depending on the direction of machine movement, as explained further hereinbelow.
In a preferred arrangement, when the machine is moving in one direction, the flexible blade means in the front of the machine and the brush means in the rear of the machine will be in operable positions. When the machine moves in the opposite direction, the operator manually reverses the blade/brush assemblies. In other words, the flexible blade means are always leading and the brush means are always trailing during any resurfacing operation. In one exemplary embodiment of the invention the blade/brush assemblies on both sides of the machine are interconnected for simultaneous movement between inoperative and operative positions.
This arrangement is particularly advantageous insofar as the flexible blade means serve to spread and smooth out the resurfacing material at a uniform predetermined thickness while the trailing brush means serve to further smooth out the resurfacing material and, particularly, to eliminate any tracks or other surface disturbances caused by either the casters or drive wheels or both.
It will be understood that the flexible blade means and brush means are angularly adjustable with respect to the ground. Moreover, the flexible blade means, preferably made of rubber, may be selected on the basis of hardness (Durometer value), so that, by careful coordination of mounting angle and blade hardness, the thickness of the coating of material may be predetermined and held uniform throughout the resurfacing operation.
It is further contemplated by this invention that the machine be capable of slight steering corrections, on the order of a degree or more, so as to insure proper alignment of the machine with respect to the boundaries of the tennis court. This is accomplished by permitting a slight angular shifting of the drive means of the machine.
The process aspects of the invention involve (1) positioning of the resurfacing machine at a first end, but outside the boundaries, of a tennis court, and preferably parallel to one of the end lines; (2) applying resurfacing material in front of the machine, preferably along its entire length in a series of spaced lengthwise masses, or windrows; and (3) moving the machine forwardly along at least the entire length of the tennis court and beyond the other end line, spreading out and smoothing the resurfacing material by the leading blade means, and smoothing out the caster and drive wheel tracks by the trailing brush means.
In the event that an adjacent, second court is to be resurfaced, the drive wheels are disengaged and the caster directions adjusted to enable the machine to be moved laterally to a position at the second end of the second court. The casters are then readjusted and the blade and brush means reversed. After additional resurfacing material is applied as described above, the machine is then driven along the length of the second court in a direction opposite that traveled during resurfacing of the first court.
It will be understood that during movement of the machine, resurfacing material is added as needed in front of, and along the length of the machine, generally parallel to the flexible blade means.
When the operation is completed, the various sections may be disassembled and transported to the next job site.
Further objects and advantages of the invention will become apparent from the detailed discussion which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a resurfacing machine in accordance with this invention, positioned for a resurfacing operation on a pair of adjacent tennis courts;
FIG. 2 is a partial front view of a center section of a resurfacing machine in accordance with an exemplary embodiment of the invention, partially cut away, and with other parts removed, in order to clearly illustrate a drive configuration for the machine;
FIG. 3 is a side sectional view taken along the line 3--3 of FIG. 2, but with supporting casters added;
FIG. 4 is a side view, partially in section, illustrating in greater detail a blade and brush assembly for a resurfacing machine in accordance with an exemplary embodiment of this invention;
FIG. 5 is a partial perspective view of the blade and brush assembly illustrated in FIG. 4;
FIG. 6 is a partially schematic side view of a interconnected front and back blade and brush assemblies for use with a resurfacing machine in accordance with another exemplary embodiment of the invention;
FIG. 7 is a partial plan view of a drive arrangement for a resurfacing machine in accordance with the invention;
FIGS. 8 and 9 are sectional views of alternative coupling configurations of a cross-beam and longitudinal frame beam in a resurfacing machine in accordance with the invention;
FIG. 10 is a side view, partially in section, illustrating a supporting caster for a resurfacing machine, the caster shown in a releasably locked directional orientation;
FIG. 11 is a partial plan view taken along the line 11--11 of FIG. 10; and
FIG. 12 is a front view of a supporting caster for a resurfacing machine, the caster shown in a releasably locked, freely rotatable position.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a typical multiple court configuration 1 includes a pair of side-by-side tennis courts 2, 3. Court 2 is defined by lengthwise boundary lines 4, 5 and widthwise boundary lines 6, 7. Similarly, court 3 is defined by lengthwise boundary lines 8, 9 and widthwise boundary lines 10, 11.
Typically, tennis courts are divided in half by lines 12, 13 which coincide with the location of nets (not shown). Court 2 is divided longitudinally by line 14 to define service areas while court 3 is similarly divided by line 15. In the context of this invention, lines 4, 5, 8 and 9 are considered the outer boundary lines typically employed in doubles matches. In other words, for purposes of this invention, it is the outermost court boundaries that are significant, and other, interior lines, such as singles match boundaries and service lines are not shown.
It will be appreciated that surrounding surfaces such as those indicated by reference numerals 16, 17, 18, 19, 20, 21, as well as the surface 22 between the two courts, typically have the same composition as the courts themselves, and are therefore subject to the same maintenance and repair requirements. Thus, any resurfacing operation would normally include all surfaces in surrounding relationship to the courts proper.
FIG. 1 also illustrates, generally, a resurfacing machine 30 positioned in surface area 16 outside the boundaries of court 2, and in generally parallel alignment with the widthwise boundary line 6.
The machine 30 consists of a generally rectangular box-like framework constructed in three separable sections 31, 32 and 33. Since the framework of each section is similar, only the center section 31 will be described in detail. Referring now to FIGS. 2 and 3, the center section of the framework includes upper horizontal front and rear beams 34, 35 and lower, horizontal front and rear beams 36, 37. In this regard, for the sake of discussion and ease of understanding, the right side of the machine in FIG. 3 shall be referred to as the front F and the left side as the rear R of the machine. At the section ends, vertical connecting beams 38, 39 extend between beams 34, 36 at the front of the machine. Similar vertical connecting beams (not shown) extend between beams 35, 37 at the rear of the machine. At one side of the center section, upper and lower front-to-back connecting beams 40 and 41 extend between upper beams 34, 35 and lower beams 36, 37, respectively. Diagonal trusswork 42 extends along the front face of the machine between vertical beams 38, 39 and interconnecting upper horizontal beam 34 and lower horizontal beam 36. Similar trusswork 43 extends along the rear face of the machine interconnecting upper horizontal beam 35 and lower horizontal beam 37.
A pair of supporting or cross beams 44, 45 extend between lower front and rear horizontal beams 36, 37 and are provided for reasons discussed in greater detail hereinbelow.
Side sections 32 and 33 are bolted or otherwise suitably fastened to the center section 31, as partially shown in FIG. 2.
As best seen in FIG. 3, the center section 31 is supported on four casters, two of which 46, 47 are shown mounted to cross beam 45 via caster brackets 48, 49, respectively. A second pair of casters (not shown) are identically mounted on the cross beam 44. It will be appreciated that side sections 32, 33 are similarly supported by four casters each. The caster assemblies have been removed from FIG. 2 in order to more clearly illustrate the drive means described below.
A pair of drive wheels 50, 51 are keyed to a drive axle 52 for rotation therewith. Axle 52 has a pair of connecting arms 53, 54 which mount the axle for rotation about a parallel shaft 55 rotatably journaled in a pair of bearings 56, 57 mounted on cross beams 44, 45. A handle 58 is fixed to shaft 55 for selectively moving drive wheels 50, 51 via connecting arms 53, 54 from a ground engaging, or operable position, shown in solid lines in FIG. 3, to an inoperative position, shown in phantom, where the drive wheels are raised an inch or so above the ground.
In order to drive the wheels 50, 51, a standard variable speed, reversible motor M is employed. The motor, which may be a gasoline or diesel internal combustion engine, is fixedly secured to cross-beam 45 and includes an output shaft 60 connected by chain or other suitable drive belt means 61 to a gear 62. Gear 62 is secured to a sleeve bearing 63 supported on shaft 55 for rotation relative thereto. A second gear 64 is secured to the sleeve bearing 63 for driving connection with shaft 52. To this end, a gear 65 is mounted on shaft 52 and is connected to gear 64 by chain 66 or other suitable drive belt means.
It will thus be understood that shaft 52 and drive wheels 50, 51 are driven by motor M through a drive train consisting of gears 62, 64, and 65 and a pair of drive chains 61 and 66. It will be further understood that the drive train remains unaffected by the movement of drive wheels 50, 51 from an inoperative to an operative position, particularly by reason of the rotatable sleeve bearing unit 63 which is able to rotate relative to shaft 55.
In FIG. 2, a third cross-beam 67 is shown extending between beams 36, 37 intermediate cross-beams 44 and 45. Aside from adding rigidity to the structure, this third cross-beam supports an intermediate bearing 68 through which shaft 55 rotatably passes.
FIGS. 4 and 5 illustrate in detail the mounting arrangement for a flexible blade and brush means assembly 59 which serve to spread and smooth the resurfacing material. As can be appreciated from FIG. 3, identical blade/brush assemblies are mounted so as to extend along both front and rear faces of the machine, co-extensive with its length.
Because the assemblies 59 associated with the front and rear faces of the machine are substantially identical, only one mounting configuration need be described in detail.
As shown in FIG. 4, the lower horizontal beam 36, which extends the length of center section 31, mounts at least one, and preferably at least a pair of angle brackets 69 via C-shaped bracket studs 70 having threaded free end portions, end plate 71, and nuts 72. In an exemplary embodiment, the bracket 69 is welded to plate 71 at a fixed angle of inclination such that bracket 69 extends downwardly and away from the machine. A second, generally horizontally oriented angle bracket 73 is mounted for rotation with respect to angle bracket 69 by a link arm 74 pivotally mounted to bracket 69 by a pin 75. It will be understood that angle bracket 73 extends longitudinally along at least the full length of center section 31, supported by at least a pair of spaced brackets 69 (see FIG. 2).
A flexible blade element 76, preferably of a rubber composition, is fixedly secured to one side 77 of bracket 73, as by a plurality of bolts 78 or other suitable fasteners, while a flexible bristle brush 79 is fixedly secured to the other side 80 of the bracket by a plurality of screws 81 (only one of which is shown) or other suitable fasteners.
At the opposite end of the angle bracket 69 and adjacent beam 36, a sleeve 82 and associated link arm 83 are received on a shaft 84 for rotation therewith.
The link arm 83 rotatable within limits set by adjustable screws or bolts 85, 86 threadably secured in L-shaped angles 87 and 88, respectively, which are welded or otherwise secured to one side surface of bracket 69. As best seen in FIG. 5, the shaft 84 is journaled in a sleeve bearing 89 welded or otherwise secured to another side surface of the bracket. Link arms 74 and 83 are operatively connected by a rod 90 threadably received in U-shaped coupling elements 91, 92 which are pivotally secured to the arms 74, 83 by pins 93, 94.
The above described arrangement permits the machine operator to choose which of the flexible blade means 76 and bristle brush means 79 will be in an operative position, depending on the direction of motion of the machine. As shown in FIGS. 4 and 5, the flexible blade 76 is in operable position to spread and smooth out the resurfacing material applied to the court surface ahead of the machine proper.
In the event the direction of machine movement is reversed (not shown), to resurface a second adjacent court, shaft 84 is rotated, by an attached handle, for example, to rotate link arm 74, via link arm 83 and threaded rod 90, and thereby move blade means 76 into an inoperative position (shown in phantom in FIG. 4) and brush means 79 into operative position.
It should be understood that for any of sections 31, 32 or 33, the flexible blade means and bristle brush means are co-extensive with the length of the particular section. Adjacent blade sections should be in closely abutting, side-by-side relationship to avoid surface irregularities at the interface thereof. Any such irregularities appearing at the interface of adjacent sections of the leading blades could easily be smoothed out, however, merely by slightly offsetting the interface of the trailing brushes.
In all cases, in order to assure accurate and uniform thickness of the resurface coating, it is important that the blade supporting angle bracket 73 be precisely positioned. To this end, it will be appreciated that such precise positioning is enabled through adjustment of limit bolts 85, 86 and adjustment of the effective length of the threaded rod 90. Since link arm 83 and rod 90 control the movement of link arm 74, they also define the position of angle bracket 73 in its operative position.
It will further be appreciated that the flexibility of the blade means 76 (as determined by its hardness, or Durometer value) also has a significant effect on the thickness of the applied coating, insofar as its flexibility determines in part the contact angle of the blade means with the resurfacing material. Thus, careful selection of an appropriate rubber composition for the blade means, and precise adjustment of the variously described supporting bracket elements, enables precise and uniform spreading of resurfacing material at a predetermined thickness.
Turning now to FIG. 6, an alternative embodiment is illustrated wherein front and rear blade and brush assemblies 59 are linked by a tie rod 98 connected at its ends to link arms 83, 83' which are, in turn, connected to link arms 74, 74' via adjustable rods 90, 90'.
A control rod 99, pivotally mounted at 100 to a fixed frame member 101, engages a pin 102 provided on tie rod 98 to move the tie rod back and forth in directions generally indicated by arrow 103. Because movement of tie rod 98 follows a slightly arcuate path, due to pivoting movement of arms 83, 83', a slot 104 is provided in control rod 99 to accommodate such movement.
As viewed in FIG. 6, the blade and brush assemblies are positioned for left to right machine movement, i.e., with a leading blade means 76 and a trailing brush means 79'. For machine movement in the opposite direction, the blade/brush assemblies are reversed by actuation of control rod 99. Thus, clockwise movement of rod 99 will simultaneously move blade means 76' and brush means 79 from inoperative to operative positions, and brush means 79' and blade means 76 from operative to inoperative positions. This arrangement greatly facilitates resurfacing operations of multiple court surfaces in side-by-side relationship, since the machine is not limited to movement in a single direction during resurfacing.
FIG. 7 is a partial top view of the center section 31 of the machine illustrating an arrangement which permits a slight degree of steerability of the machine. Cross beam 45 which supports the motor M as well as the shaft bearing means 57, is movable transversely with respect to the lower horizontal beams 36, 37 by reason of slots 106, 107 formed in beams 36 and 37. At the same time, shaft 55 is permitted a slight pivoting action in the bearing 56 mounted on cross beam 44. The pivoting action of shaft 55 is necessary to maintain proper alignment of the various components of the drive means upon shifting of the cross beam 45. It is to be understood that the degree of movement of cross beam 45 is slight, such that shaft 55 may pivot perhaps only one degree or so in either direction from its normal position. By this arrangement, the machine operator, may slightly alter the path of travel of the machine if he visually determines that the machine is slightly askew with respect to, for example, the center line of the court being resurfaced.
FIGS. 8 and 9 illustrate alternative coupling arrangements, utilizing L-brackets 109, 110 to secure the cross beam 45 to the lower horizontal beam members, and which permit shifting of the cross beam.
FIGS. 10, 11 and 12 disclose a caster of mounting arrangement which permits the various supporting casters to be releasably locked for movement in any one of four directions, or in a position where the caster is free to swivel in any direction. In FIG. 10, a caster 46 is shown mounted to a cross beam 45 by a bolt 120 and nut 121. The caster bracket 48 is provided on its top surface with four raised projections 123 arranged 90 degrees with respect to one another in an X-shaped configuration, as best seen in FIG. 11. These projections cooperate with a series of indentations formed by pie-shaped projections 124 formed in a mounting plate 125 which is welded or otherwise securely fixed to the cross beam 45. A coil spring 122 or other suitable resilient biasing means, is placed between the bolt head and the cross beam 45 to bias the bolt 120 and the caster upwardly to a position where projections 123 are received within the indentations formed between projections 124 on the plate 125. It will be appreciated that by pressing downwardly on the bolt head 120, projections 123 disengage from the indentations between projections 124, permitting rotation of the caster and caster bracket 48 to any one of the four illustrated detent positions arranged at 90 degree intervals.
It will be noted that the lateral projection or handle 126, integrally formed with or attached to the bolt head 120, facilitates turning of the caster, but also serves to lock the caster in a depressed position where projections 123 are disengaged from the plate 125 so as to allow free rotation of the caster. As clearly shown in FIGS. 10 and 12, an L-shaped angle member 127 is provided on the cross beam 44 at a position where it may receive handle 126 in a downwardly compressed position. By simply pressing even further downwardly on bolt head 120 and/or handle 126, the bolt may be rotated out of engagement with the angle member 127 so that the caster may again be releasably locked in one of the detent positions.
This capability to releasably lock the casters enables the machine to be accurately moved both longitudinally and laterally with respect to a court surface without the "drifting" motion usually associated with freely rotatable casters.
Referring back now to FIG. 1, the operation of the machine will be described in connection with a resurfacing operation for two adjacent tennis courts. Initially, the machine is placed beyond the boundary 6 of the court for movement lengthwise of the court as indicated by arrows 128. Prior to machine actuation, a number of windrows 130 of resurfacing material are applied ahead of the machine in a manner as generally indicated in FIG. 1. It will be understood, of course, that additional windrows are applied between the machine itself and, for example, the boundary line 6 of the court. After application of the resurfacing material, the machine drive is actuated to cause the machine to traverse the entire length of court until it reaches a position indicated in phantom by the reference numeral 132. During this path of travel, it will be understood that leading flexible blade means spread and smooth out the windrows 130 of resurfacing material to form a uniform coating of predetermined thickness over the entire surface of the court. At the same time, flexible brush means trailing the machine smooth out and eliminate any tracks or other surface irregularities caused by movement of the casters and drive wheels through the resurfacing material.
Once the machine has reached the position indicated by reference numeral 132, the casters on sections 31, 32 and 33 are releasably locked for movement in a lateral direction and the drive wheels are retracted to their inoperative position so that the machine may be pushed laterally to a position indicated by reference numeral 133 at the end of a second court 3. Upon readjustment of the casters, and upon reversal of the flexible blade and brush assemblies as previously described, the machine is ready to traverse a path indicated by arrows 134. Prior to actuation, additional windrows 130 of resurfacing material would, of course, be applied to the surface of court 3.
During lateral movement of the machine from position 132 to 133, it will be advantageous to have additional flexible brush means depending from widthwise frame members of the device to smooth out any tracks caused by the casters as the machine is moved laterally from court 2 to court 3.
While the invention has been described in what is presently perceived to be its most practical embodiments, those of ordinary skill in the art will understand that various changes and modifications may be made without departing from the spirit and scope of the claims which define the invention as follows.
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Method and apparatus are provided for resurfacing one or more adjacent tennis court surfaces. An elongated, box-like frame structure, supported for rolling movement on a plurality of casters, is provided with flexible blade and brush elements for engaging, spreading, and smoothing court resurfacing material at a predetermined thickness as the structure traverses the court surface. In accordance with method aspects of the invention, the device is movable in one direction to resurface an entire tennis court, and after lateral movement to an adjacent second court area, reversible to move in the opposite direction to resurface an entire second court surface. For a given resurfacing direction, the flexible blade elements engage the resurfacing material ahead of the device while the flexible brush elements engage the resurfacing material behind the device to effect final smoothing.
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RELATED APPLICATIONS
[0001] There are no related applications.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] None.
FIELD OF THE INVENTION
[0004] The present invention generally relates to an insert member for a conventional toaster usable for cooking any liquid, semi-liquid, semi-solid, or batter material that solidifies with the application of heat. More specifically, this invention relates to cooking forms insertable in a conventional toaster, shaped to permit the cooking of foods that are liquid, semi-liquid, or semi-solid in their uncooked state, for example, breakfast foods such as waffles or pancakes.
BACKGROUND OF THE INVENTION
[0005] The cooking of food products that start from a batter and subsequently solidify with the application of heat while cooking is well known. For example, so-called “waffle irons” are widely available for creating a crisp, flat, food item traditionally eaten during breakfast or as a dessert ingredient. The familiar rectangular or circular shape with multiple indentations is designed to advantageously contain various syrups, jams and jellies, or other condiments. Nevertheless, making “homemade” waffles or pancakes is a time consuming, equipment intensive undertaking generally reserved for weekends or special occasions. The process generally involves pulling a heavy, unwieldy, waffle iron or flat plate from storage in one of the kitchen cabinets (put there because the device is so rarely used and counter space is limited), plugging it in, greasing it, pre-heating it, mixing the batter, lifting the iron's top and pouring the batter in, closing the top and waiting a sufficient time for cooking. Thereafter, clean-up can be equally daunting because these cookware devices cannot be put into the dishwasher or submerged in the sink. Hence, they are generally wiped clean as best as possible instead of being washed, thereby increasing the likelihood of bacterial colonization, and placed back into the dark confines of the kitchen cabinet, further increasing the opportunity for the growth fungi and bacteria. Similarly, pancakes or griddle cakes are slightly less problematic to cook but equally time consuming and messy to prepare.
[0006] What is needed is a cooking appliance that can quickly and easily cook batter-based food items, yet is easy to manipulate and clean, and optimally, can make use of existing kitchen appliances in order to maximize their efficiency and conserve counter space. The prior art is replete with various waffle and pancake making devices. The instant invention solves the above noted disadvantages.
[0007] A number of cooking devices are shown in the prior art. U.S. Pat. No. 1,546,347 issued 9 Jan. 1923 is a waffle iron that cooks waffles in a generally vertical orientation. This device is a large, counter-top appliance utilizing the familiar clamshell-like configuration used commonly in current waffle makers. Flat, textured cooking surfaces are joined at a hinged connection in a vertical orientation. These cooking surfaces are pressed together while cooking, then separated when cooking is complete in order to permit access to the food item within. The traditional means of using these waffle cooking devices is that an appropriate amount of batter is poured onto one cooking surface, thereafter the other surface is closed upon it until cooking is complete. This device is used by first closing the cooking surfaces against one another, then filling the device via its fill spout, and cooking.
[0008] U.S. Pat. No. 5,596,922 issued 28 Jan. 1997 is a hamburger grilling appliance including a bifurcated sidewall assembly that effectively seals the device while cooking but allows easy access to the cooked food when the device is opened, thereby facilitating removal of the cooked product. It is inappropriate for use with batters, however, with a problem of leakage of the uncooked material.
SUMMARY OF THE INVENTION
[0009] The present invention is an insert for conventional toasters enabling the user to cook batter-based foods, for example, waffles and pancakes, using the toaster's heating mechanism. It solves the aforementioned problems in the prior art regarding unwieldiness or difficulty in cleaning up, and additionally makes more efficient use of an already existing kitchen appliance. It includes two hingedly connected complimentary cooking surfaces, that when closed one upon the other, define an interior volume shaped in the form of the desired product, for example a waffle or pancake. Additional features include a clamping mechanism built into the handles and an overflow reservoir positioned to vent gasses, steam, and/or contain excess batter when the device is placed in the toaster for cooking, thereby protecting the interior mechanism of the toaster from spillage or other deleterious materials which may ultimately affect its functioning. The handles may also serve as a means of suspending the device within the toaster slot in the event that the aforementioned slot is particularly deep and/or the desired food product is designed to be significantly smaller in one dimension compared to the depth of the aforementioned slot. This placement additionally enables easier manipulation of the entire device, for example, when opening the device and removing the cooked food product.
[0010] It is an object of the invention to provide a device that is easy to clean, and because it relies upon the heating source within the toaster, the entire device is dishwasher safe.
[0011] It is another object of the invention to provide a device that is light in weight and takes up little space for storage.
[0012] It is yet another object of the invention that it will permit the existing toaster that users already own to function in multiple roles, thereby eliminating the need for traditional electric waffle iron and its attendant inconveniences.
[0013] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the waffle maker invention showing the entire cooking form assembly when filled and closed.
[0015] FIG. 2 is an enlarged side elevation view of the invention shown in FIG. 1 .
[0016] FIG. 3 is a top plan view of the invention shown in FIG. 1 .
[0017] FIG. 4 is an enlarged sectioned side elevation view of a base member of the invention.
[0018] FIG. 5 is a plan view of the base member of the invention with handles removed depicting its non-stick coated cooking surface.
[0019] FIG. 6 is a plan view of the cover member of the invention with handles removed depicting its non-stick coated cooking surface.
[0020] FIG. 6A is an enlarged side elevation view of the cover member shown in FIG. 6 .
[0021] FIG. 7 is a side elevation view of the handle assembly.
[0022] FIG. 8 is a top plan view of the handle assembly in FIG. 7 .
[0023] FIG. 9 is an end view of the handle assembly in FIG. 7 .
[0024] FIG. 10 is a plan view of the handle assembly as shown in FIG. 10 .
[0025] FIG. 11 is a detailed side elevation of the handle assembly in FIG. 7 without the silicone insulating cushion depicted in FIG. 7 .
[0026] FIG. 12 is a perspective plan view of a pancake maker in a closed position.
[0027] FIG. 13 is a front end view of the pancake maker shown in FIG. 12 .
[0028] FIG. 14 is rear end view of the pancake maker shown in FIG. 12 , and
[0029] FIG. 15 is an enlarged side elevation view of the pancake maker shown in FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
[0030] The preferred embodiments and best modes of the invention are shown in FIGS. 1 through 11 . While the invention is described in connection with certain preferred embodiments, it is not intended that the present invention be so limited. On the contrary, it is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims.
[0031] This invention may be constructed from any heat resistant, yet heat conductive material. Such heat conductive materials have been made from metallic material, including aluminum for the primary cooking elements. However, it is noted that this invention may also successfully using sheet steel, stainless steel, copper, cast iron, Pyrex® (or similar borosilicate glass), porcelain, ceramic, or polymeric material. The cooking surfaces are also preferably coated with one or more non-stick coatings, for example Teflon® (i.e., fluorocarbon polymers), (e.g., tetrafluoroethylene and fluorinated ethylene propylene).
[0032] The present cooking device 20 includes a base member 25 having a hinge 26 at one end and cover member 30 with a hinge 31 at a corresponding end. Not shown is a hinge pin interconnecting the aforementioned hinge elements 26 , 31 , which are themselves incorporated into the base member 25 and cover member 30 . A cooking cavity 28 best shown in FIG. 4 is shaped in the relief of the form of the food product to be cooked. Additionally, a plurality of square shaped protuberances 45 with tapered side walls 46 and a top planar surface 47 extend outward from the cooking surface to form the waffle embodiment. Each adjacent protuberance in linear alignment ranges from about 0.55 inches to about 0.75 inches from center point to center point of each protuberance. In a most preferred arrangement, the protuberances 45 are spaced about 0.65 inches apart. A complimentary cooking cavity 33 is also present in the cover member 30 . The aforementioned members 25 , 30 and cavities 28 , 33 are shaped to define complimentary portions of the final form of the cooked food material. The entire cooking apparatus 20 is sized for insertion into a conventional toaster. The base member 25 and cover member 30 , when closed, define a substantially sealed cavity shaped in the desired final form of the food product to be cooked. It is an important feature of this invention that the aforementioned compartment is substantially sealed in order to effectively contain food material placed therein, but permits sufficient leakage at the seam for venting steam or excess batter during the cooking process. The batter leaking into the seam between base member 25 and cover member 30 in effect becomes its own sealant, thereby preventing leakage of additional material into the heat source, typically a conventional toaster. In practice, metal (or other heat resistant but heat conductive material) in the vicinity of the seam or sealing area will heat rapidly because it is not in direct contact with the batter. As batter leakage occurs into the seam, the batter contacts this relatively highly heated material and immediately solidifies, thereby creating its own seal thus preventing leakage of additional batter. An area of the cooking apparatus which operates differently in this regard is the top or overflow reservoir cup area located between the handles.
[0033] An overflow reservoir or cup 50 is defined by the two end cup halves 27 , 32 defined in the base member 25 and cover 30 shown in FIGS. 1 and 2 . In use, steam created by the cooking process tends to rise, following a path in the direction of the cup 50 . Consequently, excess batter follows this path of lower resistance and since a seal has not been formed, tends to collect in the cup 50 .
[0034] Another important feature of this invention is the placement of its handles 38 , 39 and the clamping feature formed by the handles. As illustrated in FIGS. 1 , 2 , and 3 , L shaped handles 38 , 39 are preferably positioned at the opposite end of base member 25 and cover member 30 , away from the hinge 26 , 31 . The handles 38 , 39 are generally co-axial when the apparatus is in its closed position and ready for insertion as shown in FIG. 2 . Hence, when in a closed position, the handles 38 , 39 are ideally positioned for easy insertion or extraction of the apparatus from a toaster slot. The handles are individually mounted on the base and cover members 25 , 30 , such that when the device is open, one handle 38 is mounted to the base member 25 , with the other handle 39 mounted to the cover member 30 . Handling characteristics of the apparatus are thereby maximized whether opened or closed, consequently obviating any need for oven mitts, hot pads, or the like. In use, all required manipulation of the device may be accomplished using the handles exclusively. The handles have one leg 36 which has a generally U shaped configuration as is shown in FIGS. 7 , 8 , and 9 and acts as a clamp with an insulating silicone grip or cushion 37 mounted on the other leg.
[0035] A handle attaching pin 42 permits rotational or pivoting movement of the handle 38 attached to the base member 25 as shown in FIG. 3 . Not shown is a similar pin mounting its respective handle 39 to cover member 30 . The handles 38 , 39 each have a clamping leg member 36 manufactured from a resilient material, sized to fit over the combined thicknesses of the base and cover members 25 , 30 when closed. In use, the handles 38 and 39 and their respective leg clamp members 36 are rotated around pin 42 away from the base and cover members 25 , 30 so that the cooking apparatus 20 may be opened. In closing, the handles and their respective leg clamps are rotated downward with the leg clamps 36 frictionally moving over the top portion of the base and cover members, thereby locking the base and cover members 25 , 30 into their respective closed positions, ready for insertion into the toaster.
[0036] FIGS. 12 through 15 are drawings show a pancake making assembly 60 using the same structural components as previously discussed without the waffle protuberances 45 . This assembly has a central cavity with a curved side wall 62 and a planar end wall. 64 .
[0037] Handles 38 , 39 and clamping members 40 , and 41 are rotated away from base member 25 and cover member 30 in order to open the device. The now open apparatus may be placed on a table or countertop, and either the base member 25 or cover member 30 filled with an appropriate amount of batter. The unfilled member is rotated about hinge 26 , 31 and allowed to rest atop the filled member. Handles 38 , 39 are rotated inward, towards the now adjacent base and cover members 25 , 30 , and clamps 40 , and 41 rotate on pin 42 to lock the base member and cover member together. The entire assembly is then placed into a conventional toaster, wherein heat produced therein cooks the batter in the cooking cavity. Small amounts of batter may leak due to imperfect sealing at the interface of said base member 25 and cover member 30 , but the apparatus self seals by solidifying instantly upon coming in contact with the comparatively highly heated portions of the base and cover members 25 , 30 not previously in contact with the batter. Steam or other byproducts of the cooking process tend to vent upward into the portion of the base and cover members 27 , 32 that form the overflow reservoir 50 . Excess batter will tend to follow this path of less resistance, thereby tending to collect into said overflow reservoir 50 rather than into the toaster, thereby simplifying cleanup.
[0038] It is noted that the critical features of this invention are equally amenable for use with regard to cooking any batter-based product that solidifies with the application of heat. The specific embodiments described herein include waffle making and pancake making incarnations, but are not limited to same. Moreover, it is understood that while this invention is ideally suited for use in a conventional toaster, this invention may be used with any heat source with little or no modification. For example, this invention may be equally useful in conjunction with an open flame, so-called toaster oven, or conventional oven.
[0039] The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention should not be construed as limited to the particular embodiments which have been described above. Instead, the embodiments described here should be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the scope of the present invention as defined by the following claims:
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A cooking apparatus for batter based foods that can be inserted into the slot of a traditional toaster and cooked using the toaster's heating mechanism. The apparatus has two hingedly connected complimentary cooking members, that when closed one upon the other, define an interior cavity shaped in the form of the desired cooked product. A clamping mechanism is built into the handles of each of the two cooking members and an overflow reservoir is formed by each of the cooking members and is positioned between the handles to vent gasses, steam, and/or excess batter upward when the device is placed in the toaster for cooking, thereby protecting the interior mechanism of the toaster from spillage.
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